Generac Power Systems 14KW, 20KW, 17KW, 10KW, 12KW Owner's Manual

LISTED

O Manual

,10, 12, 14, 16, 17 & Air-cooled,

Automatic Standby Generators

DO NOT LiFT UNiT BY ROOF!

z_ Not intended for use as Primary Power in place of utility Z_

DEADLY EXHAUST FUMES. OUTDOOR iNSTALLATiON ONLY!

or in life-support applications.

iNTRODUCTiON

Thank you for purchasing this compact, high per-

formance, air-cooled, engine-driven generator. It is
designed to automatically supply electrical power to
operate critical loads during a utility power failure.

This unit is factory installed in an all-weather, metal

enclosure that is intended exclusively for outdoor
installation. This generator will operate using either

vapor withdrawn liquid propane (LP) or natural gas

(NG).

NOTE:

This generator is suitable for supplying typical

residential loads such as Induction Motors (sump
pumps, refrigerators, air conditioners, furnaces,

etc.), Electronic Components (computer, monitor,

TV, etc.), Lighting Loads and Microwaves.

@ READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, con-
tact the nearest 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:

After this heading, read instructions that, if not
strictly complied with, wi[[ result in serious person-

al injury, including death, in addition to property
damage.

-_ WARN|NG _k-

After this heading, read instructions that, if not
strictly complied with, may result in serious person-

al injury or property damage.

& CAUTIONA-

After this heading, read instructions that, if not
strictly complied with, could result in damage to

equipment and/or property.

NOTE:

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

These safety warnings cannot eliminate the 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 potential explosion haz-
ard.

Z_ This symbol points out potential fire hazard.

/_ This symbol points out potential electrical shock

hazard.

The operator is responsible for proper and safe use
of the equipment. The manufacturer strongly 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
for these models:

. 7 kW NG, 8 kW LR single-cylinder GH-410 Engine
. 9 kW NG, 10 kW LR V-twin GT-530 Engine

. 12 kW NG, 12 kW LR V-twin GT-990 Engine
. 13 kW NG, 14 kW LR V-twin GT-990 Engine

. 16 kW NG, 16 kW LR V-twin GT-990 Engine
. 16 kW NG, 17 kW LR V-twin GT-990 Engine

. 18 kW NG, 20 kW LR V-twin GT-999 Engine

@ OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety
checks, to make sure that all maintenance for safe

operation is performed promptly, and to have the
equipment checked periodically by a 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 mainte-
nance service.

Proper maintenance and care of the generator ensures
a minimum number of problems and keep operating

expenses at a minimum. See a Dealer for service aids
and accessories.

@ HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs,
contact a Dealer for assistance. Service technicians

are factory-trained and are capable of handling all
service needs.

When contacting a Dealer about parts and service,
always supply the complete model number and serial
number of the unit as given on its data decal, which is
located on the generator. See section "The Generator"

for decal location.
Model No. Serial No.

/_ This symbol points out important safety infor-

mation that, if not followed, could endanger
personal safety and/or property of others.

Table of Contents

Air-cooled Generators

NTS

introduction ........................ inside Front Cover

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

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

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

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

Table of Contents ...............................................1

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

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

Section 1 - General information ................... 4

1.1

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

1.2

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

1.3

NEC Requirement for Arc Fault Circuit

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

1.4

Emission Information .................................... 5

1.5

The Generator ............................................... 6

1.6

Specifications ................................................ 7

1.7

System Set LED ............................................ 8

1.8

Fuel Requirements and Recommendations .... 8

1.9

Fuel Consumption ......................................... 8

1.10

Reconfiguring the Fuel System ....................... 9

1.11

Location ...................................................... 10

1.12

Battery Requirements .................................. 11

1.13

Battery Installation ...................................... 11

1.14

The Battery .................................................. 12

1.15

Battery Charger ........................................... 12

Section 3 - Operation .....................................16

3.1 Control Panel Interface ................................ 16

3.2 Automatic Transfer Operation ..................... 17

3.3 Sequence of Automatic Operation ................ 18

3.4 Manual Transfer Operation ......................... 19

3.5 Side Compartment (V-twin Only) ................. 20

3.6 Protection Systems ...................................... 20

Section 4 - Maintenance .............................. 22

4.1 Fuse ............................................................. 22

4.2 Checking the Engine Oil Level ..................... 22

4.3 Changing the Engine Oil .............................. 23

4.4 Changing the Engine Air Cleaner ................. 23

4.5 Spark Plug(s) .............................................. 24

4.6 Battery Maintenance .................................... 25

4.7 Adjusting GH-410/GT-530/990/999

Valve Clearance ............................................ 25

4.8

Cooling System ............................................ 26

4.9

Attention After Submersion ......................... 26

4.10

Corrosion Protection ................................... 27

4.11

Out of Service Procedure ............................. 27

4.12

Service Schedule ......................................... 28

Section 5 - Troubleshooting ........................ 29

5.1 Troubleshooting Guide ................................ 29

Section 6 - Appendix .....................................30

6.1 Menu System Navigation ............................. 30

Section 2 - Post installation Start-up

and Adjustments ........................13

2.1 Before Initial Startup ................................... 13

2.2 Check Transfer Switch Operation ................ 13

2.3 Electrical Checks ......................................... 13

2.4 Generator Tests Under Load ....................... 14

2.5 Checking Automatic Operation .................... 14

2.6 Engine Governor Adjustment ...................... 15

2.7 Voltage Regulator Adjustment ...................... 15

Section 7 - Notes ............................................ 32

Section 8 - installation Diagrams .............. 33

Section 9 - Warranty ...................................... 36

SAFETYRULES

iMPORTANT SAFETYiNSTRUCTiONS

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-
tots and potential operators of this equipment.

A GENERALHAZARDSA

. For safety reasons, the manufacturer recommends

that the installation, initial start-up and main-
tenance of this equipment is carried out by a

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. Do NOT alter or

add to the exhaust system or do anything that

Study these SAFETY RULES carefully before install-
ing, operating or servicing this equipment. Become

familiar with this Owner's Manual and with the
unit. The generator can operate safely, efficiently and

reliably only if it is properly installed, operated and
maintained. Many accidents are caused by failing to
follow simple and fundamental rules or precautions.

The manufacturer cannot anticipate every possible

circumstance that might involve a hazard. The 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.

/_ 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.

might render the system unsafe or in noncompli-
ance with applicable codes and standards.

. Keep hands, feet, clothing, etc., away from drive

belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit
is operating.

. Adequate, unobstructed flow of cooling and 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 Dealer for parts needing repair or replace-
ment.

. 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

(-) 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.

2

iMPORTANT SAFETY iNSTRUCTiONS

Air-cooled Generators

SAFETYRULES

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 unit, stand on an insulated, dry surface to
reduce shock hazard.

* Do not handle any kind of electrical device while

standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK

MAY RESULT.

. The National Electrical Code (NEC) requires the

frame and external electrically conductive parts of
the generator to be connected to an approved earth

ground. Local electrical codes also may require

proper grounding of the generator electrical system.

* After installing this home standby electrical 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 injury if such a

start and transfer occur, always set the generator's

AUTO/OFF/MANUAL switch to its OFF position
before working on equipment and remove the 15A

fuse from the generator control panel.

* In case of accident caused by electric shock, imme-

diately shut down the source of electrical power. If
this is not possible, attempt to free the victim from

the live conductor. AVOID DIRECT CONTACT WITH

THE VICTIM. Use a nonconducting implement,

such as a dry rope or board, to free the victim from
the live conductor. If the victim is unconscious,

apply first aid and get immediate medical help.

* Never wear jewelry when working on this equip-

ment. Jewelry can conduct electricity resulting in

electric shock, or may get caught in moving com-

ponents causing injury.

FiREHAZARDS/g,

* For fire safety, the generator must be installed and

maintained properly. Installation must always
comply with applicable codes, standards, laws

and regulations. Adhere strictly to local, state
and national electrical and building codes. Comply

with regulations the Occupational Safety and

Health Administration (OSHA) has established.

Also, ensure that the generator is installed in

accordance with the manufacturer's instructions
and recommendations. Following proper 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.

* Keep a fire extinguisher near the generator at all

times. Extinguishers rated 'TkBC" 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.

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
ENGINES AND GAS TURBINES, available from

the National Fire Protection Association, 470

Atlantic Avenue, Boston, MA 02210.

2. NFPA No. 76A, ESSENTIAL ELECTRICAL
SYSTEMS FOR HEALTH CARE FACILITIES,
available same as Item 1.

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

4. NFPA No. 58, AMERICAN NATIONAL STANDARD
FOR STORAGE AND HANDLING OF LIQUEFIED

PETROLEUM GAS, available same as Item 1.

5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL
ELECTRIC CODE, available same as Item 1.

6. Article X, NATIONAL BUILDING CODE, available
from the American Insurance Association, 85
John Street, New York, N.Y. 10038.

7. AGRICULTURAL WIRING HANDBOOK, avail-
able from the Food and Energy Council, 909

University Avenue, Columbia, MO 65201.

8. ASAE EP-3634, INSTALLATION AND
MAINTENANCE OFFARM STANDBYELECTRICAL

SYSTEMS, available from the American Society
of Agricultural Engineers, 2950 Niles Road, St.

Joseph, MI 49085.

9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE, available same as Item 1.

3

" GENERAL "

INFORMATON

/_ Only qualified electricians or contractors should

attempt such installations, which must comply
strictly with applicable codes, standards and regu-

lations.

Air-cooled Generators

1.1 UNPACKING/INSPECTION

After 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 may be pack-

aged with an automatic transfer switch with built
in load center. The combination transfer switch

and load center is pre-wired with a two foot and
30 foot conduit. Circuit breakers for emergency
circuit connections are included (if equipped).

. This UL listed, 2-pole switch is rated at 100 or 200

AC amperes at 250 volts maximum. The 100 Amp
transfer switch is for indoor use only. The 200

Amp transfer switch is for indoor/outdoor use

(if equipped).

-,_ WARNING _-

/_ if this generator is used to power electrical load

circuits normally powered by a utility power
source, it is required by code to install a transfer

switch. The transfer switch must effectively isolate
the electrical system from the utility distribution

system when the generator is operating (NEC 700,
701 & 702). Failure to isolate an electrical system

by such means will result in damage to the 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 person(s) making the delivery note all damage on
the freight bill or affix their signature under the con-
signor'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.

To properly open the roof, press down on the cen-

ter top lip and release the latch. If pressure is not
applied from the top, the roof may appear stuck.

Always verify that the side lock is unlocked before

attempting to lift the roof.

Section 1 - Genera[ information

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 condi-

tions:

1. Low Oil Pressure Sensor

2. High Temperature Sensor

3. Overcrank

4. Overspeed

5. RPM Sensor

6. Low Battery

There are readouts on the control panel to notify
personnel that one of these failures has occurred.
There is also a System Set LED (single cylinder) or a
Status message on the display (V-twins) that displays

when all of the conditions described in the "System

Set LED" section are true.

1.3 NEC REQUIREMENTFORARC

FAULTCIRCUITiNTERRUPTION

BREAKER FOR BEDROOMS

In 2001, the National Electric 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 110.11 ARC FAUET CIRCUIT

INTERRUPTER PROTECTION

1. Definition: An arc fault circuit interrupter is a
device intended to provide protection from the
effects of arc faults by recognizing characteristics

unique to arcing and by functioning to de-ener-
gize the circuit when an arc fault is detected.

2. Dwelling Unit Bedrooms: All branch circuits that
supply 125 volt, single-phase, 15 and 20 ampere
outlets installed in dwelling unit bedrooms shall

be protected by an arc fault circuit interrupter
listed to provide protection of the entire branch

circuit.

Section 210.12 requires that AFCI protection be
provided on branch circuits that supply outlets
(receptacle, lighting, etc.) in dwelling bedrooms. The
requirement is limited to 15 and 20 ampere, 125

volt circuits. There is no prohibition against provid-

ing AFCI protection on other circuits or in locations
other than bedrooms. Because circuits are often

shared between a bedroom and other areas such as
closets and hallways, providing AFCI protection on

the complete circuit would comply with 210.12.

4

Section 1 - General information

Air-cooled Generators

GENERAL

NFORMATON

If during the installation of the home standby system
the decision is made to provide back up power to a

bedroom branch circuit, then the circuit breaker in
the transfer switch should be replaced with an Arc

Fault Circuit Interrupter.
It is most important that breakers only be switched

like for like. For instance, if replacing a 15A breaker,
it MUST be replaced with a 15A AFCI breaker.
Likewise, a 20A breaker MUST be replaced with a

20A AFCI.
These AFCI breakers are available at the nearest

hardware store.
Siemens Item #

Ql15AF
Q120AF

Description

15A Single Pole AFCI

20A Single Pole AFCI

1.4 EMISSION INFORMATION

The Environmental Protection Agency requires that
this generator complies with exhaust emission stan-
dards. This generator is certified to meet the appli-

cable EPA emission levels. Additional information
regarding the requirements set by the EPA is as fol-

lows:

The generator is certified for use as a stationary
engine for standby power generation. Any other use

may be a violation of federal and/or local laws. It is
important that to follow the maintenance specifica-

tions in the "Maintenance" section to ensure that the
engine complies with the applicable emission stan-

dards for the duration of the engine's life. This engine
is certified to operate on Liquid Propane fuel and

pipeline Natural Gas. The emission control system
on the generator consists of the following:

. Fuel Metering System

Carburetor/mixer assembly
Fuel regulator

Air Induction System

Intake pipe/manifold
Air cleaner

Ignition System

Spark plug
Ignition module

The Emissions Compliance Period referred to on the
Emissions Compliance Label indicates the number of
operating hours for which the engine has been shown
to meet Federal emission requirements. See the table
below to determine the compliance period for the
generator. The displacement of the generator is listed
on the Emissions Compliance Label.

Displacement Category Compliance Period

A 300 Hours

< 66 ce B 125 Hours

C 50 Hours

> 66 cc -

< 225 cc

> 225 ce B

A
B

C
A

C

500 Hours
250 Hours

125 Hours

1000 Hours

500 Hours
250 Hours

5

" GENERAL "

INFORMATON

Air-cooled Generators

1.5 THE GENERATOR

Section | - General information

Figure 1.1 - 8kW, Single Cylinder, GH-410 Engine

(door removed)

Roof Latch

L

Exhaust -_.

Enclosure

'b

Oil

Dipstick

Data Label Control

(see sample) Panel

\

\

\- J

Jio i

I

Composite Base Battery Compartment

Oil Filter

Circuit

J _ Breaker

2 iI !

j Air Filter

I Fuel Inlet

(back)

Fuel

Regulator

Figure 1.2 - IOkVV, V-twin, GT-530 Engine

(door removed)

Roof Latch

Oil Data Label Control _F

Dipstick (see sample) Panel

Exhaust .__

Enclosure

Composite Base Oil Filter Battery Compartment

Circuit

jBreaker

_i- Air

Filter

1Fuel Inlet

(back)

Fuel

Regulator

Exhaust

Enclosure

Figure 1.3- 12, 14, 16, 17 and 20kW, V-twin,

GT-990/GT-999 Engine (door removed)

RoofLatch

1

CircuitBreakers

(All17&20kW)

/

1_

j-Fuel Inlet

C

_ Fuel

: j

/

CompositeBase

OilFilter

Battery Compartment

GFClOutlet

(back)

Regulator

Data Label Sample

MODEL

SERIAL

VOLTS

AMPS

1 PH, 60 Hz, RPM ,3600

RAINPROOF ENCLOSURE FITTEE

CLASS H INSULATION

RATED AMBIENT TEMP - 25°(

FOR STANDBY SERVICE

IItI!UTR_L FLQ_TINQ

MAX LOAD UNBALANCE-50%

WHITEWATER, WIS

MADE IN U,S.A,

1

6

Section 1 - General information

Air-cooled Generators

GENERAL

NFORMATON

1.6 SPECiFiCATiONS

• 1.6.1 GENERATOR

Model 8kW 10kW 12kW 14kW 16kW 17kW 20kW

Rated Maximum 7,000 NG 9,000 NG 12,000 NG 13,000 NG 16,000 NG 16,000 NG 18,000 NG
Power Capacity (Watts*) 8,000 LP 10,000 LP 12,000 LP 14,000 LP 16,000 LP 17,000 LP 20,000 LP

Rated Voltage 120/240

Rated Maximum Load Current (Amps)

120 Volts** (NG/LP) 58.3/66.6 75.0/83.3 100.0/100.0 108.3/116.6 133.3/133.3 133.3/141.6 150.0/166.6

240 Volts (NG/LP) 29.2/33.3 37.5/41.6 50.0/50.0 54.2/58.3 66.6/66.6 66.6/70.8 75.0/83.3

Main Circuit Breaker 35 Amp 45 Amp 50 Amp 60 Amp 65 Amp 65 Amp 100 Amp

Circuits*** 50A, 240V 1 1 1

40A, 240V 1 1 1 1

30A, 240V 1 1 1

20A, 240V 1 1 1 1

20A, 120V 1 3 3 4 5 5

15A, 120V 5 3 5 4 5 5

Phase 1

Number of Rotor Poles 2

Rated AC Frequency 60 Hz

Battery Requirement Volts and 350 Group 26R, 12 Volts and 525 CCA Mininmm

Weight (unit only in lbs.) 340 387 439 439 439 455/421 450

Enclosure Steel Steel Steel Steel Steel Steel/Aluminum Aluminum

Normal Operating Range -20 ° F (-28.8 ° C) to 77 ° F (25 ° C)

* Maximum wattage and current are subject to and limited by such factors as fuel Btu content, ambient temperature, altitude, engine power and condition,

etc. Maximum power decreases about 3.5 percent for each 1,000 %et above sea leveh and also will decrease about 1 percent for each 6 C (10 F) above 16 C

(60 F) ambient temperature.

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

value stated for the 240 volts.

*** Circuits to be moved must be protected by same size breaker. For example, a 15 amp circuit in the main panel must be a 15 amp circuit in the trans%r

switch.

Group 26R, 12

CCA Minimum

ld_.1 ENGINE

Model 8 kW I0 kW 12/14/16/17 kW 20 kW

Type of Engine GH-410 GT-530 GT-990 GT-999

Number of Cylinders 1 2 2 2

Rated Horsepower @ 3,600 rpm 14.8 18 32 36

Displacement 410cc 530cc 992cc 999cc

Cylinder Block Aluminum w/Cast Iron Sleeve

Valve Arrangement Overhead Valves

Ignition System Solid-state w/Magneto

Recommended Spark Plug RC 14YC BPR6HS RC 14YC RC 12YC

Spark Plug Gap 0.76 mm (0.030 inch) 0.76 mm (0.030 inch) 1.02 mm (0.040 inch) 0.76 mm (0.030 inch)

Compression Ratio 8.6:1 9.5:1 9.5:1 9.5:1

Starter 12 VDC

Oil Capacity Including Filter Approx. 1.5 Qts Approx. 1.7 Qts Approx. 1.7 Qts Approx. 1.7 Qts

Recommended Oil Filter Part # 070185F

Recommended Air Filter Part # 0G3332 Part # 0E9581 Part # 0C8127 Part # 0G5894

Operating RPM 3,600

7

° GENERAL °

INFORMATION

Section ] - General information
Air-cooled Generators

1.7 SYSTEMSETLED

The "System Set" LED (single cylinder) or "Ready to

Run" on the display (v-twin) is ready 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 is not connected to the unit or if it is below
approximately 150-160 volts AC, then the system
set light will flash rapidly (8kW). 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, etc.

1.8 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

system that meets the specifications of the 1997

California Air Resources Board for tamper-proof dual
fuel systems. The unit will run on natural gas or LP

gas, but it has been factory set to run on natural gas.

Should the primary fuel need to be changed to LP

gas, the fuel system needs to be reconfigured. See the

reconfiguring the Fuel System section for instructions
on reconfiguration of the fuel system.

Recommended fuels should have a Btu content of at
least 1,000 Btus per cubic foot for natural gas; or at

least 2,520 Btus per cubic foot for LP gas. Ask the
fuel supplier for the Btu content of the fuel.

Required fuel pressure for natural gas is five (5)
inches to seven (7) inches water column (0.18 to

0.25 psi); and for liquid propane, I0 inches to 12

inches of water column (0.36 to 0.43 psi). The
primary regulator for the propane supply is NOT
INCLUDED with the generator.

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 I0 inches water column for liq-
uid propane.

Prior to installation of the generator, the installer
should consult local fuel suppliers or the fire mar-
shal to check codes and regulations for proper instal-
lation. Local codes will mandate correct routing of

gaseous fuel line piping around gardens, shrubs and

other landscaping to prevent any damage.

8

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 start-up in accordance with
local codes, standards and regulations.

1.9 FUEL CONSUMPTION

Unit

7/8kW 77 140 0.94/34 1.68/62

9/10kW 102 156 1.25/46 1.93/70
12/12kW 152 215 1.53/56 2.08/76
13/14kW 156 220 1.56/58 2.30/84
16/16kW 183 261 1.59/58 2.51/91
16/17kW 183 261 1.61/59 2.57/94
18/20kW 206 294 1.89/69 2.90/106

Natural gas is in cubic feet per hour.
** LP is in gallons per hour/cubic %et per hour.
*** Vahtes given are approximate.

Verify that gas meter is capable of providing enough
fuel flow to include household appliances.

@ 1.9.1 BTU FLOW REQUIREMENTS =

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

. 7kW-- 140,000 BTU/Hour
. 9kW-- 156,000 BTU/Hour

. 12kW-- 215,000 BTU/Hour
. 13kW-- 220,000 BTU/Hour
. 16kW-- 261,000 BTU/Hour

. 18kW-- 294,000 BTU/Hour

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.

Nat. Gas LP Vapor

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

NATURAL (;AS

Section 1 - General information

Air-cooled Generators

GENERAL

NFORMATON

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.

l.lO RECONFIGURINGTHE

FUELSYSTEM

O 1.10.1 8 KW 410CC ENGINE

To reconfigure the fuel system from NG to LR 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 I0 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. Take the plastic T-handle fuel selector in the poly
bag supplied with the generator.

5. Locate the selector knob on the air box cover,
behind the yellow air filter door and power

bulge. The unit comes from the factory in the NG

(Natural Gas) position. Grasping the T-handle,
insert the pin end into the hole in the selector
knob and pull out to overcome spring pressure
and then twist clockwise 90 degrees and allow
the selector to return in once aligned with the LP
(Liquid Propane) position.

6. Save this tool with the Owner's Manual.

7. Install the battery, door and close the roof.

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

Figure 1.4 - Fuel Selector

NOTE:

Use an approved pipe sealant or joint compound

on all threaded fittings to reduce the possibility
of leakage,

0 1.10.2 10, 12, 14, 16, 17 AND 20KW, V=TWIN

ENGINES

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

NOTE:

The primary regulator for the propane supply is
NOT INCLUDED with the generator, A fuel pres-

sure of I0 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-

ly.

For 12, 14, 16, 17 and 20kW units: remove the air

cleaner cover.

* Slide the selector lever out towards the back of

the enclosure (Figures 1.7 and 1.8).

* Return the air cleaner cover and tighten the two

thumb screws.

Figure 1.5 - lOkW, GT=530 (inlet Hose Slid Back)

FuelSelection

Lever- "in"

Positionfor

NaturalGas

Fuel

3. Close the roof.

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

9

o o o

GENERAL

NFORMATON

Section 1 - General information

Air-cooled Generators

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

Figure 1.7- 12, 14, 16, 17, & 20kW,

GT-990/GT-999 (Airbox Cover Removed)

Figure 1.8- 12, 14, 16, 17, & 20kW,

GT-990/GT-999 (Airbox Cover Removed)

1.11 LOCATION

• 1.11.1 GENERATOR

Install the generator set, in its protective enclosure,
outdoors, where adequate cooling and ventilating air
is always available (Figure 1.9). Consider these 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 unless there is
at least four (4) feet of clearance above the genera-

tor, three (3) feet of clearance on sides and front,
and 18 inches of clearance at back of unit.

* Install the unit where rain gutter down spouts,

roof run-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.

to

Figure 1.9 - Generator Clearances

. Install the generator as close as possible to the fuel

supply, to reduce the length of piping.

. Install the generator as close as possible to the

transfer switch. REMEMBER THAT LAWS OR
CODES MAY REGULATE THE DISTANCE AND

LOCATION.

. The genset must be installed on a level surface.

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

. The generator is typically placed on pea gravel or

crushed stone. Check local codes if a concrete slab
is required. If a concrete base slab is required, all

federal, state and local codes should be followed.
Special attention should be given to the concrete
base slab which should exceed the length and

width of the generator by a minimum of six (6)
inches (0.152 meters) on all sides.

"_ WARNING _-

/_ The engine exhaust fumes contain carbon mon-

oxide, which can be DEADLY. This dangerous
gas, if breathed in sufficient concentrations,

can cause unconsciousness or even death. This

exhaust system must be installed properly, in
strict compliance with applicable codes and stan-
dards. Following installation, do nothing that

might render the system unsafe or in noncompli-

ance with such codes and standards.

• Operate the generator outdoors ONLY.

• Keep exhaust gases from entering a confined area
through windows, doors, ventilation or other

openings (Figure 1.9).

• 1.11.2 TRANSFERSWITCH (if included)

+ 1.11.2.1 8, 10, 12, 14, 16, 17 and 20kW Units

(if equipped)

The transfer switch that may have shipped inside
the carton with the 8, 10, 12, 14, 16 or 17kW gen-
erator is enclosed in a NEMA 1 (indoor rated only)
enclosure. The transfer switch that may have shipped

with the 20kW generator is enclosed in a NE1VIA 3R

(indoor/outdoor rated) enclosure.
. Install the transfer switch indoors on a firm, sturdy

supporting structure.

. To prevent switch distortion, level the switch if

necessary, This can be done by placing washers
between the switch enclosure and mounting sur-

face.

. Never install the switch where water or any corro-

sive substance might drip onto the enclosure.

. Protect the switch at all times against excessive

moisture, dust, dirt, lint, construction grit and
corrosive vapors.

Section 1 - General information

Air-cooled Generators

" GENERAL "

INFORMATION

"_ WARNING _-

If the AUTO/OFF/MANUAL switch is not set to its

OFF position, the generator can crank and start
as soon as the battery cables are connected. If
the utility power supply is not turned off, spark-

ing can occur at the battery posts and cause an

explosion.

1.12 BATTERYREQUIREMENTS

See the Specifications section for correct battery size
and rating.

1.13 BATTERYiNSTALLATiON

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

installing it.
Before installing and connecting the battery, complete

the following steps:

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

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

3. Remove the 7.5A fuse from the generator control
panel.

Battery cables were factory connected at the genera-
tor (Figure 1.10). Connect cables to battery posts as

follows:

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

POS or (+).

5. Connect the black battery cable (from frame
ground) to the battery post indicated by a nega-

tive, NEG or (--).

Figure 1.10 - Battery Cable Connections

BLACKLEAD

BLACK

i

tt

GENERAL

NFORMATON

Air-cooled Generators

NOTE:

Dielectric grease should be used on battery posts

to aid in the prevention of corrosion.

NOTE:

Damage will result if battery connections are made
in reverse.

NOTE:

In areas where temperatures regularly fall below

10 ° F (-12 ° C) it is recommended that a pad type

battery heater be installed to aid in cold climate

starting.

1.14 THE BATTERY

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

/_ A battery presents a risk of electrical shock

and high short circuit current. The following pre-
cautions are to be observed when working on

batteries:

* Remove the 7.5A fuse from the generator control

panel.

, Remove watches, rings or other metal objects;
, Use tools with insulated handles;

* Wear rubber gloves and boots;
* Do not lay tools or metal parts on top of the

battery; and

* Disconnect charging source prior to connecting or

disconnecting battery terminals.

=_ WARNING

/_ Do not open or mutilate the battery. Released

electrolyte has been known to be harmful to the
skin and eyes, and to be toxic.

/_ The electrolyte isa 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 thor-

oughly 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 I gallon (4 liters) of water. The bicar-
bonate of soda solution isto be added until the

evidence of reaction (foaming) has ceased. The
resulting liquid isto be flushed with water and the

area dried.

t2

Section 1 - Genera[ information

z_ 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.

/_ Be sure the AUTO/OFF/MANUAL switch is set to

the OFF position before connecting the battery
cables. If the switch is set to AUTO or MANUAL,

the generator can crank and start as soon as the
battery cables are connected.

Be sure the utility power supply is turned off
and the 7.5A fuse is removed from the genera=

tot control panel, or sparking may occur at the
battery posts as the cables are attached and
cause an explosion.

Servicing of the battery is to be performed or super-

vised by personnel knowledgeable of batteries and

the required precautions. Keep unauthorized person-
nel away from batteries.

See the Specifications section for the correct size
and rating when replacing the battery. Have these

procedures performed at the intervals specified in
the '°Service Schedule." A negative ground system is

used. Battery connections are shown on the wiring
diagrams. Make sure the battery is correctly connect-
ed and terminals are tight. Observe battery polarity

when connecting the battery to the generator set.

1.15 BATTERY CHARGER

NOTE:

These generators DO NOT contain an internal bat-
tery charger.

NOTE:

The manufacturer provides a battery trickle char-
ger that is active when the unit is set up for auto-
matic operation. With the battery installed and
utility power source voltage available to the trans-
fer switch, the battery receives a trickle charge
to prevent self-discharge. The trickle charger is
designed to help extend the life of the battery by
maintaining the battery. The trickle charge feature
cannot be used to recharge a discharged battery.

For units shipped with a transfer switch/load center_
the battery charger is pre-installed in the transfer

switch enclosure.

For units shipped without a transfer switch!load cen-
ter, a separate battery charger module is included

with the generator.

(For battery charger installation, see the Generator
Install Guidelines and Battery Charger Instructions

included with the unit.)

Section 2 = Post Installation Start-up and Adjustments

Air-cooled Generators

POS%C_=_
iNSTALLATiON

STAR%UP
ADJUSTMENTS

2.1 BEFOREiNiTiAL 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 generator's AUTO/OFF/MANUAL switch to
the OFF position.

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

4. Turn OFF all loads connected to the transfer
switch terminals T 1 and T2.

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

be open.

During initial start up only, the generator may exceed
the normal number of start attempts and experience

an "over crank" fault (See the "Overcrank" section).

This is due to accumulated air in the fuel system dur-

ing installation. Reset the control board and restart
up to two more times, if necessary. If unit fails to

start, contact the local dealer for assistance.

"_1_ CAUTION

/_ 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

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

4. Turn on the utility power supply to the transfer
switch using the means provided (such as a utility

main line circuit breaker).

The transfer switch is now electrically "hot."

Ax

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 N 1 and the transfer switch neutral lug; then

across terminal N2 and neutral. Nominal line-to-
neutral voltage should be 120 volts AC.

7. When certain that utility supply voltage is compat-
ible with transfer switch and load circuit ratings,
turn OFF the utility power supply to the transfer

switch.

8. On the generator panel, set the Auto/Off/Manual
switch to MANUAL. The engine should crank and

start.

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

OPERATION

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

/_ 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.

/_ 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-
cy meter across transfer switch terminal lugs E1
and E2. 8kW voltage should be 230-240 volts at
a frequency of 61-63 Hertz. 12, 14, 16, 17 and
20kW voltage should be 247-249 at a frequency
of 59.5-60.5 Hertz. 10kW voltage should be
220-230 volts at a frequency of 59.5-60.5 Hertz.

11. Connect the AC voltmeter test leads across ter-
minal lugs E1 and neutral; then across E2 and

neutral. In both cases, voltage reading should be

121-126 volts AC (8kWL and 125-126 volts AC

(10, 12, 14, 16, 17 and 20kW).

t3

POS%_

iNSTALLATiON

STAR%UP
ADJUSTMENTS

Section 2 - Post Installation Start=up and Adjustments
Air-cooled Generators

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 to stabilize internal engine

generator temperatures.

13. Set the generator's AUTO/OFF/MANUAL switch to
OFE The engine should shut down.

NOTE:

It is important not to proceed until certain that
generator AC voltage and frequency are correct
and within the stated limits. Generally, if both AC
frequency and voltage are high or low, the engine
governor requires adjustment* (*GH410 only). If
frequency is correct, but voltage is high or low, the
generator's voltage regulator requires adjustment.

2.4 GENERATOR TESTS UNDER LOAD

To test the generator set with electrical loads applied,

proceed as follows:

1. Set generator's main circuit breaker to its OFF
(or OPEN) position.

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
OFE

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 wARN,NO

/_ 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.

5. Manually set the transfer switch to the STANDBY
position, i.e., load terminals connected to the

generator's El/E2 terminals. The transfer switch

operating lever should be down.

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

immediately.

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

8. Set the generator's main circuit breaker to its ON
(or CLOSED) position. Loads are now powered

by the standby generator.

9. Turn ON the load center of the transfer switch
(T1 and T2).

10. Connect an accurate AC voltmeter and a frequen-
cy meter across terminal lugs E 1 and E2.

. 8kW voltage should be greater than 230 volts and

frequency should be greater than 58 Hz.

. 10, 12, 14, 16, 17 and 20kW voltage should be

greater than 240 volts and frequency should be

60 Hz.

11. Let the generator run at full rated load for 20-30
minutes. Listen for unusual noises, vibration or

other indications of abnormal operation. Check
for oil leaks, evidence of overheating, etc.

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

13. Set the generator's main circuit breaker to its
OFF (or OPEN) position.

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

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

2.5 CHECKINGAUTOMATIC

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 OFE

3. Turn OFF the utility power supply to the transfer
switch, using means provided (such as a utility

main line circuit breaker).

4. Manually set the transfer switch to the UTILITY
position, i.e., load terminals connected to the util-
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 is now ready for automatic operation.

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

With the AUTO/OFF!MANUAL switch at AUTO, the
engine should crank and start when the utility source

power is turned OFF after a 10 second delay. After
starting, the transfer switch should connect load
circuits to the standby side after a five (5) 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 re-transfer, the engine

should shut down.

t4

Section 2 - Post Installation Start-up and Adjustments

Air-cooJedGenerators

POS%_
iNSTALLATiON

STAR.UP
ADJUSTMENTS

2.6 ENGINE GOVERNORADJUSTMENT

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

• 2.6.1 8 KWUNITS
=_ WARNING

Z_ The engine must be OFF to perform steps I and

2.

1.

Loosen the governor clamp bolt (Figure 2.1).

2.

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

(8 N-m).

Figure 2.1 -- Engine Governor Adjustment

Single Cylinder Engines

SECONDARY

ADJUST SCREW

• 2,6,3 ADDiTiONAL CORROSION

PR_

Periodically spray all engine linkage parts and brack-
ets with corrosion inhibiting spray such as WD-40 or

a comparable product.

2.7 VOLTAGEREGULATOR
ADJUSTMENT

2.7,] 1 KW NiT

Due to the brushless design of these two alternators,
no voltage regulator is used and therefore no voltage
adjustment is required.

2.7.2 ]2 14 ] 17 2 KW NiT

With the frequency between 59.5 -60.5 Hertz at no-
load, slowly turn the slotted potentiometer (Figure

2.2) until line voltage reads 247-249 volts.

Figure 2.2 - Voltage Adjustment Potentiometer

f"_ _'_

, /-o-_ \ /

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

4. Connect a frequency meter across the generators

AC output leads.

5. Turn the primary adjust screw to obtain a fre-
quency reading of 61.5 Hertz. Turn the secondary

adjust screw to obtain a frequency of 62.5 Hz.

2..2 ]2 14 ] ]7 2 KW NiT

NOTE:

All V-twin units DO NOT require an engine gover-

nor adjustment due to their design,

i

[---_J

Turnto
adjust voltage.

O

[]

.@ Q

NOTE:

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

NOTE:

The voltage regulator is housed behind the genera-
tot's control panel. The regulator maintains a volt-
age in direct proportion to frequency at a 2-to-I

ratio. For example, at 60 Hertz, line-to-neutral
voltage will be 124 volts.

15

OPERATION

Section 3 - Operation
Air-cooled Generators

3.1 CONTROL PANEL iNTERFACE

• 3.1.1 USING THE AUTO/OFF/MANUAL

WiT H FI RE .1 .2

1. 'AUTO" Position - Selecting this switch activates
fully automatic system operation. It also allows

the unit to automatically start and exercise the
engine every seven days with the setting of the

exercise timer (see the Setting the Exercise Timer
section).

2. '°OFF" Position - This switch position shuts down
the engine. This position also prevents automatic
operation.

3. "MANUAE' Position - Set the switch to MANUAL
to crank and start the engine. Transfer to standby

power will not occur unless there is a utility fail-
ure.

Figure 3.1 - 8kW Generator Control Panel

Figure 3.2 - 10/12/14/16/17 & 20kW Generator

Control Panel

THE EXERIC_E TIMER

=_ WARNING _=

/_ With the switch set to AUTO, the engine may

crank and start at any time without warning.
Such automatic starting occurs when utility
power source voltage droops below a preset
level or during the normal exercise cycle. To
prevent possible injury that might be caused
by such sudden starts, always set the switch to
OFF and remove the fuses before working on or
around the generator or transfer switch. Then,
place a "DO NOT OPERATE" tag on the genera=
tot panel and on the transfer switch.

t6

This generator is equipped with an exercise timer.
Once it is set, the generator will start and exercise
every seven days, on the day of the week and at the
time of day specified. During this exercise period,
the unit runs for approximately 12 minutes and then
shuts down. Transfer of loads to the generator out-
put does not occur during the exercise cycle unless
utility power is lost.

+ 8kw

A switch on the control panel (see Figure 3.1) per-

mits 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 settings.

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

2. Press and hold the "Set Exercise" switch for sev-
eral seconds. All the red LED's will stop flashing

immediately and the generator will start.

3. The generator will start and run for approximate-
ly 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" pressed on Saturday
afternoon at 2:00 p.m., the generator will start and

exercise for approximately 12 minutes every Saturday
at 2:00 p.m.

Section 3 - Operation

Air-cooled Generators

OPERATION

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 fuse is removed and/
or replaced,

+ 10 to 20 KIN - INSTALLATION ASSISTANT

Upon first power up of the generator, the display
interface will begin an installation assistant. The
assistant will prompt the user to set the minimum
settings to operate. These settings are simply: Current
Date/Time and Exercise Day/Time. The maintenance

intervals will be initialized when the exercise time is
entered (Figure 3.2).

The exercise settings can be changed at any time via

the "EDIT" menu (see Appendix, "Menu System").
If the 12 volt battery is disconnected or the fuse

removed, the Installation Assistant will operate upon
power restoration. The only difference is the display

will only prompt the customer for the current Time

and Date.

IF THE INSTALLER TESTS THE GENERATOR
PRIOR TO INSTALLATION, PRESS THE "ENTER"

KEY TO AVOID SETTING UP THE EXERCISE

TIME, THIS WILL ENSURE THAT WHEN THE

CUSTOMER POWERS UP THE UNIT, HE WILL
STILL BE PROMPTED TO ENTER AN EXERCISE

TIME,

NOTE:

The exerciser will only work in the AUTO mode and
will not work unless this procedure is performed.

The current date/time will need to be reset every
time the 12 volt battery is disconnected and then

reconnected, and/or when the fuse is removed,

• 3.1.3 DISPLAY INTERFACE

+ 8 kW LED Display

Seven (7) LED's are provided for user status indica-
tions. The LED functions are:

1. System Ready (green)

2. Low Battery (red)

3. Low Oil Pressure (red)

4. High Oil Temperature (red)

5. Over Speed (red)

6. RPM Sensor Loss (red)

7. Over Crank (red)
See the Protection Systems section for details.

+ 10 to 20KW DISPLAY iNTERFACEMENUS

The LCD display is organized as detailed below:

. The "Home" page, this page is the default page

which will be displayed if no keys are pressed for

30 seconds. This page normally shows the current
Status message and the current date and time.
The highest priority active Alarm and/or Warning

will be automatically posted on this page as well as

flashing the backlight when such an event is detect-
ed. In the case of multiple Alarms or Warnings,
only the first message will be displayed. To clear
an Alarm or Warning, see the Protection Systems

section - Clear Alarm.

* The display backlight is normally off. If the user

presses any key, the backlight will come on auto-
maritally and remain on for 30 seconds after the
last key was pressed.

,, The "Main Menu" page will allow the user to

navigate to all other pages or sub-menus by using
the Left/Right and Enter keys. This page can be

accessed at any time with several presses of the
dedicated Escape key. Each press of the Escape
key takes you back to the previous menu until the

main menu is reached. This page displays the fol-
lowing options: HISTORY; STATUS; EDIT; AND

DEBUG. (See the Appendix - "Menu System".)

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, i.e., 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
N 1 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. After the unit starts, loads are

transferred to the standby power source. Refer to the
Sequence of Automatic Operation section.

t7

OPERATION

Section 3 - Operation

Air-cooled Generators

3.3

SEQUENCEOF AUTOMATIC

OPERATION

• 3.3.] UTiLiTY FAILURE

Initial Conditions: Generator in Auto, ready to run,
load being supplied by utility source. When utility
fails (below 65% of nominal), a 10 second (optionally
programmable on the 17 and 20kW only) line inter-
rupt delay time is started. If the utility is still gone

when the timer expires, the engine will crank and

start. Once started, a five (5) second engine warm-
up timer will be initiated. When the warm-up timer
expires, the control will transfer the load to the gen-
erator. If the utility power is restored (above 75% of
nominal) at any time from the initiation of the engine
start until the generator is ready to accept load (5
second warm-up time has not elapsed), the control-
ler will complete the start cycle and run the genera-
tor through its normal cool down cycle; however, the
load will remain on the utility source.

• 3.3.2 CRANKING

The system will control the cyclic cranking as follows:

16 second crank, seven (7) second rest, 16 second

crank, seven (7) second rest followed by three (3)
additional cycles of seven (7) second cranks followed

by seven (7) second rests.

+ Choke Operation

1. The 990/999cc engines have an electric choke in
the air box that is automatically controlled by the

electronic control board.

2. The 530ce engines have an electric choke on the
divider panel air inlet hose that is automatically

controlled by the electronic control board.

3. The 410cc engines have a choke behind the air

box that is automatically controlled by the elec-

tronic control board.

+ Failure to Start

This is defined as any of the following occurrences

during cranking.

1. Not reaching starter dropout within the specified
crank cycle. Starter dropout is defined as four (4)

cycles at 1,000 RPM.

2. Reaching starter dropout, but then not reaching
2200 RPM within 15 seconds. In this case the

control board will go into a rest cycle for seven
(7) seconds, then continue the rest of the crank

cycle.

During a rest cycle the start and fuel outputs are
de-energized and the magneto output is shorted to

ground.

+ Cranking Conditions

The following notes apply during cranking cycle.

1. Starter motor will not engage within five (5) sec-
onds of the engine shutting down.

2. The fuel output will not be energized with the
starter.

3. The starter and magneto outputs will be ener-
gized together.

4. Once the starter is energized the control board

will begin looking for engine rotation. If it does

not see an RPM signal within three (3) seconds
it will shut down and latch out on RPM sensor

loss.

5. Once the control board sees an RPM signal it will
energize the fuel solenoid, drive the throttle open

and continue the crank sequence.

6. Starter motor will disengage when speed reaches
starter dropout.

7. If the generator does not reach 2200 RPM within

15 seconds, re-crank cycle will occur.

8. If engine stops turning between starter dropout
and 2200 RPM, the board will go into a rest cycle

for seven (7) seconds then re-crank (if additional
crank cycles exist).

9. Once started, the generator will wait for a hold-
off period before starting to monitor off pressure
and off temperature (refer to the Alarm Messages

section for hold-off times).

10. During Manual start cranking, if the Mode switch
is moved from the Manual position, the cranking
stops immediately.

11. During Auto mode cranking, if the Utility returns,
the cranking cycle does NOT abort but continues
until complete. Once the engine starts, it will run

for one (1) minute, then shut down.

0 3.3.3 LOAD TRANSFER

The transfer of load when the generator is running is
dependent upon the operating mode as follows:

1. Manual

. Will not transfer to generator if utility is present.
. Will transfer to generator if utility fails (below

65% of nominal for 10 consecutive seconds.

. Will transfer back when utility returns for 15 con-

secutive seconds. The engine will continue to run
until removed from the Manual mode.

t8

2. Auto
, Will start and run if Utility fails for 10 consecu-

tive seconds.

, Will start a five (5) second engine warm-up

timer.

, Will not transfer if utility subsequently returns.
, Will transfer to generator if utility is still not pres-

ent.

, Will transfer back to utility once utility returns

(above 75% of nominal) for 15 seconds.

, Will transfer back to utility if the generator is

shut down for any reason (such as the switch is
in the OFF position or a shutdown alarm.

, After transfer, will shut down engine after one (1)

minute cool-down time.

3. Exercise
, Will not exercise if generator is already running

in either Auto or Manual mode.

, During exercise, the controller will only transfer

if utility fails during exercise for 10 seconds, and

will switch to Auto mode.

Section 3 - Operation

OPERATION

Air-cooled Generators

-A A

Do not attempt to activate the transfer switch

Ax

manually until all power voltage supplies to the
switch have been positively turned off. Failure
to turn off all power voltage supplies may result
in extremely hazardous and possibly fatal elec-

trical shock.

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

STANDBY position, i.e., loads connected to the
standby power source (Figure 3.3).

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

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

7. Set the generator's main circuit breaker to its ON
(or CLOSED) position. The standby power source
now powers the loads.

Figure 3.3 - Manual Transfer Switch Operation

. .4 TILITY RE T RED

Initial Condition: Generator supplying power to
customer load. When the utility returns (above 75%
of nominal), a 15 second return to utility timer will
start. At the completion of this timer, if the utility
supply is still present and acceptable, the control

will transfer the load back to the utility and run the

engine through a one (1) minute cool down period
and then shut down. If utility fails for three (3) sec-

onds during this cool down period, the control will
transfer load back to the generator and continue to
run while monitoring for utility to return.

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
OFE

2. Set the generator's main circuit breaker to its
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).

LOADCONNECTED TO UTILITY POWERSOURCE

LOAD CONNECTEDTO STANDBY POWERSOURCE

MANUALTRANSFER

HANDLE

TRANSFER SWITCH

OPERATING LEVER

@ 3.4.2 TRANSFER BACK TO UTiLiTY POWER

When utility 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 OFE

t9

OPERATION

Section 3 - Operation

Air-cooled Generators

-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 possibly fatal elec-

trical shock.

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

UTILITY position, i.e., 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. Set the system to automatic operation as outlined
in Automatic Transfer Operation section.

3.5 SIDE COMPARTMENT (V-TWIN

ONLY) (nCURES3.4&3.s)

Local codes may require this compartment to be
locked. A hasp is provided so the owner can secure
the compartment with their own padlock. Check

local codes in the area.

____,3_..1 MAiN IR IT BREAKER

Figure 3.4 - Side Compartment

Figure 3.5- Open Side Compartment

_.o_._o_ 120VGECL0utlet_.

This is a 2-pole breaker rated according to the

Specifications section.

EXTERIORREADY LI NT

. Green LED 'Ready' light (10, 12, 14, 16, 17 & 20

KW) is on when utility is present and switch is in

AUTO indicating the generator is ready and when

the generator is running.

. Red LED 7klarm' light (10, 12, 14, 16, 17 & 20

KW) is on when the generator is OFF or a fault is
detected. (See the Protections Systems section.)

. Yellow LED 'Maintenance' light (17 & 20 KW) (See

the Protections Systems section.)

@ 3.5.3 120 VAC GFCI OUTLET & 15 AMP

BREAKER (17 & 20 KW ONLY)

These models are equipped with an external, 15 amp,

120 volt, GFCI convenience outlet that is located in

a compartment on the right side of generator (Figure

1.3).

When the generator is running, in the absence of util-

ity power, this outlet may also be used to power items
outside your home such as lights or power tools. This

outlet may also be used when utility power is pres-
ent by running the generator in manual mode. This
outlet does not provide power if the generator is not
running. This outlet is protected by a 15 amp circuit

breaker in the same compartment as the outlet. (Do

not use when the generator is running in exercise
mode.)

2o

3.6 PROTECTION SYSTEMS

ALARM_

Highest Priority {Latching) Displayed on the con-
trol panel and the external red LED (V-twins only).

They must be cleared before the alarm message goes
away. The alarm log records each occurrence (see

Appendix - "Menu System").

+ Low Oil Pressure (Shutdown Alarm)

A five (5) second delay on start-up and seven (7) sec-

ond delay once the engine is running.
This switch (Figure 3.6) has normally closed con-

tacts that are held open by engine oil pressure dur-
ing operation. Should the oil pressure drop below
the five (5) PSI range, switch contacts close and the
engine shuts down. The unit should not be restarted

until oil level is verified.

Section 3 - Operation

Air-cooled Generators

OPERATION

+ High Engine Temperature (Shutdown Alarm =

Auto Reset)

A 10 second delay on start-up and one (1) second

delay before shutdown. Auto reset when the condition
clears and restart the engine if a valid start signal is
still present.

This switch's contacts (Figure 3.6) close if the tem-

perature should exceed approximately 144 ° C (293 °

F), initiating an engine shutdown. Once the oil tem-

perature drops to a safe level the switch's contacts
open again.

+ Over Crank (Shutdown Alarm)

This occurs if the engine has not started within the

specified crank cycle. (See "Cranking" section.)

Figure 3.6 - Low Oil Pressure and

High Temperature Switches

LowOilSwitch

HighT_,mpSwitch

OilFilter

Oil

Drain

Hose

NOTE:

The oil drain hose may be routed in the opposite

direction as shown in figure.

+ Over Speed (Shutdown Alarm)

4320 RPM for three (3) seconds or 4500 RPM imme-
diately. This feature protects the generator from dam-

age by shutting it down if it happens to run faster
than the preset limit. This protection also prevents
the generator from supplying an output that could
potentially damage appliances connected to the

generator circuit. Contact the nearest Dealer if this

failure occurs.

+ RPM Sense Loss (Shutdown Alarm)

During cranking, if the Control Board does not see
a valid RPM signal within three (3) seconds, it will

shut down and lock out on RPM sense loss. While
engine is running, if RPM signal is lost for one (1)

second the Control Board will shut the engine down,

wait 15 seconds, then re-crank the engine. If no RPM

signal is 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 nor-

mally. If the RPM signal is subsequently lost again,
the Control Board will try one more re-crank attempt
before latching out and displaying the RPM sensor
failure message.

+ Under-frequency(Shutdown Alarm)

After starting, if the generator stays under frequency

for more than 30 seconds it will shut down. The

under-frequency setting is 50 Hz.

+ Internal Fault (Shutdown Alarm)

This alarm cannot be cleared, call service dealer.

+ CLEARALARM

. 8kW -- Clear the alarm by setting the AUTO/OFF/

MANUAL switch to the OFF position and back to

AUTO.

. 10 - 20kW -- Clear the alarm by setting the AUTO/

OFF/MANUAL switch to the OFF position. Press
the ENTER key to unlatch any active fault and
clear the corresponding alarm message.

____5..2 WARNING__S_

Second Priority (Nondatching) Displayed on the
control panel and the external yellow LED (V-twins
only). Warnings automatically clear when the moni-
tored condition goes away. Warnings are recorded in
the alarm log. Warnings cannot cause shutdowns.

+ Low Battery

The Control Board monitors battery voltage and dis-
plays a warning if the battery voltage fails below 11.0

volts for one (1) minute. Warning is automatically

cleared if the battery voltage rises above 11.0 volts.
Battery voltage is not monitored during the crank

cycle.

+ Exercise Set Error

If the exercise period becomes corrupted, a warning
message will be displayed. This message will only
clear when the exercise period is reset.

2t

MAINTENANCE

Section 4 - Maintenance
Air-cooled Generators

• 3.6.3 MAINTENANCE ALERTS(10 = 20KW

ONLY)

Third priority

+ Maintenance Message

When a maintenance period expires, a warning mes-

sage will be displayed. (16 through 20kW models

include an external yellow LED which will illuminate.)
The alert can be reset by pressing the Enter key,
which will cause the user to be prompted to confirm

the action. Resetting will clear the alert and reset the

maintenance counters for all conditions annunciated.
The history log will record the alert. The maintenance

counter will not accumulate without battery power.

Once battery power is restored, the set time prompt
will be displayed. The maintenance counters will be

adjusted to the new time and date.

NOTE:

Since most maintenance alerts will occur at the

same time (most have two (2) year intervals), only

one will appear on the display at any one time.

Once the first alert is cleared, the next active alert
will be displayed.

4.1 FUSE

The 7.5 amp fuse on the control panel protects the

DC control circuit against overload (Figures 3.1 and

3.2). This fuse is wired in series with the battery out-

put 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 7.5 amp

replacement fuse. Whenever the fuse is removed or

replaced, the exercise timer needs to be reset.

4. Install the dipstick.

5. Reset the AUTO/OFF/MANUAL switch to its origi-
nal position,

Figure 4.1 -- Oil Dipstick and Fill, 8kW

Dipstickand Fill

Figure 4.2 -- Oil Dipstick, lOkW

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 4.1, 4.2 and 4.3):

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 "FULE' MARK.

"_ CAUTION

/_ Never operate the engine with the oil level

below the "Add" mark on the dipstick. Doing
this could damage the engine.

22

Figure 4.3 -- Oil Dipstick and Fill,

12, 14, 16, 17 & 20kW

Section 4 - Maintenance

Air-cooled Generators

MAINTENANCE

4.3 CHANGING THE ENGINE OiL

4..1 IL HAN E iNTERVAL

See the "Service Schedule" section.

4..2 EN INE ILRE MMENDATI N

All oil should meet minimum American Petroleum

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

according to the expected operating temperature.

. SAE 30 --) Above 32 ° F
. 10W-30 -_ Between 40 ° F and -10 ° F

. Synthetic 5W-30 ") 10 ° F and below

"_I_ CAUTION _"

Z_ 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.

°F -20 -10 0 10 20 32 40 60 80 100

°c-3'o -2'o -;o o Io 2o 3'o &

Temperature Range of Expected Use

4. Refill with the proper recommended oil (see the
Engine Oil Recommendations section). See the
Specifications section for oil capacities.

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

6. Shutdown and recheck oil level, add as needed.
DO NOT OVER FILL.

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

AUTO position.

Figure 4.4 - Oil Drain Hose and Filter

LowOil Switch

\

HighTqmp Switch

Oil Filter

Oil

Drain
Hose

NOTE:

@ 4.3.3 OiL & OiL FILTER CHANGE PROCEDURE

To change the oil, proceed as follows:

1. Start the engine by moving the
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 4.4) free of its retaining
clip. Remove the cap from the hose and drain the

oil into a suitable container.

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

clip.

Change the engine oil filter as follows:

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

2. Apply a light coating of clean engine oil to the 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).

AUTO/OFF/

The oil drain hose may be routed in the opposite
direction as shown in figure.

4.4 CHANGING THE ENGINE

AIR CLEANER

@ 4.4.1 12 14 16 17 & 20KWGENERATORS

See "The Generator" section for the location of the air
cleaner. Use the following procedures (Figure 4.5):

1. Lift the roof and remove the door.

2. Turn the two screws counterclockwise to loosen.

3. Remove the cover and air filter.

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

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

6. Install the cover. Turn the two cover screws clock-

wise to tighten.

See the Service Schedule section for air cleaner main-
tenance. See the Specifications section for air filter

replacement part number.

23

MAINTENANCE

Section 4 - Maintenance
Air-cooledGenerators

Figure 4.5 -- 12, 14, 16, 17 & 20kW

Engine Air Cleaner

Screw

:z

Cover

_ENERAT_

See "The Generator" section for the location of the air
cleaner. Use the following procedure (Figure 4.6):

1. Lift the roof and remove the door.

2. Turn the worm gear clamp screw counterclock-
wise to loosen.

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

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

5. Install the new air cleaner onto the hub.

6. Turn the worm gear clamp screw clockwise to

tighten.

7. Replace door and roof.

_,_TL_tJf_W_ ENERAT(_.

See "The Generator" section to locate the air box. Use
the following procedures to replace the dirty air filter

within the air box (Figure 4.7).

1. Lift the roof and remove the door.

2. Push back on the latch of the yellow air filter
access door to swing open.

3. Pull out the old air filter and discard appropri-
ately.

4. Install the new filter, open end first into the air
box.

5. Swing the yellow door shut and snap to close,

6. Replace door and close roof securely,

Figure 4.7 -- 8kW Engine Air Cleaner Location

j AirCleaner

J

Cover

Figure 4.6 -- lOkW Engine Air Cleaner

24

4.5 SPARK PLUG(S}

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

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

2. Remove the spark plug(s) and check the 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.

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

for 8, 10 and 20kW; and 1.02 mm {0.040 inch)
for 12, 14, 16 and 17kW by carefully bending the

ground electrode (Figure 4.8).

Section 4 -- Maintenance

Air-cooled Generators

MAINTENANCE

Figure 4.8 - Setting the Spark Plug Gap

SET PLUG GAP AT 0.76 mm (.030 inch) - 8, 10 &

20kW; 1.02 mm (.040 inch)=12, 14, 16 & 17kW

4.6 BATTERYMAINTENANCE

The battery should be inspected per the "Service

Schedule" section. The following procedure should be
followed for inspection:

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

2. Check the battery fluid level of unsealed batteries
and, if necessary, fill with Distilled Water Only. Do

not use tap water in batteries.

3. Have the state of charge and condition checked.

This should be done with an automotive-type bat-

tery hydrometer.

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

/_ A battery presents a risk of electrical shock

and high short circuit current. The following pre-
cautions are to be observed when working on

batteries:

• Remove the 7.5A fuse from the generator control

panel.

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

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

battery; and

• Disconnect charging source prior to connecting or

disconnecting battery terminals.

-_ WARNING

/_ Do not open or mutilate the battery. Released

electrolyte has been known to be harmful to the
skin and eyes, and to be toxic.

/_ The electrolyte isa 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 thor-
oughly 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 isto be flushed with water and the
area dried.

z_ 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.

Be sure the AUTO/OFF/MANUAL switch is set to

AX

the OFF position before connecting the battery
cables. If the switch is set to AUTO or MANUAL,

the generator can crank and start as soon as the
battery cables are connected.

Be sure the utility power supply is turned off
and the 7.5A fuse is removed from the genera=
tot control panel, or sparking may occur at the
battery posts as the cables are attached and
cause an explosion.

4.7 ADJUSTINGGH-410/GT-530/

990/999 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 Dealer for service assistance. This
is a very important step to ensure 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. lmm),

adjustment is not needed.

+ Remove spark plug wires and position wires away

from plugs.

+ Remove spark plugs.

25

MAINTENANCE

Section 4 - Maintenance
Air-cooledGenerators

, 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), (Figure

4,9):

* Make sure the engine is at 60 ° to 80 ° E
* 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.
. Loosen the rocker jam nut. Use an 10ram 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 ram).

Figure 4.9 - Valve Clearance Adjustment

Rocker

Jam Nut

Pivot Ball

Stud

Arm

Valve

Stem

* Install spark plugs.
* Re-attach the spark plug wire to the spark plug.

. On the GT-530 and GT-990/999, 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 4.10 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 4.10 - Cooling Vent Locations

NOTE:

Hold the rocker arm jam nut in place as the pivot

ball stud is turned.

When valve clearance is correct, hold the pivot ball

stud in place with the allen wrench and tighten the
rocker arm jam nut. Tighten the jam nut to 174 in!
lbs. torque. After tightening the jam nut, recheck

valve clearance to make sure it did not change.

. Install new valve cover gasket.
. Re-attach the valve cover.

NOTE:

Start all four screws before tightening or it will not

be possible to get all the screws in place, Make

sure the valve cover gasket is in place,

26

"_ WARNING _-

Z_ 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 CAUT!ONA-

Z_ The maximum ambient temperature for the gen-

erator is 25° C (77° F).

4.9 ATTENTIONAFTERSUBMERSION

If the generator has been submerged in water, it must
not be started and operated. Following any submer-
sion in water, have a Dealer thoroughly clean, dry
and inspect the generator. If the structure (ex. home)

has been flooded, it should be inspected by a certi-
fied electrician to ensure there won't be any electrical

problems during generator operation or when utility
is returned.

Section 4 - Maintenance

Air-cooled Generators

MAINTENANCE

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
linkages with a light oil such as WD-40.

4.11 OUT OF SERVICE PROCEDURE

4,! lJ REMOVAL FROMSERVICE

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, switch to the OFF
position.

4. Set the generator's main circuit breaker to its
OFF (or OPEN) position.

5. Set the AUTO/OFF/MANUAL switch to OFF and
turn off the utility power to the transfer switch.
Remove the 7.5A fuse from the generator control

panel. Disconnect the battery cables as outlined
in "General Hazards".

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

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

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

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

10. Clean and wipe the entire generator.

0 4.11.2 RETURN TO SERVIC_

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 OFE

2. Check the tag on the engine for oil viscosity and
classification. Verify that the correct recommend-
ed oil is used in the engine (see the Engine Oil
Recommendations section). If necessary, drain
and refill with the proper oil.

3. Check the state of the battery. Fill all cells of
unsealed batteries to the proper level with 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.
See "Specifications," for type and size.

4. Clean and wipe the entire generator.

5. Make sure the 7.5A fuse is removed from the
generator control panel. Reconnect the battery.

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

6. Open the fuel shutoff valve.

7. Insert the 7.5A 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 OFE

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 (single cylinder), current date and time

(v-twin) must be reset,

O 4.11.3 ACCESSORIES

There are performance enhancing accessories avail-
able for the air-cooled generators.

• Cold Weather Kits are recommended in areas

where temperatures regularly fall below 10 ° F (-12 °

C).

. Scheduled Maintenance Kits include all pieces

necessary to perform maintenance on the genera-
tor along with oil recommendations.

. Auxiliary Transfer Switch Lockout enables any

of the transfer switches to completely lock out
one large electrical load by tying into its control
system.

. A Fascia Skirt Wrap is standard on all 20kW

units. It's available for all other current produc-
tion air-cooled units. It snaps together to provide a
smoothing, contoured look as well as rodent/insect
protection.

. The PowerMaster load prioritization device allows

home owners to potentially operator two (2) large
electrical loads by giving one (1) priority over the

other.

. The Remote Monitor System is a wireless, indoor

mounted, box that indicates generator run status
and allows for exercise programing as well as pro-

vide maintenance reminders.
Touch-up Paint Kits are very important to main-

tain the look and integrity of the generator enclo-
sure. These kits include touch-up paint and
instructions if the need should arise.

For more details on accessories, please contact a
Dealer.

27

Section 4 - Maintenance

MAINTENANCE

Air-cooled Generators

4.12 SERVICE SCHEDULE

ATTENTION: it is recommended that all service work

be performed by the nearest Dealer.

SYSTEM/COMPONENT

X = Action

R = Replace as Necessary

* = Notify Dealer if Repair is

Needed.

FUEL

Fuel lines and connections*

LUBRICATION

Oil level X M or 24 hours of

Oil X 2Y or 200 hours

Oil filter X 2Y or 200 hours

COOLING

Enclosure louvers X X W

BATTERY

Remove corrosion, ensure X X M
dryness

Clean and tighten battery X X M
terminals

Check charge state X R EVERY 6 M
Electrolyte level X R EVERY 6 M

ENGINE AND MOUNTING

Air cleaner X R 2Y or 200 hours

Spark plug(s) X R 2Y or 200 hours

GENERAL CONDITION

Vibration, Noise, Leakage, X M

Temperature*

COMPLETE TUNE-UP* TO BE COMPLETED BY A DEALER 2Y or 200 hours

* Contact the nearest dealer for assistance if necessary.

** Change oil and filter after first eight (8) hours of operation and then every 200 hours thereafter, or 2 years, which-

ever occurs first. Change sooner when operating under a heavy load or in a dusty or dirty environment or in high
ambient temperatures.

Inspect

X M

PROCEDURE

Change

Clean

FREQUENCY

W = Weekly

M = Monthly

Y = Yearly

continuous operation.

of operation.**

of operation.**

28

5.1 TROUBLESHOOTING GUIDE

Section 5 - Troubleshooting

Air-cooled Generators

TROUBLESHOOTING

Problem

The engine will not crank.

The engine cranks but
will not start.

The engine starts hard

and runs rough.

Cause

1. Fuse blown.

2. Loose, corroded or defective
battery cables.

3. Defective starter contactor. (8 kW)

4. Defective starter motor.

5. Dead Battery.

1. Out of fuel.

2. Defective fuel solenoid (FS).

3. Open #14 wire from

engine control board.

4. Fouled spark plug(s).

5. Valve lash out of adjustment.

6. Choke not operating.

1. Air cleaner plug__ged
or damaged.

2. Fouled spark plug(s).

3. Fuel pressure incorrect.

4. Fuel selector in wrong position.

5. Choke remains closed.

Correction

1. Correct short circuit condition,
replace 7.5A fuse in generator

control panel.

2. Tighten, clean or replace
as necessary.

3. *

4.

5.

Charge or replace battery.

1. Replenish fuel/Turn on fuel valve.

2. *

3. *

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

5. Reset valve lash.

6. Verify choke plate moves freely.

1. Check, replace air cleaner.

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

3. Confirm fuel pressure to regulator
is 10-12" water column (0.36-0.43

psi) for LR and 5-7" water column
(0.18-0.25 psi) for natural gas.

4. Move selector to correct position.

5. Verify choke plate moves freely.

The AUTO/OFF/MANUAL

switch is set to OFE but
the engine continues

to run.

There is no AC output

from the generator.

There is no transfer to

standby after utility
source failure.

Unit consumes large
amounts of oil.

1. Defective switch.

2. AUTO/OFF/MANUAL switch
wired incorrectly.

3. Defective control board.

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

2. Generator internal failure.

1. Defective transfer switch coil.

2. Defective transfer relay.

3. Transfer relay circuit open.

4. Defective control logic board.

1. Engine over filled with oil.

2. Improper type or viscosity of oil.

3. Damaged gasket, seal or hose.

4. Engine breather defective.

*Contact the nearest Dealer for assistance.

1.

2.

3.

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

2. *

1.

2.

3.

4.

1. Adjust oil to proper level.

2. See "Engine Oil Recommendations".

3. Check for oil leaks.

4. *

29

Section 6 - Appendix
Air-cooJedGenerators

6.1 MENU SYSTEM NAViGATiON

To get to the MENU, use the "Esc" key from any
page. It may need to be pressed many times before
getting to the menu page. The currently selected
menu is displayed as a flashing word. Navigate to
the menu required by using the +/- keys. When the
menu required is flashing, press the ENTER key.
Depending on the menu selected, there may be a
list of choices presented. Use the same navigation

method to select the the desired screen (refer to the
Menu System diagram).

• 6.1.1 CHANGING SETTINGS {EDIT MENU)

To change a setting such as display contrast, go to the
EDIT menu and use the +/- keys to navigate to the

setting to change. Once this setting is displayed (e.g.

Contrast), press the ENTER key to go into the edit
mode. Use the +/- keys to change the setting, press
the ENTER key to store the new setting.

NOTE:

If the ENTER key is not pressed to save the new
setting, it will only be saved temporarily. The next

time the battery is disconnected, the setting will
revert back to the old setting.

3O

MENU SYSTEM

l

I TO q

!

f

[ Ru.LooJ TAT;

Pressthe"ESCAPE"key
tojumpbackupthrough

themenulevels.

Usethe"+/-"key
tonavigatethrough

themenu.

Usethe"ENTER"key
toselectitemsor
enterdata.

The possible Status messages of the display
are as follows:

• Switched Off/Time & Date

• Ready to Run/Time & Date

• Utility Loss Delay/Pausing for X Seconds

• Cranking/Attempt # X
, Running in Exercise/Time & Date

• Running/Cooling Down

, Running - Warning/_Narning Message
, Running- Alarm/Alarm Message

• Stopped - Alarm/Alarm Message

, Stopped-Warning/Warning Message

• Cranking/Pausing for X Seconds

• Running/Time & Date

, Running/Warming Up
, Cranking-Warning/Warning Message

• Cranking- Alarm/Alarm Message

MAINMENU

l

STATUS[ _ t

{

HOURSJ

l

ENGINE 17&20kW

RP_M j on,y

l

AT''_R J 17&G-_ER 20kW

FREQU_ENCYJ only

l

BATTERY 17&20kW
VOLTAGE J only

Thepossiblecommands

on Line2 ofthe display
are asfollows:

SwitchedOff

• RunningManually

• StoppedinAuto Mode

• Running- Utility Lost

• Runningin Exercise

• Runningfrom Radio

[

EDIT

RT_'_ 17&

20kW

[ DELAY only

M

CONTRAST

[

LANGUAGE English

orOther

FREQUENCY 60Hz

I

TIME

[

]

i--1

RESET

MAINTENANCE

_, tD

#'t

O O't

ZI

Section 7 - Notes

Air-cooled Generators

32

Section 8 - Installation Diagrams

Air-cooled Generators

Circuit Breakers - Drawing No. 0G8573-A

_x

iNSTALLATiON

o o

z

J

w

>

o

\

LT

/

33

INSTALLATION

_299_

698

[27.5]

747

[29.4]

Section 8 - Installation Diagrams
Air-cooled Generators
Generator - Drawing No. 0G8280-C

[11,8]

1 2o7 1

[8.2]

TRANSFER SWITCH

8KW - 17KW

(IF SUPPLIED)

637.6

[25.1]

454
[17.9]

_508

[2O.O]

TRANSFER SWITCH

is i ..........

LIFTING HOLES 4 CORNERS

20KW

(IF SUPPLIED)

"'DO NOT LIFT BY ROOF"

_30.2 1_1.2_ ............

1218

[47.91

J

H

H

H

H

642

[25.31

LEFT SIDE VIEW

34

76.2 [3.0] y

PEA GRAVEL

MINIMUM

1226

148.31

FRONT VIEW

AIR INTAKE

!

Section 8 - Installation Diagrams

Air-cooled Generators

Generator - Drawing No. 0G8280-C

/

/

/

/

457.2 MINIMUMDISTANCE
[18.0]

914 [36.0]

MINIMUM OPEN AREA

ON SIDES AND FRONT

iNSTALLATiON

/

AIR OUTLET

_'__

o HO°i"

i

_,_ AIR INTAKE

_UEL INLET - 14-20KW (1/2" NPT)

REOUIRED FUEL PRESSURE: NATURAL GAS : 5-7" WATER COLUMN

8 & IOKW {3/4" NPT} - USE SUPPLIED ADAPTER

LIQUID PROPANE (VAPOR} : 10-12" WATER COLUMN

,_._, ,_AIIIEIIE.IIII.......................................

Y

/

y

Y_

/

RIGHT SIDE VIEW

244.4

19.61

T

178.9

17.01

i _ROUND,NOLO0

REAR VIEW

,,ALL DIMENSIONS IN:

MILLIMETERS [INCHESI

'C

35

Section 9 - 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 Calilbrnia Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission
Control System Warranty on your new engine.* In Calilornia, new utility, and lawn and garden equipment engines must be

designed, built and equipped to meet the state's stringent anti-smog standards. Generac will warrant the emission control
system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modifica-
tion 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 lbr two years as hereinalier noted. If, dur-
ing such warranty period, any emission-related component or system on your engine is lbund to be del_ctive in materials or

workmanship, repairs or replacement will be perlormed by a Generac Authorized Warranty Service Facility.

PU RCHASER'S/OWN ER'S WARRANTY RESPON SIBILIT! ES:

As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory
supplied Owner's Manual° For warranty purposes, Generac recommends that you retain all receipts covering maintenance

on your engine. However, Generac cannot deny warranty solely due to the lack of receipts or for your IMlure to ensure the
completion of all scheduled maintenance.

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

You are responsible for contacting a Generac Authorized Warranty Service Facility as soon as a problem occurs. The
warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility.
To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number:

1-800-333-1322

IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System
Warranty (ECS Warranty), which is provided to you by Generac pursuant to California law. See also the "Generac Limited
Warranties for Generac Power Systems, Inc.," which is enclosed herewith on a separate sheet, also provided to you by
Generac. The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in

terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where
the Generac Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe
important rights and obligations with respect to your new engine.

Warranty service can be perlbrmed 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 addresses:

For Air-cooled Product ...

ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297
WHITEWATER, Wi 53190

Part 1

For Liquid-cooled Product ...

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

211 MURPHY DRIVE

EAGLE,WI 53119

36

Section 9 - 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
lbr 24 consecutive months therealler.

(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or

equipment and to each subsequent purchaser/owner that each of its engines is ...

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

authority, and

(2) Free from delkcts in materials and workmanship which, at any time during the ECS Warranty Period, may cause a

warranted emissions-related part to lail to be identical in all material respects to the part as described in the engine

manulacturer's application lbr certification.

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

( 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 lails 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 lbr the remainder of the ECS Warranty Period.

(2) Any warranted, emissions-related part that is scheduled only lbr regular inspection as specified in the Owner's Manual

shall be warranted for the ECS Warranty Period. A statement in such written instructions to the eflkct of "repair or
replace as necessary" shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS

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

(3) Any warranted, emissions-related part that is scheduled lbr replacement as required maintenance in the Owner's

Manual shall be warranted lbr the period of time prior to the first scheduled replacement point lbr that part. If the part

lulls 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 lbr the

remainder of the ECS Warranty Period prior to the first scheduled replacement point lbr 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 lailure under warranty of any emission-related part covered by the ECS Warranty.

(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient

to meet the expected demand lbr such emission-related parts.

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

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

ECS Warranty obligations.

(9) Unapproved, add-on, modified, counterlkit and/or "grey market" parts may not be used to modify or repair a Generac

engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim.
Generac shall not be held liable hereunder lbr lailures of any warranted parts of a Generac engine caused by the use of
such an unapproved, add-on, modified, counterlkit and/or "grey market" part.

EMISSION RELATED PARTS iNCLUDE THE FOLLOWING:

1) Fuel Metering System:

1.2) LPG/Natural Gas earburetion assembly and its internal com-
ponents.

a) Fuel controller {if so equipped)
b) Mixer and its gaskets {if so equipped)

c) Carburetor and its gaskets {if so equipped)

d) Primary gas regulator {if so equipped)

e) LP liquid vaporizer {if so equipped)

2) Air Induction System including:
a) Intake pipe/manilold

b) Air cleaner

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

1) Prepackaged Standby Generator

2) Auxiliary Power Unit (APU) Generator

3) Standby Generator

Part 2

3) Ignition System including:
a) Spark plug

b) Ignition module

4) Catalytic Mufller Assembly {if so equipped) including:
a) Muffler gasket

b) Exhaust manifold

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

37

Psrt No_ 0G8334 Revision 8 (04/24/08) Csts|og No_ OMASPCAoS_01 Printed in U_S_A_