Guardian Technologies 5280, 5281, 5283, 5284, 5242 User Manual

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Installation and

Owner’s Manual

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

Automatic Standby Generators

Models: 005240, 005280 (6 kW NG, 7 kW LP) 005241, 005281 (9 kW NG, 10 kW LP) 005242, 005282 (13 kW NG, 13 kW LP) 005243, 005244, (15 kW NG, 16 kW LP) 005283, 005284



GENERAC

POWER SYSTEMS, INC.

Not intended for use as Primary Power in place of utility or in

life-support applications.

DANGER

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!



INTRODUCTION

Thank you for purchasing this model of the Guardian product line by Generac Power Systems Inc. This model is a compact, high performance, air-cooled, engine-driven generator designed to automatically supply electrical power to operate critical loads during a utility power failure.

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 This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG).

READ THIS MANUAL THOROUGHLY



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

Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:

DANGER

After this heading, read instructions that, if not

strictly complied with, will result in serious personal injury, including death, in addition to property damage.

After this heading, read instructions that, if not

strictly complied with, may result in serious personal injury or property damage.

After this heading, read instructions that, if not

strictly complied with, could result in damage to equipment and/or property.

NOTE:

After this heading, read explanatory statements

that require special emphasis.

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

Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of information each indicates follows:

This symbol points out important safety infor-



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

This symbol points out potential explosion haz-



ard.

This symbol points out potential fire hazard.



This symbol points out potential electrical shock



hazard.

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

CONTENTS



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

05240 & 05280 – 6 kW NG, 7 kW LP, single-cylin-

• der GH-410 Engine

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

• GT-530 Engine

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

• 990 Engine

05243, 05244, 05283 & 05284 – 15 kW NG, 16 kW

• LP, V-twin GT-990 Engine

OPERATION AND MAINTENANCE



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

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



HOW TO OBTAIN SERVICE

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

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

Model No. ____________ Serial No. ______________

AUTHORIZED

DEALER LOCATION

To locate the nearest AUTHORIZED

DEALER, please call this number:

1-800-333-1322

DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER or visit

www.guardiangenerators.com.

Table of Contents

Air-cooled Generators

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

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

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

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

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

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

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

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

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

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

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

1.3 NEC Requirement for Arc Fault Circuit

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

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

1.5 Specifications ................................................ 6

1.6 System Set LED ............................................ 7

1.7 Fuel Requirements and Recommendations ...7

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

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

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

1.11 Battery Requirements .................................. 10

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

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

Section 2 – Post Installation Start-up

and Adjustments .......................12

2.1 Before Initial Startup...................................12

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

2.3 Electrical Checks ........................................12

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

2.5 Checking Automatic Operation .................... 13

2.6 Adjusting the Fuel Regulator -

7kW (Natural Gas Only) ............................... 13

2.7 Engine Governor Adjustment ...................... 14

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

Section 3 – Operation ....................................15

3.1 Using the AUTO/OFF/MANUAL Switch ........ 15

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

3.3 Sequence of Automatic Operation ...............16

3.4 Manual Transfer Operation .........................16

3.5 Setting the Exercise Timer .......................... 17

3.6 Protection Systems ...................................... 18

Section 4 – Maintenance ...............................19

4.1 Fuses ........................................................... 19

4.2 Checking the Engine Oil Level ..................... 19

4.3 Changing the Engine Oil .............................. 20

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

4.5 Spark Plug(s) .............................................. 21

4.6 Battery Maintenance .................................... 22

4.7 Adjusting GH-410/GT-530/990

Valve Clearance ............................................ 22

4.8 Cooling System ...........................................23

4.9 Attention After Submersion ......................... 23

4.10 Corrosion Protection ...................................24

4.11 Out of Service Procedure ............................. 24

4.12 Service Schedule .........................................25

Section 5 – Troubleshooting ........................ 26

5.1 Troubleshooting Guide ................................ 26

Section 6 – Notes ............................................27

Section 7 – Mounting Dimensions ............. 30

Section 8 – Electrical Data ........................... 31

Section 9 – Exploded Views and

Parts Lists ................................... 42

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

IMPORTANT SAFETY INSTRUCTIONS

Air-cooled Generators

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation

be copied and posted near the unit’s installation site. Safety should be stressed to all opera-



tors and potential operators of this equipment.



The engine exhaust from this product

• contains chemicals known to the state

defects or other reproductive harm.



This product contains or emits chemicals

• known to the state of California to cause

cancer, birth defects or other reproductive harm.

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

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

WARNING:•

of California to cause cancer, birth

WARNING:•



DANGER

Despite the safe design of this generator,



operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to operate or maintain this equipment.

Potentially lethal voltages are generated by



these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator.

Parts of the generator are rotating and/or hot



during operation. Exercise care near running generators.

GENERAL HAZARDS



For safety reasons, the manufacturer recommends

• that the installation, initial start-up and maintenance of this equipment is carried out by an Authorized Dealer.

The engine exhaust fumes contain carbon monox-

• ide, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. This exhaust system must be installed properly, in strict compliance with applicable codes and standards. Following installation, do nothing that might render the system unsafe or in noncompliance with such codes and standards.

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

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

Adequate, unobstructed flow of cooling and 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 seriously affect safe operation of the generator. The generator MUST be installed outdoors.

When working on this equipment, remain alert

• at all times. Never work on the equipment when physically or mentally fatigued.

Inspect the generator regularly, and contact the

• nearest Authorized Dealer for parts needing repair or replacement.

Before performing any maintenance on the 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 conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.



ELECTRICAL HAZARDS



All generators covered by this manual produce

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

Do not handle any kind of electrical device while

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

The National Electrical Code (NEC) requires the

• frame and external electrically conductive parts of the generator to be connected to an approved earth ground. Local electrical codes also may require proper grounding of the generator electrical system.

After installing this home standby electrical sys-

• tem, the generator may crank and start at any time without warning. When this occurs, load circuits are transferred to the STANDBY (generator) power source. To prevent possible injury if such a start and transfer occur, always set the generator’s AUTO/OFF/MANUAL switch to its OFF position before working on equipment and remove the 15A fuse from the generator control panel.

In case of accident caused by electric shock, 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 components causing injury.

FIRE HAZARDS



For fire safety, the generator must be installed and

• maintained properly. Installation must always

comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state

and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure that the generator is installed in accordance with the manufacturer’s instructions and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes, standards, laws and regulations.





IMPORTANT SAFETY INSTRUCTIONS

Air-cooled Generators

Keep a fire extinguisher near the generator at all

• times. Extinguishers rated “ABC” by the National Fire Protection Association are appropriate for use on the standby electric system. Keep the extinguisher properly charged and be familiar with its use. Consult the local fire department with any questions pertaining to fire extinguishers.

EXPLOSION HAZARDS



Do not smoke around the generator. Wipe up any

• fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.

Gaseous fluids such as natural gas and liquid 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 permitted.

STANDARDS INDEX



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

1. NFPA No. 37, STATIONARY COMBUSTION

ENGINES AND GAS TURBINES, available from the National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210.

2. NFPA No. 76A, ESSENTIAL ELECTRICAL

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

3. NFPA No. 54, NATIONAL FUEL GAS CODE,

available same as Item 1.

4. NFPA No. 58, AMERICAN NATIONAL STANDARD

FOR STORAGE AND HANDLING OF LIQUEFIED PETROLEUM GAS, available same as Item 1.

5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL

ELECTRIC CODE, available same as Item 1.

6. Article X, NATIONAL BUILDING CODE, available

from the American Insurance Association, 85 John Street, New York, N.Y. 10038.

7. AGRICULTURAL WIRING HANDBOOK, avail-

able from the Food and Energy Council, 909 University Avenue, Columbia, MO 65201.

8. ASAE EP-3634, INSTALLATION AND

MAINTENANCE OF FARM STANDBY ELECTRICAL SYSTEMS, available from the American Society of Agricultural Engineers, 2950 Niles Road, St. Joseph, MI 49085.

9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE

LIQUIDS CODE, available same as Item 1.



Section 1 — General Information

Air-cooled Generators

DANGER

Only qualified electricians or contractors should



attempt such installations, which must comply strictly with applicable codes, standards and regulations.

1.1 UNPACKING/INSPECTION

After unpacking, carefully inspect the contents for damage.

This standby generator set is ready for installa-

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

This UL listed standby generator set is packaged

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

This UL listed, 2-pole switch is rated at 100 AC

• amperes at 250 volts maximum. This transfer

switch is for indoor use only (if equipped).

If this generator is used to power electrical load



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

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

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

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

1.2 PROTECTION SYSTEMS

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

1. Low Oil Pressure Sensor 4. Overspeed

2. High Temperature Sensor 5. RPM Sensor

3. Overcrank 6. Low Battery

There are LED readouts on the control panel to notify personnel that one of these faults has occurred. There is also a System Set LED that is lit when all of the conditions described in section "System Set LED" are true. (See the "Protection Systems" section for details.)

1.3 NEC REQUIREMENT FOR ARC FAULT CIRCUIT INTERRUPTION BREAKER FOR BEDROOMS

In 2001, the National Electric Code (NEC) introduced a requirement for new construction. This new requirement indicates the need for Arc Fault Circuit Interrupters to be used to protect the complete branch circuit that feeds a dwelling bedroom. The actual NEC requirement is indicated below.

1.3.1 SECTION 210.12 ARC FAULT 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-energize the circuit when an arc fault is detected.

2. Dwelling Unit Bedrooms: All branch circuits that

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

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

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

It is most important that breakers only be switched like for like. For instance, if replacing a 15A breaker, it MUST be replaced with a 15A AFCI breaker. Likewise, a 20A breaker MUST be replaced with a 20A AFCI.

These AFCI breakers are available at the nearest hardware store.

Siemens Item # Description

Q115AF 15A Single Pole AFCI

Q120AF 20A Single Pole AFCI

1.4 THE GENERATOR

Section 1 — General Information

Air-cooled Generators

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

Control Panel

Fuel Inlet (Back)

Fuel Regulator

Exhaust Enclosure

Composite Base

Oil Dipstick

Data Decal

Air Filter Cover

Battery CompartmentOil Filter

Figure 1.2 – 10kW, V-twin GT-530 Engine

Control Panel

Exhaust Enclosure

Composite Base

Oil Dipstick

Data Decal

Battery CompartmentOil Filter

Air Filter

Fuel Inlet (Back)

Fuel Regulator

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

Air Filter Cover

Oil Dipstick

Exhaust Enclosure

Composite Base

Data Decal

Control Panel

Fuel Inlet (Back)

Fuel Regulator

Battery CompartmentOil Filter

Section 1 — General Information

Air-cooled Generators

1.5 SPECIFICATIONS

1.5.1 GENERATOR



Model 05240 & 05280 05241 & 05281 05242 & 05282 05243 & 05244 05283 & 05284

Rated Max. Continuous 6,000 NG/7,000 LP 9,000 NG/10,000 LP 13,000 NG/13,000 LP 15,000 NG/16,000 LP Power Capacity (Watts*)

Rated Voltage 120/240 120/240 120/240 120/240 Rated Max. Continuous

Load Current (Amps)

120 Volts** 50.0 NG/58.3 LP 75.0 NG/83.3 LP 108.3 NG/108.3 LP 125 NG/133.3 LP

240 Volts 25.0 NG/29.2 LP 37.5 NG/41.7 LP 54.1 NG/54.1 LP 52.5 NG/66.6 LP Main Line Circuit Breaker 30 Amp 45 Amp 55 Amp 65 Amp Circuits***

50A, 240V - - - 1

40A, 240V - - 1 1

30A, 240V 1 1 1 -

20A, 240V - 1 - 1

20A, 120V 1 3 3 5

15A, 120V 5 3 5 5 Phase 1 1 1 1 Number of Rotor Poles 2 2 2 2 Rated AC Frequency 60 Hz 60 Hz 60 Hz 60 Hz Power Factor 1 1 1 1 Recommended Air Filter Part # 0C8127 Part # 0E9581 Part # 0C8127 Part # 0C8127 Battery Requirement Group 26 Group 26 Group 26 Group 26

12 Volts and 12 Volts and 12 Volts and 12 Volts and 350 Cold-cranking 525 Cold-cranking 525 Cold-cranking 525 Cold-cranking Amperes Minimum Amperes Minimum Amperes Minimum Amperes Minimum

Battery Warming Blanket 0F6148DSRV Weight (Unit Only) 336 Pounds 375 Pounds 425.5 Pounds 445 & 414 Pounds Enclosure Steel/Aluminum Normal Operating Range -20°F (-28.8°C) to 104°F (40°C)

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

decreases about 3.5 percent for each 1,000 feet above sea level; and also will decrease about 1 percent for each 6° C (10° F) above 16° C (60° F) ambient temperature.

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

volts.

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



1.5.2 ENGINE

Model 05240 & 05280 05241 & 05281 05242 & 05282 05243 & 05244 05283 & 05284

Type of Engine GH-410 GT-530 GT-990 GT-990 Number of Cylinders 1 2 2 2 Rated Horsepower 14.5 @ 3,600 rpm 18 @ 3,600 rpm 30 @ 3,600 rpm 30 @ 3,600 rpm Displacement 410cc 530cc 992cc 992cc Cylinder Block Aluminum w/Cast Aluminum w/Cast Aluminum w/Cast Aluminum w/Cast Iron Sleeve Iron Sleeve Iron Sleeve Iron Sleeve Valve Arrangement Overhead Valves Overhead Valves Overhead Valves Overhead Valves Ignition System Solid-state w/Magneto Solid-state w/Magneto Solid-state w/Magneto Solid-state w/Magneto Recommended Spark Plug RC14YC BPR6HS RC12YC RC12YC Spark Plug Gap 0.76 mm (0.030 inch) 0.76 mm (0.030 inch) 1.02 mm (0.040 inch) 1.02 mm (0.040 inch) Compression Ratio 8.6:1 9.5:1 9.5:1 9.5:1 Starter 12 Vdc 12 Vdc 12 Vdc 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 # 070185B Part # 070185B Part # 070185B Part # 070185B Recommended Air Filter Part # 0C8127 Part # 0E9581 Part # 0C8127 Part # 0C8127 Operating RPM 3,600 3,600 3,600 3,600

Section 1 — General Information

Air-cooled Generators

1.6 SYSTEM SET LED

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

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

AUTO position.

2. The utility voltage being supplied to the unit is

being sensed by the PCB. If the utility sense voltage is not connected to the unit or if it is below approximately 150-160 volts AC, then the system set light will flash rapidly. This indicates that if the AUTO/OFF/ MANUAL switch is placed in the Auto position, the generator will start.

3. No alarms are present, for example, low oil pres-

sure, high temperature, etc.

1.7 FUEL REQUIREMENTS

AND RECOMMENDATIONS

With LP gas, use only the vapor withdrawal system. This type of system uses the vapors formed

above the liquid fuel in the storage tank.

The engine has been fitted with a fuel carburetion system that meets the specifications of the 1997 California Air Resources Board for tamper-proof dual fuel systems. The unit will run on natural gas or LP gas, but it has been factory set to run on natural gas. Should the primary fuel need to be changed to LP gas, the fuel system needs to be reconfigured. See the Reconfiguring the Fuel System section for instructions on reconfiguration of the fuel system.

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

Required fuel pressure for natural gas is 5 inches

to 7 inches water column (0.18 to 0.25 psi); and for liquid propane, 10 inches to 12 inches of water column (0.36 to 0.43 psi).

NOTE:

All pipe sizing, construction and layout must comply with NFPA 54 for natural gas applications and NFPA 58 for liquid propane applications. Once the generator is installed, verify that the fuel pressure NEVER drops below four (4) inches water column for natural gas or 10 inches water column for liquid propane.

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

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

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

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

1.8 FUEL CONSUMPTION

Unit Nat. Gas (*) LP Vapor (**) 1/2 Load Full Load 1/2 Load Full Load

6/7 kW 66 119 0.82/30 1.47/54 9/10 kW 102 156 1.25/46 1.93/70 13/13 kW 156 220 1.55/57 2.18/80 15/16 kW 173 245 1.59/59 2.51/92

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

1.8.1 BTU FLOW REQUIREMENTS -



NATURAL GAS

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

6kW — 119,000 BTU/Hour

• 9kW — 156,000 BTU/Hour

• 13kW — 220,000 BTU/Hour

• 15kW — 245,000 BTU/Hour

•

DANGER

 Gaseous fuels such as natural gas and liquid

propane (LP) gas are highly explosive. Even the slightest spark can ignite such fuels and cause an explosion. No leakage of fuel is permitted. Natural gas, which is lighter than air, tends to collect in high areas. LP gas is heavier than air and tends to settle in low areas.

NOTE:

A minimum of one approved manual shut-off valve must be installed in the gaseous fuel supply line. The valve must be easily accessible. Local codes determine the proper location.

Section 1 — General Information

Air-cooled Generators

1.9 RECONFIGURING THE FUEL SYSTEM

1.9.1 7 KW, 410CC ENGINE



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

NOTE:

The primary regulator for the propane supply is NOT INCLUDED with the generator. A fuel pressure of 10 to 12 inches of water column (0.36 to

0.43 psi) to the fuel inlet of the generator MUST

BE SUPPLIED.

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

2. Open the roof and remove the door.

3. Remove the battery (if installed).

4. Disconnect wire #0 and wire #14 from the gas

solenoid on top of the demand regulator.

5. Remove the carburetor fuel hose from the outlet

port of the demand regulator.

6. Remove the demand regulator by removing the

fastener that retains the regulator mounting bracket.

7. Remove the square headed steel pipe plug from

outlet port #1 and the brass hose barb fitting from outlet port #2.

8. Refit the brass hose barb fitting to outlet port #1

and the square headed steel pipe plug to outlet port #2.

Figure 1.4 – Demand Regulator

HOSE & PLUG SWITCHED SIDES

FUEL HOSE

BRASS HOSE FITTING

OUTLET PORT

FUEL JET

BRASS HOSE

FITTING

ADJUSTMENT

SCREW

PIPE PLUG

NOTE:

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

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

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

4.6).

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

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

1.9.2 10, 13 AND 16KW, V-TWIN ENGINES



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

NOTE:

The primary regulator for the propane supply is NOT INCLUDED with the generator. A fuel pressure of 10 to 12 inches of water column (0.36 to

0.43 psi) to the fuel inlet of the generator MUST

BE SUPPLIED.

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 securely.

For 13 and 16kW units: remove the air cleaner

cover.

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

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

3. Close the roof.

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

NG FUEL SYSTEM

RUNNING

PRESSURE

TAP

LP FUEL SYSTEM

STATIC PRESSURE TAP

Section 1 — General Information

Air-cooled Generators

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

Fuel Selection

Lever - "In" Position for Natural Gas

Fuel

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

Fuel Selection

Lever - "Out"

Position for

Liquid Propane

(Vapor) Fuel

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

Removed)

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

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

Removed)

Fuel Selection Lever - "Out" Position for Liquid Propane

(Vapor) Fuel

1.10 LOCATION

1.10.1 GENERATOR



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

The installation of the generator must comply

•

strictly with NFPA 37, NFPA 54, NFPA 58, and NFPA 70 standards.

Install the unit where air inlet and outlet open-

• ings will not become obstructed by leaves, grass, snow, etc.. If prevailing winds will cause blowing or drifting, consider using a windbreak to protect the unit.

Install the generator on high ground where water

• levels will not rise and endanger it.

Allow sufficient room on all sides of the generator

• for maintenance and servicing. This unit must be installed in accordance with current applicable NFPA 37 and NFPA 70 standards; as well as any other federal, state and local codes for minimum distances from other structures. DO NOT install under wooden decks or structures.

Install the unit where rain gutter down spouts,

• roof fun-off, landscape irrigation, water sprinklers or sump pump discharge does not flood the unit or spray the enclosure, including any air inlet or outlet openings.

Install the unit where services will not be affected

• or obstructed, including concealed, underground or covered services such as electrical, fuel, phone, air conditioning or irrigation.

Where strong prevailing winds blow from one

• direction, face the generator air inlet openings to the prevailing winds.

Section 1 — General Information

Air-cooled Generators

Install the generator as close as possible to the fuel

• supply, to reduce the length of piping.

Install the generator as close as possible to the

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

The genset must be installed on a level surface.

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

The generator is typically placed on pea gravel or

• crushed stone. Check local codes if a concrete slab is required. If a concrete base slab is required, all federal, state and local codes should be followed. Special attention should be given to the concrete base slab which should exceed the length and width of the generator by a minimum of six (6) inches (0.152 meters) on all sides.

Figure 1.9 – Generator Clearances

Install the transfer switch indoors on a firm, sturdy

• supporting structure.

To prevent switch distortion, level the switch if

• necessary. This can be done by placing washers between the switch enclosure and mounting surface.

Never install the switch where water or any 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.

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



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

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

• Operate the generator outdoors ONLY.

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

1.10.2 TRANSFER SWITCH



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

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

1.11 BATTERY REQUIREMENTS

See the Specifications section for correct battery size and rating.

1.12 BATTERY INSTALLATION

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

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

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

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

3. Remove the 15A fuse from the generator control panel.

Battery cables were factory connected at the generator (Figure 1.10). Connect cables to battery posts as follows:

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

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

NOTE:

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

NOTE:

Damage will result if battery connections are made in reverse.

Figure 1.10 – Battery Cable Connections

NOTE: In areas where temperatures regularly fall below 10° F (-12° C) it is recommended that a pad type battery heater be installed to aid in cold climate starting (see Specifications).

NOTE:

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

1.13 THE BATTERY

DANGER

Do not dispose of the battery in a fire. The



battery is capable of exploding.

A battery presents a risk of electrical shock



and high short circuit current. The following precautions are to be observed when working on batteries:

• Remove the 15A fuse from the generator control

panel.

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

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

battery; and

• Disconnect charging source prior to connecting or

disconnecting battery terminals.

Section 1 — General Information

Air-cooled Generators

Do not open or mutilate the battery. Released



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

The electrolyte is a dilute sulfuric acid that is



harmful to the skin and eyes. It is electrically conductive and corrosive.

The following procedures are to be observed:

• Wear full eye protection and protective clothing;

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

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

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

Lead-acid batteries present a risk of fire because



they generate hydrogen gas. The following procedures are to be followed:

• DO NOT SMOKE when near the battery;

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

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

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



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

Be sure the utility power supply is turned off



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

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

See the Specifications section for the correct size and rating when replacing the battery. When using a maintenance-free battery, it is not necessary to check the specific gravity or electrolyte level. Have these procedures performed at the intervals specified in the “Service Schedule.” A negative ground system is used. Battery connections are shown on the wiring diagrams. Make sure the battery is correctly connected and terminals are tight. Observe battery polarity when connecting the battery to the generator set.

Section 2 — Post Installation Start-up and Adjustments

Air-cooled Generators

2.1 BEFORE INITIAL START-UP

NOTE:

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

Before starting, complete the following:

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

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

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

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

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

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

DANGER

The transfer switch is now electrically “hot.”



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

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

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

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

8. On the generator panel, set the AUTO/OFF/ MANUAL switch to MANUAL. The engine should crank and start.

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

Never operate the engine with the oil level



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

2.2 CHECK TRANSFER SWITCH OPERATION

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

DANGER

Do not attempt manual transfer switch opera-



tion until all power voltage supplies to the transfer switch have been positively turned off. Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock.

2.3 ELECTRICAL CHECKS

Complete electrical checks as follows:

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

OFF (or OPEN) position.

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

the OFF position.

3. 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).

DANGER

Proceed with caution! Generator power voltage



is now supplied to the transfer switch. Contact with live transfer switch parts will result in dangerous and possibly fatal electrical shock.

10. Connect an accurate AC voltmeter and a frequency meter across transfer switch terminal lugs E1 and E2. 7kW voltage should be 242-252 volts at a frequency of 61-63 Hertz. 10, 13, and 16kW voltage should be 250-252 volts at a frequency of

57.5-59.5 Hertz.

11. Connect the AC voltmeter test leads across terminal lugs E1 and neutral; then across E2 and neutral. In both cases, voltage reading should be 121-126 volts AC (7kW), and 125-126 volts AC (10, 13 and 16kW).

12. Set the generator’s main circuit breaker to its OFF (or OPEN) position. Let the engine run at noload for a few minutes to stabilize internal engine generator temperatures.

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

NOTE:

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

Section 2 — Post Installation Start-up and Adjustments

Air-cooled Generators

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 OFF.

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

Do not attempt manual transfer switch opera-



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

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

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

8. Set the generator’s main circuit breaker to its ON (or closed) position. Loads are now powered by the standby generator.

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

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

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

• 10, 13 & 16kW voltage should be greater than 240 volts and frequency should be greater than 60 Hz.

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

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

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

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

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

2.5 CHECKING AUTOMATIC OPERATION

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

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

(or OPEN) position.

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

to OFF.

3. Turn OFF the utility power supply to the transfer

switch, using means provided (such as a utility main line circuit breaker).

4. Manually set the transfer switch to the UTILITY

position, i.e., load terminals connected to the utility power source side.

5. Turn ON the utility power supply to the transfer

switch, using the means provided (such as a utility main line circuit breaker).

6. Set the generator's main circuit breaker to its ON

(or CLOSED)) position.

7. Set the AUTO/OFF/MANUAL switch to AUTO. The

system is now ready for automatic operation.

8. Turn OFF the utility power supply to the transfer

switch.

With the AUTO/OFF/MANUAL switch at AUTO, the engine should crank and start when the utility source power is turned OFF after a 10 second delay. After starting, the transfer switch should connect load circuits to the standby side after a 15 second delay. Let the system go through its entire automatic sequence of operation.

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

After about 15 seconds, the switch should transfer

•

loads back to the utility power source.

About one minute after retransfer, the engine

•

should shut down.

2.6 ADJUSTING THE FUEL REGULATOR

- 7KW (NATURAL GAS ONLY)

NOTE:

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

Although the generator has been factory set to provide maximum power, it may be necessary in some areas to adjust this setting. If experiencing engine problems at high or full load conditions, follow these steps. It will require a frequency meter to perform this procedure.

Section 2 — Post Installation Start-up and Adjustments

Air-cooled Generators

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

2. Allow the generator to start. Before loading the generator, confirm that the No Load Frequency, with the roof open and door off, is set to 63-63.5 Hz. Transfer load to emergency circuits.

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

Unit 120 Volts 240 Volts

7 kW 50.0 amps 25.0 amps

4. When 3/4 load has been achieved. Connect a frequency meter to the output lugs of the generator’s main line circuit breaker.

5. The fuel regulator is fitted with one adjustment screw. While watching the frequency meter, slowly turn the adjustment screw clockwise or counterclockwise until the highest frequency is read on the meter. Only limited adjustment is available because of the set pin. Under no circumstances should any of the pins be removed (Figure 2.1).

Figure 2.1 — 7kW Fuel Regulator

410cc Engine

Do not make any unnecessary adjustments.



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

If this procedure or the test equipment is not available, locate the nearest Dealer and they can perform the adjustments.

NOTE:

A service fee may be charged for this adjustment.

2.7 ENGINE GOVERNOR ADJUSTMENT

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

2.7.1 7 KW UNITS



The engine must be OFF to perform steps 1 and



1. Loosen the governor clamp bolt (Figures 2.2).

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

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

Adjustment Screw

(One Side Only)

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

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

Set Pin

Figure 2.2 — Engine Governor Adjustment

Single Cylinder Engines

SECONDARY

ADJUST SCREW

GOVERNOR

SHAFT

GOVERNOR

CLAMP

BOLT

PRIMARY

ADJUST

SCREW

Section 3 — Operation

Air-cooled Generators

4. Connect a frequency meter across the generators AC output leads.

5. Turn the primary adjust screw to obtain a frequency reading of 61.5 Hertz. Turn the secondary adjust screw to obtain a frequency of 62.5 Hz.

6. When frequency is correct at no load, check the AC voltage reading. If voltage is incorrect, the voltage regulator may require adjustment (See the Voltage Regulator Adjustment section).

2.7.2 13 KW AND 16 KW UNITS



NOTE:

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

2.7.3 ADDITIONAL CORROSION



PROTECTION

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

2.8 VOLTAGE REGULATOR

ADJUSTMENT

NOTE:

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

NOTE:

The voltage regulator is housed above the generator's control panel. The regulator maintains a voltage in direct proportion to frequency at a 2-to1 ratio. For example, at 62 Hertz, line-to-neutral voltage will be 124 volts.

3.1 USING THE AUTO/OFF/MANUAL SWITCH (FIGURE 3.1)

3.1.1 “AUTO” POSITION



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



3.1.2 “OFF” POSITION

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

2.8.1 7KW UNITS



With the frequency between 62-63 Hertz at no-load, slowly turn the slotted potentiometer (Figure 2.3) until line voltage reads 248-252 volts.

2.8.2 10, 13, AND 16KW UNITS



With the frequency between 58-59 Hertz at no-load, slowly turn the slotted potentiometer (Figure 2.3) until line voltage reads 232-236 volts.

Figure 2.3 – Voltage Adjustment Potentiometer

Tur n t o adjust voltage.

Figure 3.1 – Generator Control Panel

CONTROL AND INFORMATION CENTER

SYSTEM SET

LOW BATTERY

AUTO. MAN.

OFF

SYSTEM FUSE

15A

ASSY: 0F8418/0F8419



3.1.3 “MANUAL” POSITION

SET

EXERCISE

TIME

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

With the switch set to AUTO, the engine may



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

LOW OI L

HIGH TEMP

OVER SPEED NO RPM SENSE IF FLASHING

OVER CRANK

FLASHING GREEN LED= NO UTILITY SENSE 5 FLASHING RED LEDS= EXERCISER NOT SET

Section 3 — Operation

Air-cooled Generators

3.1.4 CHOKE OPERATION



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

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

3. 410 engines do not have a choke.

3.2 AUTOMATIC TRANSFER

OPERATION

To select automatic operation, do the following:

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

2. Be sure that normal UTILITY power source voltage is available to transfer switch terminal lugs N1 and N2 (Refer to the Electrical Data section).

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

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.

3.3 SEQUENCE OF AUTOMATIC

OPERATION

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

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

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

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

A. Utility Voltage Dropout Sensor

• This sensor monitors utility source voltage.

• If utility source voltage drops below about 65 percent of the nominal supply voltage, the sensor energizes a 10 second timer.

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

B. Engine Warm-up Time Delay

• This mechanism lets the engine warm up for about five (5) seconds before the load is transferred to the standby source.

C. Standby Voltage Sensor

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

D. Utility Voltage Pickup Sensor

• This sensor monitors utility power supply voltage. When that voltage is restored above 75 percent of the nominal source voltage, a retransfer time delay starts timing.

E. Retransfer Time Delay

• This timer runs for about 15 seconds.

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

• Retransfer to utility power source then occurs.

F. Engine Cool-down Timer

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

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

3.4 MANUAL TRANSFER OPERATION

3.4.1 TRANSFER TO GENERATOR



POWER SOURCE

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

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

2. Set the generator’s main circuit breaker to 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).

DANGER

Do not attempt to activate the transfer switch



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

Section 3 — Operation

Air-cooled Generators

4. Use the manual transfer handle inside the transfer switch to move the main contacts to their STANDBY position, i.e., loads connected to the standby power source (Figure 3.2).

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

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

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

Figure 3.2 – Manual Transfer Switch Operation

3.4.2 TRANSFER BACK TO UTILITY POWER



SOURCE

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

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

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

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

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

DANGER

Do not attempt to activate the transfer switch



5. Use the manual transfer handle inside the transfer switch to move the main contacts back to their UTILITY position, i.e., loads connected to the utility power source (Figure 3.2).

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

7. Set the system to automatic operation as outlined in Automatic Transfer Operation section.

3.5 SETTING THE EXERCISE TIMER

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

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

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

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

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

Example: If the "Set Exercise Time" switch is

pressed on Saturday afternoon at 2:00 p.m., the generator will start and exercise for approximately 12 minutes every Saturday at 2:00 p.m..

NOTE:

The exerciser will only work in the AUTO mode and will not work unless this procedure is performed. The exerciser will need to be reset every time the 12-volt battery is disconnected and then reconnected, and when the 15A fuse is removed.

The 16kW unit has a low speed exercise option. Dip switch 1 on the control board is factory set to OFF. This allows the engine to run at a slower speed during weekly exercise periods for quieter operation. If this Dip switch is set to ON, the generator will exercise at it's normal speed.

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

Section 3 — Operation

Air-cooled Generators

Low speed exercise will be handled as follows:

1. The standard start sequence will be initiated.

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

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

• Wait 10 seconds for utility to return.

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

• If utility is still lost after 10 seconds, run the engine up to 3600 RPM and transfer the load. At this time the controller will exit the exercise routine and assume full automatic operation.

3.6 PROTECTION SYSTEMS

3.6.1 LOW OIL PRESSURE SWITCH



This switch (Figure 3.3) has normally closed contacts that are held open by engine oil pressure during cranking and operating. Should oil pressure drop below the 8 psi range, switch contacts close, and the engine shuts down. The unit should not be restarted until oil is added. The AUTO/OFF/MANUAL switch must then be turned to OFF and then back to AUTO.

3.6.2 HIGH TEMPERATURE SWITCH



This switch’s contacts (Figure 3.3) close if the temperature should exceed approximately 140º C (284º F), initiating an engine shutdown. The generator will automatically restart and the LED on the generator control panel will reset once the temperature has returned to a safe operating level.

Figure 3.3 – Low Oil Pressure and

High Temperature Switches

Oil Filter

Oil Drain Hose

Low Oil Switch

High Temp Switch

3.6.3 OVERCRANK



This feature prevents the generator from damaging itself when it continually attempts to start and another problem, such as no fuel supply, prevents it from starting. The unit will crank and rest for a preset time limit. Then, it will stop cranking, and the LED on the generator control panel will light indicating an overcrank failure. The AUTO/OFF/MANUAL switch will need to be set to OFF and then back to AUTO to reset the generator control board.

NOTE:

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

3.7.3.1 Approximate Crank Cycle Times

7kW Units:

15 seconds ON

• 7 seconds OFF

• 7 seconds ON

• 7 seconds OFF

• 7 seconds ON

• 7 seconds OFF

• 7 seconds ON

• 7 seconds OFF

• 7 seconds ON

• 7 seconds OFF

• 7 seconds ON

•

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

10kW, 13kW and 16kW Units:

16 seconds ON

• 7 seconds OFF

• 16 seconds ON

• 7 seconds OFF

• 7 seconds ON

• 7 seconds OFF

• 7 seconds ON

• 7 seconds OFF

• 7 seconds ON

• 7 seconds OFF

•

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

3.6.4 OVERSPEED



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

3.6.5 RPM SENSOR FAILURE



During cranking, if the board does not see a valid RPM signal within three (3) seconds, it will shut down and latch out on RPM sensor loss.

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

If an RPM signal is not detected within the first

• three (3) seconds of cranking, the control board will shut the engine down and latch out on RPM sensor loss.

If the RPM signal is detected the engine will start

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

Section 4 — Maintenance

Air-cooled Generators

4.2 CHECKING THE ENGINE OIL LEVEL

For oil capacities, see the Specifications section. For engine oil recommendations, see the Engine Oil Recommendations section. To check the engine oil level, proceed as follows (Figures 4.2, 4.3 and 4.4):

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

position.

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

cloth.

3. Completely insert the dipstick; then, remove it

again. The oil level should be at the dipstick “Full” mark. If necessary, add oil to the “Full” mark only. DO NOT FILL ABOVE THE “FULL” MARK.

3.6.6 LOW BATTERY



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

4.1 FUSES

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

Figure 4.1 – Generator Control Panel

CONTROL AND INFORMATION CENTER

Never operate the engine with the oil level



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

4. Install the dipstick.

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

nal position.

Figure 4.2 — Oil Dipstick and Fill, 7kW

Oil Dipstick and Fill

OFF

AUTO. MAN.

SYSTEM FUSE

15A

ASSY: 0F8418/0F8419

SET

EXERCISE

TIME

SYSTEM SET

LOW BATTERY

LOW OIL

HIGH TEMP

OVER SPEED NO RPM SENSE IF FLASHING

OVER CRANK

FLASHING GREEN LED= NO UTILITY SENSE 5 FLASHING RED LEDS= EXERCISER NOT SET

Section 4 — Maintenance

Air-cooled Generators

Figure 4.3 — Oil Dipstick and Fill, 10kW

Oil Dipstick

Oil Fill

Figure 4.4 — Oil Dipstick and Fill,

13kW and 16kW

Oil Dipstick

4.3.3 OIL & OIL FILTER CHANGE PROCEDURE



To change the oil, proceed as follows:

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

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

2. Immediately after the engine shuts OFF, pull the

oil drain hose (Figure 4.5) free of its retaining clip. Remove the cap from the hose and drain the oil into a suitable container.

3. After the oil has drained, replace the cap onto the

end of the oil drain hose. Retain the hose in the clip.

Figure 4.5 – Oil Drain Hose and Filter

Low Oil Switch

High Temp Switch

Oil Fill

4.3 CHANGING THE ENGINE OIL

4.3.1 OIL CHANGE INTERVALS



See the "Service Schedule" section.

4.3.2 ENGINE OIL RECOMMENDATIONS



Use all season SAE 5W-30 synthetic oil or use SAE 30 oil of American Petroleum Institute (API) Service Class SG, SH, SJ or SL.

 Any attempt to crank or start the engine before

it has been properly serviced with the recommended oil may result in an engine failure.

Oil Filter

Oil Drain Hose

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).

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.

Section 4 — Maintenance

Air-cooled Generators

4.4 CHANGING THE ENGINE AIR CLEANER

4.4.1 7, 13, AND 16KW GENERATORS



See Figures 1.1 and 1.2, for the location of the air cleaner. Use the following procedures (Figure 4.6, 7kW; Figure 4.8, 13/16kW):

1. Lift the roof and remove the door.

2. Turn the two screws counterclockwise to loosen.

3. Remove the cover and air filter.

4. Wipe away dust or debris from inside of the air

box and around edges.

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

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

wise to tighten.

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

Figure 4.6 — 7 kW, Engine Air Cleaner Location

Figure 4.7 — 10kW Engine Air Cleaner

Control Panel

Air Filter

Figure 4.8 — 13 kW and 16 kW Engine

Air Cleaner

Screw

Air Cleaner

3/4” Hole



4.4.2 10KW GENERATORS

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

1. Lift the roof and remove the door.

2. Turn the worm gear clamp screw 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.

Cover

Filter

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

Section 4 — Maintenance

Air-cooled Generators

3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 0.76 mm (0.030 inch) for 7 and 10kW; and 1.02 mm (0.040 inch) for 13/16 kW by carefully bending the ground electrode (Figure 4.9).

Figure 4.9 – Setting the Spark Plug Gap

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

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

4.6 BATTERY MAINTENANCE

The battery should be inspected per the "Service Schedule" section. The following procedure should be followed for inspection:

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

2. Check the battery fluid level of unsealed batteries and, if necessary, fill with Distilled Water Only. Do not use tap water in batteries.

3. Have the state of charge and condition checked. This should be done with an automotive-type battery hydrometer.

DANGER

Do not dispose of the battery in a fire. The



battery is capable of exploding.

A battery presents a risk of electrical shock



and high short circuit current. The following precautions are to be observed when working on batteries:

• Remove the 15A fuse from the generator control

panel.

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

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

battery; and

• Disconnect charging source prior to connecting or

disconnecting battery terminals.

Do not open or mutilate the battery. Released



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

The electrolyte is a dilute sulfuric acid that is



harmful to the skin and eyes. It is electrically conductive and corrosive. The following procedures are to be observed:

• Wear full eye protection and protective clothing;

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

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

Lead-acid batteries present a risk of fire because



they generate hydrogen gas. The following procedures are to be followed:

• DO NOT SMOKE when near the battery;

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

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

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



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

Be sure the utility power supply is turned off



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

4.7 ADJUSTING GH-410/GT-530/990

VALVE CLEARANCE

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

Important: If feeling uncomfortable about doing

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

To check valve clearance:

The engine should be cool before checking. If

•

valve clearance is 0.002" - 0.004" (0.05 - 0.1mm), adjustment is not needed.

Remove spark plug wires and position wires away

• from plugs.

Remove spark plugs.

•

Make sure the piston is at Top Dead Center (TDC)

• of its compression stroke (both valves closed). To get the piston at TDC, remove the intake screen at the front of the engine to gain access to the flywheel nut. Use a large socket and socket wrench to rotate the nut and hence the engine in a clockwise direction. While watching the piston through the spark plug hole. The piston should move up and down. The piston is at TDC when it is at its highest point of travel.

To adjust valve clearance (if necessary):

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

•

Make sure that the spark plug wire is removed

• from the spark plug and out of the way.

Remove the four screws attaching the valve cover

• with a #2 or #3 Phillips screwdriver.

Loosen the rocker jam nut. Use an 10mm allen

• wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge. Correct clearance is

0.002-0.004 inch (0.05-0.1 mm).

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.

Section 4 — Maintenance

Air-cooled Generators

Install spark plugs.

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

• On the GT-530 and GT-990, repeat the process for

•

the other cylinder.

4.8 COOLING SYSTEM

Air inlet and outlet openings in the generator compartment must be open and unobstructed for continued proper operation. This includes such obstructions as high grass, weeds, brush, leaves and snow.

Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to quickly shut down. (See Figure 4.11 for vent locations.)

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

Figure 4.11 – Cooling Vent Locations

Figure 4.10 - Valve Clearance Adjustment

Pivot Ball

Jam Nut

Install new valve cover gasket.

• Re-attach the valve cover.

•

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.

Stud

NOTE:

Rocker

Arm

Valve Stem

The exhaust from this product gets extremely



hot and remains hot after shutdown. High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such materials may ignite and burn from the heat of the exhaust system.

The maximum ambient temperature for the gen-



erator is 40° C (104° F).

4.9 ATTENTION AFTER SUBMERSION

If the generator has been submerged in water, it must not be started and operated. Following any submer-

sion in water, have an Authorized Dealer thoroughly clean, dry and inspect the generator. If the structure (ex. home) has been flooded, it should be inspected by a certified electrician to ensure there won't be any electrical problems during generator operation or when utility is returned.

Section 4 — Maintenance

Air-cooled Generators

4.10 CORROSION PROTECTION

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

4.11 OUT OF SERVICE PROCEDURE

4.11.1 REMOVAL FROM SERVICE



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

1. Start the engine and let it warm up.

2. Close the fuel shutoff valve in the fuel supply line

and allow the unit to shut down.

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

oil fault.

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

6. While the engine is still warm from running,

drain the oil completely. Refill the crankcase with oil. See ”Engine Oil Recommendations".

7. Attach a tag to the engine indicating the viscosity

and classification of the oil in the crankcase.

8. Remove the spark plug(s) and spray fogging

agent into the spark plug(s) threaded openings. Reinstall and tighten the spark plug(s).

9. Remove the battery and store it in a cool, dry

room on a wooden board. Never store the battery on any concrete or earthen floor.

10. Clean and wipe the entire generator.

4.11.2 RETURN TO SERVICE



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

1. Verify that utility power is turned off and that the AUTO/OFF/MANUAL switch is set to OFF.

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

3. Check the state of the battery. Fill all cells of unsealed batteries to the proper level with distilled water. DO NOT USE TAP WATER IN THE BATTERY. Recharge the battery to 100 percent state of charge, or, if defective, replace the battery. See “Specifications,” for type and size.

4. Clean and wipe the entire generator.

5. Make sure the 15A fuse is removed from the generator control panel. Reconnect the battery. Observe battery polarity. Damage may occur if the battery is connected incorrectly.

6. Open the fuel shutoff valve.

7. Insert the 15A fuse into the generator control panel. Start the unit by moving the AUTO/OFF/ MANUAL switch to MANUAL. Allow the unit to warm up thoroughly.

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

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

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

11. The generator is now ready for service.

NOTE:

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

Section 4 — Maintenance

Air-cooled Generators

4.12 SERVICE SCHEDULE

ATTENTION: It is recommended that all service work

be performed by the nearest Authorized Dealer.

SYSTEM/COMPONENT PROCEDURE FREQUENCY

X = Action Inspect Change Clean W = Weekly R = Replace as Necessary M = Monthly * = Notify Dealer Y = Yearly

if Repair is Needed.

FUEL

Fuel lines and connections* X M

LUBRICATION

Oil level X M

Oil X EVERY 100 HOURS**,

AND Y

Oil filter X EVERY 100 HOURS**,

AND Y

COOLING

Enclosure louvers X X W

BATTERY

Remove corrosion, X X M

ensure dryness

Clean and tighten

battery terminals

Check charge state

Electrolyte level X R EVERY 6 M (unsealed batteries only)*

ENGINE AND MOUNTING

Air cleaner X R Y

Spark plug(s) X R Y

GENERAL CONDITION

Vibration, Noise, Leakage, X M Temperature*

COMPLETE TUNE-UP* TO BE COMPLETED BY AN Y AUTHORIZED DEALER

X X M

X R EVERY 6 M

* Contact the nearest Authorized Dealer for assistance if necessary.

** Change oil and ﬁ lter after ﬁ rst eight (8) hours of operation and then every 100 hours thereafter. Change sooner

when operating under a heavy load or in a dusty or dirty environment or in high ambient temperatures.

Section 5 — Troubleshooting

Air-cooled Generators

5.1 TROUBLESHOOTING GUIDE

Problem Cause Correction

The engine will not crank. 1. Fuse blown. 1. Correct short circuit condition,

replace 15A fuse in generator control panel.

2. Loose, corroded or defective 2. Tighten, clean or replace battery cables. as necessary.

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

4. Defective starter motor. 4. *

5. Dead Battery. 5. Charge or replace battery.

The engine cranks but 1. Out of fuel. 1. Replenish fuel/Turn on fuel valve. will not start. 2. Defective fuel solenoid (FS). 2. *

3. Open #14 wire from 3. * engine control board.

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

5. Valve lash out of adjustment. 5. Reset valve lash.

6. Choke not operating. 6. Verify choke plate moves freely.

The engine starts hard 1. Air cleaner plugged 1. Check, replace air cleaner. and runs rough. or damaged.

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

3. Fuel regulator not set. 3. Set Fuel Regulator.

4. Fuel pressure incorrect. 4. Confirm fuel pressure to regulator

is 10-12” water column (0.36-0.43 psi) for LP, and 5-7” water column (0.18-0.25 psi) for natural gas.

5. Fuel selector in wrong position. 5. Move selector to correct position.

6. Choke remains closed. 6. Verify choke plate moves freely.

The AUTO/OFF/MANUAL switch 1. Defective switch. 1. * is set to OFF, but the engine 2. AUTO/OFF/MANUAL switch 2. *

continues to run. wired incorrectly.

3. Defective control board. 3. *

There is no AC output from 1. Main line circuit breaker is in 1. Reset circuit breaker the generator. the OFF (or OPEN) position. to ON (or CLOSED).

2. Generator internal failure. 2. *

There is no transfer to 1. Defective transfer switch coil. 1. * standby after utility 2. Defective transfer relay. 2. * source failure. 3. Transfer relay circuit open. 3. *

4. Defective control logic board. 4. *

Unit consumes large 1. Engine over filled with oil. 1. Adjust oil to proper level. amounts of oil. 2. Engine breather defective. 2. *

*Contact the nearest Authorized Dealer for assistance.

Section 6 — Notes

Air-cooled Generators

27 27

Section 6 — Notes

Air-cooled Generators

Section 6 — Notes

Air-cooled Generators

Section 7 — Mounting Dimensions

Air-cooled Generators Drawing No. 0F9424

Section 8 — Electrical Data

Air-cooled Generators

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

N1A

194

174

N1A

126

205

N2A

N1AN1A

OPEN

194

12Vdc TRANSER COIL

240VAC OUTPUT

TS TO GENERATOR CONTROL PANEL

N1A

NEUTRAL CONNECTION

INSIDE SWITCH

N2A

205

126

N1A

N2A

COM

NC NC

VR1

COM

VR2

CIRCUIT 14

CIRCUIT 13

CIRCUIT 10

CIRCUIT 9

BLACK

RED

NEUTRAL (WHITE)

RED (MAIN 2)

BLACK (MAIN 1)

TO GENERATOR OUTPUT CIRCUIT BREAKER

240VAC TO MAIN DISTRIBUTION PAN E L

T1 T2

AT S

CIRCUIT 6

N2A

LEGEND ATS-AUTOMATIC TRANSFER SWITCH C1-UTILITY COIL & RECTIFIER C2-GENERATOR COIL & RECTIFIER F1,F2-5A, 600V FUSE LC-CIRCUIT BREAKER (LOADS) TR-TRANSFER RELAY TS-TERMINAL STRIP XA,XB-LIMIT SWITCHES

CIRCUIT 5

CIRCUIT 2

CIRCUIT 1

CIRCUIT 3

CIRCUIT 4

8 CIRCUIT LOAD CENTER

10 CIRCUIT LOAD CENTER

16 CIRCUIT LOAD CENTER

12 CIRCUIT LOAD CENTER

CIRCUIT 7

CIRCUIT 8

CIRCUIT 11

CIRCUIT 12

CIRCUIT 15

CIRCUIT 16

Section 8 — Electrical Data

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

DIAGRAM KEY

BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB - MAIN OUTPUT BREAKER CS - IDLE CHOKE SOLENOID C1 - ENGINE HARNESS C2 - ALTERNATOR HARNESS C3 - SOLENOID HARNESS DSW - PCB MOUNTED DIP SWITCH FS1 - FUEL SOLENOID FS2 - FUEL SOLENOID(530cc V-TWIN ONLY) F1 - FUSE 15 AMP GRD 1 - GROUND CONNECTIONS IN CONTROL PANEL GRD 2 - GROUND CONNECTIONS AT ENGINE HTO - HIGH OIL TEMPERATURE SWITCH IC - INLINE CONNECTOR ICT - IDLE CURRENT TRANSFORMER IM1 - IGNITION MODULE, CYL 1 IM2 - IGNITION MODULE, CYL 2 LOP - LOW OIL PRESSURE SWITCH SC - STARTER CONTACTOR SCR - STARTER CONTACTOR RELAY SM - STARTER MOTOR SP1 - SPARK PLUG, CYL 1 SP2 - SPARK PLUG, CYL 2 SW1 - AUTO / OFF / MANUAL SWITCH SW2 - SET EXERCISE SWITCH TB - INSULATED TERMINAL BLOCK, 4 TAB TS - INSULATED TERMINAL STRIP, 4 POSITION TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)

ENGINE WIRING

FS1

3 2

BATTERY

CHARGER

FS2

(UTILITY)

224B

225B

224B

225B

SP1

IM1

SP2

IM2

HTO

LOP

BLACK

12V

BATTERY

CUSTOMER SUPPLIED

GRD 2

CONTROL

PRINTED CIRCUIT BOARD

ALARM INDICATORS

1- ON=NORMAL EXERCISE OFF=LOW SPEED EXERCISE

2- SPARE

GOVERNOR

RED

ACTUATOR

234 768

864

15A 1823 LC1

11910 1213141516J120

L.E.D -

DSW

17 18 19 21 22 23

14239

225224 85 LC2

15B 90

1886

225

LC2

224

LC1

239

15A

15B

Section 8 — Electrical Data

Air-cooled Generators

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

225

224

224B

225B

225

224

N1 N2 13 0

224A

225A

224A

657910

224B

VOLTAGE

REGULATOR

BCR

CONTROL PANEL BOX

225A

225B

4N2

N1 0

CLOSEST TO BEARING

STATOR

22 33

224 0

LC2

LC1

239

15A

15B

SCR

56A0

23225456

11 44

ICT

194

NEUTRAL CONNECTION

RELAY COIL

240VAC UTILITY INPUT

12Vdc TRANSFER

LC2

LC1

AUTO

SW2

15B

LC2

LC1

MANUAL

1515

15A

SW1

194

15A

239

GRD 1

BLACK

RED

194

240V GENERATOR

OUTPUT TO TRANSFER

SWITCH CONTACTOR

CUSTOMER

CONNECTION

SCR

Section 8 — Electrical Data

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

BATTERY

CHARGER

ELECTRONIC

VOLTAGE

REGULATOR

224B

225B

4 0 6

224B

16 0

225B

MANUAL

194 15A

CONTROL

PRINTED CIRCUIT

BOARD

GOVERNOR

ACTUATOR

AUTO

194

15A

194

SW1

23915

239

SW2

15B

15A

4 3 4 5 6 7 8 9

11 12 13 14 15 16 17 18 19 20 21 22 23

LC1

224

239

LC2

225

15B

90 CS

194

15A

22 11

1823

86 LC2140

85LC1

LC1

LC2

194

225B

224B

224

225

LC1

LC2

Section 8 — Electrical Data

Air-cooled Generators

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

ENGINE AND ALTERNATOR

IM2

SP2

HTO

LOP

7766

FS1

FS2

IM1

SP1

LC1

LC2

RED

BATTERY

12V

I.C.T.

BATTERY

CHARGE

WINDING

DPE

WINDING

POWER

WINDING

FIELD

S TATO R

POWER

WINDING

194

225B

224B

224

225

23194 N2 N1

TRANSFER UTILITY

RELAY

COIL

240VAC

INPUT

LOP - LOW OIL PRESSURE SWITCH SC - STARTER CONTACTER SCR - STARTER CONTACTOR RELAY SM - STARTER MOTOR SP1, SP2 - SPARK PLUGS SW1 - SWITCH, AUTO / OFF / MANUAL DPDT, ON-OFF-ON

SW2 - SWITCH, SET EXERCISE SPST, N.C., ON-(OFF)

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

7766

224A

67394

77 66

224A 225A

225A

56VA

224A

225

1VA

224

BCR

NEUTRAL

240VAC GENERATOR 12Vdc

OUTPUT TO

TRANSFER SWITCH

CONTACTOR

DIAGRAM KEY

BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB - CIRCUIT BREAKER, MAIN OUTPUT CS - IDLE CHOKE SOLENOID FS1 - FUEL SOLENOID FS2 - FUEL SOLENOID(530cc V-TWIN ONLY) F1 - FUSE 15 AMP HTO - HIGH OIL TEMPERATURE SWITCH

ICT - IDLE CONTROL TRANSFORMER

IM1 - IGNITION MODULE, CYLINDER #1

IM2 - IGNITION MODULE, CYLINDER #2

Section 8 — Electrical Data

Air-cooled Generators Wiring Diagram – 7kW, Single Cylinder – Drawing No. 0F7820

DIAGRAM KEY

BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB - MAIN OUTPUT BREAKER C1 - ENGINE HARNESS C2 - ALTERNATOR HARNESS FS - FUEL SOLENOID F1 - FUSE 15 AMP GRD 1 - GROUND CONNECTIONS IN CONTROL PANEL GRD 2 - GROUND CONNECTIONS AT ENGINE HTO - HIGH OIL TEMPERATURE SWITCH IC - INLINE CONNECTOR ICT - INTERCONNECTION TERMINALS IM - IGNITION MODULE LOP - LOW OIL PRESSURE SWITCH SC - STARTER CONTACTOR SM - STARTER MOTOR SP - SPARK PLUG SW1 - AUTO / OFF / MANUAL SWITCH SW2 - SET EXERCISE SWITCH TB - INSULATED TERMINAL BLOCK, 4 TAB TS - INSULATED TERMINAL STRIP, 4 POSITION TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)

ENGINE WIRING

3 2

BATTERY

CHARGER

(UTILITY)

224B

225B

224B

225B

HTO

CUSTOMER SUPPLIED

BLACK

BATTERY

LOP

GRD 2

RED

12V

13 0 56

2143

15A

CONTROL

PRINTED CIRCUIT BOARD

657

239

18 224

ALARM INDICATORS

981110

85 225

15B

1312 14

L.E.D -

1886

225

224

239

15A

15B

Section 8 — Electrical Data

Air-cooled Generators

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

225

224

224B

225B

225

224

N1 N2 0

224A

225A

224A

657910

224B

VOLTAGE

REGULATOR

BCR

CONTROL PANEL BOX

225A

225B

CLOSEST TO BEARING

STATOR

04N2

22 33

GRD 1

AUTO

0225234

224

239

15A

SW2

239

15A

15B

MANUAL

194

15A

SW1

194

15A

239

194

11 44 22

194

NEUTRAL CONNECTION

RELAY COIL

240VAC UTILITY INPUT

12Vdc TRANSFER

240V GENERATOR

OUTPUT TO TRANSFER

SWITCH CONTACTOR

CUSTOMER

CONNECTION

Section 8 — Electrical Data

Air-cooled Generators Electrical Schematic – 7kW, Single Cylinder – Drawing No. 0F7821

BATTERY

CHARGER

ELECTRONIC

VOLTAGE

REGULATOR

MANUAL

194 15A

194

SW1

CONTROL

PRINTED CIRCUIT

BOARD

224B

225B

4 0 6

22 11

AUTO

194

15A

194

15A

23915

239

SW2

15B

15A

224

239

225

15B

224B

225B

86 85140

194

225B

224B

224

225

Section 8 — Electrical Data

Air-cooled Generators

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

ENGINE AND ALTERNATOR

BATTERY

HTO

LOP

7766

18 IM

RED

BATTERY

12V

CHARGE

WINDING

DPE

WINDING

FIELD

WINDING

POWER

STATOR

POWER

WINDING

194

225B

224B

224

225

67394

7766

77 66

224A 225A

224A

225A

56VA

224A 225

1VA

224

BCR

NEUTRAL

DIAGRAM KEY

BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB - CIRCUIT BREAKER, MAIN OUTPUT FS - FUEL SOLENOID F1 - FUSE 15 AMP HTO - HIGH OIL TEMPERATURE SWITCH

IM - IGNITION MODULE

113344

240VAC GENERATOR 12Vdc

OUTPUT TO

TRANSFER SWITCH

CONTACTOR

TRANSFER UTILITY

RELAY

COIL

23194 N2 N1

240VAC

INPUT

LOP - LOW OIL PRESSURE SWITCH SC - STARTER CONTACTER SM - STARTER MOTOR SP - SPARK PLUG SW1 - SWITCH, AUTO / OFF / MANUAL DPDT, ON-OFF-ON SW2 - SWITCH, SET EXERCISE SPST, N.C., ON-(OFF) TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)

Section 8 — Electrical Data

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

Section 8 — Electrical Data

Air-cooled Generators

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

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators Enclosure – Drawing No. 0F9431-B

SHEET METAL PAINT/MATERIAL CODE LEGEND

The following exploded views contain part numbers of various sheet metal components. Only the base part number is listed. When ordering sheet metal, the correct color and material information must be included as a sufﬁ x at the end of the part number as shown below. Material Color Example: Desc. Part No. Material Color Order As" S = Steel N = Tan Roof 0F6522 S = Steel N = Tan 0F6522SN A = Aluminum G = Gray Door 0F6555 A = Aluminum G = Gray 0F6555AG B = Black Divider 0F6558 S = Steel B = Black 0F6558SB

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

Enclosure – Drawing No. 0F9431-B

ITEM PART NO. QTY. DESCRIPTION

1 0F9653 1 PAD, 24 X 48” WITH MOUNTING HOLES 2 045771 4 NUT HEX M8-1.25 3 022129 4 WASHER LOCK 5/16 022129 5 WASHER LOCK 5/16 (7KW) 4 022145 8 WASHER FLAT 5/16 5 043107 4 SCREW HHC M8-1.25 X 25 6 090388 15 SCREW TAPTITE M6-1.0 X 12 7 0D3700 24 NUT, LOCKING FLANGE M6-1.0 (7KW) 8 0D4662 14 SCREW HHTR 5/16-18 X 3/4" (7KW) 0D4662 13 SCREW HHTR 5/16-18 X 3/4" 9 0F8871 1 SCROLL, FAN (7KW, 10KW) 0F8080 1 SCROLL, FAN 10 0F8246 1 PANEL, ALTERNATOR DIVIDER (7KW) 0F8915 1 PANEL, ALTERNATOR DIVIDER (10KW) 0F6558 1 PANEL, ALTERNATOR DIVIDER 11 092120 4 NUT LOCK TRIC M6 X 1.0 12 0F7825 1 FOAM, MUFFLER BOX FRONT 13 0F7824 1 FOAM, MUFFLER BOX END 14 0F6549 1 ENCLOSURE, EXHAUST SIDE 15 0F7824A 1 FOAM, MUFFLER BOX END 16 0D1840 2 BRACKET, BOTTOM SUPPORT 17 047411 6 SCREW HHC M6-1.0 X 16 G8.8 (7KW) 047411 8 SCREW HHC M6-1.0 X 16 G8.8 18 0F0710 12 RIVET POP 0.125” X 0.337” 19 0A2115 4 WASHER NYLON M6-1/4” 20 0C6735 2 SUPPORT, ROOF FOLDING 21 0D2979D 2 CLOTH HARDWARE 266.7mm X 387.4mm 22 0D7176 34 WASHER, SELF LOCKING 23 0F7827 2 FOAM, EXHAUST ENCLOSURE COVER 24 0F6570 1 COVER, BACK EXHAUST ENCLOSURE 25 0F6571 1 COVER, FRONT EXHAUST ENCLOSURE 26 0D2979B 1 CLOTH, HARDWARE 266.7mm X 146mm 27 0D2979C 1 CLOTH, HARDWARE 543mm X 146mm 28 022097 4 WASHER LOCK M6-1/4 (7KW) 022097 3 WASHER LOCK M6-1/4 29 022473 2 WASHER FLAT M6-1/4 30 0F7826 1 FOAM, MUFFLER BOX BACK 31 0F0165A 1 HINGE TYPE B WITH STUDS, SOCKET 32 0F6550 1 ENCLOSURE, SIDE & BACK 33 0F0164A 1 HINGE TYPE A WITH STUDS, SOCKET 34 0E1330A 1 GROMMET, 38.1 CROSS SLIT WITH HOLE 35 021267A 2 PLUG PLASTIC 1.5 BLIND GROMMET 36 0E5968 11 GASKET, EXTRUDED TRIM 37 0F0165 1 HINGE TYPE B WITH STUDS, PIN 38 0F0164 1 HINGE TYPE A WITH STUDS, PIN 39 0C1085 1 SCREW PPHM M3-0.5 X 8 40 0A8475 1 L/WASH SPECIAL #10 41 0G0400 1 WIRE ASSEMBLY, GROUND 42 0F6552 1 ENCLOSURE, ROOF 43 0F9379 1 FOAM, ROOF ENCLOSURE 44 0D1839 2 BRACKET, TOP SUPPORT 45 0F8210 1 REGULATOR ASSEMBLY (7KW) 0F8209 1 REGULATOR ASSEMBLY (10KW) 0F9078 1 REGUALTOR ASSEMBLY 46 0F5458 4 SCREW PLASTITE HI-LOW #10 X 3/8 47 0F5438 1 HARNESS, ENGINE (7KW) 0F5434 1 HARNESS ENG V-T HSB

ITEM PART NO. QTY. DESCRIPTION

48 0F8263 1 PANEL, ENGINE DIVIDER (7KW) 0F7886 1 PANEL, ENGINE DIVIDER (10KW) 0F7885 1 PANEL, ENGINE DIVIDER 49 023484H 1 BUSHING SNAP SB-1500-18 50 0D3058A 1 FOAM, FRONT INTAKE BAFFLE (7KW) 0E4245 1 FOAM, FRONT INTAKE BAFFLE 51 0D3058C 1 FOAM, BACK INTAKE BAFFLE (7KW) 52 0D1605A 1 BAFFLE, INTAKE (7KW) 0F7798 1 BAFFLE, INTAKE 53 0F8380 1 FOAM, TOP INTAKE BAFFLE 54 0D3472 1 GROMMET OVAL 31.75 X 50.8 55 0C8285 1 BRACKET, BATTERY SUPPORT 56 0D3167 1 GASKET, BATTERY SUPPORT BRACKET 57 0E1330 1 GROMMET, 38.1 DIA. CROSS SLIT 58 043116 3 SCREW HHC, M6-1.0 X 12 G8.8(7KW) 043116 1 SCREW HHC M6-1.0 X 12 G8.8 59 086729 1 CONTACTOR, STARTER (7KW) 60 0F8039 1 MOUNTING CLIP 61 022127 1 NUT HEX 1/4-20 (7KW) 62 0388040AJ0 1 CABLE, #6 RED BATTERY 38.5” 63 0F8847 1 GASKET, FRONT DIVIDER 0F8434 1 GASKET, FRONT DIVIDER (10KW) 64 0F9968 1 FUEL LINE, 1/2” OUTDOOR (NOT SHOWN) 65 0C2937 1 BRACKET, BATTERY HOLD DOWN (7KW) 66 049813 1 NUT HEX M6-1.0 G8 67 0A1658 1 LOCK WASHER SPECIAL 1/4 68 0G0617 1 EXTERNAL CONNECTION BOX 69 092079 1 SCREW TAPTITE M6-1.0 X 25 BP 70 055414 1 LUG SLDLSS #2-#8 X 17/64 CU 71 0F8234 1 ASSEMBLY, ENCLOSURE BASE (7KW) 0F7711 1 ASSEMBLY, ENCLOSURE BASE 72 0F8257 1 FOAM, FRONT ENCLOSURE 73 0C3906 2 SELF-ALIGN SCREW M6 HH 74 0F6555 1 ENCLOSURE, FRONT 75 0F8555 1 GASKET, DOOR SEAL 76 0D3037 1 LATCH, QUARTER TURN LOCKING 77 0D3037A 1 LATCH, QUARTER TURN NON-LOCKING 78 0F9143 2 PAWL, DOOR 79 0F8261 1 FOAM, BACK ENCLOSURE 80 0F5440 1 HARNESS GENERATOR TO EXTERNAL

CONNECTION BOX (7KW)

0F9328 1 HARNESS GENERATOR TO EXTERNAL

CONNECTION BOX (10KW)

0F5478 1 HARNESS GENERATOR TO EXTERNAL

CONNECTION BOX 81 051713 2 WASHER FLAT M5 82 022152 5 WASHER LOCK #10 83 036937 2 SCREW PPHM#10-32 X 1 84 022158 5 NUT HEX #10-32 85 0C8911 1 POWER BLOCK 86 026850 1 WASHER SHAKEPROOF EXT 1/4 STEEL 87 031879 2 WASHER FLAT #4 88 0D9784 1 NUT HEX LOCK M3-0.5

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators Control Panel – Drawing No. 0F9695-B

8,9

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

Control Panel – Drawing No. 0F9695-B

ITEM PART NO. QTY. DESCRIPTION

1 0E7886A 1 CIRCUIT BREAKER 30A X 2P 240V (7KW) 0E7886D 1 CIRCUIT BREAKER 45A X 2P 240V (10KW) 0E7886K 1 CIRCUIT BREAKER 55A X 2P 240V (13KW) 0E7886J 1 CIRCUIT BREAKER 65A X 2P 240V (16KW) 2 0A1801 1 ASSEMBLY, BATTERY CHARGER ENGINE 3 0F9719 1 ASSEMBLY, POTTED REGULATOR 4 0C2174 1 RELAY, 12V 25A SPST (NON 7KW) 5 075210A 1 BLOCK TERMINAL 1 POSITION 6 038750 1 SCREW HHC M6-1.0 x 30mm 7 0F8992 1 ASSEMBLY, HOME STANDBY CONTROLLER 0F1504 1 ASSEMBLY, HOME STANDBY CONTROLLER (7KW) 8 032300 1 HOLDER, FUSE 9 022676 1 FUSE, 15 AMP X AGC15 10 0E4494 1 SWITCH, ROCKER DPDT ON-OFF-ON 11 0E7890 1 CIRCUIT BREAKER MOUNTING BRACKET 12 023484E 1 SNAP BUSHING 13 075476 4 SCREW PPHM M4-0.7 x 16mm 14 043182 2 M3 LOCK WASHER (NON 7KW) 15 0E6480 6 NUT HEX LOCK M4-0.7 NYLON INSERT 16 0D4804A 1 CURRENT TRANSFORMER, IDLE CONTROL (NON 7KW) 17 0C1085 12 SCREW PPHM M3-0.5 x 8mm 0C1085 8 SCREW PPHM M3-0.5 x 8mm (7KW) 18 058000H 2 M3-0.5 TRIC NUT (NON 7KW) 19 023897 2 WASHER FLAT #10 20 0F8040 1 CONTROL, PANEL BOTTOM 0F9282 1 CONTROL, PANEL BOTTOM (7KW) 21 075235 4 SCREW HHC M5-0.8 x 30mm 22 0E3928 1 SWITCH, SPST 23 0D9784 4 NUT HEX LOCK M3-0.5 NYLON INSERT 0D9784 2 NUT HEX LOCK M3-0.5 NYLON INSERT (7KW) 24 0D8502 1 NEUTRAL BLOCK 25 031879 4 WASHER FLAT #4 031879 2 WASHER FLAT #4 (7KW) 26 0F5433 1 HARNESS, CONTROL PANEL WIRE (NOT SHOWN) 0F5437 1 HARNESS, CONTROL PANEL WIRE (NOT SHOWN) (7KW) 27 074908 4 SCREW HHTT, M5-0.8 x 10 BP 28 049813 1 NUT HEX M6-1.0 29 082025 6 NUT HEX LOCK M5-0.8 NYLON INSERT 30 0G0627 1 XFMR 240/16V 1VA&56VA W/PTC 31 022507 2 SCREW HHC 1/4”-20 x 1/2” 32 022097 3 WASHER LOCK M6-1/4” 33 046689 1 TERMINAL STRIP 4 POSITION 34 063617 1 RELAY PANEL 12VDC DPDT 10A 240VAC 35 075475 2 SCREW PPHM M4-0.7 x 10mm 36 043180 2 WASHER FLAT M4 37 0F8041 1 COVER, CONTROL PANEL COMPONENT 0F9283 1 COVER, CONTROL PANEL COMPONENT (7KW) 38 045770 2 SCREW HHC M5-0.8 x10mm 39 0E7866 1 COVER, CONTROL PANEL 0E7867 1 COVER, CONTROL PANEL (7KW) 40 0D3700 8 NUT FLANGE M6-1.0 NYLOK 41 0G0400 1 WIRE ASSEMBLY, GROUND 42 0E2874 1 SCREW HHTR 1/4"-20 X 3/4" 43 0A1658 2 WASHER LOCK SPECIAL 1/4” 44 022473 4 WASHER FLAT 1/4”-M6

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators Transfer Switch Assembly – Drawing No. 0F9774-A

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

Transfer Switch Assembly – Drawing No. 0F9774-A

ITEM PART NO. QTY. DESCRIPTION

1 0F8278 1 BOX LOAD CENTER 2 0D4800 1 COVER, 8 CIRCUIT LOAD CENTER 0F5211 1 COVER, 10 CIRCUIT LOAD CENTER 0D3092 1 COVER, 12 CIRCUIT LOAD CENTER 0F8312 1 COVER, 16 CIRCUIT LOAD CENTER 3 0C2237 1 TRANSFER SWITCH HOME STANDBY

100A 2P 250V 3A 077220 1 COIL UTILITY 3B 077220A 1 COIL STANDBY 3C 082574 1 INSULATOR-SIDEWALL (NOT SHOWN) 3D 084464 1 LIMIT SWITCH OPERATION (NOT

SHOWN) 4 074908 6 SCREW HHTT M5-0.8 X 10 5 024912 1 SCREW HHTT 1/4-20 X 5/8 6 0A1658 1 LOCK WASHER, SPECIAL-1/4” 7 063617 1 RELAY PANEL 12VDC DPDT 10A@240VAC 8 0E7889A 1 8 CIRCUIT LOAD CENTER 0E7889 1 12 CIRCUIT LOAD CENTER (ALSO USED

FOR 10 CIRCUIT) 0F9213 1 16 CIRCUIT LOAD CENTER 9 0A1495 4 SCREW HHTT M4-0.7 X 10 10 0A1661 2 RIVET POP .156” X .675” 11 022473 1 WASHER FLAT 1/4-M6 ZINC 12 081108 1 PLUG PLASTIC 0F9199 1 PLUG PLASTIC 13 0D4684 1 HARNESS ADAPTER PLATE 0D4684A 1 8 CIRCUIT HARNESS ADAPTER PLATE 14 0F8279 1 SUBPLATE, LOAD CENTER 15 0F4790 10.5” U-CHANNEL 16 022152 6 WASHER LOCK #10 17 064526 2 SCREW HWHS #6-25 X 3/8” 18 0E6155 1 ARM EXTENDER PIN 19 063378 4 HOLDER CABLE TIE 20 0G0979 1 HARNESS, 8 CIRCUIT LOAD CENTER TO

MAIN PANEL 0G0980 1 HARNESS, 10 CIRCUIT LOAD CENTER

TO MAIN PANEL 0G0981 1 HARNESS, 12 CIRCUIT LOAD CENTER

TO MAIN PANEL 0G0982 1 HARNESS, 16 CIRCUIT LOAD CENTER

TO MAIN PANEL

ITEM PART NO. QTY. DESCRIPTION

21 074138 2 LUG QUICK DISCONNECT NI-S 10X45

DEG BRASS / TIN 22 036933 6 SCREW PPHM #10-32 X 3/8” 23 077033 6 LUG SLDLSS 1/0-#14X9/16 AL/CU 24 048850 1 BLOCK TERMINAL 20A 5 X 6 X 1100V 25 028739 4 TIE WRAP 3.9" X .10" 26 0A2110 4 SCREW SWAGE 1/4-20 X 1/2" ZINC 27 0D3191 1 COVER, RELAY & TERMINAL BLOCK 28 0D3088 1 WIRE HARNESS, LOAD CENTER (NOT

SHOWN) 29 073591 2 FUSE HOLDER 30 073590A 2 FUSE 5A 31 040213B 4 SUPPORT SNAP-IN 1-3/8" 8 10 12 16 CIRCUIT 32 0E7888 A/R CIR BRK 20A 2P 1 1 33 0E7888A A/R CIR BRK 30A 2P 1 1 1 34 0E7888B A/R CIR BRK 15A 1P 5 3 5 5 35 0E7888C A/R CIR BRK 20A 1P 1 3 3 5 36 0E7888D A/R CIR BRK 40A 2P 1 1 37 0E7888E A/R CIR BRK 50A 2P 1 38 0D3320 1 COVER - HARNESS ENTRY 39 0F5439 1 HARNESS, 8 CIRCUIT LOAD CENTER TO

EXT CONN BOX 0F9327 1 HARNESS, 10 CIRCUIT LOAD CENTER

TO EXT CONN BOX 0F6720 1 HARNESS, 12 CIRCUIT LOAD CENTER

TO EXT CONN BOX 0F6720 1 HARNESS, 16 CIRCUIT LOAD CENTER

TO EXT CONN BOX 40 075475 2 SCREW PPHM M4-0.7 X 10 41 0A7215 4 SCREW SW 1/4"-20 X 5/8” WITH WASHER 42 0E6193 1 BRACKET, ARM EXTENDER

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators 13 & 16kW, GT-990 Engine – Drawing No. 0F9430-C - Part 1

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

13 & 16kW, GT-990 Engine – Drawing No. 0F9430-C - Part 1

ITEM PART NO. QTY. DESCRIPTION

1 0C5729 1 ASSEMBLY, CRANKCASE HOUSING WITH

SLEEVE 2 0E9843 1 SEAL, 38 I.D. CRANKSHAFT 3 090388 3 SCREW, TAPTITE M6-1.0 X 12 YC 4 0C5372 1 ASSEMBLY, BREATHER 5 0C3005 1 GASKET, BREATHER COVER 6 0E3372B 1 SEPARATOR, OIL BREATHER 7 0D8067A 1 ASSEMBLY, HEAD #1 G&S 8 071983 4 RETAINER, PISTON PIN 20 9 0C2981F 1 ROCKER, COVER NO OIL FILL 11 0E2985 2 PISTON, HC 12 021533 2 SET, PISTON RING 90MM 13 0E1466 2 PIN PISTON 14 0D4041 1 ASSEMBLY, CAMSHAFT & GEAR 15 0C2977 1 GASKET, CRANK CASE 16 0C5943 1 SEAL, OIL PASSAGE 17 0E4357E 1 ASSEMBLY, CRANKSHAFT HORIZONTAL

DIRECT DRIVE 18 0E3223 2 ASSEMBLY, CONNECTING ROD 19 0D2157 2 SCREW SHC M6-1.0 X 50 G8.8 20 0E6098 1 SCREEN, OIL PICKUP 21 0D4123A 1 ASSEMBLY, OIL PUMP 22 0E8152 1 O-RING .49 ID X .07 THICK 23 0C3011 2 COVER, OIL RELIEF 24 0C3009 2 SPRING, OIL RELIEF 25 0C3010 2 BALL, 1/2D OIL RELIEF 26 093873 2 WASHER, LOCK RIB M6 27 0F5458 1 SCREW, PLASTITE HI-LOW #10 28 0C3027 3 O-RING, 3/8” X 1/2” 29 0C5998 1 CLAMP, OIL TUBE 30 0D4497 1 PLUG-CRANKCASE 31 0F2664C 1 ASSEMBLY, DIPSTICK WITH HANDLE 32 0C5305 1 TUBE, DIPSTICK 33 0D6147 7 SCREW HHFC M6-1.0 X 10mm

ITEM PART NO. QTY. DESCRIPTION

34 043790 1 BARBED ELBOW 90 3/8NPT X 3/8 35 0E9842 1 SEAL, 42 I.D. CRANKSHAFT 36 0C5731 1 ASSEMBLY, HOUSING COVER WITH

SLEEVE 37 0C3006 10 SCREW, HHFC M10-1.5 X 55 38 080318 8 SCREW HHFC M6-1.0 X 25 39 093064 1 ASSEMBLY, OIL FILL CAP 40 0C8808 2 HOOK, LIFTING 41 0D2723D 1 ROCKER, COVER WITH OIL FILL 42 0C2979 2 GASKET, VALVE COVER 43 086515 8 KEEPER, VALVE SPRING 44 0D2274 4 RETAINER, VALVE SPRING 45 0D3867 4 SPRING, VALVE 46 078672 2 SEAL, VALVE STEM D7 47 0C5371 4 WASHER, VALVE SPRING 48 072694 4 STUD, ROCKER ARM PIVOT 49 0D5313 4 ROCKER ARM 50 0D3998 4 NUT HEX M8-1.0 G8 YEL CHR 51 0D6024 2 PLATE, PUSH ROD GUIDE 52 0C2976 12 SCREW HHFC M8-1.25 X 65 53 086516 2 VALVE, EXHAUST 54 0C2229 2 VALVE, INTAKE 55 083897 4 TAPPET, SOLID 56 0D8067B 1 ASSEMBLY, HEAD #2 G&S 57 0D9853D 4 PUSHROD, 147 58 0C2978 2 GASKET, HEAD 59 0D4010 1 KIT GASKET 60 0D4012 1 KIT BREATHER ASSEMBLY 61 0D8675A 1 KIT HEAD ASSEMBLY CYLINDER 1 62 0D8675B 1 KIT HEAD ASSEMBLY CYLINDER 2 63 0D4015 1 KIT OIL RELIEF 64 078699C 2 SLEEVE DOWEL PIN 14 DIA. 65 078699B 4 SLEEVE DOWEL PIN 12 DIA.

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators 13 & 16kW, GT-990 Engine – Drawing No. 0F9430-C - Part 2

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

13 & 16kW, GT-990 Engine – Drawing No. 0F9430-C - Part 2

ITEM PART NO. QTY. DESCRIPTION

64 022145 1 WASHER FLAT M8 – 5/16 65 0C5136A 2 KNOB, AIR CLEANER 66 0C3024 1 COVER, AIRBOX NG/LP 67 0C3040 1 PRE-CLEANER, 68 0C8127 1 ELEMENT, AIR CLEANER 69 0F9255 1 ASSEMBLY, MIXER/AIRBOX 990 70 0E9582 4 SCREW SHLDR(8MM) M6-1.0 X 21 71 0D4417 4 WASHER,RUBBER 1/4" X 1/8" THICK 72 0G0767A 2 SPARKPLUG,GT990 HSB 73 0E6043 2 SCREW TAPTITE M5 – 0.8 X 8 74 0D1142A 1 WRAPPER, LOWER CYLINDER 2 75 0C3025 1 SWITCH, OIL PRESS 76 0C7292 1 NIPPLE, ¾”-16 UNF 77 070185B 1 OIL FILTER 78 0D3083 1 ASSY, OIL DRAIN HOSE 79 0F2094 2 SCREW M3 – 0.5 X 6 SEMS 80 075281 1 SWITCH, THERMAL 284F 81 035461 2 BARBED STRAIGHT 1/4NPT X 3/8 82 0F6301 4 CLAMP, HOSE OETIKER 16.5MM 83 0G0286 2 HOSE, 3/8” I.D. X 6” LG 84 0E9506 1 COOLER, OIL 85 0C9764 4 SCREW PLASTITE 1/4-15 X 3/4 86 0C3043 2 GASKET, MANIFOLD / PORT 87 0C7694 1 MANIFOLD CYLINDER 2 88 070008 4 WASHER FLAT M8 SS 89 070006 4 WASHER LOCK M8 SSTL 90 040976 4 SCREW SHC M8 – 1.25 X 20 G12.9 91 045756 17 SCREW TAPTITE M6 – 1X10 YELLOW

CHROME 92 0E4997 1 ASSY,GROUND WIRE CONNECTOR 93 0C3033 1 WASHER, 25MM I.D. 94 0C3034 1 NUT, HEX M24 95 0C9763 4 NUT, GROMMET 1/4 PLUG 96 0D1131 1 GUARD, FAN 97 0F1169K 1 HOUSING, BLOWER NG COOLER 98 051754 2 SCREW HHC M8 – 1.25 X 12 G8.8 99 0A5992 2 WASHER SHAKEPROOF INT M8 SS 100 0C3032 1 PLATE, FAN 101 0C3031 1 FAN, NYLON 102 0C3725E 1 FLYWHEEL ASSEMBLY 103 0F1170A 1 PLATE, BACKING WITH OIL COOLER 104 0C7693 1 MANIFOLD CYLINDER 1 105 0C3041A 2 SLEEVE, RUBBER 106 082774 1 KEY, WOODRUFF 4 X 19D 107 0C3036A 1 HOSE BREATHER 108 0C3019 1 WRAPPER, LOWER CYLINDER 1 109 0C3018 1 WRAPPER, UPPER CYLINDER 1

ITEM PART NO. QTY. DESCRIPTION

110 0D1143 1 WRAPPER, UPPER CYLINDER 2 111 0E9323 1 STARTER MOTOR HEAR REDUCED 1KW 112 061906 2 SCREW HHC M8 – 1.25 X 85 G8.8 113 022129 3 WASHER LOCK M8 – 5/16 114 0F1177 1 ASSEMBLY, GROUND WIRE 115 022097 6 WASHER LOCK M6 – 1/4 116 092079 4 SCREW TAPTITE M6 – 1.0 X 25 BP 117 0G0798A 1 ASSY, IGN COIL W/DIODE, CYLINDER 1 118 0G0798B 1 ASSY, IGN COIL W/DIODE, CYLINDER 2 119 0E9568 1 ASSY, THROTTLE SHAFT 120 0E9565 2 THROTTLE VALVE 121 074027 4 SCREW PPHM M3 – 0.5 X 5 122 0C3044 1 COVER, DUST, MIX/AIRBOX 123 0C4756 1 SPRING, IDLE ADJUST 124 075477 1 SCREW PPHM M5 – 0.58 X 20 125 043116 2 SCREW HHC M6 – 1.0 X 12 126 0E1644 1 SCREW BHSC M6-1.0 X 12 SS 127 0E9572 1 BRACKET, STEPPER MOTOR 128 0D9784 1 NUT HEX LOCK M3 – 0.5 NYLON INSERT 129 0E5108 1 ASSY, CONTROLLER 130 0D6342 1 BALL STUD, 10MM 131 0E9570 1 ASSY, THROTTLE ROD 132 0E9577 1 BELLOWS, INTAKE 133 0E5846 1 EXPANSION PLUG 134 0E9419 3 #10 O-RING 135 0C4760 1 PLUG, MANIFOLD 136 0F9253 1 ASSY, AIR BOX BASE 137 0E9553 1 PIN, FUEL SELECTOR 138 0E9554 1 PIN, FUEL SEL STOP 139 0E9348 1 SOLENOID COVER 140 0E9599 1 LINKAGE, CHOKE 141 0E9595 4 SCREW PPPH HI-LO #6 X 1/2 142 090987 1 SCREW PHTT M3 – 0.5 X 8 143 0E9403 1 RETAINER, CHOKE RETURN SPRING 144 0E9571 1 SPRING, CHOKE RETURN 145 0E9380 1 WASHER, BELLEVILLE SPRING 146 0A6345 1 SCREW PPHM M2 – 0.4 X 8 147 0E9598 1 CHOKE ARM 148 0E9593 1 SCREW SHOULDER M3 – 0.5 X 6 149 0E9564 1 VALVE, CHOKE 150 0E9575 1 SHAFT, CHOKE 151 0E9357 1 SEAL, GOVERNOR ARM 152 0A7094 2 SCREW PHM #4 – 40 X 1/4 153 0E9574 1 BRACKET, SOLENOID 154 0F9273 1 SOLENOID, 6VDC 155 0F5467 1 NUT HEX M8 – 1.25 YELLOW ZINC 156 0E9557 1 SPRING, CHOKE VALVE ADJUST

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators 10kW, GT-530 Engine – Drawing No. 0F9429-C - Part 1

Section 9 — Exploded Views and Parts Lists

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

ITEM PART NO. QTY. DESCRIPTION

1 0E9428B 1 CRANKCASE 2 0E3812 2 SEAL D 35 X 48.2 3 0C8566 2 SCREW HHFC M6 – 1.0 X 20 4 0E9367A 1 ASSY, BREATHER 5 0E9366 1 GASKET BREATHER ASSY 6 0E9304 1 CYLINDER HEAD 1 7 0E9334C 1 COVER, ROCKER PLAIN 8 076390 4 PISTON PIN RETAINER RING 9 076389 2 PISTON PIN 10 088057 2 PISTON 11 088411 2 PISTON RING SET 12 0E9322A 2 ASSY CONNECTING ROD 13 0E9407A 1 ASSY, CAM & GEAR 14 0E9350 1 GASKET CRANKCASE 15 0E9318E 1 ASSY CRANKSHAFT W/PLUG 16 043116 3 SCREW HHC M6 – 1.0 X 12 17 093873 3 WASHER LOCK M6 RIBBED 18 0G0272 1 ASSY GEROTOR 19 0E9482 1 SPRING OIL PRESSURE RELIEF 20 0A5776 1 BALL 11/32 DIA PRESSURE RELIEF 21 0C5315A 1 GEROTOR OUTER 9MM THICK 22 0C5314A 1 GEROTOR INNER 9MM THICK 23 0E9473 1 GEAR COVER 24 073144 9 SCREW HHFC M8 – 1.25 X 45 25 0C3027 2 O-RING 3/8 X 1/2 26 0E9358 1 SCREEN OIL PICK-UP 27 093064 1 ASSY, OIL FILL CAP 28 0E9334A 1 COVER, ROCKER, W/ FILL 29 0E9352 2 GASKET, VALVE COVER 30 0C3592 8 KEEPER, VALVE SPRING 31 0C3733 4 VALVE RETAINER 32 0C4390 4 SPRING VALVE 33 088156 2 SEAL, VALVE STEM 34 084186 4 WASHER, VALVE SPRING 35 0E9368 2 SPARKPLUG 36 077168 12 SCREW HHC M8 – 1.25 X 56 37 0E9305 1 CYLINDER HEAD 2 38 0C3590 2 VALVE EXHAUST 39 0E9351 2 GASKET CYLINDER HEAD 40 0C3591 2 VALVE INTAKE 41 083235 4 TAPPET, SOLID 42 0E9455E 4 PUSHROD, ALUMINUM 43 0E9353A 2 PLATE, PUSH ROD GUIDE 44 076307 4 NUT JAM (ROCKER ARM) 45 077160 4 ROCKER ARM 46 077161 4 STUD ROCKER ARM PIVOT 47 0G0273 1 GASKET KIT 48 0G0274 1 BREATHER KIT 49 0G0275 1 KIT HEAD ASSY CYLINDER #1 50 0G0276 1 KIT HEAD ASSEMBLY CYLINDER #2 51 0E9502 1 SEPERATOR, OIL, GT530 52 080318 12 SCREW HHFC M6 – 1.0 X 25 53 0E3372C 1 SEPARATOR, OIL BREATHER GT530 54 078699B 6 SLEEVE DOWEL PIN 12 DIA. 55 0C5943 1 SEAL, OIL PASSAGE 56 043790 1 BARBED EL 90 3/8 NPT X 3/8 57 0D4788 1 PLUG STD PIPE 3/8 STEEL SQ HD

Air-cooled Generators

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators 10kW, GT-530 Engine – Drawing No. 0F9429-C - Part 2

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

10kW, GT-530 Engine – Drawing No. 0F9429-C - Part 2

ITEM PART NO. QTY. DESCRIPTION

58 022097 3 WASHER LOCK M6-1/4 59 0E9561 1 INTAKE ADAPTER 60 0E9472 1 GASKET, AIRBOX TO CARB/MIXER 61 0E9471 1 GASKET, MANIFOLD TO CARB/MIXER 62 078643B 4 BOLT, CARB MOUNT M6 – 1.0 X 85 63 0D9784 1 NUT HEX LOCK M3 – 0.5 64 0E9584 1 ASSY, CONTROLLER 65 0D6342 1 BALL STUD, 10 MM 66 0E9587 1 ASSY, THROTTLE ROD 67 0C9997 1 GUARD, FAN 68 0E9319 2 GASKET INTAKE 69 0E9597 1 BREATHER HOSE 70 040976 4 SCREW SHC M8 – 1.25 X 20 G12.9 71 022129 2 WASHER LOCK M8 – 5/16 72 061906 2 SCREW HHC M8 – 1.25 X 85 73 0E9323 1 STARTER MOTOR 74 0E9507 6 SCREW HHFC M8 – 1.25 X 14 75 0E9362 2 LIFTING HOOK 76 0E9337 1 WRAPPER OUTER CYLINDER 1 77 0E9339 1 WRAPPER INNER CYLINDER 1 78 0E9402 1 TUBE, DIPSTICK 79 0F2664H 1 ASSY, DIPSTICK /TEXT 80 0E9336F 1 BLOWER HOUSING 81 0D6147 6 SCREW HHFC M6-1.0 X 10 G8.8 82 0E5139 3 SCREW HHFC M6-1.0 X 8 G8.8 83 0E9432 1 WRAPPER INNER CYLINDER 2 84 0E9338 1 WRAPPER OUTER CYLINDER 2 85 0E9370 1 GASKET, OIL FILTER ADAPTER 86 0E9505A 1 ASSY, DIRECT OIL COOLER ADAPTER 87 0F5458 2 SCREW PLASTITE HI-LOW #10X3/8

ITEM PART NO. QTY. DESCRIPTION

88 045757 3 SCREW HHC M6 – 1.0 X 25 89 070185B 1 OIL FILTER 90 094090 1 THERMAL SWITCH 91 0F2094 2 SCREW PPHM M3-0.5 X 6 SEMS 92 0D3083 1 ASSEMBLY, OIL DRAIN HOSE 93 0A8584 1 OIL PRESSURE SWITCH 94 082774 1 KEY, WOODRUFF 4 X 19D 95 0E7209 1 ASSY, GROUNDING WIRE 96 0E9514B 1 ASSY IGNITION COIL CYLINDER 1 0E9514C 1 ASSY IGNITION COIL CYLINDER 2 97 026850 4 WASHER SHAKEPROOF EXT 1/4 98 0E9443 1 ASSY, MIXER DUAL FUEL 99 0F6301 4 CLAMP, HOSE OETIKER 16.5MM 100 0G0286 1 HOSE 3/8”ID X 6” SAE J30R9 101 0G0479 1 HOSE 3/8”ID X 7.25 SAE J30R9 102 0E9340 1 BACKING PLATE 103 0E9525C 1 ASSY, FLYWHEEL & RING GEAR 104 0E9486 1 FAN, FLYWHEEL, 20 FIN, 218.8 OD 105 0A5992 2 WASHER LOCK INT M8 106 048571 2 SCREW HHC M8 – 1.25 X 10 107 067890 1 NUT HEX M20 – 1.5 108 067198N 1 WASHER BELV – 20 X 2.2 109 0C3032 1 PLATE, FAN 110 0E4997 1 ASSY, GROUND WIRE CONNECTOR 111 0E9406 1 OIL COOLER 112 0G1705 14 SCREW HHFC M6 – 1.0 X 14 113 0E9450 1 CENTER BAFFLE 114 0E9376 1 INTAKE MANIFOLD 115 0E9550 1 FRONT COVER

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators 7kW, GN-410 Engine – Drawing No. 0F9428 - Part 1

27 28

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

ITEM PART NO. QTY. DESCRIPTION

1 0E3221 1 ASSEMBLY, CONNECTING ROD 2 0E1466 1 PIN, PISTON D20 3 021533 1 SET, PISTON RING 90MM 4 0E2985 1 PISTON, HC 5 071983 2 RETAINER, PISTON PIN 20 6 0E8440 1 ASSEMBLY, CRANKSHAFT GH410 SMALL TAPER 7 0A7628 1 ARM, GOVERNOR RC45 8 078658 1 PIN, “R” GOVERNOR ARM 9 078659 2 WASHER, GOVERNOR ARM THRUST 10 088261E 1 CRANKCASE, SUBASSEMBLY WITH PLUGS GH410 11 0E3812 2 SEAL, 35 I.D. CRANKSHAFT 12 0E6519 1 ASSEMBLY, GOVERNOR GEAR 13 078645 1 C-RING, GOVERNOR GEAR RETAINER 14 0A7811 1 SPOOL, GOVERNOR- MACHINE 15 0A9877 1 ASSEMBLY, CAMSHAFT & GEAR 16 076701 1 GASKET , CRANKCASE 17 021713B 1 GASKET, HEAD 410 18 078691 1 COVER, OIL PRESSURE RELIEF 19 0A5771 1 SPRING, OIL RELIEF 360 20 0A5776 1 BALL, DIA 11/32 PRESSURE RELIEF 21 076361 1 WASHER, THRUST GOVERNOR GEAR 22 0A8898D 1 ASSEMBLY, COVER, GEAR TOP CHECK / FILL 23 0D2274 2 RETAINER, VALVE SPRING 24 0C4391 2 VALVE SPRING LF 25 086025 1 SET,GEROTOR 12 THK 26 0E3341 1 BALANCER 27 021714 1 ASSEMBLY,CYLINDER HEAD SEATS & GUIDES 28 086516 1 VALVE, EXHAUST 29 086517 1 VALVE, INTAKE 30 0D9853B 2 PUSH ROD 174.9 31 083897 2 TAPPET 32 077158 1 ASSEMBLY, SCREEN OIL PICK-UP 33 0C3150 1 GASKET, ROCKER COVER 410 34 072694 2 STUD, D20 PIVOT BALL 35 083907 2 ROCKER ARM 36 072696 2 NUT, JAM (ROCKER ARM) 37 078694 1 PLATE, PUSH ROD GUIDE 38 021742 4 SCREW, HHFL M10-1.5 X 105 39 0D6094 1 ASSEMBLY, ROCKER COVER BREATHER 40 076329 1 PLUG, OIL FILL PLASTIC 41 0E0057 1 O-RING 17.8 I.D. x 2.4 42 0D4788 1 PLUG, STANDARD PIPE 3/8 STEEL SQUARE HEAD 43 074908 1 SCREW, TAPTITE M5-0.8 X 10 BP 44 086515 4 KEEPER, VALVE SPRING 45 078606 4 SCREW & LOCKWASHER M6-1 X 12 46 0A1442 8 SCREW, HHFC M8-1.25 X 42 47 078672 1 SEAL, VALVE STEM D7 48 089673 2 WASHER, VALVE SPRING 49 0B2104 1 WASHER, LARGE SPRING 50 078699C 2 DOWEL, SEAMED SLEEVE 51 0A7627 1 SHAFT, GOVERNOR RC55 52 043790A 1 BARBED ELBOW 90 3/8NPT X 3/8 LOCKTITE 53 088590 1 DOWEL DIA 12 X 18L 54 078699B 1 DOWEL, SLEEVE SEAMED 12 DIA.

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators 7kW, GN-410 Engine – Drawing No. 0F9428 - Part 2

485210

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

7kW, GN-410 Engine – Drawing No. 0F9428 - Part 2

ITEM PART NO. QTY. DESCRIPTION

1 0C1069 5 SCREW, TAPTITE M6-1.0X8 YELLOW CHROME 2 0D2922 1 HOUSING, BLOWER 3 0F8426 1 TUBE, DIPSTICK 4 0C9997 1 GUARD, FAN 5 088434 1 WRAPPER, BOTTOM 6 045756 11 SCREW, TAPTITE M6-1X10 YELLOW CHROME 7 0C4176A 1 WRAPPER, TOP 8 0D9004A 1 ASSY, STARTER 9 059985 2 SCREW, SHC M8-1.25 X 45 G12.9 10 022129 3 WASHER, LOCK M8-5/16 11 0C2458A 1 BACKPLATE, L/F D/F 12 083512 1 SCREW, TAPTITE M8-1.25 X 16 BP 13 0D1401A 1 BREATHER TUBE 14 091039 1 GASKET, INTAKE ADAPTER 15 0C9619 1 ASSEMBLY, PLASTIC CARB 16 049811 2 WASHER, FLAT M6 17 022097 4 WASHER, LOCK M6-1/4 18 040945 2 SCREW, SHC M6-1.0 X 20 G12.9 19 086999 1 GASKET,OIL FILTR ADAPTER 20 0D5667A 1 ADAPTER, OIL FILTER 21 049821 2 SCREW, SHC M8-1.25 X 30 G12.9 22 099236 1 SWITCH, OIL 8.0 PSI 23 070185B 1 OIL FILTER 24 082774 1 KEY, WOODRFF 4 X 19D 25 091222E 1 FLYWHEEL WITH RING GEAR 32DEG. 26 067198N 1 WASHER,BELV-20 X 2.2 27 067890 1 NUT, HEX - FLYWHEEL 28 0E7585 1 SPARKPLUG 29 072734 1 ASSEMBLY,GOVERNOR LEVER 12 HP 30 072735 1 ROD,GOVERNOR CONTROL. 31 0C3978 1 SPRING, ANTI-LASH 32 0C6040 1 ASSEMBLY, WIRE 33 0D9760 1 ASSEMBLY, IGNITION COIL 34 092079 2 SCREW, TAPTITE M6-1.0 X 25 BP 35 0F3800 1 SPRING GOVERNOR 36 083502 1 BOLT, GOVERNOR ADJUST M5 37 082025 1 NUT HEX LOCK M5-0.8 NYINS ZINC 38 0D3083 1 ASSEMBLY, OIL DRAIN HOSE 39 0E7887C 1 ASSEMBLY, CAP & DIPSTICK 40 090072 1 O-RING 9/16 X 3/4 X 3/32 41 075281 1 SWITCH, THERMAL 42 022145 1 WASHER FLAT 5/16 - M8 43 0F2094 2 SCREW, M3-0.5 X 6 SEMS 44 0C4373 1 SPACER, ENDFRAME 45 022717B 1 GOMMET 46 0F3865 1 SPRING SECONDARY 47 0F3855 1 BRACKET SECONDARY GOVERNOR SPRING 48 039253 1 SCREW HHC M8-1.25 x 20 49 0D3751 1 SPRING, IDLE RETURNING 50 0F3921 1 BARREL GOVERNOR ADJUSTMENT 51 0C8493 1 SCREW SHC M5-0.8 x 30 52 0D8758 1 ENGINE LIFT HOOK

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators 7kW, GN-410 Engine – Drawing No. 0F9422-B

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

ITEM PART NO. QTY. DESCRIPTION

1 0F8186 1 ADAPTOR, ENGINE 2 0F5540H 1 STATOR 3 0C9934H 1 ROTOR 4 0F7774A 1 CARRIER, REAR BEARING 5 0C8096 1 FAN, 8” CURVED BLADE 6 0F6591 1 MUFFLER 7 0F8078 1 TAIL PIPE, MUFFLER 9 056482 1 BEARING 10 0C3168 3 5/16 SPECIAL L/WASH 11 056147 1 BOLT ROTOR HHCS 5/16”-24 X 13-1/2” G5 12 0D1847 4 BOLT STATOR IHHCS M8-1.25 x 305mm 13 0C7038C 1 BRACKET, ALTERNATOR MOUNTING 14 0F9445 1 DUCT, ALTERNATOR AIR 15 0F9497 1 GASKET, ALTERNATOR AIR DUCT 16 0C7038B 1 BRACKET, ENGINE MOUNTING 17 0C7758 4 RUBBER MOUNT 18 0388050AE0 1 CABLE, #6 40” BLACK BATTERY 19 0C2417A 1 EARTH STRAP 3/8X 3/8 20 0F6528 1 EXHAUST FLEX 21 066386 1 ASSEMBLY BRUSH HOLDER 22 029451 1.8 FT TAPE ELEC UL FOAM 1/8 X 1/2 23 049451 1 WASHER FLAT .406ID X 1.62OD 24 022237 4 WASHER LOCK 3/8 25 022511 4 BOLT HHC 3/8-16 X 1-1/4 G5 26 022131 4 WASHER FLAT 3/8 27 039287 4 SCREW HHC M8-1.25 X 45 G8.8 28 022145 18 WASHER FLAT 5/16 29 049820 4 NUT LOCK HEX M8-1.25 NYL INSRT 30 090388 8 SCREW TAP M6-1.0X12 31 022129 17 WASHER LOCK M8-5/16 32 022259 8 NUT HEX 5/16-18 33 059637 2 SCREW TAPTITE 3/8-16X 3/4” 34 048031K 3 BAND, HOSE CLAMP 35.05 DIA. 35 0C9592 1 BELLOWS 36 048031M 2 HOSE CLAMP 3/4" 37 040976 2 SCREW SHC M8-1.25 X 20 G12.9 38 0G0414 1 PLATE “HOT” 39 028237 3 U-BOLT 5/16”-18 X 1.38” W/ SADDLE 40 090239 1 GASKET, EXHAUST 41 0C6989 1 STINGER, ENGINE AIR IN 42 0D1214 1 BASE, AIR CLEANER 43 0C8127 1 ELEMENT, AIR CLEANER 44 0C3024 1 COVER, AIR CLEANER NG/LP 45 0D2273 1 TUBE, 1.25"O.D. x 20Ga. x 12.125" LONG 46 055934N 1 CLAMP VINYL 1.31 X .281 Z 47 0F7065 1.25 FT HOSE LP 1/2" I.D. 48 0C5136A 2 KNOB, AIR CLEANER 49 039253 2 SCREW HHC M8-1.25 X 20 G8.8 50 022473 4 WASHER FLAT 1/4 52 066849 2 SCREW HHTT M5-0.8 X 16 53 0F6551 1 FLEX COVER 54 0F8079 1 BRACKET MUFFLER ACCESS 55 0F0710 2 RIVET POP 0.125” X 0.337” 56 0F8256 1 EXHAUST MANIFOLD 57 045771 4 NUT HEX M8-1.25 NY INS 58 0G0676 2 SCREW THTT M6-1.0 X 10 59 074906 4 SCREW HHTT M6-1.0 X 20

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators 10, 13, and 16kW, V-twin Generators – Drawing No. 0F9423-C

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

10, 13, and 16kW, V-twin Generators – Drawing No. 0F9423-C

ITEM PART NO. QTY. DESCRIPTION

1 0F8186 1 ADATOR, ENGINE 2 0F6694 1 STATOR (16KW) 0F5538 1 STATOR (13KW) 0F7548 1 STATOR (10KW) 3 0F9795 1 ROTOR (16KW) 0F5539 1 ROTOR (13KW) 0F7549 1 ROTOR (10KW) 4 0F7774 1 CARRIER, REAR BEARING 5 0E9579 1 FAN, 12” CURVED BLADE 0F8998 1 FAN, 12” CURVED BLADE (10KW) 6 0F6591 1 MUFFLER 7 0F8078 1 TAIL PIPE, MUFFLER 8 0F7797 1 FLEX BASE 0F8141 1 FLEX BASE (10KW) 9 056482 1 BEARING 10 0C3168 3 5/16 SPECIAL LOCK WASHER 11 0D1838 1 BOLT, IHHCS 3/8”-24 X 15.50” 12 0D1846 4 BOLT, IHHCS M8-1.25 X 345mm 13 0C7038 1 BRACKET, ALTERNATOR MOUNTING 14 0F9396 1 DUCT, ALTERNATOR AIR 15 0D2559 1 GASKET, ALTERNATOR AIR DUCT 16 0C7038A 1 BRACKET, ENGINE MOUNTING 0F4179 1 PLATE, MOUNTING ENG 530HSB 17 0C7758 4 RUBBER MOUNT 18 0388050AD0 1 CABLE, #6 48” BLACK BATTERY 19 0C2417A 1 EARTH STRAP 3/8 X 3/8 20 0F6528 1 EXHAUST FLEX 21 066386 1 ASSEMBLY BRUSH HOLDER 22 029451 2.6 FT TAPE ELEC UL FOAM 1/8 X 1/2 23 049451 1 WASHER FLAT .406ID X 1.62OD 24 022237 5 WASHER LOCK 3/8 25 022511 4 SCREW HHC 3/8 X 16 X 1-1/4 26 022131 4 WASHER FLAT 3/8 ZINC 27 051731 4 SCREW HHC M8-1.25 X 50 28 022145 18 WASHER FLAT 5/16 ZINC 29 049820 4 NUT LOCK HEX M8-1.25 NYL INSERT 30 0G0676 2 SCREW THTT M6-1.0 X 10 31 022129 18 WASHER LOCK M8-5/16 32 022259 8 NUT LOCK HEX 5/16-18 33 059637 2 SCREW TAPTITE 3/8-16 X ¾

ITEM PART NO. QTY. DESCRIPTION

34 0D4662 3 SCREW 5/16-18 X 3/4” 35 0F7065 3 FT HOSE RES ½ LP GAS 36 048031M 4 HOSE CLAMP ¾” I.D. 38 0G0414 1 PLATE, “HOT” 39 0D5823 3 U-BOLT 5/16”-18 X 1.62” WITH SADDLE 40 0E9369 2 GASKET, EXHAUST PORT (10KW) 0C4138 2 GASKET, EXHAUST PORT 41 040173 2 CLAMP HOSE #5.5 0.62”-0.62” (10KW) 42 074995 1.44 FT HOSE ¼ ID LPG 350PSI UL21 (10KW) 43 066849 2 SCREW HHTT M5-0.8 X 16 44 0F7799 1 EXHAUST MANIFOLD 0F8115 1 EXHAUST MANIFOLD (10KW) 45 0F7796 1 FLEX COVER 0F8204 1 FLEX COVER (10KW) 46 0F9385 1 FLEX COVER EXTENSION (10KW) 47 090388 13 SCREW TAPTITE M6-1.0 X 12 48 045771 4 NUT HEX M8-1.25 49 039253 2 SCREW HHC M8-1.25 X 20 50 0F0710 5 RIVET POP 0.125” X 0.337” (10KW) 0F0710 2 RIVET POP 0.125” X 0.337” 51 0F8079 1 BRACKET MUFFLER ACCESS 52 0F9273 1 SOLENOID, 6 VOLTS DC (10KW) 53 0E9592 2 SCREW PPHM $4-40 X 3/8 SEMS (10KW) 54 0E9588 1 LINKAGE, CHOKE (10KW) 55 077091 1 COTTER PIN (10KW) 56 0E9581 1 AIR CLEANER GTH530 HSB (10KW) 57 0E9594 3 SCREW PPPH HI-LO #14-15 X ½ (10KW) 58 0E9590 1 ASSEMBLY, CHOKE SHAFT (10KW) 59 0E9542 1 VALVE, CHOKE (10KW) 60 0D1683 2 SCREW PFHM M3-0.5 X 5 (10KW) 61 077075 1 BOOT, CHOKE SOLENOID (10KW) 62 0E9595 2 SCREW PPPH HI-LO #6/1/2 W/ #5HD

(10KW) 63 0E9589 1 CHOKE HSG (10KW) 64 0E9591 1 SPRING-CHOKE RETURN (10KW) 65 0E9549 1 HOSE, INTAKE GTH530 HSB (10KW) 66 035685 1 CLAMP HOSE #28 1.32-2.25 67 099502 2 CLAMP HOSE #24 B1.06-2.00 68 0C8565 4 SCREW SHC M8-1.25 X 18 G8.8

Section 9 — Exploded Views and Parts Lists

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

7KW

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

ITEM PART NO. QTY. DESCRIPTION

1 0D5694 1 CASTING, TWIN REGULATOR HOUSING (7KW) 0F9285 1 CASTING, TWIN REGULATOR HOUSING 2 0F5022 1 SOLENOID COIL, 12VDC 3 0C4647 1 GASKET , SOLENOID 4 0D4166 1 PLUNGER, LP REGULATOR ASSEMBLY 5 0F8822 1 REGULATOR BRACKET 6 022145 2 WASHER FLAT 5/16-M8 7 022129 2 WASHER LOCK 5/16-M8 8 0F4795 4 SCREW PPHM SEMS M4-0.7 X 10 9 0C5760P 1 FUEL JET GASEOUS REGULATOR (7KW) 10 0C6606 1 BARBED STRAIGHT ½ NPT x ½ (7KW) 0C6606 2 BARBED STRAIGHT ½ NPT x ½ 11 097934 1 O-RING (7KW) 12 0C4645 1 ADJUSTER SCREW, TWIN REGULATOR (7KW) 13 0C5761 2 LEVER, REGULATOR 14 0C5968 2 SUPPORT, INLET SEAL 15 0C6066 2 SEAL, INLET 16 0C5759 2 PIN, PIVOT ARM 17 0C5764A 2 SPRING, REGULATOR (7KW) 0C5764 2 SPRING, REGULATOR 18 070728 4 SCREW, PFHMS M3-0.5 x 5 19 0C6069 2 GASKET, DIAPHRAGM 20 0C5762 2 COVER, TWIN REGULATOR (7KW) 0F9189 2 COVER, TWIN REGULATOR 21 045764 16 SCREW, TAPTITE M4X8 BP 22 0C6731 2 RIVET, POP .118 X .125 23 0C6067 2 SUPPORT, DIAPHRAGM 24 0C4706 2 DIAPHRAGM, TWIN REGULATOR 25 0C6068 2 CAP, DIAPHRAGM SUPPORT 26 0C4643A 2 INLET, TWIN REGULATOR 11.11 DIA. 27 072683A 2 PLUG STD PIPE 1/8 SOCKET HEAD (7KW) 072683A 1 PLUG STD PIPE 1/8 SOCKET HEAD 28 0A4032 1 PIN, LIMITED ADJUSTMENT (7KW) 29 0D3308 4 WASHER, FLAT M3 X 10mm O.D. 30 024310 1 PLUG, STANDARD PIPE 1/2” STEEL SQUARE HEAD (7KW) 31 0D3973 1 PLUG, EXPANSION 16mm (7KW) 32 042907 2 SCREW HHC M8-1.25 X 16 33 028414A 1 BARBED STRAIGHT 1/8”NPT X ¼” (10KW) 34 035578A 1 NIPPLE CLOSE 1/8NPT (10KW) 35 0G0247 1 SOLENOID, LP/NG DC12V (10KW) 36 0F9773B 1 SOLENOID WIRE, #0 (10KW) 37 0F9773A 1 SOLENOID WIRE, #14 (10KW)

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators 13 & 16kW, GT-990 Regulator – Drawing No. 0F9426

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

ITEM PART NO. QTY. DESCRIPTION

1 0F9285 1 CASTING, TWIN REGULATOR HOUSING 2 0F5022 1 SOLENOID COIL, 12VDC 3 0C4647 2 GASKET , SOLENOID 4 0D4166 1 PLUNGER, LP REGULATOR ASSEMBLY 5 0F8096 1 BRKT REGULATOR MOUNTING 990 6 022145 4 WASHER FLAT 5/16-M8 7 022129 4 WASHER LOCK 5/16-M8 8 0F4795 8 SCREW PPHM SEMS M4-0.7 X 10 9 045771 2 NUT HEX M8-1.25 10 0C6606 2 BARBED STRAIGHT ½ NPT x ½ 11 042907 2 SCREW HHC M8-1.25 X 16 12 026915A 1 NIPPLE CLOSE ¾ X 1.375 WITH VIBRA SEAL 13 0C5761 2 LEVER, REGULATOR 14 0C5968 2 SUPPORT, INLET SEAL 15 0C6066 2 SEAL, INLET 16 0C5759 2 PIN, PIVOT ARM 17 0C5764 2 SPRING, REGULATOR 18 070728 4 SCREW, PFHMS M3-0.5 x 5 19 0C6069 2 GASKET, DIAPHRAGM 20 0F9189 2 COVER, TWIN REGULATOR 21 045764 16 SCREW, TAPTITE M4X8 BP 22 0C6731 2 RIVET, POP .118 X .125 23 0C6067 2 SUPPORT, DIAPHRAGM 24 0C4706 2 DIAPHRAGM, TWIN REGULATOR 25 0C6068 2 CAP, DIAPHRAGM SUPPORT 26 0C4643A 2 INLET, TWIN REGULATOR 11.11 DIA. 27 072683A 3 PLUG STD PIPE 1/8 SOCKET HEAD 28 049226 4 WASHER, LOCK, M5 29 0D3308 4 WASHER, FLAT M3 X 10mm O.D. 30 051713 4 WASHER, FLAT, M5 31 0F8979 1 SOLENOID COVER PLATE 32 051716 4 NUT HEX M5-0.8 33 0E9533 1 SOLENOID ADAPTER 34 0E9534 1 ASSY, FUEL SYSTEM PLENUM 35 0E9535 1 PLENUM GASKET

Section 10 – Warranty

Air-cooled Generators

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

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new engine.* In California, new utility, and lawn and garden equipment engines must be designed, built and equipped to meet the state’s stringent anti-smog standards. Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modification or improper maintenance of your engine.

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

MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted. If, during such warranty period, any emission-related component or system on your engine is found to be defective in materials or workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Facility.

PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:

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

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

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

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

1-800-333-1322

IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System Warranty (ECS Warranty), which is provided to you by Generac pursuant to California law. See also the “Generac Limited Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine.

Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service, evidence must be presented showing the date of the sale to the original purchaser/owner.

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

For Air-cooled Product ... For Liquid-cooled Product ...

ATTENTION WARRANTY DEPARTMENT ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS, INC. GENERAC POWER SYSTEMS, INC. P.O. BOX 297 211 MURPHY DRIVE WHITEWATER, WI 53190 EAGLE, WI 53119

Part 1

Section 10 – Warranty

Air-cooled Generators

EMISSION CONTROL SYSTEM WARRANTY

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

(a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on the

date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.

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

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

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

authority, and

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

warranted emissions-related part to fail to be identical in all material respects to the part as described in the engine manufacturer’s application for certification.

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

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

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

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

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

Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection (4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.

(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no

charge to the owner at a Generac Authorized Warranty Service Facility.

(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsible

for diagnostic costs if the repair is deemed warrantable.

(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused

by a failure under warranty of any emission-related part covered by the ECS Warranty.

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

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

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

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

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

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

EMISSION RELATED PARTS INCLUDE THE FOLLOWING:

1) Fuel Metering System:

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

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

2) Air Induction System including:

a) Intake pipe/manifold b) Air cleaner

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

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

Section 10 – Warranty

Air-cooled Generators

GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR GUARDIAN

"PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"

For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Guardian generator will be free from defects in material and workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Guardian Authorized Warranty Service Dealer, is found to be defective. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Guardian Authorized Warranty Service Dealer. All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to Generac Guardian prepackaged emergency automatic standby generators sold and rated for use in "Standby" applications.

WARRANTY SCHEDULE

YEARS ONE and TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed (proof of purchase and maintenance is required): Engine - All Components Alternator - All Components Transfer System - All Components Steel enclosures are warranted against rusting for the first year of ownership only. Damage caused after receipt of generator is the responsibility of the owner and is not covered by this warranty. Nicks, scrapes, dents or scratches to the painted enclosure should be repaired promptly by the owner. All warranty expense allowances are subject to the conditions defined in Guardian's Warranty Policies, Procedures and Flat Rate Manual.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

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

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

• Repairs or diagnostics performed by individuals other than Guardian/Generac authorized dealers not authorized in writing by Generac Power Systems.

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

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

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

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

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

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

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

• Damage related to rodent and/or insect infestation.

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

• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the defective part(s).

• Failure due to misapplication.

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

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

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

• Rental equipment used while warranty repairs are being performed.

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

• Overnight freight costs for replacement part(s).

• Overtime labor.

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

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you. This warranty gives you specific legal rights. You also have other rights from state to state.

GENERAC

P.O. BOX 297 • WHITEWATER, WI 53190

Part No. 0F9421 Revision C (05/22/06) Printed in U.S.A.

POWER SYSTEMS, INC.

Revision (02/01/05)

Guardian Technologies 5280, 5281, 5283, 5284, 5242 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual