Guardian Technologies 5240 Users Manual 0F9421revC

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2015-02-09

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Installation and
Owner’s Manual
7, 10, 13 and 16kW Air-cooled,
Automatic Standby Generators

C
LISTED

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vapor withdrawn liquid propane (LP) or natural gas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:

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

CONTENTS
This manual contains pertinent owner’s information,
including warranty, electrical diagrams, exploded
views and lists of repair parts, for these different
models:
• 05240 & 05280 – 6 kW NG, 7 kW LP, single-cylinder GH-410 Engine
• 05241 & 05281 – 9.0 kW NG, 10 kW LP, V-twin
GT-530 Engine
• 05242 & 05282 – 13 kW NG, 13 kW LP, V-twin GT990 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

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

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.

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.

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.

Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type
of information each indicates follows:
This symbol points out important safety information that, if not followed, could endanger
personal safety and/or property of others.

Model No. ____________



symbol points out potential explosion haz This
ard.

 This symbol points out potential fire hazard.
symbol points out potential electrical shock
 This
hazard.

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

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

1.1

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

4.2

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

1.2

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

4.3

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

1.3

NEC Requirement for Arc Fault Circuit
Interruption Breaker for Bedrooms .............. 4

4.4

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

1.4

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

4.5

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

1.5

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

4.6

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

1.6

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

4.7

Adjusting GH-410/GT-530/990
Valve Clearance............................................ 22

1.7

Fuel Requirements and Recommendations ... 7

4.8

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

1.8

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

4.9

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

1.9

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

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

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

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

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

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

1.12 Battery Installation ...................................... 10
1.13 The Battery ................................................. 11

Section 5 – Troubleshooting ........................ 26
5.1

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

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

Section
Section
Section
Section

6
7
8
9

–
–
–
–

Notes ............................................27
Mounting Dimensions ............. 30
Electrical Data ........................... 31
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 operators and potential operators of this equipment.



• WARNING:



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



• WARNING:



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

Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become
familiar with this Owner’s Manual and with the
unit. The generator can operate safely, efficiently and
reliably only if it is properly installed, operated and
maintained. Many accidents are caused by failing to
follow simple and fundamental rules or precautions.
The manufacturer cannot anticipate every possible
circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed
to the unit are, therefore, not all-inclusive. If using
a procedure, work method or operating technique
the manufacturer does not specifically recommend,
ensure that it is safe for others. Also make sure the
procedure, work method or operating technique utilized does not render the generator unsafe.

DANGER
the safe design of this generator,
 Despite
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.
lethal voltages are generated by
 Potentially
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
of the generator are rotating and/or hot
 Parts
during operation. Exercise care near running
generators.



 GENERAL HAZARDS 
• For safety reasons, the manufacturer recommends
that the installation, initial start-up and maintenance of this equipment is carried out by an
Authorized Dealer.
• The engine exhaust fumes contain carbon monoxide, which can be DEADLY. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death. This exhaust
system must be installed properly, in strict compliance with applicable codes and standards.
Following installation, do nothing that might render the system unsafe or in noncompliance with
such codes and standards.
• Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit
is operating.
• Adequate, unobstructed flow of cooling and ventilating air is critical to correct generator operation.
Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seriously affect safe operation of the generator. The
generator MUST be installed outdoors.
• When working on this equipment, remain alert
at all times. Never work on the equipment when
physically or mentally fatigued.
• Inspect the generator regularly, and contact the
nearest Authorized Dealer for parts needing repair
or replacement.
• Before performing any maintenance on the generator, disconnect its battery cables to prevent
accidental start up. Disconnect the cable from the
battery post indicated by a NEGATIVE, NEG or
(–) first, then remove the POSITIVE, POS or (+)
cable. When reconnecting the cables, connect the
POSITIVE cable first, the NEGATIVE cable last.
• Never use the generator or any of its parts as a
step. Stepping on the unit can stress and break
parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.

IMPORTANT SAFETY INSTRUCTIONS
Air-cooled Generators

 ELECTRICAL HAZARDS 

• All generators covered by this manual produce
dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely
high and dangerous voltages to the transfer switch
as does the standby generator when it is in operation. Avoid contact with bare wires, terminals,
connections, etc., while the unit is running. Ensure
all appropriate covers, guards and barriers are in
place, secured and/or locked before operating the
generator. If work must be done around an operating unit, stand on an insulated, dry surface to
reduce shock hazard.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
• The National Electrical Code (NEC) requires the
frame and external electrically conductive parts of
the generator to be connected to an approved earth
ground. Local electrical codes also may require
proper grounding of the generator electrical system.
• After installing this home standby electrical system, the generator may crank and start at any
time without warning. When this occurs, load circuits are transferred to the STANDBY (generator)
power source. To prevent possible injury if such a
start and transfer occur, always set the generator’s
AUTO/OFF/MANUAL switch to its OFF position
before working on equipment and remove the 15A
fuse from the generator control panel.
• In case of accident caused by electric shock, immediately shut down the source of electrical power. If
this is not possible, attempt to free the victim from
the live conductor. AVOID DIRECT CONTACT WITH
THE VICTIM. Use a nonconducting implement,
such as a dry rope or board, to free the victim from
the live conductor. If the victim is unconscious,
apply first aid and get immediate medical help.
• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving components causing injury.

 FIRE HAZARDS 
• For fire safety, the generator must be installed and
maintained properly. Installation must always
comply with applicable codes, standards, laws
and regulations. Adhere strictly to local, state
and national electrical and building codes. Comply
with regulations the Occupational Safety and
Health Administration (OSHA) has established.
Also, ensure that the generator is installed in
accordance with the manufacturer’s instructions
and recommendations. Following proper installation, do nothing that might alter a safe installation
and render the unit in noncompliance with the
aforementioned codes, standards, laws and regulations.

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

 EXPLOSION HAZARDS 
• Do not smoke around the generator. Wipe up any
fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.
• Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE. Install
the fuel supply system according to applicable
fuel-gas codes. Before placing the home standby
electric system into service, fuel system lines must
be properly purged and leak tested according to
applicable code. After installation, inspect the fuel
system periodically for leaks. No leakage is permitted.

STANDARDS INDEX
In the absence of pertinent standards, codes, regulations and laws, the published information listed
below may be used as installation guide for this
equipment.
1. NFPA No. 37, STATIONARY COMBUSTION
ENGINES AND GAS TURBINES, available from
the National Fire Protection Association, 470
Atlantic Avenue, Boston, MA 02210.
2. NFPA No. 76A, ESSENTIAL ELECTRICAL
SYSTEMS FOR HEALTH CARE FACILITIES,
available same as Item 1.
3. NFPA No. 54, NATIONAL FUEL GAS CODE,
available same as Item 1.
4. NFPA No. 58, AMERICAN NATIONAL STANDARD
FOR STORAGE AND HANDLING OF LIQUEFIED
PETROLEUM GAS, available same as Item 1.
5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL
ELECTRIC CODE, available same as Item 1.
6. Article X, NATIONAL BUILDING CODE, available
from the American Insurance Association, 85
John Street, New York, N.Y. 10038.
7. AGRICULTURAL WIRING HANDBOOK, available from the Food and Energy Council, 909
University Avenue, Columbia, MO 65201.
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.
3

Section 1 — General Information
Air-cooled Generators

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

1.1

UNPACKING/INSPECTION

After unpacking, carefully inspect the contents for
damage.
• This standby generator set is ready for installation with a factory supplied and pre-mounted base
pad and has a weather protective enclosure that is
intended for outdoor installation only.
• This UL listed standby generator set is packaged
with an automatic transfer switch with built in
load center. The combination transfer switch and
load center is pre-wired with a two foot and 30 foot
conduit. Circuit breakers for emergency circuit
connections are included (if equipped).
• This UL listed, 2-pole switch is rated at 100 AC
amperes at 250 volts maximum. This transfer
switch is for indoor use only (if equipped).

this generator is used to power electrical load
 Ifcircuits
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
2. High Temperature Sensor
3. Overcrank
4

4. Overspeed
5. RPM Sensor
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

Section 1 — General Information
Air-cooled Generators

1.4

THE GENERATOR

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

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

Control
Panel
Oil
Dipstick

Data
Decal

Oil
Dipstick

Air Filter
Cover

Data
Decal

Control
Panel

Exhaust
Enclosure

Air Filter

Fuel
Inlet
(Back)

Fuel
Regulator

Composite Base

Oil Filter

Fuel
Regulator

Composite Base

Battery Compartment

Oil Filter

Battery Compartment

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

Air Filter
Cover
Oil
Dipstick

Data
Decal

Control
Panel

Exhaust
Enclosure
Fuel
Inlet
(Back)
Fuel
Regulator

Composite Base

Oil Filter

Battery Compartment

Section 1 — General Information
Air-cooled Generators

1.5

SPECIFICATIONS

1.5.1 GENERATOR
Model
Rated Max. Continuous
Power Capacity (Watts*)
Rated Voltage
Rated Max. Continuous
Load Current (Amps)
120 Volts**
240 Volts
Main Line Circuit Breaker
Circuits***
50A, 240V
40A, 240V
30A, 240V
20A, 240V
20A, 120V
15A, 120V
Phase
Number of Rotor Poles
Rated AC Frequency
Power Factor
Recommended Air Filter
Battery Requirement

Battery Warming Blanket
Weight (Unit Only)
Enclosure
Normal Operating Range

05240 & 05280

05241 & 05281

6,000 NG/7,000 LP

9,000 NG/10,000 LP

120/240

50.0 NG/58.3 LP
25.0 NG/29.2 LP
30 Amp

75.0 NG/83.3 LP
37.5 NG/41.7 LP
45 Amp

108.3 NG/108.3 LP
54.1 NG/54.1 LP
55 Amp

125 NG/133.3 LP
52.5 NG/66.6 LP
65 Amp

1
1
5
1
2
60 Hz
1
Part # 0C8127
Group 26
12 Volts and
350 Cold-cranking
Amperes Minimum
336 Pounds

05242 & 05282

05243 & 05244
05283 & 05284
13,000 NG/13,000 LP 15,000 NG/16,000 LP

1
1
1
1
3
3
3
5
1
1
2
2
60 Hz
60 Hz
1
1
Part # 0E9581
Part # 0C8127
Group 26
Group 26
12 Volts and
12 Volts and
525 Cold-cranking
525 Cold-cranking
Amperes Minimum
Amperes Minimum
0F6148DSRV
375 Pounds
425.5 Pounds

1
1
1
5
5
1
2
60 Hz
1
Part # 0C8127
Group 26
12 Volts and
525 Cold-cranking
Amperes Minimum
445 & 414 Pounds
Steel/Aluminum

-20°F (-28.8°C) to 104°F (40°C)

* Maximum wattage and current are subject to and limited by such factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc. Maximum power
decreases about 3.5 percent for each 1,000 feet above sea level; and also will decrease about 1 percent for each 6° C (10° F) above 16° C (60° F) ambient temperature.
** Load current values shown for 120 volts are maximum TOTAL values for two separate circuits. The maximum current in each circuit must not exceed the value stated for 240
volts.
*** Circuits to be moved must be protected by same size breaker. For example, a 15 amp circuit in main panel must be a 15 amp circuit in transfer switch.

1.5.2 ENGINE
Model
Type of Engine
Number of Cylinders
Rated Horsepower
Displacement
Cylinder Block
Valve Arrangement
Ignition System
Recommended Spark Plug
Spark Plug Gap
Compression Ratio
Starter
Oil Capacity Including Filter
Recommended Oil Filter
Recommended Air Filter
Operating RPM
6

05240 & 05280

05241 & 05281

05242 & 05282

GH-410
1
14.5 @ 3,600 rpm
410cc
Aluminum w/Cast
Iron Sleeve
Overhead Valves
Solid-state w/Magneto
RC14YC
0.76 mm (0.030 inch)
8.6:1
12 Vdc
Approx. 1.5 Qts
Part # 070185B
Part # 0C8127
3,600

GT-530
2
18 @ 3,600 rpm
530cc
Aluminum w/Cast
Iron Sleeve
Overhead Valves
Solid-state w/Magneto
BPR6HS
0.76 mm (0.030 inch)
9.5:1
12 Vdc
Approx. 1.7 Qts
Part # 070185B
Part # 0E9581
3,600

GT-990
2
30 @ 3,600 rpm
992cc
Aluminum w/Cast
Iron Sleeve
Overhead Valves
Solid-state w/Magneto
RC12YC
1.02 mm (0.040 inch)
9.5:1
12 Vdc
Approx. 1.7 Qts
Part # 070185B
Part # 0C8127
3,600

05243 & 05244
05283 & 05284
GT-990
2
30 @ 3,600 rpm
992cc
Aluminum w/Cast
Iron Sleeve
Overhead Valves
Solid-state w/Magneto
RC12YC
1.02 mm (0.040 inch)
9.5:1
12 Vdc
Approx. 1.7 Qts
Part # 070185B
Part # 0C8127
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 pressure, 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.

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 (*)
1/2 Load Full Load
6/7 kW
66
119
9/10 kW
102
156
13/13 kW
156
220
15/16 kW
173
245

LP Vapor (**)
1/2 Load
Full Load
0.82/30
1.47/54
1.25/46
1.93/70
1.55/57
2.18/80
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
fuels such as natural gas and liquid
 Gaseous
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.

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.

Section 1 — General Information
Air-cooled Generators

1.9

RECONFIGURING THE
FUEL SYSTEM

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

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.
2.
3.
4.

Turn off the main gas supply (if connected).
Open the roof and remove the door.
Remove the battery (if installed).
Disconnect wire #0 and wire #14 from the gas
solenoid on top of the demand regulator.
Remove the carburetor fuel hose from the outlet
port of the demand regulator.
Remove the demand regulator by removing the
fastener that retains the regulator mounting
bracket.
Remove the square headed steel pipe plug from
outlet port #1 and the brass hose barb fitting
from outlet port #2.
Refit the brass hose barb fitting to outlet port #1
and the square headed steel pipe plug to outlet
port #2.

5.
6.
7.
8.

Figure 1.4 – Demand Regulator
HOSE & PLUG
SWITCHED SIDES

FUEL HOSE

PIPE
PLUG

BRASS HOSE
FITTING

BRASS HOSE
FITTING
OUTLET
PORT

ADJUSTMENT
SCREW

FUEL JET

NG FUEL SYSTEM

LP FUEL SYSTEM

STATIC
PRESSURE
TAP

RUNNING
PRESSURE
TAP

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.

Section 1 — General Information
Air-cooled Generators

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

Figure 1.8 - 13/16kW, GT-990 (Airbox Cover
Removed)
Fuel Selection Lever - "Out" Position for Liquid Propane
(Vapor) Fuel

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

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

1.10 LOCATION
1.10.1 GENERATOR
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

Install the generator set, in its protective enclosure,
outdoors, where adequate cooling and ventilating air
is always available (Figure 1.9). Consider these factors:
• The installation of the generator must comply
strictly with NFPA 37, NFPA 54, NFPA 58, and
NFPA 70 standards.
• Install the unit where air inlet and outlet openings will not become obstructed by leaves, grass,
snow, etc.. If prevailing winds will cause blowing
or drifting, consider using a windbreak to protect
the unit.
• Install the generator on high ground where water
levels will not rise and endanger it.
• Allow sufficient room on all sides of the generator
for maintenance and servicing. This unit must be
installed in accordance with current applicable
NFPA 37 and NFPA 70 standards; as well as any
other federal, state and local codes for minimum
distances from other structures. DO NOT install
under wooden decks or structures.
• Install the unit where rain gutter down spouts,
roof fun-off, landscape irrigation, water sprinklers
or sump pump discharge does not flood the unit
or spray the enclosure, including any air inlet or
outlet openings.
• Install the unit where services will not be affected
or obstructed, including concealed, underground
or covered services such as electrical, fuel, phone,
air conditioning or irrigation.
• Where strong prevailing winds blow from one
direction, face the generator air inlet openings to
the prevailing winds.
9

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

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

1.11 BATTERY REQUIREMENTS
See the Specifications section for correct battery size
and rating.

1.12 BATTERY INSTALLATION
Fill the battery with the proper electrolyte fluid if
necessary and have the battery fully charged before
installing it.
Before installing and connecting the battery, complete
the following steps:

engine exhaust fumes contain carbon mon The
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 enclosure is intended for indoor use only. Follow these
rules:
10

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.

Section 1 — General Information
Air-cooled Generators

Figure 1.10 – Battery Cable Connections
not open or mutilate the battery. Released
 Do
electrolyte has been known to be harmful to the
skin and eyes, and to be toxic.
electrolyte is a dilute sulfuric acid that is
 The
harmful to the skin and eyes. It is electrically
conductive and corrosive.

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
not dispose of the battery in a fire. The
 Do
battery is capable of exploding.
presents a risk of electrical shock
 Aandbattery
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.

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.
batteries present a risk of fire because
 Lead-acid
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.



sure the utility power supply is turned off
 Be
and the 15A fuse is removed from the generator
control panel, or sparking may occur at the battery posts as the cables are attached and cause
an explosion.
Servicing of the battery is to be performed or supervised by personnel knowledgeable of batteries and
the required precautions. Keep unauthorized personnel away from batteries.
See the Specifications section for the correct size
and rating when replacing the battery. When using a
maintenance-free battery, it is not necessary to check
the specific gravity or electrolyte level. Have these
procedures performed at the intervals specified in
the “Service Schedule.” A negative ground system is
used. Battery connections are shown on the wiring
diagrams. Make sure the battery is correctly connected and terminals are tight. Observe battery polarity
when connecting the battery to the generator set.
11

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

2.1

BEFORE INITIAL START-UP

DANGER

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.

operate the engine with the oil level
 Never
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
not attempt manual transfer switch opera Do
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).
12

transfer switch is now electrically “hot.”
 The
Contact with “hot” parts will result in extremely

8.
9.

hazardous and possibly fatal electrical shock.
Proceed with caution.
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.
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.
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.
On the generator panel, set the AUTO/OFF/
MANUAL switch to MANUAL. The engine should
crank and start.
Let the engine warm up for about five minutes to
allow internal temperatures to stabilize. Then, set
the generator’s main circuit breaker to its ON (or
CLOSED) position.

DANGER
with caution! Generator power voltage
 Proceed
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).

not attempt manual transfer switch opera Do
tion until all power voltage supplies to the
transfer switch have been positively turned off.
Failure to turn off all power voltage supplies
will result in extremely hazardous and possibly
fatal electrical shock.
5. Manually set the transfer switch to the STANDBY
position, i.e., load terminals connected to the
generator's 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
7 kW

120 Volts
50.0 amps

240 Volts
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

not make any unnecessary adjustments.
 Do
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

engine must be OFF to perform steps 1 and
 The
2.
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.

Figure 2.2 — Engine Governor Adjustment
Single Cylinder Engines

Adjustment
Screw
(One Side
Only)

SECONDARY
ADJUST SCREW

Set
Pin

GOVERNOR
SHAFT

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.
14

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:

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)

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

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

Figure 3.1 – Generator Control Panel

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.

CONTROL AND INFORMATION CENTER
SYSTEM SET

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.

LOW BATTERY
AUTO.

OFF

MAN.

15A
ASSY: 0F8418/0F8419

LOW OIL
HIGH TEMP
OVER SPEED
NO RPM SENSE IF FLASHING
OVER CRANK

SYSTEM FUSE

SET
EXERCISE
TIME

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

Figure 2.3 – Voltage Adjustment Potentiometer

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

Turn to
adjust voltage.

the switch set to AUTO, the engine may
 With
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.
15

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
not attempt to activate the transfer switch
 Do
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

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.

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
not attempt to activate the transfer switch
 Do
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.

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.
17

Section 3 — Operation
Air-cooled Generators

Low speed exercise will be handled as follows:

3.6.3 OVERCRANK

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.

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.

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
Low Oil Switch

High Temp Switch

Loos

Oil Filter
Oil
Drain
Hose

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.

Section 4 — Maintenance
Air-cooled Generators

3.6.5 RPM SENSOR FAILURE

4.2

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.

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

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.

operate the engine with the oil level
 Never
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 original position.

Figure 4.2 — Oil Dipstick and Fill, 7kW

Oil Dipstick and Fill

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
SYSTEM SET
LOW BATTERY
AUTO.

OFF

MAN.

15A
ASSY: 0F8418/0F8419

LOW OIL
HIGH TEMP
OVER SPEED
NO RPM SENSE IF FLASHING
OVER CRANK

SYSTEM FUSE

SET
EXERCISE
TIME

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

4.3.3 OIL & OIL FILTER CHANGE PROCEDURE
To change the oil, proceed as follows:

Oil Dipstick

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.

Oil Fill

Figure 4.5 – Oil Drain Hose and Filter
Low Oil Switch

High Temp Switch

Figure 4.4 — Oil Dipstick and Fill,
13kW and 16kW
Oil Dipstick
Loos

Oil Filter
Oil Fill

Oil
Drain
Hose

Change the engine oil filter as follows:

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.

attempt to crank or start the engine before
 Any
it has been properly serviced with the recommended oil may result in an engine failure.
20

1. With the oil drained, remove the old oil filter by
turning it counterclockwise.
2. Apply a light coating of clean engine oil to the gasket of the new filter. See the Specifications section
for recommended filter.
3. Screw the new filter on by hand until its gasket
lightly contacts the oil filter adapter. Then, tighten
the filter an additional 3/4 to one turn (Figure
4.4).
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

Figure 4.7 — 10kW Engine Air Cleaner

4.4.1 7, 13, AND 16KW GENERATORS

Control
Panel

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.
2.
3.
4.

Lift the roof and remove the door.
Turn the two screws counterclockwise to loosen.
Remove the cover and air filter.
Wipe away dust or debris from inside of the air
box and around edges.
5. Install the new air cleaner into the air box.
6. Install the cover. Turn the two cover screws clockwise to tighten.
See the Service Schedule section for air cleaner maintenance. See the Specifications section for air filter
replacement part number.

Air Filter

Figure 4.8 — 13 kW and 16 kW Engine
Air Cleaner

Figure 4.6 — 7 kW, Engine Air Cleaner Location

Screw

Air
Cleaner

Cover
Filter

3/4”
Hole

4.4.2 10KW GENERATORS

4.5

SPARK PLUG(S)

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

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

1. Lift the roof and remove the door.
2. Turn the worm gear clamp screw counterclockwise to loosen.
3. Pull the old filter off the divider panel hub.
4. Wipe away dust or debris from the panel hub.
5. Install the new air cleaner onto the hub.
6. Turn the worm gear clamp screw clockwise to
tighten.
7. Replace door and roof.

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.
21

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

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

•
•
•
•

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
not dispose of the battery in a fire. The
 Do
battery is capable of exploding.
presents a risk of electrical shock
 Aandbattery
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.

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.

batteries present a risk of fire because
 Lead-acid
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.
sure the AUTO/OFF/MANUAL switch is set to
 Be
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.
sure the utility power supply is turned off
 Be
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:



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

Section 4 — Maintenance
Air-cooled Generators

• 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:

• 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

Hold the rocker arm jam nut in place as the pivot
ball stud is turned.
When valve clearance is correct, hold the pivot ball
stud in place with the allen wrench and tighten the
rocker arm jam nut. Tighten the jam nut to 174
in/lbs. torque. After tightening the jam nut, recheck
valve clearance to make sure it did not change.

Figure 4.10 - Valve Clearance Adjustment

Jam Nut

Pivot Ball
Stud

exhaust from this product gets extremely
 The
hot and remains hot after shutdown. High grass,

Rocker
Arm
Valve
Stem

weeds, brush, leaves, etc. must remain clear of
the exhaust. Such materials may ignite and burn
from the heat of the exhaust system.

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

4.9
• Install new valve cover gasket.
• Re-attach the valve cover.
NOTE:
Start all four screws before tightening or it will not
be possible to get all the screws in place. Make
sure the valve cover gasket is in place.

ATTENTION AFTER SUBMERSION

If the generator has been submerged in water, it must
not be started and operated. Following any submersion in water, have an Authorized Dealer thoroughly
clean, dry and inspect the generator. If the structure
(ex. home) has been flooded, it should be inspected
by a certified electrician to ensure there won't be any
electrical problems during generator operation or
when utility is returned.
23

Section 4 — Maintenance
Air-cooled Generators

4.10 CORROSION PROTECTION

4.11.2 RETURN TO SERVICE

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.

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

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.

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
X = Action
R = Replace as Necessary
* = Notify Dealer
if Repair is Needed.

PROCEDURE
Inspect

Change

FREQUENCY
Clean

W = Weekly
M = Monthly
Y = Yearly

FUEL
Fuel lines and connections*

LUBRICATION
Oil level
Oil

EVERY 100 HOURS**,
AND Y

Oil filter

EVERY 100 HOURS**,
AND Y

COOLING
X

Remove corrosion,
ensure dryness

Clean and tighten
battery terminals

Check charge state

EVERY 6 M

Electrolyte level
(unsealed batteries only)*

EVERY 6 M

Air cleaner

Spark plug(s)

Enclosure louvers

BATTERY

ENGINE AND MOUNTING

GENERAL CONDITION
Vibration, Noise, Leakage,
Temperature*

COMPLETE TUNE-UP*

M
TO BE COMPLETED BY AN
AUTHORIZED DEALER

* Contact the nearest Authorized Dealer for assistance if necessary.
** Change oil and filter after first 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. Tighten, clean or replace
as necessary.
3. *
4. *
5. Charge or replace battery.

2. Loose, corroded or defective
battery cables.
3. Defective starter contactor. (7 kW)
4. Defective starter motor.
5. Dead Battery.
The engine cranks but
will not start.

The engine starts hard
and runs rough.

1. Out of fuel.
2. Defective fuel solenoid (FS).
3. Open #14 wire from
engine control board.
4. Defective spark plug(s).
5. Valve lash out of adjustment.
6. Choke not operating.

1. Replenish fuel/Turn on fuel valve.
2. *
3. *

1. Air cleaner plugged
or damaged.
2. Defective spark plug(s).
3. Fuel regulator not set.
4. Fuel pressure incorrect.

1. Check, replace air cleaner.

5. Fuel selector in wrong position.
6. Choke remains closed.

4. Clean, re-gap or replace plug(s).
5. Reset valve lash.
6. Verify choke plate moves freely.

2. Clean, re-gap or replace plug(s).
3. Set Fuel Regulator.
4. Confirm fuel pressure to regulator
is 10-12” water column (0.36-0.43
psi) for LP, and 5-7” water column
(0.18-0.25 psi) for natural gas.
5. Move selector to correct position.
6. Verify choke plate moves freely.

The AUTO/OFF/MANUAL switch 1. Defective switch.
is set to OFF, but the engine
2. AUTO/OFF/MANUAL switch
continues to run.
wired incorrectly.
3. Defective control board.

1. *
2. *

There is no AC output from
the generator.

1. Main line circuit breaker is in
the OFF (or OPEN) position.
2. Generator internal failure.

1. Reset circuit breaker
to ON (or CLOSED).
2. *

There is no transfer to
standby after utility
source failure.

1.
2.
3.
4.

Unit consumes large
amounts of oil.

1. Engine over filled with oil.
2. Engine breather defective.

Defective transfer switch coil.
Defective transfer relay.
Transfer relay circuit open.
Defective control logic board.

3. *

*
*
*
*

1. Adjust oil to proper level.
2. *

*Contact the nearest Authorized Dealer for assistance.

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

E1
N1A

194

194
12Vdc TRANSER
COIL

194
A
7

7
1

N1A

TS TO
GENERATOR
CONTROL PANEL

OPEN

B
23

205

126

N2A

BLACK

RED

240VAC
OUTPUT

N1A

N1A
N1A
E1

TO GENERATOR
OUTPUT
CIRCUIT BREAKER

E1
E2
B

NEUTRAL (WHITE)

NEUTRAL
CONNECTION
INSIDE SWITCH

NEUTRAL (WHITE)

N2A
B

126

240VAC TO
MAIN DISTRIBUTION
PANEL

RED (MAIN 2)

205
N1A

N2A

BLACK (MAIN 1)
E1

CIRCUIT 13

CIRCUIT 14

COM

CIRCUIT 10

B
VR2

CIRCUIT 9
T1

ATS

CIRCUIT 6

CIRCUIT 2

CIRCUIT 1

CIRCUIT 3
CIRCUIT 4

16 CIRCUIT LOAD CENTER

12 CIRCUIT LOAD CENTER

CIRCUIT 5

N2A

10 CIRCUIT LOAD CENTER

VR1

8 CIRCUIT LOAD CENTER

N2A

CIRCUIT 7

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 8
CIRCUIT 11
CIRCUIT 12
CIRCUIT 15
CIRCUIT 16

LC
31

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.)

3
2
1

ENGINE WIRING

1
2

14
14

224B

FS1

225B

FS2

224B
225B

0
0

SP1

BATTERY
CHARGER
(UTILITY)

IM1
C1

SP2

IM2

C3
86

HTO

LOP
0

L.E.D ALARM INDICATORS

CONTROL
PRINTED CIRCUIT BOARD
ON

GRD 2

1
2

DSW

1- ON=NORMAL EXERCISE
OFF=LOW SPEED EXERCISE
2- SPARE

BLACK

GOVERNOR
ACTUATOR

RED

J1
1

4
15A

86
23

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
239

56
18

LC1

224

14
85

LC2

0
225

15B

86
85

12V
BATTERY

14
225

CUSTOMER SUPPLIED

LC2
224

0
4
23
LC1
239

15A
15B

18
85

Section 8 — Electrical Data
Air-cooled Generators
Wiring Diagram – 10, 13 & 16kW, V-Twin – Drawing No. 0F7822

CONTROL PANEL BOX
225
224

224A
225A

CLOSEST TO BEARING

225A

224A
10

1 3
5

4
0

66
224B
N1

77
225B

A B

STATOR

N2
14

224B

BCR

225B
14

0
77

13
0
0

VOLTAGE
REGULATOR

225
224
N1

2
6

77
66

0
0

0
N2
N1

13
4

0
0

GRD 1

SCR
15
A

B
0

ICT

0
0
0

LC2
LC1

BLACK
RED
N2
N1

23
194

AUTO
15

13
15A

F1
225

56
224

23
194

N1
N2

MANUAL
15

23
4

15A

1a
15

SW1
194

194

SW2
15

15A

1b
239
194

240VAC UTILITY INPUT

240V GENERATOR
OUTPUT TO TRANSFER
SWITCH CONTACTOR

12Vdc TRANSFER
RELAY COIL

LC1
0
4
23
LC1

NEUTRAL CONNECTION

15B

LC2
LC2

239
15A
15B

CUSTOMER
CONNECTION

Section 8 — Electrical Data
Air-cooled Generators
Electrical Schematic – 10, 13 & 16kW, V-Twin – Drawing No. 0F7823

3
2
1

BATTERY
CHARGER

224B
225B

1
2

13
0

85
SCR
16
56

56
0
224B

11
22

225B

ELECTRONIC
VOLTAGE
REGULATOR

0
6

6
2

16
14

GOVERNOR

ACTUATOR
0
0
MANUAL

AUTO

194
15A
194

15A

194

LC1

15A

LC2

SW1
15

239

194
239
15
15

225B
224B

SW2

15B

CONTROL
PRINTED CIRCUIT
BOARD

1 15A
2
4
3
23
4 86
5
18
6
7
8
LC1
9
56
10 224
11
239
12
85
13
14
15
LC2
14
16
17 225
18
19
15B
20
0
21
22
23
90

LC1

LC2

224

14
14

14
225

Section 8 — Electrical Data
Air-cooled Generators
Electrical Schematic – 10, 13 & 16kW, V-Twin – Drawing No. 0F7823

ENGINE AND
ALTERNATOR
IM2

BATTERY
CHARGE
WINDING

SP2

66
18

IM1

SP1

86
85

STATOR

LOP

2
DPE
WINDING

HTO

POWER
WINDING

33
0

SC
16

BATTERY
12V

2
16

FIELD

RED

13
6

66
0

FS1

FS2

0
0

22
33
33

22
LC1

LC1

LC2

I.C.T.

0
23
194
225B
224B
0
44
7

7
1

9
6

9
3

77
224A

BCR
4

11
CB

194

225A
NEUTRAL
240VAC GENERATOR
OUTPUT TO
TRANSFER SWITCH
CONTACTOR

224
224A

12Vdc
TRANSFER
RELAY
COIL

240VAC
UTILITY
INPUT

225A
DIAGRAM KEY

14
225

225A

56VA
224A
225

1VA
224

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

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.)

Section 8 — Electrical Data
Air-cooled Generators
Wiring Diagram – 7kW, Single Cylinder – Drawing No. 0F7820

3
2
1

ENGINE WIRING

1
2

DIAGRAM KEY

BATTERY
CHARGER
(UTILITY)

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.)

224B
225B

224B
225B
14

14
0

TB
14

SP
IM
85

HTO
86

LOP
CONTROL
PRINTED CIRCUIT BOARD

GRD 2

L.E.D ALARM INDICATORS

BLACK

J1
1

SC
15A

4
23

56
18

9 10 11 12 13 14

239
224

14
85

0
225

15B
86
85
18

RED

14
225
16

12V
BATTERY
CUSTOMER SUPPLIED

224
56
4
23
0
239
15A
15B

18
85

Section 8 — Electrical Data
Air-cooled Generators
Wiring Diagram – 7kW, Single Cylinder – Drawing No. 0F7820

CONTROL PANEL BOX
225
224

224A
225A

224A
10

CLOSEST TO BEARING

225A

1 3
5

4
0

66
224B
N1

77
225B

A B

STATOR

N2
14

224B

BCR

225B
0

13
0
0

VOLTAGE
REGULATOR

225
224
N1

2
6

77
66

0
0
22
0

0
0

44
11

13
4

0
0

GRD 1

0
N2
4

23
194

AUTO

15A

4
224

15A

194

N1
N2

MANUAL
15

225

SW1
194

194

0
23
15

15A

239
194

15A

239
15A
15B

SW2
15

240V GENERATOR
OUTPUT TO TRANSFER
SWITCH CONTACTOR

240VAC UTILITY INPUT

12Vdc TRANSFER
RELAY COIL

23
0

NEUTRAL CONNECTION

239

15B

CUSTOMER
CONNECTION

Section 8 — Electrical Data
Air-cooled Generators
Electrical Schematic – 7kW, Single Cylinder – Drawing No. 0F7821

18
0

2
1

85
BATTERY
CHARGER

224B
225B

1
2

13
0

224B

11
22

225B

ELECTRONIC
VOLTAGE
REGULATOR

4
4

0
6

2
56
14

11
0
0

MANUAL

AUTO
194

15A
194

15A

194

15A
0

0
23

SW1
15

194

239

225B
239

224B

15
SW2

15B
14
J1

3
4

PRINTED CIRCUIT
BOARD

6
7

56
224

224

239

85
14

10
12

15B

13
14

14
225

225

5
CONTROL

1 15A
2
4

Section 8 — Electrical Data
Air-cooled Generators
Electrical Schematic – 7kW, Single Cylinder – Drawing No. 0F7821

ENGINE AND
ALTERNATOR
18

BATTERY
CHARGE
WINDING

IM
SP

85
77

STATOR

6
LOP

HTO

2
DPE
WINDING
POWER
WINDING
11

POWER
44 WINDING

22
33

13
6

RED
SC

BATTERY
12V

2
56

FIELD

0
0

22
33
44
33

0
23
194
225B
0

224B
7

9
6

9
3

77
224A

BCR
4

66
22

225A

194

14
NEUTRAL

224A

240VAC GENERATOR
OUTPUT TO
TRANSFER SWITCH
CONTACTOR

225A
224

12Vdc
TRANSFER
RELAY
COIL

240VAC
UTILITY
INPUT

DIAGRAM KEY

14
225

225A

56VA
224A
225

1VA
224

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

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 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 suffix 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
42

Section 9 — Exploded Views and Parts Lists
Air-cooled Generators
Enclosure – Drawing No. 0F9431-B

ITEM PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
7
8
9
10

11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45

46
47

0F9653
045771
022129
022129
022145
043107
090388
0D3700
0D4662
0D4662
0F8871
0F8080
0F8246
0F8915
0F6558
092120
0F7825
0F7824
0F6549
0F7824A
0D1840
047411
047411
0F0710
0A2115
0C6735
0D2979D
0D7176
0F7827
0F6570
0F6571
0D2979B
0D2979C
022097
022097
022473
0F7826
0F0165A
0F6550
0F0164A
0E1330A
021267A
0E5968
0F0165
0F0164
0C1085
0A8475
0G0400
0F6552
0F9379
0D1839
0F8210
0F8209
0F9078
0F5458
0F5438
0F5434

1
4
4
5
8
4
15
24
14
13
1
1
1
1
1
4
1
1
1
1
2
6
8
12
4
2
2
34
2
1
1
1
1
4
3
2
1
1
1
1
1
2
11
1
1
1
1
1
1
1
2
1
1
1
4
1
1

PAD, 24 X 48” WITH MOUNTING HOLES
NUT HEX M8-1.25
WASHER LOCK 5/16
WASHER LOCK 5/16 (7KW)
WASHER FLAT 5/16
SCREW HHC M8-1.25 X 25
SCREW TAPTITE M6-1.0 X 12
NUT, LOCKING FLANGE M6-1.0 (7KW)
SCREW HHTR 5/16-18 X 3/4" (7KW)
SCREW HHTR 5/16-18 X 3/4"
SCROLL, FAN (7KW, 10KW)
SCROLL, FAN
PANEL, ALTERNATOR DIVIDER (7KW)
PANEL, ALTERNATOR DIVIDER (10KW)
PANEL, ALTERNATOR DIVIDER
NUT LOCK TRIC M6 X 1.0
FOAM, MUFFLER BOX FRONT
FOAM, MUFFLER BOX END
ENCLOSURE, EXHAUST SIDE
FOAM, MUFFLER BOX END
BRACKET, BOTTOM SUPPORT
SCREW HHC M6-1.0 X 16 G8.8 (7KW)
SCREW HHC M6-1.0 X 16 G8.8
RIVET POP 0.125” X 0.337”
WASHER NYLON M6-1/4”
SUPPORT, ROOF FOLDING
CLOTH HARDWARE 266.7mm X 387.4mm
WASHER, SELF LOCKING
FOAM, EXHAUST ENCLOSURE COVER
COVER, BACK EXHAUST ENCLOSURE
COVER, FRONT EXHAUST ENCLOSURE
CLOTH, HARDWARE 266.7mm X 146mm
CLOTH, HARDWARE 543mm X 146mm
WASHER LOCK M6-1/4 (7KW)
WASHER LOCK M6-1/4
WASHER FLAT M6-1/4
FOAM, MUFFLER BOX BACK
HINGE TYPE B WITH STUDS, SOCKET
ENCLOSURE, SIDE & BACK
HINGE TYPE A WITH STUDS, SOCKET
GROMMET, 38.1 CROSS SLIT WITH HOLE
PLUG PLASTIC 1.5 BLIND GROMMET
GASKET, EXTRUDED TRIM
HINGE TYPE B WITH STUDS, PIN
HINGE TYPE A WITH STUDS, PIN
SCREW PPHM M3-0.5 X 8
L/WASH SPECIAL #10
WIRE ASSEMBLY, GROUND
ENCLOSURE, ROOF
FOAM, ROOF ENCLOSURE
BRACKET, TOP SUPPORT
REGULATOR ASSEMBLY (7KW)
REGULATOR ASSEMBLY (10KW)
REGUALTOR ASSEMBLY
SCREW PLASTITE HI-LOW #10 X 3/8
HARNESS, ENGINE (7KW)
HARNESS ENG V-T HSB

ITEM PART NO. QTY. DESCRIPTION
48

49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80

81
82
83
84
85
86
87
88

0F8263
0F7886
0F7885
023484H
0D3058A
0E4245
0D3058C
0D1605A
0F7798
0F8380
0D3472
0C8285
0D3167
0E1330
043116
043116
086729
0F8039
022127
0388040AJ0
0F8847
0F8434
0F9968
0C2937
049813
0A1658
0G0617
092079
055414
0F8234
0F7711
0F8257
0C3906
0F6555
0F8555
0D3037
0D3037A
0F9143
0F8261
0F5440

1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1

0F9328

0F5478

051713
022152
036937
022158
0C8911
026850
031879
0D9784

2
5
2
5
1
1
2
1

PANEL, ENGINE DIVIDER (7KW)
PANEL, ENGINE DIVIDER (10KW)
PANEL, ENGINE DIVIDER
BUSHING SNAP SB-1500-18
FOAM, FRONT INTAKE BAFFLE (7KW)
FOAM, FRONT INTAKE BAFFLE
FOAM, BACK INTAKE BAFFLE (7KW)
BAFFLE, INTAKE (7KW)
BAFFLE, INTAKE
FOAM, TOP INTAKE BAFFLE
GROMMET OVAL 31.75 X 50.8
BRACKET, BATTERY SUPPORT
GASKET, BATTERY SUPPORT BRACKET
GROMMET, 38.1 DIA. CROSS SLIT
SCREW HHC, M6-1.0 X 12 G8.8(7KW)
SCREW HHC M6-1.0 X 12 G8.8
CONTACTOR, STARTER (7KW)
MOUNTING CLIP
NUT HEX 1/4-20 (7KW)
CABLE, #6 RED BATTERY 38.5”
GASKET, FRONT DIVIDER
GASKET, FRONT DIVIDER (10KW)
FUEL LINE, 1/2” OUTDOOR (NOT SHOWN)
BRACKET, BATTERY HOLD DOWN (7KW)
NUT HEX M6-1.0 G8
LOCK WASHER SPECIAL 1/4
EXTERNAL CONNECTION BOX
SCREW TAPTITE M6-1.0 X 25 BP
LUG SLDLSS #2-#8 X 17/64 CU
ASSEMBLY, ENCLOSURE BASE (7KW)
ASSEMBLY, ENCLOSURE BASE
FOAM, FRONT ENCLOSURE
SELF-ALIGN SCREW M6 HH
ENCLOSURE, FRONT
GASKET, DOOR SEAL
LATCH, QUARTER TURN LOCKING
LATCH, QUARTER TURN NON-LOCKING
PAWL, DOOR
FOAM, BACK ENCLOSURE
HARNESS GENERATOR TO EXTERNAL
CONNECTION BOX (7KW)
HARNESS GENERATOR TO EXTERNAL
CONNECTION BOX (10KW)
HARNESS GENERATOR TO EXTERNAL
CONNECTION BOX
WASHER FLAT M5
WASHER LOCK #10
SCREW PPHM#10-32 X 1
NUT HEX #10-32
POWER BLOCK
WASHER SHAKEPROOF EXT 1/4 STEEL
WASHER FLAT #4
NUT HEX LOCK M3-0.5

8,9

27
29

44
43

17
14

15
36

29
19

Section 9 — Exploded Views and Parts Lists

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

Section 9 — Exploded Views and Parts Lists
Air-cooled Generators
Control Panel – Drawing No. 0F9695-B

ITEM
1

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44

PART NO.
0E7886A
0E7886D
0E7886K
0E7886J
0A1801
0F9719
0C2174
075210A
038750
0F8992
0F1504
032300
022676
0E4494
0E7890
023484E
075476
043182
0E6480
0D4804A
0C1085
0C1085
058000H
023897
0F8040
0F9282
075235
0E3928
0D9784
0D9784
0D8502
031879
031879
0F5433
0F5437
074908
049813
082025
0G0627
022507
022097
046689
063617
075475
043180
0F8041
0F9283
045770
0E7866
0E7867
0D3700
0G0400
0E2874
0A1658
022473

QTY.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
2
6
1
12
8
2
2
1
1
4
1
4
2
1
4
2
1
1
4
1
6
1
2
3
1
1
2
2
1
1
2
1
1
8
1
1
2
4

DESCRIPTION
CIRCUIT BREAKER 30A X 2P 240V (7KW)
CIRCUIT BREAKER 45A X 2P 240V (10KW)
CIRCUIT BREAKER 55A X 2P 240V (13KW)
CIRCUIT BREAKER 65A X 2P 240V (16KW)
ASSEMBLY, BATTERY CHARGER ENGINE
ASSEMBLY, POTTED REGULATOR
RELAY, 12V 25A SPST (NON 7KW)
BLOCK TERMINAL 1 POSITION
SCREW HHC M6-1.0 x 30mm
ASSEMBLY, HOME STANDBY CONTROLLER
ASSEMBLY, HOME STANDBY CONTROLLER (7KW)
HOLDER, FUSE
FUSE, 15 AMP X AGC15
SWITCH, ROCKER DPDT ON-OFF-ON
CIRCUIT BREAKER MOUNTING BRACKET
SNAP BUSHING
SCREW PPHM M4-0.7 x 16mm
M3 LOCK WASHER (NON 7KW)
NUT HEX LOCK M4-0.7 NYLON INSERT
CURRENT TRANSFORMER, IDLE CONTROL (NON 7KW)
SCREW PPHM M3-0.5 x 8mm
SCREW PPHM M3-0.5 x 8mm (7KW)
M3-0.5 TRIC NUT (NON 7KW)
WASHER FLAT #10
CONTROL, PANEL BOTTOM
CONTROL, PANEL BOTTOM (7KW)
SCREW HHC M5-0.8 x 30mm
SWITCH, SPST
NUT HEX LOCK M3-0.5 NYLON INSERT
NUT HEX LOCK M3-0.5 NYLON INSERT (7KW)
NEUTRAL BLOCK
WASHER FLAT #4
WASHER FLAT #4 (7KW)
HARNESS, CONTROL PANEL WIRE (NOT SHOWN)
HARNESS, CONTROL PANEL WIRE (NOT SHOWN) (7KW)
SCREW HHTT, M5-0.8 x 10 BP
NUT HEX M6-1.0
NUT HEX LOCK M5-0.8 NYLON INSERT
XFMR 240/16V 1VA&56VA W/PTC
SCREW HHC 1/4”-20 x 1/2”
WASHER LOCK M6-1/4”
TERMINAL STRIP 4 POSITION
RELAY PANEL 12VDC DPDT 10A 240VAC
SCREW PPHM M4-0.7 x 10mm
WASHER FLAT M4
COVER, CONTROL PANEL COMPONENT
COVER, CONTROL PANEL COMPONENT (7KW)
SCREW HHC M5-0.8 x10mm
COVER, CONTROL PANEL
COVER, CONTROL PANEL (7KW)
NUT FLANGE M6-1.0 NYLOK
WIRE ASSEMBLY, GROUND
SCREW HHTR 1/4"-20 X 3/4"
WASHER LOCK SPECIAL 1/4”
WASHER FLAT 1/4”-M6

Section 9 — Exploded Views and Parts Lists
Air-cooled Generators
Transfer Switch Assembly – Drawing No. 0F9774-A

ITEM PART NO. QTY. DESCRIPTION
1
2

0F8278
0D4800
0F5211
0D3092
0F8312
0C2237

1
1
1
1
1
1

3A
3B
3C
3D

077220
077220A
082574
084464

1
1
1
1

4
5
6
7
8

074908
024912
0A1658
063617
0E7889A
0E7889

6
1
1
1
1
1

0F9213
0A1495
0A1661
022473
081108
0F9199
0D4684
0D4684A
0F8279
0F4790
022152
064526
0E6155
063378
0G0979

1
4
2
1
1
1
1
1
1
10.5”
6
2
1
4
1

0G0980

0G0981

0G0982

9
10
11
12
13
14
15
16
17
18
19
20

BOX LOAD CENTER
COVER, 8 CIRCUIT LOAD CENTER
COVER, 10 CIRCUIT LOAD CENTER
COVER, 12 CIRCUIT LOAD CENTER
COVER, 16 CIRCUIT LOAD CENTER
TRANSFER SWITCH HOME STANDBY
100A 2P 250V
COIL UTILITY
COIL STANDBY
INSULATOR-SIDEWALL (NOT SHOWN)
LIMIT SWITCH OPERATION (NOT
SHOWN)
SCREW HHTT M5-0.8 X 10
SCREW HHTT 1/4-20 X 5/8
LOCK WASHER, SPECIAL-1/4”
RELAY PANEL 12VDC DPDT 10A@240VAC
8 CIRCUIT LOAD CENTER
12 CIRCUIT LOAD CENTER (ALSO USED
FOR 10 CIRCUIT)
16 CIRCUIT LOAD CENTER
SCREW HHTT M4-0.7 X 10
RIVET POP .156” X .675”
WASHER FLAT 1/4-M6 ZINC
PLUG PLASTIC
PLUG PLASTIC
HARNESS ADAPTER PLATE
8 CIRCUIT HARNESS ADAPTER PLATE
SUBPLATE, LOAD CENTER
U-CHANNEL
WASHER LOCK #10
SCREW HWHS #6-25 X 3/8”
ARM EXTENDER PIN
HOLDER CABLE TIE
HARNESS, 8 CIRCUIT LOAD CENTER TO
MAIN PANEL
HARNESS, 10 CIRCUIT LOAD CENTER
TO MAIN PANEL
HARNESS, 12 CIRCUIT LOAD CENTER
TO MAIN PANEL
HARNESS, 16 CIRCUIT LOAD CENTER
TO MAIN PANEL

ITEM PART NO. QTY. DESCRIPTION
21

074138

22
23
24
25
26
27
28

036933
077033
048850
028739
0A2110
0D3191
0D3088

6
6
1
4
4
1
1

29
30
31

073591
073590A
040213B

2
2
4

32
33
34
35
36
37
38
39

0E7888
0E7888A
0E7888B
0E7888C
0E7888D
0E7888E
0D3320
0F5439

A/R
A/R
A/R
A/R
A/R
A/R
1
1

40
41
42

0F9327

0F6720

075475
0A7215
0E6193

2
4
1

LUG QUICK DISCONNECT NI-S 10X45
DEG BRASS / TIN
SCREW PPHM #10-32 X 3/8”
LUG SLDLSS 1/0-#14X9/16 AL/CU
BLOCK TERMINAL 20A 5 X 6 X 1100V
TIE WRAP 3.9" X .10"
SCREW SWAGE 1/4-20 X 1/2" ZINC
COVER, RELAY & TERMINAL BLOCK
WIRE HARNESS, LOAD CENTER (NOT
SHOWN)
FUSE HOLDER
FUSE 5A
SUPPORT SNAP-IN 1-3/8"
8 10 12 16 CIRCUIT
CIR BRK 20A 2P
1
1
CIR BRK 30A 2P
1 1 1
CIR BRK 15A 1P
5 3 5 5
CIR BRK 20A 1P
1 3 3 5
CIR BRK 40A 2P
1 1
CIR BRK 50A 2P
1
COVER - HARNESS ENTRY
HARNESS, 8 CIRCUIT LOAD CENTER TO
EXT CONN BOX
HARNESS, 10 CIRCUIT LOAD CENTER
TO EXT CONN BOX
HARNESS, 12 CIRCUIT LOAD CENTER
TO EXT CONN BOX
HARNESS, 16 CIRCUIT LOAD CENTER
TO EXT CONN BOX
SCREW PPHM M4-0.7 X 10
SCREW SW 1/4"-20 X 5/8” WITH WASHER
BRACKET, ARM EXTENDER

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

2
3
4
5
6
7
8
9
11
12
13
14
15
16
17

0E9843
090388
0C5372
0C3005
0E3372B
0D8067A
071983
0C2981F
0E2985
021533
0E1466
0D4041
0C2977
0C5943
0E4357E

1
3
1
1
1
1
4
1
2
2
2
1
1
1
1

18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33

0E3223
0D2157
0E6098
0D4123A
0E8152
0C3011
0C3009
0C3010
093873
0F5458
0C3027
0C5998
0D4497
0F2664C
0C5305
0D6147

2
2
1
1
1
2
2
2
2
1
3
1
1
1
1
7

ASSEMBLY, CRANKCASE HOUSING WITH
SLEEVE
SEAL, 38 I.D. CRANKSHAFT
SCREW, TAPTITE M6-1.0 X 12 YC
ASSEMBLY, BREATHER
GASKET, BREATHER COVER
SEPARATOR, OIL BREATHER
ASSEMBLY, HEAD #1 G&S
RETAINER, PISTON PIN 20
ROCKER, COVER NO OIL FILL
PISTON, HC
SET, PISTON RING 90MM
PIN PISTON
ASSEMBLY, CAMSHAFT & GEAR
GASKET, CRANK CASE
SEAL, OIL PASSAGE
ASSEMBLY, CRANKSHAFT HORIZONTAL
DIRECT DRIVE
ASSEMBLY, CONNECTING ROD
SCREW SHC M6-1.0 X 50 G8.8
SCREEN, OIL PICKUP
ASSEMBLY, OIL PUMP
O-RING .49 ID X .07 THICK
COVER, OIL RELIEF
SPRING, OIL RELIEF
BALL, 1/2D OIL RELIEF
WASHER, LOCK RIB M6
SCREW, PLASTITE HI-LOW #10
O-RING, 3/8” X 1/2”
CLAMP, OIL TUBE
PLUG-CRANKCASE
ASSEMBLY, DIPSTICK WITH HANDLE
TUBE, DIPSTICK
SCREW HHFC M6-1.0 X 10mm

ITEM PART NO. QTY. DESCRIPTION
34
35
36

043790
0E9842
0C5731

1
1
1

37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65

0C3006
080318
093064
0C8808
0D2723D
0C2979
086515
0D2274
0D3867
078672
0C5371
072694
0D5313
0D3998
0D6024
0C2976
086516
0C2229
083897
0D8067B
0D9853D
0C2978
0D4010
0D4012
0D8675A
0D8675B
0D4015
078699C
078699B

10
8
1
2
1
2
8
4
4
2
4
4
4
4
2
12
2
2
4
1
4
2
1
1
1
1
1
2
4

BARBED ELBOW 90 3/8NPT X 3/8
SEAL, 42 I.D. CRANKSHAFT
ASSEMBLY, HOUSING COVER WITH
SLEEVE
SCREW, HHFC M10-1.5 X 55
SCREW HHFC M6-1.0 X 25
ASSEMBLY, OIL FILL CAP
HOOK, LIFTING
ROCKER, COVER WITH OIL FILL
GASKET, VALVE COVER
KEEPER, VALVE SPRING
RETAINER, VALVE SPRING
SPRING, VALVE
SEAL, VALVE STEM D7
WASHER, VALVE SPRING
STUD, ROCKER ARM PIVOT
ROCKER ARM
NUT HEX M8-1.0 G8 YEL CHR
PLATE, PUSH ROD GUIDE
SCREW HHFC M8-1.25 X 65
VALVE, EXHAUST
VALVE, INTAKE
TAPPET, SOLID
ASSEMBLY, HEAD #2 G&S
PUSHROD, 147
GASKET, HEAD
KIT GASKET
KIT BREATHER ASSEMBLY
KIT HEAD ASSEMBLY CYLINDER 1
KIT HEAD ASSEMBLY CYLINDER 2
KIT OIL RELIEF
SLEEVE DOWEL PIN 14 DIA.
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

ITEM PART NO. QTY. DESCRIPTION
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91

022145
0C5136A
0C3024
0C3040
0C8127
0F9255
0E9582
0D4417
0G0767A
0E6043
0D1142A
0C3025
0C7292
070185B
0D3083
0F2094
075281
035461
0F6301
0G0286
0E9506
0C9764
0C3043
0C7694
070008
070006
040976
045756

1
2
1
1
1
1
4
4
2
2
1
1
1
1
1
2
1
2
4
2
1
4
2
1
4
4
4
17

92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109

0E4997
0C3033
0C3034
0C9763
0D1131
0F1169K
051754
0A5992
0C3032
0C3031
0C3725E
0F1170A
0C7693
0C3041A
082774
0C3036A
0C3019
0C3018

1
1
1
4
1
1
2
2
1
1
1
1
1
2
1
1
1
1

WASHER FLAT M8 – 5/16
KNOB, AIR CLEANER
COVER, AIRBOX NG/LP
PRE-CLEANER,
ELEMENT, AIR CLEANER
ASSEMBLY, MIXER/AIRBOX 990
SCREW SHLDR(8MM) M6-1.0 X 21
WASHER,RUBBER 1/4" X 1/8" THICK
SPARKPLUG,GT990 HSB
SCREW TAPTITE M5 – 0.8 X 8
WRAPPER, LOWER CYLINDER 2
SWITCH, OIL PRESS
NIPPLE, ¾”-16 UNF
OIL FILTER
ASSY, OIL DRAIN HOSE
SCREW M3 – 0.5 X 6 SEMS
SWITCH, THERMAL 284F
BARBED STRAIGHT 1/4NPT X 3/8
CLAMP, HOSE OETIKER 16.5MM
HOSE, 3/8” I.D. X 6” LG
COOLER, OIL
SCREW PLASTITE 1/4-15 X 3/4
GASKET, MANIFOLD / PORT
MANIFOLD CYLINDER 2
WASHER FLAT M8 SS
WASHER LOCK M8 SSTL
SCREW SHC M8 – 1.25 X 20 G12.9
SCREW TAPTITE M6 – 1X10 YELLOW
CHROME
ASSY,GROUND WIRE CONNECTOR
WASHER, 25MM I.D.
NUT, HEX M24
NUT, GROMMET 1/4 PLUG
GUARD, FAN
HOUSING, BLOWER NG COOLER
SCREW HHC M8 – 1.25 X 12 G8.8
WASHER SHAKEPROOF INT M8 SS
PLATE, FAN
FAN, NYLON
FLYWHEEL ASSEMBLY
PLATE, BACKING WITH OIL COOLER
MANIFOLD CYLINDER 1
SLEEVE, RUBBER
KEY, WOODRUFF 4 X 19D
HOSE BREATHER
WRAPPER, LOWER CYLINDER 1
WRAPPER, UPPER CYLINDER 1

ITEM PART NO. QTY. DESCRIPTION
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156

0D1143
0E9323
061906
022129
0F1177
022097
092079
0G0798A
0G0798B
0E9568
0E9565
074027
0C3044
0C4756
075477
043116
0E1644
0E9572
0D9784
0E5108
0D6342
0E9570
0E9577
0E5846
0E9419
0C4760
0F9253
0E9553
0E9554
0E9348
0E9599
0E9595
090987
0E9403
0E9571
0E9380
0A6345
0E9598
0E9593
0E9564
0E9575
0E9357
0A7094
0E9574
0F9273
0F5467
0E9557

1
1
2
3
1
6
4
1
1
1
2
4
1
1
1
2
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1

WRAPPER, UPPER CYLINDER 2
STARTER MOTOR HEAR REDUCED 1KW
SCREW HHC M8 – 1.25 X 85 G8.8
WASHER LOCK M8 – 5/16
ASSEMBLY, GROUND WIRE
WASHER LOCK M6 – 1/4
SCREW TAPTITE M6 – 1.0 X 25 BP
ASSY, IGN COIL W/DIODE, CYLINDER 1
ASSY, IGN COIL W/DIODE, CYLINDER 2
ASSY, THROTTLE SHAFT
THROTTLE VALVE
SCREW PPHM M3 – 0.5 X 5
COVER, DUST, MIX/AIRBOX
SPRING, IDLE ADJUST
SCREW PPHM M5 – 0.58 X 20
SCREW HHC M6 – 1.0 X 12
SCREW BHSC M6-1.0 X 12 SS
BRACKET, STEPPER MOTOR
NUT HEX LOCK M3 – 0.5 NYLON INSERT
ASSY, CONTROLLER
BALL STUD, 10MM
ASSY, THROTTLE ROD
BELLOWS, INTAKE
EXPANSION PLUG
#10 O-RING
PLUG, MANIFOLD
ASSY, AIR BOX BASE
PIN, FUEL SELECTOR
PIN, FUEL SEL STOP
SOLENOID COVER
LINKAGE, CHOKE
SCREW PPPH HI-LO #6 X 1/2
SCREW PHTT M3 – 0.5 X 8
RETAINER, CHOKE RETURN SPRING
SPRING, CHOKE RETURN
WASHER, BELLEVILLE SPRING
SCREW PPHM M2 – 0.4 X 8
CHOKE ARM
SCREW SHOULDER M3 – 0.5 X 6
VALVE, CHOKE
SHAFT, CHOKE
SEAL, GOVERNOR ARM
SCREW PHM #4 – 40 X 1/4
BRACKET, SOLENOID
SOLENOID, 6VDC
NUT HEX M8 – 1.25 YELLOW ZINC
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
Air-cooled Generators
10kW, GT-530 Engine – Drawing No. 0F9429-c - Part 1

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57

PART NO.
0E9428B
0E3812
0C8566
0E9367A
0E9366
0E9304
0E9334C
076390
076389
088057
088411
0E9322A
0E9407A
0E9350
0E9318E
043116
093873
0G0272
0E9482
0A5776
0C5315A
0C5314A
0E9473
073144
0C3027
0E9358
093064
0E9334A
0E9352
0C3592
0C3733
0C4390
088156
084186
0E9368
077168
0E9305
0C3590
0E9351
0C3591
083235
0E9455E
0E9353A
076307
077160
077161
0G0273
0G0274
0G0275
0G0276
0E9502
080318
0E3372C
078699B
0C5943
043790
0D4788

QTY.
1
2
2
1
1
1
1
4
2
2
2
2
1
1
1
3
3
1
1
1
1
1
1
9
2
1
1
1
2
8
4
4
2
4
2
12
1
2
2
2
4
4
2
4
4
4
1
1
1
1
1
12
1
6
1
1
1

DESCRIPTION
CRANKCASE
SEAL D 35 X 48.2
SCREW HHFC M6 – 1.0 X 20
ASSY, BREATHER
GASKET BREATHER ASSY
CYLINDER HEAD 1
COVER, ROCKER PLAIN
PISTON PIN RETAINER RING
PISTON PIN
PISTON
PISTON RING SET
ASSY CONNECTING ROD
ASSY, CAM & GEAR
GASKET CRANKCASE
ASSY CRANKSHAFT W/PLUG
SCREW HHC M6 – 1.0 X 12
WASHER LOCK M6 RIBBED
ASSY GEROTOR
SPRING OIL PRESSURE RELIEF
BALL 11/32 DIA PRESSURE RELIEF
GEROTOR OUTER 9MM THICK
GEROTOR INNER 9MM THICK
GEAR COVER
SCREW HHFC M8 – 1.25 X 45
O-RING 3/8 X 1/2
SCREEN OIL PICK-UP
ASSY, OIL FILL CAP
COVER, ROCKER, W/ FILL
GASKET, VALVE COVER
KEEPER, VALVE SPRING
VALVE RETAINER
SPRING VALVE
SEAL, VALVE STEM
WASHER, VALVE SPRING
SPARKPLUG
SCREW HHC M8 – 1.25 X 56
CYLINDER HEAD 2
VALVE EXHAUST
GASKET CYLINDER HEAD
VALVE INTAKE
TAPPET, SOLID
PUSHROD, ALUMINUM
PLATE, PUSH ROD GUIDE
NUT JAM (ROCKER ARM)
ROCKER ARM
STUD ROCKER ARM PIVOT
GASKET KIT
BREATHER KIT
KIT HEAD ASSY CYLINDER #1
KIT HEAD ASSEMBLY CYLINDER #2
SEPERATOR, OIL, GT530
SCREW HHFC M6 – 1.0 X 25
SEPARATOR, OIL BREATHER GT530
SLEEVE DOWEL PIN 12 DIA.
SEAL, OIL PASSAGE
BARBED EL 90 3/8 NPT X 3/8
PLUG STD PIPE 3/8 STEEL SQ HD
53

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
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87

022097
0E9561
0E9472
0E9471
078643B
0D9784
0E9584
0D6342
0E9587
0C9997
0E9319
0E9597
040976
022129
061906
0E9323
0E9507
0E9362
0E9337
0E9339
0E9402
0F2664H
0E9336F
0D6147
0E5139
0E9432
0E9338
0E9370
0E9505A
0F5458

3
1
1
1
4
1
1
1
1
1
2
1
4
2
2
1
6
2
1
1
1
1
1
6
3
1
1
1
1
2

WASHER LOCK M6-1/4
INTAKE ADAPTER
GASKET, AIRBOX TO CARB/MIXER
GASKET, MANIFOLD TO CARB/MIXER
BOLT, CARB MOUNT M6 – 1.0 X 85
NUT HEX LOCK M3 – 0.5
ASSY, CONTROLLER
BALL STUD, 10 MM
ASSY, THROTTLE ROD
GUARD, FAN
GASKET INTAKE
BREATHER HOSE
SCREW SHC M8 – 1.25 X 20 G12.9
WASHER LOCK M8 – 5/16
SCREW HHC M8 – 1.25 X 85
STARTER MOTOR
SCREW HHFC M8 – 1.25 X 14
LIFTING HOOK
WRAPPER OUTER CYLINDER 1
WRAPPER INNER CYLINDER 1
TUBE, DIPSTICK
ASSY, DIPSTICK /TEXT
BLOWER HOUSING
SCREW HHFC M6-1.0 X 10 G8.8
SCREW HHFC M6-1.0 X 8 G8.8
WRAPPER INNER CYLINDER 2
WRAPPER OUTER CYLINDER 2
GASKET, OIL FILTER ADAPTER
ASSY, DIRECT OIL COOLER ADAPTER
SCREW PLASTITE HI-LOW #10X3/8

ITEM PART NO. QTY. DESCRIPTION
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115

045757
070185B
094090
0F2094
0D3083
0A8584
082774
0E7209
0E9514B
0E9514C
026850
0E9443
0F6301
0G0286
0G0479
0E9340
0E9525C
0E9486
0A5992
048571
067890
067198N
0C3032
0E4997
0E9406
0G1705
0E9450
0E9376
0E9550

3
1
1
2
1
1
1
1
1
1
4
1
4
1
1
1
1
1
2
2
1
1
1
1
1
14
1
1
1

SCREW HHC M6 – 1.0 X 25
OIL FILTER
THERMAL SWITCH
SCREW PPHM M3-0.5 X 6 SEMS
ASSEMBLY, OIL DRAIN HOSE
OIL PRESSURE SWITCH
KEY, WOODRUFF 4 X 19D
ASSY, GROUNDING WIRE
ASSY IGNITION COIL CYLINDER 1
ASSY IGNITION COIL CYLINDER 2
WASHER SHAKEPROOF EXT 1/4
ASSY, MIXER DUAL FUEL
CLAMP, HOSE OETIKER 16.5MM
HOSE 3/8”ID X 6” SAE J30R9
HOSE 3/8”ID X 7.25 SAE J30R9
BACKING PLATE
ASSY, FLYWHEEL & RING GEAR
FAN, FLYWHEEL, 20 FIN, 218.8 OD
WASHER LOCK INT M8
SCREW HHC M8 – 1.25 X 10
NUT HEX M20 – 1.5
WASHER BELV – 20 X 2.2
PLATE, FAN
ASSY, GROUND WIRE CONNECTOR
OIL COOLER
SCREW HHFC M6 – 1.0 X 14
CENTER BAFFLE
INTAKE MANIFOLD
FRONT COVER

Section 9 — Exploded Views and Parts Lists

28
27
37

33
45

43
39

19
18

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

Section 9 — Exploded Views and Parts Lists
Air-cooled Generators
7kW, GN-410 Engine – Drawing No. 0F9428 - Part 1

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54

PART NO.
0E3221
0E1466
021533
0E2985
071983
0E8440
0A7628
078658
078659
088261E
0E3812
0E6519
078645
0A7811
0A9877
076701
021713B
078691
0A5771
0A5776
076361
0A8898D
0D2274
0C4391
086025
0E3341
021714
086516
086517
0D9853B
083897
077158
0C3150
072694
083907
072696
078694
021742
0D6094
076329
0E0057
0D4788
074908
086515
078606
0A1442
078672
089673
0B2104
078699C
0A7627
043790A
088590
078699B

QTY.
1
1
1
1
2
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
2
1
1
2
2
2
1
4
1
1
1
1
1
4
4
8
1
2
1
2
1
1
1
1

DESCRIPTION
ASSEMBLY, CONNECTING ROD
PIN, PISTON D20
SET, PISTON RING 90MM
PISTON, HC
RETAINER, PISTON PIN 20
ASSEMBLY, CRANKSHAFT GH410 SMALL TAPER
ARM, GOVERNOR RC45
PIN, “R” GOVERNOR ARM
WASHER, GOVERNOR ARM THRUST
CRANKCASE, SUBASSEMBLY WITH PLUGS GH410
SEAL, 35 I.D. CRANKSHAFT
ASSEMBLY, GOVERNOR GEAR
C-RING, GOVERNOR GEAR RETAINER
SPOOL, GOVERNOR- MACHINE
ASSEMBLY, CAMSHAFT & GEAR
GASKET , CRANKCASE
GASKET, HEAD 410
COVER, OIL PRESSURE RELIEF
SPRING, OIL RELIEF 360
BALL, DIA 11/32 PRESSURE RELIEF
WASHER, THRUST GOVERNOR GEAR
ASSEMBLY, COVER, GEAR TOP CHECK / FILL
RETAINER, VALVE SPRING
VALVE SPRING LF
SET,GEROTOR 12 THK
BALANCER
ASSEMBLY,CYLINDER HEAD SEATS & GUIDES
VALVE, EXHAUST
VALVE, INTAKE
PUSH ROD 174.9
TAPPET
ASSEMBLY, SCREEN OIL PICK-UP
GASKET, ROCKER COVER 410
STUD, D20 PIVOT BALL
ROCKER ARM
NUT, JAM (ROCKER ARM)
PLATE, PUSH ROD GUIDE
SCREW, HHFL M10-1.5 X 105
ASSEMBLY, ROCKER COVER BREATHER
PLUG, OIL FILL PLASTIC
O-RING 17.8 I.D. x 2.4
PLUG, STANDARD PIPE 3/8 STEEL SQUARE HEAD
SCREW, TAPTITE M5-0.8 X 10 BP
KEEPER, VALVE SPRING
SCREW & LOCKWASHER M6-1 X 12
SCREW, HHFC M8-1.25 X 42
SEAL, VALVE STEM D7
WASHER, VALVE SPRING
WASHER, LARGE SPRING
DOWEL, SEAMED SLEEVE
SHAFT, GOVERNOR RC55
BARBED ELBOW 90 3/8NPT X 3/8 LOCKTITE
DOWEL DIA 12 X 18L
DOWEL, SLEEVE SEAMED 12 DIA.

Section 9 — Exploded Views and Parts Lists

31
29

17 18

48
10

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

Section 9 — Exploded Views and Parts Lists
Air-cooled Generators
7kW, GN-410 Engine – Drawing No. 0F9428 - Part 2

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52

PART NO.
0C1069
0D2922
0F8426
0C9997
088434
045756
0C4176A
0D9004A
059985
022129
0C2458A
083512
0D1401A
091039
0C9619
049811
022097
040945
086999
0D5667A
049821
099236
070185B
082774
091222E
067198N
067890
0E7585
072734
072735
0C3978
0C6040
0D9760
092079
0F3800
083502
082025
0D3083
0E7887C
090072
075281
022145
0F2094
0C4373
022717B
0F3865
0F3855
039253
0D3751
0F3921
0C8493
0D8758

QTY.
5
1
1
1
1
11
1
1
2
3
1
1
1
1
1
2
4
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1

DESCRIPTION
SCREW, TAPTITE M6-1.0X8 YELLOW CHROME
HOUSING, BLOWER
TUBE, DIPSTICK
GUARD, FAN
WRAPPER, BOTTOM
SCREW, TAPTITE M6-1X10 YELLOW CHROME
WRAPPER, TOP
ASSY, STARTER
SCREW, SHC M8-1.25 X 45 G12.9
WASHER, LOCK M8-5/16
BACKPLATE, L/F D/F
SCREW, TAPTITE M8-1.25 X 16 BP
BREATHER TUBE
GASKET, INTAKE ADAPTER
ASSEMBLY, PLASTIC CARB
WASHER, FLAT M6
WASHER, LOCK M6-1/4
SCREW, SHC M6-1.0 X 20 G12.9
GASKET,OIL FILTR ADAPTER
ADAPTER, OIL FILTER
SCREW, SHC M8-1.25 X 30 G12.9
SWITCH, OIL 8.0 PSI
OIL FILTER
KEY, WOODRFF 4 X 19D
FLYWHEEL WITH RING GEAR 32DEG.
WASHER,BELV-20 X 2.2
NUT, HEX - FLYWHEEL
SPARKPLUG
ASSEMBLY,GOVERNOR LEVER 12 HP
ROD,GOVERNOR CONTROL.
SPRING, ANTI-LASH
ASSEMBLY, WIRE
ASSEMBLY, IGNITION COIL
SCREW, TAPTITE M6-1.0 X 25 BP
SPRING GOVERNOR
BOLT, GOVERNOR ADJUST M5
NUT HEX LOCK M5-0.8 NYINS ZINC
ASSEMBLY, OIL DRAIN HOSE
ASSEMBLY, CAP & DIPSTICK
O-RING 9/16 X 3/4 X 3/32
SWITCH, THERMAL
WASHER FLAT 5/16 - M8
SCREW, M3-0.5 X 6 SEMS
SPACER, ENDFRAME
GOMMET
SPRING SECONDARY
BRACKET SECONDARY GOVERNOR SPRING
SCREW HHC M8-1.25 x 20
SPRING, IDLE RETURNING
BARREL GOVERNOR ADJUSTMENT
SCREW SHC M5-0.8 x 30
ENGINE LIFT HOOK

Section 9 — Exploded Views and Parts Lists
Air-cooled Generators
7kW, GN-410 Engine – Drawing No. 0F9422-B

ITEM
1
2
3
4
5
6
7
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
52
53
54
55
56
57
58
59

PART NO.

QTY.

DESCRIPTION

0F8186
0F5540H
0C9934H
0F7774A
0C8096
0F6591
0F8078
056482
0C3168
056147
0D1847
0C7038C
0F9445
0F9497
0C7038B
0C7758
0388050AE0
0C2417A
0F6528
066386
029451
049451
022237
022511
022131
039287
022145
049820
090388
022129
022259
059637
048031K
0C9592
048031M
040976
0G0414
028237
090239
0C6989
0D1214
0C8127
0C3024
0D2273
055934N
0F7065
0C5136A
039253
022473
066849
0F6551
0F8079
0F0710
0F8256
045771
0G0676
074906

1
1
1
1
1
1
1
1
3
1
4
1
1
1
1
4
1
1
1
1
1.8 FT
1
4
4
4
4
18
4
8
17
8
2
3
1
2
2
1
3
1
1
1
1
1
1
1
1.25 FT
2
2
4
2
1
1
2
1
4
2
4

ADAPTOR, ENGINE
STATOR
ROTOR
CARRIER, REAR BEARING
FAN, 8” CURVED BLADE
MUFFLER
TAIL PIPE, MUFFLER
BEARING
5/16 SPECIAL L/WASH
BOLT ROTOR HHCS 5/16”-24 X 13-1/2” G5
BOLT STATOR IHHCS M8-1.25 x 305mm
BRACKET, ALTERNATOR MOUNTING
DUCT, ALTERNATOR AIR
GASKET, ALTERNATOR AIR DUCT
BRACKET, ENGINE MOUNTING
RUBBER MOUNT
CABLE, #6 40” BLACK BATTERY
EARTH STRAP 3/8X 3/8
EXHAUST FLEX
ASSEMBLY BRUSH HOLDER
TAPE ELEC UL FOAM 1/8 X 1/2
WASHER FLAT .406ID X 1.62OD
WASHER LOCK 3/8
BOLT HHC 3/8-16 X 1-1/4 G5
WASHER FLAT 3/8
SCREW HHC M8-1.25 X 45 G8.8
WASHER FLAT 5/16
NUT LOCK HEX M8-1.25 NYL INSRT
SCREW TAP M6-1.0X12
WASHER LOCK M8-5/16
NUT HEX 5/16-18
SCREW TAPTITE 3/8-16X 3/4”
BAND, HOSE CLAMP 35.05 DIA.
BELLOWS
HOSE CLAMP 3/4"
SCREW SHC M8-1.25 X 20 G12.9
PLATE “HOT”
U-BOLT 5/16”-18 X 1.38” W/ SADDLE
GASKET, EXHAUST
STINGER, ENGINE AIR IN
BASE, AIR CLEANER
ELEMENT, AIR CLEANER
COVER, AIR CLEANER NG/LP
TUBE, 1.25"O.D. x 20Ga. x 12.125" LONG
CLAMP VINYL 1.31 X .281 Z
HOSE LP 1/2" I.D.
KNOB, AIR CLEANER
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 1/4
SCREW HHTT M5-0.8 X 16
FLEX COVER
BRACKET MUFFLER ACCESS
RIVET POP 0.125” X 0.337”
EXHAUST MANIFOLD
NUT HEX M8-1.25 NY INS
SCREW THTT M6-1.0 X 10
SCREW HHTT M6-1.0 X 20
61

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
2

4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33

0F8186
0F6694
0F5538
0F7548
0F9795
0F5539
0F7549
0F7774
0E9579
0F8998
0F6591
0F8078
0F7797
0F8141
056482
0C3168
0D1838
0D1846
0C7038
0F9396
0D2559
0C7038A
0F4179
0C7758
0388050AD0
0C2417A
0F6528
066386
029451
049451
022237
022511
022131
051731
022145
049820
0G0676
022129
022259
059637

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
4
1
1
1
1
1
4
1
1
1
1
2.6 FT
1
5
4
4
4
18
4
2
18
8
2

ADATOR, ENGINE
STATOR (16KW)
STATOR (13KW)
STATOR (10KW)
ROTOR (16KW)
ROTOR (13KW)
ROTOR (10KW)
CARRIER, REAR BEARING
FAN, 12” CURVED BLADE
FAN, 12” CURVED BLADE (10KW)
MUFFLER
TAIL PIPE, MUFFLER
FLEX BASE
FLEX BASE (10KW)
BEARING
5/16 SPECIAL LOCK WASHER
BOLT, IHHCS 3/8”-24 X 15.50”
BOLT, IHHCS M8-1.25 X 345mm
BRACKET, ALTERNATOR MOUNTING
DUCT, ALTERNATOR AIR
GASKET, ALTERNATOR AIR DUCT
BRACKET, ENGINE MOUNTING
PLATE, MOUNTING ENG 530HSB
RUBBER MOUNT
CABLE, #6 48” BLACK BATTERY
EARTH STRAP 3/8 X 3/8
EXHAUST FLEX
ASSEMBLY BRUSH HOLDER
TAPE ELEC UL FOAM 1/8 X 1/2
WASHER FLAT .406ID X 1.62OD
WASHER LOCK 3/8
SCREW HHC 3/8 X 16 X 1-1/4
WASHER FLAT 3/8 ZINC
SCREW HHC M8-1.25 X 50
WASHER FLAT 5/16 ZINC
NUT LOCK HEX M8-1.25 NYL INSERT
SCREW THTT M6-1.0 X 10
WASHER LOCK M8-5/16
NUT LOCK HEX 5/16-18
SCREW TAPTITE 3/8-16 X ¾

ITEM PART NO. QTY. DESCRIPTION
34
35
36
38
39
40

51
52
53
54
55
56
57
58
59
60
61
62

0D4662
0F7065
048031M
0G0414
0D5823
0E9369
0C4138
040173
074995
066849
0F7799
0F8115
0F7796
0F8204
0F9385
090388
045771
039253
0F0710
0F0710
0F8079
0F9273
0E9592
0E9588
077091
0E9581
0E9594
0E9590
0E9542
0D1683
077075
0E9595

3
3 FT
4
1
3
2
2
2
1.44 FT
2
1
1
1
1
1
13
4
2
5
2
1
1
2
1
1
1
3
1
1
2
1
2

63
64
65
66
67
68

0E9589
0E9591
0E9549
035685
099502
0C8565

1
1
1
1
2
4

41
42
43
44
45
46
47
48
49
50

SCREW 5/16-18 X 3/4”
HOSE RES ½ LP GAS
HOSE CLAMP ¾” I.D.
PLATE, “HOT”
U-BOLT 5/16”-18 X 1.62” WITH SADDLE
GASKET, EXHAUST PORT (10KW)
GASKET, EXHAUST PORT
CLAMP HOSE #5.5 0.62”-0.62” (10KW)
HOSE ¼ ID LPG 350PSI UL21 (10KW)
SCREW HHTT M5-0.8 X 16
EXHAUST MANIFOLD
EXHAUST MANIFOLD (10KW)
FLEX COVER
FLEX COVER (10KW)
FLEX COVER EXTENSION (10KW)
SCREW TAPTITE M6-1.0 X 12
NUT HEX M8-1.25
SCREW HHC M8-1.25 X 20
RIVET POP 0.125” X 0.337” (10KW)
RIVET POP 0.125” X 0.337”
BRACKET MUFFLER ACCESS
SOLENOID, 6 VOLTS DC (10KW)
SCREW PPHM $4-40 X 3/8 SEMS (10KW)
LINKAGE, CHOKE (10KW)
COTTER PIN (10KW)
AIR CLEANER GTH530 HSB (10KW)
SCREW PPPH HI-LO #14-15 X ½ (10KW)
ASSEMBLY, CHOKE SHAFT (10KW)
VALVE, CHOKE (10KW)
SCREW PFHM M3-0.5 X 5 (10KW)
BOOT, CHOKE SOLENOID (10KW)
SCREW PPPH HI-LO #6/1/2 W/ #5HD
(10KW)
CHOKE HSG (10KW)
SPRING-CHOKE RETURN (10KW)
HOSE, INTAKE GTH530 HSB (10KW)
CLAMP HOSE #28 1.32-2.25
CLAMP HOSE #24 B1.06-2.00
SCREW SHC M8-1.25 X 18 G8.8

Section 9 — Exploded Views and Parts Lists

23
22
19
13

21
64

10
37

6
7
32

7KW

29 18

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

Section 9 — Exploded Views and Parts Lists
Air-cooled Generators
7 & 10kW, GN-410/GT-530 Regulator – Drawing No. 0F9425

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37

PART NO.
0D5694
0F9285
0F5022
0C4647
0D4166
0F8822
022145
022129
0F4795
0C5760P
0C6606
0C6606
097934
0C4645
0C5761
0C5968
0C6066
0C5759
0C5764A
0C5764
070728
0C6069
0C5762
0F9189
045764
0C6731
0C6067
0C4706
0C6068
0C4643A
072683A
072683A
0A4032
0D3308
024310
0D3973
042907
028414A
035578A
0G0247
0F9773B
0F9773A

QTY.
1
1
1
1
1
1
2
2
4
1
1
2
1
1
2
2
2
2
2
2
4
2
2
2
16
2
2
2
2
2
2
1
1
4
1
1
2
1
1
1
1
1

DESCRIPTION
CASTING, TWIN REGULATOR HOUSING (7KW)
CASTING, TWIN REGULATOR HOUSING
SOLENOID COIL, 12VDC
GASKET , SOLENOID
PLUNGER, LP REGULATOR ASSEMBLY
REGULATOR BRACKET
WASHER FLAT 5/16-M8
WASHER LOCK 5/16-M8
SCREW PPHM SEMS M4-0.7 X 10
FUEL JET GASEOUS REGULATOR (7KW)
BARBED STRAIGHT ½ NPT x ½ (7KW)
BARBED STRAIGHT ½ NPT x ½
O-RING (7KW)
ADJUSTER SCREW, TWIN REGULATOR (7KW)
LEVER, REGULATOR
SUPPORT, INLET SEAL
SEAL, INLET
PIN, PIVOT ARM
SPRING, REGULATOR (7KW)
SPRING, REGULATOR
SCREW, PFHMS M3-0.5 x 5
GASKET, DIAPHRAGM
COVER, TWIN REGULATOR (7KW)
COVER, TWIN REGULATOR
SCREW, TAPTITE M4X8 BP
RIVET, POP .118 X .125
SUPPORT, DIAPHRAGM
DIAPHRAGM, TWIN REGULATOR
CAP, DIAPHRAGM SUPPORT
INLET, TWIN REGULATOR 11.11 DIA.
PLUG STD PIPE 1/8 SOCKET HEAD (7KW)
PLUG STD PIPE 1/8 SOCKET HEAD
PIN, LIMITED ADJUSTMENT (7KW)
WASHER, FLAT M3 X 10mm O.D.
PLUG, STANDARD PIPE 1/2” STEEL SQUARE HEAD (7KW)
PLUG, EXPANSION 16mm (7KW)
SCREW HHC M8-1.25 X 16
BARBED STRAIGHT 1/8”NPT X ¼” (10KW)
NIPPLE CLOSE 1/8NPT (10KW)
SOLENOID, LP/NG DC12V (10KW)
SOLENOID WIRE, #0 (10KW)
SOLENOID WIRE, #14 (10KW)

Section 9 — Exploded Views and Parts Lists

28
30

7
6

6
7

29 18

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
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35

PART NO.
0F9285
0F5022
0C4647
0D4166
0F8096
022145
022129
0F4795
045771
0C6606
042907
026915A
0C5761
0C5968
0C6066
0C5759
0C5764
070728
0C6069
0F9189
045764
0C6731
0C6067
0C4706
0C6068
0C4643A
072683A
049226
0D3308
051713
0F8979
051716
0E9533
0E9534
0E9535

QTY.
1
1
2
1
1
4
4
8
2
2
2
1
2
2
2
2
2
4
2
2
16
2
2
2
2
2
3
4
4
4
1
4
1
1
1

DESCRIPTION
CASTING, TWIN REGULATOR HOUSING
SOLENOID COIL, 12VDC
GASKET , SOLENOID
PLUNGER, LP REGULATOR ASSEMBLY
BRKT REGULATOR MOUNTING 990
WASHER FLAT 5/16-M8
WASHER LOCK 5/16-M8
SCREW PPHM SEMS M4-0.7 X 10
NUT HEX M8-1.25
BARBED STRAIGHT ½ NPT x ½
SCREW HHC M8-1.25 X 16
NIPPLE CLOSE ¾ X 1.375 WITH VIBRA SEAL
LEVER, REGULATOR
SUPPORT, INLET SEAL
SEAL, INLET
PIN, PIVOT ARM
SPRING, REGULATOR
SCREW, PFHMS M3-0.5 x 5
GASKET, DIAPHRAGM
COVER, TWIN REGULATOR
SCREW, TAPTITE M4X8 BP
RIVET, POP .118 X .125
SUPPORT, DIAPHRAGM
DIAPHRAGM, TWIN REGULATOR
CAP, DIAPHRAGM SUPPORT
INLET, TWIN REGULATOR 11.11 DIA.
PLUG STD PIPE 1/8 SOCKET HEAD
WASHER, LOCK, M5
WASHER, FLAT M3 X 10mm O.D.
WASHER, FLAT, M5
SOLENOID COVER PLATE
NUT HEX M5-0.8
SOLENOID ADAPTER
ASSY, FUEL SYSTEM PLENUM
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
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297
WHITEWATER, WI 53190

ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
211 MURPHY DRIVE
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.
(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:
(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall
be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the
ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.
(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual
shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or
replace as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS
Warranty shall be warranted for the remainder of the ECS Warranty Period.
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part
fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection
(4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the
remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no
charge to the owner at a Generac Authorized Warranty Service Facility.
(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsible
for diagnostic costs if the repair is deemed warrantable.
(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused
by a failure under warranty of any emission-related part covered by the ECS Warranty.
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient
to meet the expected demand for such emission-related parts.
(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS
Warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce Generac
ECS Warranty obligations.
(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac
engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim.
Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of
such an unapproved, add-on, modified, counterfeit and/or “grey market” part.

EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
1) Fuel Metering System:
1.2) LPG/Natural Gas carburetion assembly and its internal components.
a) Fuel controller (if so equipped)
b) Mixer and its gaskets (if so equipped)
c) Carburetor and its gaskets (if so equipped)
d) Primary gas regulator (if so equipped)
e) LP liquid vaporizer (if so equipped)
2) Air Induction System including:
a) Intake pipe/manifold
b) Air cleaner

3) Ignition System including:
a) Spark plug
b) Ignition module
4) Catalytic Muffler Assembly (if so equipped) including:
a) Muffler gasket
b) Exhaust manifold
5) Crankcase Breather Assembly including:
a) Breather connection tube

*Generac engine types covered by this warranty statement include the following:
1) Prepackaged Standby Generator
2) Auxiliary Power Unit (APU) Generator
3) Standby Generator
Part 2

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® POWER SYSTEMS, INC.
P.O. BOX 297 • WHITEWATER, WI 53190
Part No. 0F9421

Revision C (05/22/06)

Revision (02/01/05)

Printed in U.S.A.

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