Guardian Technologies 5240 Users Manual 0F9421revC

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GENERAC

POWER SYSTEMS, INC.

R

R

Installation and

Owner’s Manual

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

Automatic Standby Generators

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

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

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

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

005283, 005284

DANGER

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!

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

life-support applications.

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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 dur-

ing 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vapor withdrawn liquid propane (LP) or natural gas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 person-

nel to special instructions about a particular opera-

tion that may be hazardous if performed incorrectly

or carelessly. Observe them carefully. Their defini-

tions are as follows:

DANGER

After this heading, read instructions that, if not

strictly complied with, will result in serious person-

al injury, including death, in addition to property

damage.

After this heading, read instructions that, if not

strictly complied with, may result in serious person-

al injury or property damage.

After this heading, read instructions that, if not

strictly complied with, could result in damage to

equipment and/or property.

NOTE:

After this heading, read explanatory statements

that require special emphasis.

These safety warnings cannot eliminate the haz-

ards that they indicate. Common sense and strict

compliance with the special instructions while

performing the service are essential to preventing

accidents.

Four commonly used safety symbols accompany the

DANGER, WARNING and CAUTION blocks. The type

of information each indicates follows:

 This symbol points out important safety infor-

mation that, if not followed, could endanger

personal safety and/or property of others.

 This symbol points out potential explosion haz-

ard.

 This symbol points out potential fire hazard.

 This symbol points out potential electrical shock

hazard.

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The operator is responsible for proper and safe use

of the equipment. The manufacturer strongly recom-

mends that the operator read this Owner's Manual

and thoroughly understand all instructions before

using this equipment. The manufacturer also strong-

ly recommends instructing other users to properly

start and operate the unit. This prepares them if they

need to operate the equipment in an emergency.

CONTENTS

This manual contains pertinent owner’s information,

including warranty, electrical diagrams, exploded

views and lists of repair parts, for these different

models:

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

der GH-410 Engine

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

GT-530 Engine

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

990 Engine

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

LP, V-twin GT-990 Engine

OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety

checks, to make sure that all maintenance for safe

operation is performed promptly, and to have the

equipment checked periodically by an Authorized

Dealer. Normal maintenance service and replacement

of parts are the responsibility of the owner/operator

and, as such, are not considered defects in materials

or workmanship within the terms of the warranty.

Individual operating habits and usage contribute to

the need for maintenance service.

Proper maintenance and care of the generator ensures

a minimum number of problems and keep operating

expenses at a minimum. See an Authorized Dealer

for service aids and accessories.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs,

contact an Authorized Dealer for assistance. Service

technicians are factory-trained and are capable of

handling all service needs.

When contacting an Authorized Dealer about parts

and service, always supply the complete model num-

ber and serial number of the unit as given on its data

decal, which is located on the generator. See section

"The Generator" for decal location.

Model No. ____________ Serial No. ______________

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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

1

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

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

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

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

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

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

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

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

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

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

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

1.3 NEC Requirement for Arc Fault Circuit

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

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

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

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

1.7 Fuel Requirements and Recommendations ... 7

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

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

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

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

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

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

Section 2 – Post Installation Start-up

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

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

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

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

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

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

2.6 Adjusting the Fuel Regulator -

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

4.7 Adjusting GH-410/GT-530/990

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

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

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

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

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

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

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

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

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

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

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

Section 9 – Exploded Views and

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

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

2

Study these SAFETY RULES carefully before install-

ing, operating or servicing this equipment. Become

familiar with this Owner’s Manual and with the

unit. The generator can operate safely, efficiently and

reliably only if it is properly installed, operated and

maintained. Many accidents are caused by failing to

follow simple and fundamental rules or precautions.

The manufacturer cannot anticipate every possible

circumstance that might involve a hazard. The warn-

ings in this manual, and on tags and decals affixed

to the unit are, therefore, not all-inclusive. If using

a procedure, work method or operating technique

the manufacturer does not specifically recommend,

ensure that it is safe for others. Also make sure the

procedure, work method or operating technique uti-

lized does not render the generator unsafe.

DANGER

 Despite the safe design of this generator,

operating this equipment imprudently, neglecting

its maintenance or being careless can cause

possible injury or death. Permit only responsible

and capable persons to operate or maintain this

equipment.

 Potentially lethal voltages are generated by

these machines. Ensure all steps are taken to

render the machine safe before attempting to

work on the generator.

 Parts of the generator are rotating and/or hot

during operation. Exercise care near running

generators.

 GENERAL HAZARDS 

For safety reasons, the manufacturer recommends

that the installation, initial start-up and main-

tenance of this equipment is carried out by an

Authorized Dealer.

The engine exhaust fumes contain carbon monox-

ide, which can be DEADLY. This dangerous gas, if

breathed in sufficient concentrations, can cause

unconsciousness or even death. This exhaust

system must be installed properly, in strict com-

pliance with applicable codes and standards.

Following installation, do nothing that might ren-

der the system unsafe or in noncompliance with

such codes and standards.

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

belts, fans, and other moving or hot parts. Never

remove any drive belt or fan guard while the unit

is operating.

Adequate, unobstructed flow of cooling and venti-

lating air is critical to correct generator operation.

Do not alter the installation or permit even partial

blockage of ventilation provisions, as this can seri-

ously affect safe operation of the generator. The

generator MUST be installed outdoors.

When working on this equipment, remain alert

at all times. Never work on the equipment when

physically or mentally fatigued.

Inspect the generator regularly, and contact the

nearest Authorized Dealer for parts needing repair

or replacement.

Before performing any maintenance on the gen-

erator, disconnect its battery cables to prevent

accidental start up. Disconnect the cable from the

battery post indicated by a NEGATIVE, NEG or

(–) first, then remove the POSITIVE, POS or (+)

cable. When reconnecting the cables, connect the

POSITIVE cable first, the NEGATIVE cable last.

Never use the generator or any of its parts as a

step. Stepping on the unit can stress and break

parts, and may result in dangerous operating con-

ditions from leaking exhaust gases, fuel leakage,

oil leakage, etc.

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IMPORTANT SAFETY INSTRUCTIONS

Air-cooled Generators

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

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

tors and potential operators of this equipment.



The engine exhaust from this product

contains chemicals known to the state

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.

•

WARNING:•

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3

 ELECTRICAL HAZARDS 

All generators covered by this manual produce

dangerous electrical voltages and can cause fatal

electrical shock. Utility power delivers extremely

high and dangerous voltages to the transfer switch

as does the standby generator when it is in opera-

tion. Avoid contact with bare wires, terminals,

connections, etc., while the unit is running. Ensure

all appropriate covers, guards and barriers are in

place, secured and/or locked before operating the

generator. If work must be done around an oper-

ating unit, stand on an insulated, dry surface to

reduce shock hazard.

Do not handle any kind of electrical device while

standing in water, while barefoot, or while hands or

feet are wet. DANGEROUS ELECTRICAL SHOCK

MAY RESULT.

The National Electrical Code (NEC) requires the

frame and external electrically conductive parts of

the generator to be connected to an approved earth

ground. Local electrical codes also may require

proper grounding of the generator electrical system.

After installing this home standby electrical sys-

tem, the generator may crank and start at any

time without warning. When this occurs, load cir-

cuits are transferred to the STANDBY (generator)

power source. To prevent possible injury if such a

start and transfer occur, always set the generator’s

AUTO/OFF/MANUAL switch to its OFF position

before working on equipment and remove the 15A

fuse from the generator control panel.

In case of accident caused by electric shock, imme-

diately shut down the source of electrical power. If

this is not possible, attempt to free the victim from

the live conductor. AVOID DIRECT CONTACT WITH

THE VICTIM. Use a nonconducting implement,

such as a dry rope or board, to free the victim from

the live conductor. If the victim is unconscious,

apply first aid and get immediate medical help.

Never wear jewelry when working on this equip-

ment. Jewelry can conduct electricity resulting in

electric shock, or may get caught in moving com-

ponents causing injury.

 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 installa-

tion, do nothing that might alter a safe installation

and render the unit in noncompliance with the

aforementioned codes, standards, laws and regu-

lations.

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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 extin-

guisher properly charged and be familiar with its

use. Consult the local fire department with any

questions pertaining to fire extinguishers.

 EXPLOSION HAZARDS 

Do not smoke around the generator. Wipe up any

fuel or oil spills immediately. Ensure that no com-

bustible materials are left in the generator com-

partment, or on or near the generator, as FIRE or

EXPLOSION may result. Keep the area surround-

ing the generator clean and free from debris.

Gaseous fluids such as natural gas and liquid pro-

pane (LP) gas are extremely EXPLOSIVE. Install

the fuel supply system according to applicable

fuel-gas codes. Before placing the home standby

electric system into service, fuel system lines must

be properly purged and leak tested according to

applicable code. After installation, inspect the fuel

system periodically for leaks. No leakage is permit-

ted.

STANDARDS INDEX

In the absence of pertinent standards, codes, regu-

lations and laws, the published information listed

below may be used as installation guide for this

equipment.

1. NFPA No. 37, STATIONARY COMBUSTION

ENGINES AND GAS TURBINES, available from

the National Fire Protection Association, 470

Atlantic Avenue, Boston, MA 02210.

2. NFPA No. 76A, ESSENTIAL ELECTRICAL

SYSTEMS FOR HEALTH CARE FACILITIES,

available same as Item 1.

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

available same as Item 1.

4. NFPA No. 58, AMERICAN NATIONAL STANDARD

FOR STORAGE AND HANDLING OF LIQUEFIED

PETROLEUM GAS, available same as Item 1.

5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL

ELECTRIC CODE, available same as Item 1.

6. Article X, NATIONAL BUILDING CODE, available

from the American Insurance Association, 85

John Street, New York, N.Y. 10038.

7. AGRICULTURAL WIRING HANDBOOK, avail-

able from the Food and Energy Council, 909

University Avenue, Columbia, MO 65201.

8. ASAE EP-3634, INSTALLATION AND

MAINTENANCE 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.

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IMPORTANT SAFETY INSTRUCTIONS

Air-cooled Generators

DANGER

 Only qualified electricians or contractors should

attempt such installations, which must comply

strictly with applicable codes, standards and regu-

lations.

1.1 UNPACKING/INSPECTION

After unpacking, carefully inspect the contents for

damage.

This standby generator set is ready for installa-

tion with a factory supplied and pre-mounted base

pad and has a weather protective enclosure that is

intended for outdoor installation only.

This UL listed standby generator set is packaged

with an automatic transfer switch with built in

load center. The combination transfer switch and

load center is pre-wired with a two foot and 30 foot

conduit. Circuit breakers for emergency circuit

connections are included (if equipped).

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

amperes at 250 volts maximum. This transfer

switch is for indoor use only (if equipped).

 If this generator is used to power electrical load

circuits normally powered by a utility power

source, it is required by code to install a transfer

switch. The transfer switch must effectively isolate

the electrical system from the utility distribution

system when the generator is operating (NEC 700,

701 & 702). Failure to isolate an electrical system

by such means will result in damage to the gen-

erator and also may result in injury or death to

utility power workers due to backfeed of electrical

energy.

If any loss or damage is noted at time of delivery, have

the person(s) making the delivery note all damage

on the freight bill or affix their signature under the

consignor's memo of loss or damage.

If a loss or damage is noted after delivery, separate

the damaged materials and contact the carrier for

claim procedures.

“Concealed damage” is understood to mean damage

to the contents of a package that is not in evidence at

the time of delivery, but is discovered later.

1.2 PROTECTION SYSTEMS

Unlike an automobile engine, the generator may have

to run for long periods of time with no operator pres-

ent to monitor engine conditions. For that reason, the

engine is equipped with the following systems that

protect it against potentially damaging conditions:

1. Low Oil Pressure Sensor 4. Overspeed

2. High Temperature Sensor 5. RPM Sensor

3. Overcrank 6. Low Battery

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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) intro-

duced a requirement for new construction. This new

requirement indicates the need for Arc Fault Circuit

Interrupters to be used to protect the complete

branch circuit that feeds a dwelling bedroom. The

actual NEC requirement is indicated below.

1.3.1 SECTION 210.12 ARC FAULT CIRCUIT

INTERRUPTER PROTECTION

1. Definition: An arc fault circuit interrupter is a

device intended to provide protection from the

effects of arc faults by recognizing characteristics

unique to arcing and by functioning to de-ener-

gize the circuit when an arc fault is detected.

2. Dwelling Unit Bedrooms: All branch circuits that

supply 125 volt, single-phase, 15 and 20 ampere

outlets installed in dwelling unit bedrooms shall

be protected by an arc fault circuit interrupter

listed to provide protection of the entire branch

circuit.

Section 210.12 requires that AFCI protection be

provided on branch circuits that supply outlets

(receptacle, lighting, etc.) in dwelling bedrooms. The

requirement is limited to 15 and 20 ampere, 125

volt circuits. There is no prohibition against provid-

ing AFCI protection on other circuits or in locations

other than bedrooms. Because circuits are often

shared between a bedroom and other areas such as

closets and hallways, providing AFCI protection on

the complete circuit would comply with 210.12.

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

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Section 1 — General Information

Air-cooled Generators

4

Section 1 — General Information

Air-cooled Generators

5

1.4 THE GENERATOR

Air Filter

Cover

Control

Panel

Fuel

Regulator

Battery CompartmentOil Filter

Exhaust

Enclosure

Oil

Dipstick

Data

Decal

Composite Base

Fuel

Inlet

(Back)

Air Filter

Cover Control

Panel

Fuel

Regulator

Battery CompartmentOil Filter

Exhaust

Enclosure

Oil

Dipstick

Data

Decal

Composite Base

Fuel

Inlet

(Back)

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

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

Air Filter

Control

Panel

Fuel

Regulator

Battery CompartmentOil Filter

Exhaust

Enclosure

Oil

Dipstick

Data

Decal

Composite Base

Fuel

Inlet

(Back)

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

6

Section 1 — General Information

Air-cooled Generators

1.5 SPECIFICATIONS

1.5.1 GENERATOR

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

05283 & 05284

Rated Max. Continuous 6,000 NG/7,000 LP 9,000 NG/10,000 LP 13,000 NG/13,000 LP 15,000 NG/16,000 LP

Power Capacity (Watts*)

Rated Voltage 120/240 120/240 120/240 120/240

Rated Max. Continuous

Load Current (Amps)

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

240 Volts 25.0 NG/29.2 LP 37.5 NG/41.7 LP 54.1 NG/54.1 LP 52.5 NG/66.6 LP

Main Line Circuit Breaker 30 Amp 45 Amp 55 Amp 65 Amp

Circuits***

50A, 240V - - - 1

40A, 240V - - 1 1

30A, 240V 1 1 1 -

20A, 240V - 1 - 1

20A, 120V 1 3 3 5

15A, 120V 5 3 5 5

Phase 1 1 1 1

Number of Rotor Poles 2 2 2 2

Rated AC Frequency 60 Hz 60 Hz 60 Hz 60 Hz

Power Factor 1 1 1 1

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

Battery Requirement Group 26 Group 26 Group 26 Group 26

12 Volts and 12 Volts and 12 Volts and 12 Volts and

350 Cold-cranking 525 Cold-cranking 525 Cold-cranking 525 Cold-cranking

Amperes Minimum Amperes Minimum Amperes Minimum Amperes Minimum

Battery Warming Blanket 0F6148DSRV

Weight (Unit Only) 336 Pounds 375 Pounds 425.5 Pounds 445 & 414 Pounds

Enclosure Steel/Aluminum

Normal Operating Range -20°F (-28.8°C) to 104°F (40°C)

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

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

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

volts.

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

1.5.2 ENGINE

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

05283 & 05284

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

Number of Cylinders 1 2 2 2

Rated Horsepower 14.5 @ 3,600 rpm 18 @ 3,600 rpm 30 @ 3,600 rpm 30 @ 3,600 rpm

Displacement 410cc 530cc 992cc 992cc

Cylinder Block Aluminum w/Cast Aluminum w/Cast Aluminum w/Cast Aluminum w/Cast

Iron Sleeve Iron Sleeve Iron Sleeve Iron Sleeve

Valve Arrangement Overhead Valves Overhead Valves Overhead Valves Overhead Valves

Ignition System Solid-state w/Magneto Solid-state w/Magneto Solid-state w/Magneto Solid-state w/Magneto

Recommended Spark Plug RC14YC BPR6HS RC12YC RC12YC

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

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

Starter 12 Vdc 12 Vdc 12 Vdc 12 Vdc

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

Recommended Oil Filter Part # 070185B Part # 070185B Part # 070185B Part # 070185B

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

Operating RPM 3,600 3,600 3,600 3,600

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7

1.6 SYSTEM SET LED

The “System Set” LED is lit when all of the following

conditions are true:

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

AUTO position.

2. The utility voltage being supplied to the unit is

being sensed by the PCB. If the utility sense volt-

age is not connected to the unit or if it is below

approximately 150-160 volts AC, then the system

set light will flash rapidly. This indicates that if

the AUTO/OFF/ MANUAL switch is placed in the

Auto position, the generator will start.

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

sure, high temperature, etc.

1.7 FUEL REQUIREMENTS

AND RECOMMENDATIONS

With LP gas, use only the vapor withdrawal sys-

tem. This type of system uses the vapors formed

above the liquid fuel in the storage tank.

The engine has been fitted with a fuel carburetion

system that meets the specifications of the 1997

California Air Resources Board for tamper-proof dual

fuel systems. The unit will run on natural gas or LP

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

Should the primary fuel need to be changed to LP

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

Reconfiguring the Fuel System section for instruc-

tions 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 com-

ply with NFPA 54 for natural gas applications and

NFPA 58 for liquid propane applications. Once the

generator is installed, verify that the fuel pressure

NEVER drops below four (4) inches water column

for natural gas or 10 inches water column for liq-

uid propane.

Prior to installation of the generator, the installer

should consult local fuel suppliers or the fire mar-

shall to check codes and regulations for proper

installation. Local codes will mandate correct routing

of gaseous fuel line piping around gardens, shrubs

and other landscaping to prevent any damage.

Special considerations should be given when install-

ing the unit where local conditions include flooding,

tornados, hurricanes, earthquakes and unstable

ground for the flexibility and strength of piping and

their connections.

Use an approved pipe sealant or joint compound on

all threaded fitting.

All installed gaseous fuel piping must be purged and

leak tested prior to initial start-up in accordance with

local codes, standards and regulations.

1.8 FUEL CONSUMPTION

*Natural gas is in cubic feet per hour.

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

*** Values given are approximate.

1.8.1 BTU FLOW REQUIREMENTS -

NATURAL GAS

BTU flow required for each unit based on 1000 BTU

per cubic foot.

6kW — 119,000 BTU/Hour

9kW — 156,000 BTU/Hour

13kW — 220,000 BTU/Hour

15kW — 245,000 BTU/Hour

DANGER

 Gaseous fuels such as natural gas and liquid

propane (LP) gas are highly explosive. Even the

slightest spark can ignite such fuels and cause

an explosion. No leakage of fuel is permitted.

Natural gas, which is lighter than air, tends to

collect in high areas. LP gas is heavier than air

and tends to settle in low areas.

NOTE:

A minimum of one approved manual shut-off valve

must be installed in the gaseous fuel supply line.

The valve must be easily accessible. Local codes

determine the proper location.

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•

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Section 1 — General Information

Air-cooled Generators

Unit Nat. Gas (*) LP Vapor (**)

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

6/7 kW 66 119 0.82/30 1.47/54

9/10 kW 102 156 1.25/46 1.93/70

13/13 kW 156 220 1.55/57 2.18/80

15/16 kW 173 245 1.59/59 2.51/92

1.9 RECONFIGURING THE

FUEL SYSTEM

1.9.1 7 KW, 410CC ENGINE

To reconfigure the fuel system from NG to LP, follow

these steps (Figure 1.4):

NOTE:

The primary regulator for the propane supply is

NOT INCLUDED with the generator. A fuel pres-

sure of 10 to 12 inches of water column (0.36 to

0.43 psi) to the fuel inlet of the generator MUST

BE SUPPLIED.

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

2. Open the roof and remove the door.

3. Remove the battery (if installed).

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

solenoid on top of the demand regulator.

5. Remove the carburetor fuel hose from the outlet

port of the demand regulator.

6. Remove the demand regulator by removing the

fastener that retains the regulator mounting

bracket.

7. Remove the square headed steel pipe plug from

outlet port #1 and the brass hose barb fitting

from outlet port #2.

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

and the square headed steel pipe plug to outlet

port #2.

Figure 1.4 – Demand Regulator

NG FUEL SYSTEM LP FUEL SYSTEM

FUEL HOSE

BRASS HOSE

FITTING

BRASS HOSE

FITTING

FUEL JET

OUTLET

PORT

FUEL HOSE

ADJUSTMENT

SCREW

HOSE & PLUG

SWITCHED SIDES

PIPE

PLUG

STATIC

PRESSURE

TAP

RUNNING

PRESSURE

TAP



NOTE:

Use an approved pipe sealant or joint compound

on all threaded fittings to reduce the possibility

of leakage.

9. Reverse procedure steps 1-6 to reinstall demand

regulator.

10. Take the plastic plug supplied in the poly-bag

with the generator and press it into the 3/4” hole

on the bottom of the air cleaner base (Figure

4.6).

11. Reverse the procedure to convert back to natural

gas.

12. Check for gas leakage at the pipe plug, hose con-

nection and fittings.

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

To reconfigure the fuel system from NG to LP, follow

these steps:

NOTE:

The primary regulator for the propane supply is

NOT INCLUDED with the generator. A fuel pres-

sure of 10 to 12 inches of water column (0.36 to

0.43 psi) to the fuel inlet of the generator MUST

BE SUPPLIED.

1. Open the roof.

2. For 10kW units: Loosen clamp and slide back

the air inlet hose.

• Slide fuel selector on carburetor out towards the

back of the enclosure (Figures 1.5 and 1.6).

• Return the inlet hose and tighten clamp secure-

ly.

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.

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Section 1 — General Information

Air-cooled Generators

8

9

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

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

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

Removed)

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

Removed)

1.10 LOCATION

1.10.1 GENERATOR

Install the generator set, in its protective enclosure,

outdoors, where adequate cooling and ventilating air

is always available (Figure 1.9). Consider these fac-

tors:

The installation of the generator must comply

strictly with NFPA 37, NFPA 54, NFPA 58, and

NFPA 70 standards.

Install the unit where air inlet and outlet open-

ings will not become obstructed by leaves, grass,

snow, etc.. If prevailing winds will cause blowing

or drifting, consider using a windbreak to protect

the unit.

Install the generator on high ground where water

levels will not rise and endanger it.

Allow sufficient room on all sides of the generator

for maintenance and servicing. This unit must be

installed in accordance with current applicable

NFPA 37 and NFPA 70 standards; as well as any

other federal, state and local codes for minimum

distances from other structures. DO NOT install

under wooden decks or structures.

Install the unit where rain gutter down spouts,

roof fun-off, landscape irrigation, water sprinklers

or sump pump discharge does not flood the unit

or spray the enclosure, including any air inlet or

outlet openings.

Install the unit where services will not be affected

or obstructed, including concealed, underground

or covered services such as electrical, fuel, phone,

air conditioning or irrigation.

Where strong prevailing winds blow from one

direction, face the generator air inlet openings to

the prevailing winds.

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Section 1 — General Information

Air-cooled Generators

Fuel Selection

Lever - "In"

Position for

Natural Gas

Fuel

Fuel Selection

Lever - "Out"

Position for

Liquid Propane

(Vapor) Fuel

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

Fuel Selection Lever - "Out" Position for Liquid Propane

(Vapor) Fuel

10

Install the generator as close as possible to the fuel

supply, to reduce the length of piping.

Install the generator as close as possible to the

transfer switch. REMEMBER THAT LAWS OR

CODES MAY REGULATE THE DISTANCE AND

LOCATION.

The genset must be installed on a level surface.

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

all around.

The generator is typically placed on pea gravel or

crushed stone. Check local codes if a concrete slab

is required. If a concrete base slab is required, all

federal, state and local codes should be followed.

Special attention should be given to the concrete

base slab which should exceed the length and

width of the generator by a minimum of six (6)

inches (0.152 meters) on all sides.

Figure 1.9 – Generator Clearances

 The engine exhaust fumes contain carbon mon-

oxide, which can be DEADLY. This dangerous

gas, if breathed in sufficient concentrations,

can cause unconsciousness or even death. This

exhaust system must be installed properly, in

strict compliance with applicable codes and stan-

dards. Following installation, do nothing that

might render the system unsafe or in noncompli-

ance with such codes and standards.

• Operate the generator outdoors ONLY.

• Keep exhaust gases from entering a confined area

through windows, doors, ventilation or other

openings (Figure 1.9).

1.10.2 TRANSFER SWITCH

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

The transfer switch shipped with this generator is

enclosed in a NEMA 1 enclosure. This type of enclo-

sure is intended for indoor use only. Follow these

rules:

•

•

•

•



Install the transfer switch indoors on a firm, sturdy

supporting structure.

To prevent switch distortion, level the switch if

necessary. This can be done by placing washers

between the switch enclosure and mounting sur-

face.

Never install the switch where water or any corro-

sive substance might drip onto the enclosure.

Protect the switch at all times against excessive

moisture, dust, dirt, lint, construction grit and

corrosive vapors.

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

OFF position, the generator can crank and start

as soon as the battery cables are connected. If

the utility power supply is not turned off, spark-

ing can occur at the battery posts and cause an

explosion.

1.11 BATTERY REQUIREMENTS

See the Specifications section for correct battery size

and rating.

1.12 BATTERY INSTALLATION

Fill the battery with the proper electrolyte fluid if

necessary and have the battery fully charged before

installing it.

Before installing and connecting the battery, complete

the following steps:

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

OFF.

2. Turn off utility power supply to the transfer

switch.

3. Remove the 15A fuse from the generator control

panel.

Battery cables were factory connected at the genera-

tor (Figure 1.10). Connect cables to battery posts as

follows:

4. Connect the red battery cable (from starter con-

tactor) to the battery post indicated by a positive,

POS or (+).

5. Connect the black battery cable (from frame

ground) to the battery post indicated by a nega-

tive, NEG or (—).

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.

•

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Section 1 — General Information

Air-cooled Generators

11

Figure 1.10 – Battery Cable Connections

NOTE:

In areas where temperatures regularly fall below

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

battery heater be installed to aid in cold climate

starting (see Specifications).

NOTE:

The generator is equipped with a battery trickle

charger that is active when the unit is set up for

automatic operation. With the battery installed

and utility power source voltage available to the

transfer switch, the battery receives a trickle

charge while the engine is not running, to prevent

self-discharge. The trickle charger is designed to

help extend the life of the battery by maintain-

ing the battery when the unit is not running. The

trickle charge feature cannot be used to recharge

a discharged battery.

1.13 THE BATTERY

DANGER

 Do not dispose of the battery in a fire. The

battery is capable of exploding.

 A battery presents a risk of electrical shock

and high short circuit current. The following pre-

cautions are to be observed when working on

batteries:

• Remove the 15A fuse from the generator control

panel.

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

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

battery; and

• Disconnect charging source prior to connecting or

disconnecting battery terminals.

 Do not open or mutilate the battery. Released

electrolyte has been known to be harmful to the

skin and eyes, and to be toxic.

 The electrolyte is a dilute sulfuric acid that is

harmful to the skin and eyes. It is electrically

conductive and corrosive.

The following procedures are to be observed:

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off

immediately with water;

• Where electrolyte contacts the eyes, flush thor-

oughly and immediately with water and seek

medical attention; and

• Spilled electrolyte is to be washed down with an

acid neutralizing agent. A common practice is to

use a solution of 1 pound (500 grams) bicarbonate

of soda to 1 gallon (4 liters) of water. The bicar-

bonate of soda solution is to be added until the

evidence of reaction (foaming) has ceased. The

resulting liquid is to be flushed with water and the

area dried.

 Lead-acid batteries present a risk of fire because

they generate hydrogen gas. The following

procedures are to be followed:

• DO NOT SMOKE when near the battery;

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

• Discharge static electricity from body before touch-

ing the battery by first touching a grounded metal

surface.

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

the OFF position before connecting the battery

cables. If the switch is set to AUTO or MANUAL,

the generator can crank and start as soon as the

battery cables are connected.

 Be sure the utility power supply is turned off

and the 15A fuse is removed from the generator

control panel, or sparking may occur at the bat-

tery posts as the cables are attached and cause

an explosion.

Servicing of the battery is to be performed or super-

vised by personnel knowledgeable of batteries and

the required precautions. Keep unauthorized person-

nel away from batteries.

See the Specifications section for the correct size

and rating when replacing the battery. 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 connect-

ed and terminals are tight. Observe battery polarity

when connecting the battery to the generator set.

Section 1 — General Information

Air-cooled Generators

12

2.1 BEFORE INITIAL START-UP

NOTE:

These units have been run and tested at the fac-

tory prior to being shipped and do not require any

type of break-in.

Before starting, complete the following:

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

OFF (or OPEN) position.

2. Set the 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 neces-

sary, fill to the dipstick FULL mark with the rec-

ommended oil. Do not fill above the FULL mark.

6. Check the fuel supply. Gaseous fuel lines must

have been properly purged and leak tested in

accordance with applicable fuel-gas codes. All

fuel shutoff valves in the fuel supply lines must

be open.

 Never operate the engine with the oil level

below the “Add” mark on the dipstick. Doing

this could damage the engine.

2.2 CHECK TRANSFER SWITCH

OPERATION

Refer to the "Manual Transfer Operation" section, of

the owner’s manual for procedures.

DANGER

 Do not attempt manual transfer switch opera-

tion until all power voltage supplies to the

transfer switch have been positively turned off.

Failure to turn off all power voltage supplies

will result in extremely hazardous and possibly

fatal electrical shock.

2.3 ELECTRICAL CHECKS

Complete electrical checks as follows:

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

OFF (or OPEN) position.

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

the OFF position.

3. Turn OFF all breakers on the load center of the

transfer box (T1 and T2).

4. Turn on the utility power supply to the transfer

switch using the means provided (such as a utility

main line circuit breaker).

DANGER

 The transfer switch is now electrically “hot.”

Contact with “hot” parts will result in extremely

hazardous and possibly fatal electrical shock.

Proceed with caution.

5. Use an accurate AC voltmeter to check utility

power source voltage across transfer switch ter-

minals N1 and N2. Nominal line-to-line voltage

should be 240 volts AC.

6. Check utility power source voltage across termi-

nals N1 and the transfer switch neutral lug; then

across terminal N2 and neutral. Nominal line-to-

neutral voltage should be 120 volts AC.

7. When certain that utility supply voltage is compat-

ible with transfer switch and load circuit ratings,

turn OFF the utility power supply to the transfer

switch.

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

MANUAL switch to MANUAL. The engine should

crank and start.

9. Let the engine warm up for about five minutes to

allow internal temperatures to stabilize. Then, set

the generator’s main circuit breaker to its ON (or

CLOSED) position.

DANGER

 Proceed with caution! Generator power voltage

is now supplied to the transfer switch. Contact

with live transfer switch parts will result in dan-

gerous and possibly fatal electrical shock.

10. Connect an accurate AC voltmeter and a frequen-

cy meter across transfer switch terminal lugs E1

and E2. 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 ter-

minal 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 no-

load 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

13

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 util-

ity main line circuit breaker).

 Do not attempt manual transfer switch opera-

tion until all power voltage supplies to the

transfer switch have been positively turned off.

Failure to turn off all power voltage supplies

will result in extremely hazardous and possibly

fatal electrical shock.

5. Manually set the transfer switch to the STANDBY

position, i.e., load terminals connected to the

generator's 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 frequen-

cy meter across terminal lugs E1 and E2.

• 7kW voltage should be greater than 230 volts and

frequency should be greater than 58 Hz.

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

240 volts and frequency should be greater than

60 Hz.

11. Let the generator run at full rated load for 20-30

minutes. Listen for unusual noises, vibration or

other indications of abnormal operation. Check

for oil leaks, evidence of overheating, etc.

12. When testing under load is complete, turn OFF

electrical loads.

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 util-

ity power source side.

5. Turn ON the utility power supply to the transfer

switch, using the means provided (such as a util-

ity main line circuit breaker).

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

(or CLOSED)) position.

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

system is now ready for automatic operation.

8. Turn OFF the utility power supply to the transfer

switch.

With the AUTO/OFF/MANUAL switch at AUTO, the

engine should crank and start when the utility source

power is turned OFF after a 10 second delay. After

starting, the transfer switch should connect load cir-

cuits to the standby side after a 15 second delay. Let

the system go through its entire automatic sequence

of operation.

With the generator running and loads powered by

generator AC output, turn ON the utility power supply

to the transfer switch. The following should occur:

After about 15 seconds, the switch should transfer

loads back to the utility power source.

About one minute after retransfer, the engine

should shut down.

2.6 ADJUSTING THE FUEL REGULATOR

- 7KW (NATURAL GAS ONLY)

NOTE:

All V-twin engine units DO NOT require a fuel reg-

ulator adjustment due to the fuel system design.

Although the generator has been factory set to pro-

vide maximum power, 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.

•

•

14

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 posi-

tion.

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:

4. When 3/4 load has been achieved. Connect a fre-

quency 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 counter-

clockwise until the highest frequency is read on

the meter. Only limited adjustment is available

because of the set pin. Under no circumstances

should any of the pins be removed (Figure 2.1).

Figure 2.1 — 7kW Fuel Regulator

410cc Engine

Adjustment

Screw

(One Side

Only)

Set

Pin

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 ser-

vice main breaker to the on or closed position.

Allow the generator to shut down.

 Do not make any unnecessary adjustments.

Factory settings are correct for most applica-

tions. However, when making adjustments, be

careful to avoid overspeeding the engine.

If this procedure or the test equipment is not avail-

able, locate the nearest Dealer and they can perform

the adjustments.

NOTE:

A service fee may be charged for this adjustment.

2.7 ENGINE GOVERNOR ADJUSTMENT

If both AC frequency and voltage are correspondingly

high or low, adjust the engine governor as follows:

2.7.1 7 KW UNITS

 The engine must be OFF to perform steps 1 and

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

GOVERNOR

SHAFT

PRIMARY

ADJUST

SCREW

GOVERNOR

CLAMP

BOLT

SECONDARY

ADJUST SCREW

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Unit 120 Volts 240 Volts

7 kW 50.0 amps 25.0 amps

Section 2 — Post Installation Start-up and Adjustments

Air-cooled Generators

15

4. Connect a frequency meter across the generators

AC output leads.

5. Turn the primary adjust screw to obtain a fre-

quency reading of 61.5 Hertz. Turn the secondary

adjust screw to obtain a frequency of 62.5 Hz.

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

AC voltage reading. If voltage is incorrect, the volt-

age regulator may require adjustment (See the

Voltage Regulator Adjustment section).

2.7.2 13 KW AND 16 KW UNITS

NOTE:

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

nor adjustment due to their design.

2.7.3 ADDITIONAL CORROSION

PROTECTION

Periodically spray all engine linkage parts and brack-

ets with corrosion inhibiting spray such as WD-40 or

a comparable product.

2.8 VOLTAGE REGULATOR

ADJUSTMENT

2.8.1 7KW UNITS

With the frequency between 62-63 Hertz at no-load,

slowly turn the slotted potentiometer (Figure 2.3)

until line voltage reads 248-252 volts.

2.8.2 10, 13, AND 16KW UNITS

With the frequency between 58-59 Hertz at no-load,

slowly turn the slotted potentiometer (Figure 2.3)

until line voltage reads 232-236 volts.

Figure 2.3 – Voltage Adjustment Potentiometer

Tur n t o

adjust voltage.









NOTE:

The access panel on top of the control panel must

be removed to adjust the voltage regulator.

NOTE:

The voltage regulator is housed above the gen-

erator's control panel. The regulator maintains a

voltage in direct proportion to frequency at a 2-to-

1 ratio. For example, at 62 Hertz, line-to-neutral

voltage will be 124 volts.

3.1 USING THE AUTO/OFF/MANUAL

SWITCH (FIGURE 3.1)

3.1.1 “AUTO” POSITION

Selecting this switch position activates fully automatic

system operation. It also allows the unit to automati-

cally start and exercise the engine every seven days

with the setting of the exercise timer (see the Setting

the Exercise Timer section).

3.1.2 “OFF” POSITION

This switch position shuts down the engine. This

position also prevents automatic operation.

Figure 3.1 – Generator Control Panel

OFF

EXERCISE

SYSTEM FUSE

15A

ASSY: 0F8418/0F8419

SET

TIME

AUTO. MAN.

NO UTILITY SENSE

5 FLASHING RED LEDS=

EXERCISER NOT SET

FLASHING GREEN LED=

SYSTEM SET

NO RPM SENSE IF FLASHING

OVER SPEED

CONTROL AND INFORMATION CENTER

LOW BATTERY

LOW OIL

HIGH TEMP

OVER CRANK

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.

 With the switch set to AUTO, the engine may

crank and start at any time without warning.

Such automatic starting normally occurs when

utility power source voltage drops below a pre-

set level or during the normal exercise cycle. To

prevent possible injury that might be caused

by such sudden starts, always set the switch to

OFF and remove the fuses before working on or

around the generator or transfer switch. Then,

place a “DO NOT OPERATE” tag on the genera-

tor panel and on the transfer switch.

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Section 3 — Operation

Air-cooled Generators

16

3.1.4 CHOKE OPERATION

1. 990 engines have an electric choke in the air box

that is automatically controlled by the electronic

control board.

2. 530 engines have an electric choke on the divider

panel air inlet hose that is automatically con-

trolled by the electronic control board.

3. 410 engines do not have a choke.

3.2 AUTOMATIC TRANSFER

OPERATION

To select automatic operation, do the following:

1. Make sure the transfer switch main contacts are

set to their UTILITY position, i.e., loads con-

nected to the utility power source (Figure 3.2).

2. Be sure that normal UTILITY power source volt-

age is available to transfer switch terminal lugs

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 util-

ity power source voltage. Should that voltage drop

below a preset level, circuit board action will signal

the engine to crank and start. After the engine starts,

the circuit board signals the transfer switch to acti-

vate and connect load circuits to the standby power

supply (load terminal lugs T1/T2 connect 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 trans-

ferred to the standby source.

C. Standby Voltage Sensor

• This sensor monitors generator AC output volt-

age. When the voltage has reached 50 percent of

the nominal rated voltage, transfer to standby

can occur.

D. Utility Voltage Pickup Sensor

• This sensor monitors utility power supply volt-

age. When that voltage is restored above 75 per-

cent of the nominal source voltage, a retransfer

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 tim-

ing.

• The timer will run for about one minute, and the

generator will then shut down.

3.4 MANUAL TRANSFER OPERATION

3.4.1 TRANSFER TO GENERATOR

POWER SOURCE

To start the generator and activate the transfer switch

manually, proceed as follows:

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

OFF.

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

OFF (or OPEN) position.

3. Turn OFF the utility power supply to the transfer

switch using the means provided (such as a utility

main line circuit breaker).

DANGER

 Do not attempt to activate the transfer switch

manually until all power voltage supplies to the

switch have been positively turned off. Failure

to turn off all power voltage supplies may result

in extremely hazardous and possibly fatal elec-

trical shock.



Section 3 — Operation

Air-cooled Generators

17

Section 3 — Operation

Air-cooled Generators

4. Use the manual transfer handle inside the trans-

fer switch to move the main contacts to their

STANDBY position, i.e., loads connected to the

standby power source (Figure 3.2).

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

MANUAL switch to MANUAL.

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

minutes.

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

(or CLOSED) position. The standby power source

now powers the loads.

Figure 3.2 – Manual Transfer Switch Operation

3.4.2 TRANSFER BACK TO UTILITY POWER

SOURCE

When utility power has been restored, transfer back

to that source and shut down the generator. This can

be accomplished as follows:

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

OFF (or OPEN) position.

2. Let the engine run for a minute or two at no-load

to stabilize the internal temperatures.

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

its OFF (or OPEN) position. The engine should

shut down.

4. Check that utility power supply to the transfer

switch is turned OFF.

DANGER

 Do not attempt to activate the transfer switch

manually until all power voltage supplies

to the switch have been positively turned off.

Failure to turn off all power voltage supplies

may result in extremely hazardous and possibly

fatal electrical shock.



5. Use the manual transfer handle inside the trans-

fer switch to move the main contacts back to their

UTILITY position, i.e., loads connected to the util-

ity power source (Figure 3.2).

6. Turn ON the utility power supply to the transfer

switch using the means provided.

7. Set the system to automatic operation as outlined

in Automatic Transfer Operation section.

3.5 SETTING THE EXERCISE TIMER

This generator is equipped with an exercise timer.

Once it is set, the generator will start and exercise

once every seven days, on the day of the week and at

the time of day the following sequence is completed.

During this exercise period, the unit runs for approx-

imately 12 minutes and then shuts down. Transfer of

loads to the generator output does not occur during

the exercise cycle unless utility power is lost.

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

mits selection of the day and time for the system to

exercise. At the chosen time, perform the following

sequence to select the desired day and time of day

the system will exercise. Remember seasonal time

changes affect the exercise time settings.

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

to AUTO.

2. Press and hold the "Set Exercise Time" switch for

several seconds, then release. All the red LED's

will flash for approximately 10 seconds and then

stop.

3. Once the red LED's stop flashing, the generator

will start and run for approximately 12 minutes

and then shut down. The exerciser is now set to

run at this time of day each week.

Example: If the "Set Exercise Time" switch is

pressed on Saturday afternoon at 2:00 p.m., the

generator will start and exercise for approximate-

ly 12 minutes every Saturday at 2:00 p.m..

NOTE:

The exerciser will only work in the AUTO mode

and will not work unless this procedure is per-

formed. The exerciser will need to be reset every

time the 12-volt battery is disconnected and then

reconnected, and when the 15A fuse is removed.

The 16kW unit has a low speed exercise option. Dip

switch 1 on the control board is factory set to OFF.

This allows the engine to run at a slower speed dur-

ing weekly exercise periods for quieter operation. If

this Dip switch is set to ON, the generator will exer-

cise at it's normal speed.

This DIP switch position is only read at board power

up. If the DIP switch position is changed, power to

the board must be cycled for the micro controller to

recognize the new DIP switch position.

18

Low speed exercise will be handled as follows:

1. The standard start sequence will be initiated.

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

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

do the following:

• Wait 10 seconds for utility to return.

• If utility returns within 10 seconds, continue to

exercise at 2,400 RPM.

• If utility is still lost after 10 seconds, run the

engine up to 3600 RPM and transfer the load.

At this time the controller will exit the exercise

routine and assume full automatic operation.

3.6 PROTECTION SYSTEMS

3.6.1 LOW OIL PRESSURE SWITCH

This switch (Figure 3.3) has normally closed con-

tacts that are held open by engine oil pressure dur-

ing 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 tem-

perature should exceed approximately 140º C (284º

F), initiating an engine shutdown. The generator will

automatically restart and the LED on the generator

control panel will reset once the temperature has

returned to a safe operating level.

Figure 3.3 – Low Oil Pressure and

High Temperature Switches

Oil Filter

Oil

Drain

Hose

Low Oil Switch High Temp Switch

L

o

o

s

e

n





3.6.3 OVERCRANK

This feature prevents the generator from damaging

itself when it continually attempts to start and anoth-

er problem, such as no fuel supply, prevents it from

starting. The unit will crank and rest for a preset

time limit. Then, it will stop cranking, and the LED

on the generator control panel will light indicating an

overcrank failure. The AUTO/OFF/MANUAL switch

will need to be set to OFF and then back to AUTO to

reset the generator control board.

NOTE:

If the fault is not repaired, the overcrank feature

will continue to activate.

3.7.3.1 Approximate Crank Cycle Times

7kW Units:

15 seconds ON

7 seconds OFF

7 seconds ON

7 seconds OFF

7 seconds ON

7 seconds OFF

7 seconds ON

7 seconds OFF

7 seconds ON

7 seconds OFF

7 seconds ON

If the unit fails to start, the overcrank alarm LED will

be illuminated.

10kW, 13kW and 16kW Units:

16 seconds ON

7 seconds OFF

16 seconds ON

7 seconds OFF

7 seconds ON

7 seconds OFF

7 seconds ON

7 seconds OFF

7 seconds ON

7 seconds OFF

If the unit fails to start, the overcrank alarm LED will

be illuminated.

3.6.4 OVERSPEED

This feature protects the generator from damage by

shutting it down if it happens to run faster than the

preset limit. This protection also prevents the gen-

erator from supplying an output that could poten-

tially damage appliances connected to the generator

circuit. Contact the nearest Authorized Dealer if this

failure occurs.



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•

•

•

•

•

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•

•

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Section 3 — Operation

Air-cooled Generators

19

3.6.5 RPM SENSOR FAILURE

During cranking, if the board does not see a valid

RPM signal within three (3) seconds, it will shut

down and latch out on RPM sensor loss.

During running, if the RPM signal is lost for one full

second the board will shut down the engine, wait 15

seconds, then re-crank the engine.

If an RPM signal is not detected within the first

three (3) seconds of cranking, the control board

will shut the engine down and latch out on RPM

sensor loss.

If the RPM signal is detected the engine will start

and run normally. If the RPM signal is subsequent-

ly lost again, the control board will try one more

re-crank attempt before latching out and flashing

the overspeed LED.

3.6.6 LOW BATTERY

The microprocessor will continually monitor the

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 moni-

tored during the crank cycle.

4.1 FUSES

The 15-amp fuse on the generator panel protects the

DC control circuit against overload (Figure 4.1). This

fuse is wired in series with the battery output lead

to the panel. If this fuse element has melted open,

the engine will not be able to crank or start. Replace

this fuse using only an identical 15-amp replacement

fuse. To replace the fuse, push the fuse holder cap

down and rotate it counterclockwise. Whenever the

fuse is removed or replaced, the exercise timer needs

to be reset.

Figure 4.1 – Generator Control Panel

OFF

EXERCISE

SYSTEM FUSE

15A

ASSY: 0F8418/0F8419

SET

TIME

AUTO. MAN.

NO UTILITY SENSE

5 FLASHING RED LEDS=

EXERCISER NOT SET

FLASHING GREEN LED=

SYSTEM SET

NO RPM SENSE IF FLASHING

OVER SPEED

CONTROL AND INFORMATION CENTER

LOW BATTERY

LOW OIL

HIGH TEMP

OVER CRANK



•

•



4.2 CHECKING THE ENGINE

OIL LEVEL

For oil capacities, see the Specifications section.

For engine oil recommendations, see the Engine Oil

Recommendations section. To check the engine oil

level, proceed as follows (Figures 4.2, 4.3 and 4.4):

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

position.

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

cloth.

3. Completely insert the dipstick; then, remove it

again. The oil level should be at the dipstick “Full”

mark. If necessary, add oil to the “Full” mark

only. DO NOT FILL ABOVE THE “FULL” MARK.

 Never operate the engine with the oil level

below the “Add” mark on the dipstick. Doing

this could damage the engine.

4. Install the dipstick.

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

nal position.

Figure 4.2 — Oil Dipstick and Fill, 7kW

Oil Dipstick and Fill

Section 4 — Maintenance

Air-cooled Generators

20

Figure 4.3 — Oil Dipstick and Fill, 10kW

Oil Dipstick

Oil Fill

Figure 4.4 — Oil Dipstick and Fill,

13kW and 16kW

Oil Dipstick

Oil Fill

4.3 CHANGING THE ENGINE OIL

4.3.1 OIL CHANGE INTERVALS

See the "Service Schedule" section.

4.3.2 ENGINE OIL RECOMMENDATIONS

Use all season SAE 5W-30 synthetic oil or use SAE

30 oil of American Petroleum Institute (API) Service

Class SG, SH, SJ or SL.

 Any attempt to crank or start the engine before

it has been properly serviced with the recom-

mended oil may result in an engine failure.





4.3.3 OIL & OIL FILTER CHANGE PROCEDURE

To change the oil, proceed as follows:

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

MANUAL switch to MANUAL and run until it

is thoroughly warmed up. Then shut OFF the

engine by moving the switch to the OFF position.

2. Immediately after the engine shuts OFF, pull the

oil drain hose (Figure 4.5) free of its retaining

clip. Remove the cap from the hose and drain the

oil into a suitable container.

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

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

clip.

Figure 4.5 – Oil Drain Hose and Filter

Oil Filter

Oil

Drain

Hose

Low Oil Switch High Temp Switch

L

o

o

s

e

n

Change the engine oil filter as follows:

1. With the oil drained, remove the old oil filter by

turning it counterclockwise.

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

ket of the new filter. See the Specifications section

for recommended filter.

3. Screw the new filter on by hand until its gasket

lightly contacts the oil filter adapter. Then, tighten

the filter an additional 3/4 to one turn (Figure

4.4).

4. Refill with the proper recommended oil (see the

Engine Oil Recommendations section). See the

Specifications section for oil capacities.

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

check for leaks.

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

DO NOT OVER FILL.

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

AUTO position.



Section 4 — Maintenance

Air-cooled Generators

21

4.4 CHANGING THE ENGINE

AIR CLEANER

4.4.1 7, 13, AND 16KW GENERATORS

See Figures 1.1 and 1.2, for the location of the air

cleaner. Use the following procedures (Figure 4.6,

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

1. Lift the roof and remove the door.

2. Turn the two screws counterclockwise to loosen.

3. Remove the cover and air filter.

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

box and around edges.

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

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

wise to tighten.

See the Service Schedule section for air cleaner main-

tenance. See the Specifications section for air filter

replacement part number.

Figure 4.6 — 7 kW, Engine Air Cleaner Location

Air

Cleaner

3/4”

Hole

4.4.2 10KW GENERATORS

See Figure 1.2 for the location of the air cleaner. Use

the following procedure (Figure 4.7):

1. Lift the roof and remove the door.

2. Turn the worm gear clamp screw counterclock-

wise to loosen.

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

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

5. Install the new air cleaner onto the hub.

6. Turn the worm gear clamp screw clockwise to

tighten.

7. Replace door and roof.





Figure 4.7 — 10kW Engine Air Cleaner

Air Filter

Control

Panel

Figure 4.8 — 13 kW and 16 kW Engine

Air Cleaner

Cover

Filter

Screw

4.5 SPARK PLUG(S)

Reset the spark plug(s) gap or replace the spark

plug(s) as necessary. See the Service Schedule section

for maintenance requirements.

1. Clean the area around the base of the spark

plug(s) to keep dirt and debris out of the engine.

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

tion. Replace the spark plug(s) if worn or if reuse

is questionable. See the Service Schedule section

for recommended inspection. Clean by scraping

or washing using a wire brush and commercial

solvent. Do not blast the spark plug(s) to clean.

Section 4 — Maintenance

Air-cooled Generators

22

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

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 bat-

tery hydrometer.

DANGER

 Do not dispose of the battery in a fire. The

battery is capable of exploding.

 A battery presents a risk of electrical shock

and high short circuit current. The following pre-

cautions are to be observed when working on

batteries:

• Remove the 15A fuse from the generator control

panel.

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

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

battery; and

• Disconnect charging source prior to connecting or

disconnecting battery terminals.

 Do not open or mutilate the battery. Released

electrolyte has been known to be harmful to the

skin and eyes, and to be toxic.

 The electrolyte is a dilute sulfuric acid that is

harmful to the skin and eyes. It is electrically

conductive and corrosive. The following

procedures are to be observed:

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off

immediately with water;

• Where electrolyte contacts the eyes, flush

thoroughly and immediately with water and seek

medical attention; and

• Spilled electrolyte is to be washed down with an

acid neutralizing agent. A common practice is to

use a solution of 1 pound (500 grams) bicarbonate

of soda to 1 gallon (4 liters) of water. The bicar-

bonate of soda solution is to be added until the

evidence of reaction (foaming) has ceased. The

resulting liquid is to be flushed with water and the

area dried.

 Lead-acid batteries present a risk of fire because

they generate hydrogen gas. The

following procedures are to be followed:

• DO NOT SMOKE when near the battery;

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

• Discharge static electricity from body before touch-

ing the battery by first touching a grounded metal

surface.

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

the OFF position before connecting the battery

cables. If the switch is set to AUTO or MANUAL,

the generator can crank and start as soon as the

battery cables are connected.

 Be sure the utility power supply is turned off

and the 15A fuse is removed from the generator

control panel, or sparking may occur at the bat-

tery posts as the cables are attached and cause

an explosion.

4.7 ADJUSTING GH-410/GT-530/990

VALVE CLEARANCE

After the first six (6) months of operation, check

the valve clearance in the engine, adjust if neces-

sary.

Important: If feeling uncomfortable about doing

this procedure or the proper tools are not available,

please contact the Authorized Dealer for service

assistance. This is a very important step to insure

longest life for the engine.

To check valve clearance:

The engine should be cool before checking. If

valve clearance is 0.002" - 0.004" (0.05 - 0.1mm),

adjustment is not needed.

•

Section 4 — Maintenance

Air-cooled Generators

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

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

Remove spark plug wires and position wires away

from plugs.

Remove spark plugs.

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

of its compression stroke (both valves closed). To

get the piston at TDC, remove the intake screen at

the front of the engine to gain access to the flywheel

nut. Use a large socket and socket wrench to rotate

the nut and hence the engine in a clockwise direc-

tion. While watching the piston through the spark

plug hole. The piston should move up and down.

The piston is at TDC when it is at its highest point

of travel.

To adjust valve clearance (if necessary):

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

Make sure that the spark plug wire is removed

from the spark plug and out of the way.

Remove the four screws attaching the valve cover

with a #2 or #3 Phillips screwdriver.

Loosen the rocker jam nut. Use an 10mm allen

wrench to turn the pivot ball stud while checking

clearance between the rocker arm and the valve

stem with a feeler gauge. Correct clearance is

0.002-0.004 inch (0.05-0.1 mm).

NOTE:

Hold the rocker arm jam nut in place as the pivot

ball stud is turned.

When valve clearance is correct, hold the pivot ball

stud in place with the allen wrench and tighten the

rocker arm jam nut. Tighten the jam nut to 174

in/lbs. torque. After tightening the jam nut, recheck

valve clearance to make sure it did not change.

Figure 4.10 - Valve Clearance Adjustment

Jam Nut

Pivot Ball

Stud

Rocker

Arm

Valve

Stem

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.

•

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•

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•

•

Install spark plugs.

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

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

the other cylinder.

4.8 COOLING SYSTEM

Air inlet and outlet openings in the generator com-

partment must be open and unobstructed for con-

tinued proper operation. This includes such obstruc-

tions as high grass, weeds, brush, leaves and snow.

Without sufficient cooling and ventilating air flow, the

engine/generator quickly overheats, which causes it

to quickly shut down. (See Figure 4.11 for vent loca-

tions.)

Make sure the doors and roof are in place dur-

ing operation as running the generator with them

removed can effect cooling air movement.

Figure 4.11 – Cooling Vent Locations

 The exhaust from this product gets extremely

hot and remains hot after shutdown. High grass,

weeds, brush, leaves, etc. must remain clear of

the exhaust. Such materials may ignite and burn

from the heat of the exhaust system.

 The maximum ambient temperature for the gen-

erator is 40° C (104° F).

4.9 ATTENTION AFTER SUBMERSION

If the generator has been submerged in water, it must

not be started and operated. Following any submer-

sion in water, have an Authorized Dealer thoroughly

clean, dry and inspect the generator. If the structure

(ex. home) has been flooded, it should be inspected

by a certified electrician to ensure there won't be any

electrical problems during generator operation or

when utility is returned.

•

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23

Section 4 — Maintenance

Air-cooled Generators

24

4.10 CORROSION PROTECTION

Periodically wash and wax the enclosure using auto-

motive type products. Frequent washing is recom-

mended in salt water/coastal areas. Spray engine

linkages with a light oil such as WD-40.

4.11 OUT OF SERVICE PROCEDURE

4.11.1 REMOVAL FROM SERVICE

If the generator cannot be exercised every seven days,

and will be out of service longer than 90 days, pre-

pare the generator for storage as follows:

1. Start the engine and let it warm up.

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

and allow the unit to shut down.

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

oil fault.

4. Set the generator’s main circuit breaker to its

OFF (or OPEN) position.

5. Set the AUTO/OFF/MANUAL switch to OFF and

turn off the utility power to the transfer switch.

Remove the 15A fuse from the generator control

panel. Disconnect the battery cables as outlined

in “General Hazards”.

6. While the engine is still warm from running,

drain the oil completely. Refill the crankcase with

oil. See ”Engine Oil Recommendations".

7. Attach a tag to the engine indicating the viscosity

and classification of the oil in the crankcase.

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

agent into the spark plug(s) threaded openings.

Reinstall and tighten the spark plug(s).

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

room on a wooden board. Never store the battery

on any concrete or earthen floor.

10. Clean and wipe the entire generator.



4.11.2 RETURN TO SERVICE

To return the unit to service after storage, proceed

as follows:

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

AUTO/OFF/MANUAL switch is set to OFF.

2. Check the tag on the engine for oil viscosity and

classification. Verify that the correct recommend-

ed oil is used in the engine (see the Engine Oil

Recommendations section). If necessary, drain

and refill with the proper oil.

3. Check the state of the battery. Fill all cells of

unsealed batteries to the proper level with dis-

tilled water. DO NOT USE TAP WATER IN THE

BATTERY. Recharge the battery to 100 percent

state of charge, or, if defective, replace the battery.

See “Specifications,” for type and size.

4. Clean and wipe the entire generator.

5. Make sure the 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 exer-

cise timer must be reset.



Section 4 — Maintenance

Air-cooled Generators

25

Section 4 — Maintenance

Air-cooled Generators

4.12 SERVICE SCHEDULE

ATTENTION: It is recommended that all service work

be performed by the nearest Authorized Dealer.

SYSTEM/COMPONENT PROCEDURE FREQUENCY

X = Action Inspect Change Clean W = Weekly

R = Replace as Necessary M = Monthly

* = Notify Dealer Y = Yearly

if Repair is Needed.

FUEL

Fuel lines and connections* X M

LUBRICATION

Oil level X M

Oil X EVERY 100 HOURS**,

AND Y

Oil filter X EVERY 100 HOURS**,

AND Y

COOLING

Enclosure louvers X X W

BATTERY

Remove corrosion, X X M

ensure dryness

Clean and tighten X X M

battery terminals

Check charge state X R EVERY 6 M

Electrolyte level X R EVERY 6 M

(unsealed batteries only)*

ENGINE AND MOUNTING

Air cleaner X R Y

Spark plug(s) X R Y

GENERAL CONDITION

Vibration, Noise, Leakage, X M

Temperature*

COMPLETE TUNE-UP* TO BE COMPLETED BY AN Y

AUTHORIZED DEALER

* Contact the nearest Authorized Dealer for assistance if necessary.

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

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

5.1 TROUBLESHOOTING GUIDE

Problem Cause Correction

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

replace 15A fuse in generator

control panel.

2. Loose, corroded or defective 2. Tighten, clean or replace

battery cables. as necessary.

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

4. Defective starter motor. 4. *

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

The engine cranks but 1. Out of fuel. 1. Replenish fuel/Turn on fuel valve.

will not start. 2. Defective fuel solenoid (FS). 2. *

3. Open #14 wire from 3. *

engine control board.

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

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

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

The engine starts hard 1. Air cleaner plugged 1. Check, replace air cleaner.

and runs rough. or damaged.

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

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

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

is 10-12” water column (0.36-0.43

psi) for LP, and 5-7” water column

(0.18-0.25 psi) for natural gas.

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

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

The AUTO/OFF/MANUAL switch 1. Defective switch. 1. *

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

continues to run. wired incorrectly.

3. Defective control board. 3. *

There is no AC output from 1. Main line circuit breaker is in 1. Reset circuit breaker

the generator. the OFF (or OPEN) position. to ON (or CLOSED).

2. Generator internal failure. 2. *

There is no transfer to 1. Defective transfer switch coil. 1. *

standby after utility 2. Defective transfer relay. 2. *

source failure. 3. Transfer relay circuit open. 3. *

4. Defective control logic board. 4. *

Unit consumes large 1. Engine over filled with oil. 1. Adjust oil to proper level.

amounts of oil. 2. Engine breather defective. 2. *

*Contact the nearest Authorized Dealer for assistance.

26

Section 5 — Troubleshooting

Air-cooled Generators

27 27

Section 6 — Notes

Air-cooled Generators

28

Section 6 — Notes

Air-cooled Generators

29

Section 6 — Notes

Air-cooled Generators

30

Section 7 — Mounting Dimensions

Air-cooled Generators

Drawing No. 0F9424

31

NEUTRAL

CONNECTION

INSIDE SWITCH

XB

NO

C1

COM

XA

VR1

NC NC

COM

C2

VR2

NO

TR

194

23

1

7

4

79

36

9

F2

CIRCUIT 10

BLACK (MAIN 1)

12Vdc TRANSER

COIL

RED (MAIN 2)

NEUTRAL (WHITE)

NEUTRAL (WHITE)

23

OPEN

F1

N2

N1

194

23

BLACK

RED

N2

N1

194

240VAC TO

TO GENERATOR

OUTPUT

PAN E L

MAIN DISTRIBUTION

LC-CIRCUIT BREAKER (LOADS)

F1,F2-5A, 600V FUSE

XA,XB-LIMIT SWITCHES

TS-TERMINAL STRIP

TR-TRANSFER RELAY

C2-GENERATOR COIL & RECTIFIER

LEGEND

C1-UTILITY COIL & RECTIFIER

T1

T2

T1 T2

E2

E2

E2

E2

E1

E1

N1A

N1A

N2A

N2A

B

B

B

B

B

E1

E1

E1

N1AN1A

N1A

194

23

E1

E2

205

205

126

126

E2

N1A

N2A

N2A

A

N2A

240VAC

OUTPUT

GENERATOR

TS TO

CONTROL PANEL

CIRCUIT BREAKER

A

B

ATS

ATS-AUTOMATIC TRANSFER SWITCH

LC

CIRCUIT 9

CIRCUIT 6

CIRCUIT 5

CIRCUIT 2

CIRCUIT 1

CIRCUIT 3

CIRCUIT 4

CIRCUIT 7

CIRCUIT 8

CIRCUIT 11

CIRCUIT 12

CIRCUIT 13

CIRCUIT 14

CIRCUIT 16

CIRCUIT 15

16 CIRCUIT LOAD CENTER

12 CIRCUIT LOAD CENTER

10 CIRCUIT LOAD CENTER

8 CIRCUIT LOAD CENTER

Section 8 — Electrical Data

Air-cooled Generators

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

32

Section 8 — Electrical Data

Air-cooled Generators

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

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

HTO

SP1

85

IM1

CB - MAIN OUTPUT BREAKER

BA - BRUSH ASSEMBLY

BCR - BATTERY CHARGE RELAY

SC - STARTER CONTACTOR

ICT - IDLE CURRENT TRANSFORMER

IC - INLINE CONNECTOR

GRD 1 - GROUND CONNECTIONS IN CONTROL PANEL

FS1 - FUEL SOLENOID

SW1 - AUTO / OFF / MANUAL SWITCH

LOP - LOW OIL PRESSURE SWITCH

IM2 - IGNITION MODULE, CYL 2

F1 - FUSE 15 AMP

SP2 - SPARK PLUG, CYL 2

TS - INSULATED TERMINAL STRIP, 4 POSITION

SW2 - SET EXERCISE SWITCH

DSW - PCB MOUNTED DIP SWITCH

DIAGRAM KEY

14

86

C1

3

1

2

0

85

18

6

4

5

14

TB

16

0

ENGINE WIRING

0

FS2

14

225B

14

13

BATTERY

(UTILITY)

CHARGER

224B

224B

225B

0

14

13

0

13

14

1886

85

13

16

0

14

13

16

86

18

85

14

SP2

IM2

IC

13

SC

SM

13

16

CUSTOMER SUPPLIED

BATTERY

12V

BLACK

RED

1

2

3

1

2

SCR - STARTER CONTACTOR RELAY

IM1 - IGNITION MODULE, CYL 1

SP1 - SPARK PLUG, CYL 1

TB - INSULATED TERMINAL BLOCK, 4 TAB

GRD 2 - GROUND CONNECTIONS AT ENGINE

GRD 2

ACTUATOR

GOVERNOR

LC1

LC2

239

15B

15A

56

224

23

225

4

15A 1823 LC1

14

0

225224 85 LC2

85

18

15B 90

56

2- SPARE

OFF=LOW SPEED EXERCISE

1- ON=NORMAL EXERCISE

15

864

234 768

14239

11910 1213141516

J1

20

0

17 18 19 21 22 23

1

2

DSW

CONTROL

PRINTED CIRCUIT BOARD

ALARM INDICATORS

ON

L.E.D -

90

86

14

90

CS

CS - IDLE CHOKE SOLENOID

1

2

C3

HTO - HIGH OIL TEMPERATURE SWITCH

LOP

86

0

0

0

FS1

14

0

FS2 - FUEL SOLENOID(530cc V-TWIN ONLY)

14

0

00

SM - STARTER MOTOR

C2 - ALTERNATOR HARNESS

C1 - ENGINE HARNESS

C3 - SOLENOID HARNESS

14

-+

33

Section 8 — Electrical Data

Air-cooled Generators

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

0

4

CLOSEST TO BEARING

OUTPUT TO TRANSFER

240V GENERATOR

SWITCH CONTACTOR

6

2

N2

N1

VOLTAGE

REGULATOR

0

0

2

4

6

0

22

11

4

11

SW2

1

MANUAL

SW1

15A

AUTO

1a

CONNECTION

CUSTOMER

15B

GRD 1

0

77

6

22

66

11

0

1

C2

2

5

4

3

225B

CONTROL PANEL BOX

224A

224B

0

225B

14

13

225

224

N1

14

66

224B

TX

225A

225A

77

7

8

0

4

2

194

RELAY COIL

NEUTRAL CONNECTION

CB

11 44 22

240VAC UTILITY INPUT

12Vdc TRANSFER

N1

23

N2

77

44

44

22

66

22 33

11

611

BA

STATOR

N2

16

0

0

33

1b

1515

15A

1

6

5

7910

4

0

0

0

225

224

0

4

23

0

22

4

0

6

2

0

66

224A

77

4

BCR

N2

N1

23

194

239

15A

194

56

A

0

B

SCR

13

15

13

0

0

16

15

13

23225

4

56

224 0

N1 N2 13 0

4N2

N1 0

00

0

0

15

194

F1

TS

0

15B

239

15A

4

23

0

11

11 44

RED

BLACK

IC

IC

LC1

LC2

LC2

LC1

194

LC1

LC2

ICT

0

64

97

BA

31

34

Section 8 — Electrical Data

Air-cooled Generators

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

225B

224B

13

15

56

16

86

15A

224

15B

PRINTED CIRCUIT

11

13

14

12

CONTROL

BOARD

5

8

9

10

6

7

J1

2

3

4

1

VOLTAGE

REGULATOR

ELECTRONIC

MANUAL

SW2

AUTO

23915

SW1

194

194 15A

15A

194

6

2

4

0

4

11

22

56

0

0

13

0

CHARGER

2

1

0

BATTERY

3

1

2

13

18

85

239

56

4

23

14

14

56

15A

239

15

194 4

F1

15

0

22 11

16 0

225

86 LC2

14

0

225B

23

225B

224B

194

0

86

2

14

16

13

4

6

0

0

224B

85

18

86

13

GOVERNOR

ACTUATOR

J2

18

1823

224

0

0

11

22

15

15

15

16

17

18

19

20

21

22

23

LC1

LC2

85

85LC1

LC2

LC1

14

225

15B

0

90 CS

14

14

SCR

35

Section 8 — Electrical Data

Air-cooled Generators

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

WINDING

22

22

225A

56VA

225A

224A

224

225

225

14

224A

1VA

14

TX

0

0

23

224B

225B

194

0

1

7

2

16

14

0

0

4

6

0

0

0

BCR

6

7

3

9

4

9

22

0

FS1

62

0

0

11

16

13

BCR - BATTERY CHARGE RELAY

CB - CIRCUIT BREAKER, MAIN OUTPUT

IM1 - IGNITION MODULE, CYLINDER #1

HTO - HIGH OIL TEMPERATURE SWITCH

IM2 - IGNITION MODULE, CYLINDER #2

F1 - FUSE 15 AMP

FS1 - FUEL SOLENOID

44

DIAGRAM KEY

BA - BRUSH ASSEMBLY

33 CB

11

23194 N2 N1

33

0

SC SM

SC

33

22

44

BATTERY

12V

RED

0

0

11

85

18

86

HTO

LOP

IM2

IM1

ENGINE AND

ALTERNATOR

SP1

SP2

FIELD

BA

0

SW1 - SWITCH, AUTO / OFF / MANUAL

TX - TRANSFORMER, 16 Vac 56 VA &

SW2 - SWITCH, SET EXERCISE

16 Vac 1 VA (DUAL SEC.)

SPST, N.C., ON-(OFF)

SCR - STARTER CONTACTOR RELAY

SP1, SP2 - SPARK PLUGS

DPDT, ON-OFF-ON

SC - STARTER CONTACTER

44

DPE

POWER

WINDING 22

11

33

STATO R

CHARGE

WINDING

BATTERY

77 66

224A 225A

13

66

6

77

2

4

224

N2

N1

7766

11

22

0

7766

WINDING

POWER

I.C.T.

LC2

LC1

LC2

LC1

ICT - IDLE CONTROL TRANSFORMER

CS - IDLE CHOKE SOLENOID

11

0

FS2

LOP - LOW OIL PRESSURE SWITCH

SM - STARTER MOTOR

FS2 - FUEL SOLENOID(530cc V-TWIN ONLY)

16

NEUTRAL

CONTACTOR

OUTPUT TO

TRANSFER SWITCH

240VAC GENERATOR 12Vdc

COIL

RELAY

TRANSFER UTILITY

INPUT

240VAC

36

Section 8 — Electrical Data

Air-cooled Generators

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

CB - MAIN OUTPUT BREAKER

BA - BRUSH ASSEMBLY

BCR - BATTERY CHARGE RELAY

SC - STARTER CONTACTOR

ICT - INTERCONNECTION TERMINALS

IC - INLINE CONNECTOR

HTO - HIGH OIL TEMPERATURE SWITCH

GRD 2 - GROUND CONNECTIONS AT ENGINE

FS - FUEL SOLENOID

SW1 - AUTO / OFF / MANUAL SWITCH

LOP - LOW OIL PRESSURE SWITCH

IM - IGNITION MODULE

F1 - FUSE 15 AMP

SP - SPARK PLUG

TB - INSULATED TERMINAL BLOCK, 4 TAB

SW2 - SET EXERCISE SWITCH

DIAGRAM KEY

14

86

C1

3

1

2

0

85

18

6

4

5

14

15A

23

15B

224

0

239

86

14

18

85

225

4

0

ENGINE WIRING

0

FS

14

225B

14

13

BATTERY

(UTILITY)

CHARGER

224B

224B

225B

0

14

13

0

13

86

PRINTED CIRCUIT BOARD

J1

15A

2143

23

4

CONTROL

239

657

56

18 224

981110

85 225

14

1312 14

15B

0

14

1886

85

13

56

0

0

13

56

86

18

85

0

13

56

1

2

3

1

2

12V

BATTERY

CUSTOMER SUPPLIED

RED

SM

16

SC

13 0 56

56

0

0

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

TS - INSULATED TERMINAL STRIP, 4 POSITION

SP

IM

IC

14

0

7

0

TB

GRD 1 - GROUND CONNECTIONS IN CONTROL PANEL

86

85

LOP

HTO

GRD 2

BLACK

0

L.E.D -

ALARM INDICATORS

SM - STARTER MOTOR

C2 - ALTERNATOR HARNESS

C1 - ENGINE HARNESS

14 14

0

+

-

37

Section 8 — Electrical Data

Air-cooled Generators

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

0

4

CLOSEST TO BEARING

OUTPUT TO TRANSFER

240V GENERATOR

SWITCH CONTACTOR

6

2

15A

0

239

15A

239

N2

N1

0

11

SW2

1

MANUAL

SW1

15A

AUTO

1a

CONNECTION

CUSTOMER

194

GRD 1

0

77

6

22

66

11

1

C2

2

5

4

3

225B

CONTROL PANEL BOX

224A

224B

0

225B

14

13

225

224

N1

14

66

224B

TX

225A

225A

77

7

8

0

4

2

194

RELAY COIL

NEUTRAL CONNECTION

CB

11 44 22

240VAC UTILITY INPUT

12Vdc TRANSFER

N1

23

N2

77

11

11

44

22

66

22 33

44

611

BA

STATOR

N2

0

33

1b

15

15B

23

15A

1

6

5

7910

4

0

0

0

225

224

0

4

23

0

22

4

0

6

2

0

66

224A

77

0

4

00

BCR

N2

N1

23

194

239

15A

194

15B

15

13

13

13

0225

23

4

224

N1 N2 0

04N2

N1

00

0

F1

13

15

194

TS

VOLTAGE

4

22

6

0

REGULATOR

11

4

0

0

00

0

0

2

0

0

64

97

BA

31

38

Section 8 — Electrical Data

Air-cooled Generators

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

225B

224B

13

86

15A

224

0

15B

PRINTED CIRCUIT

11

13

14

12

CONTROL

BOARD

5

8

9

10

6

7

J1

2

3

4

1

VOLTAGE

REGULATOR

ELECTRONIC

MANUAL

SW2

AUTO

23915

SW1

194

194 15A

15A

194

6

2

4

0

4

11

22

0

0

13

0

CHARGER

2

1

0

BATTERY

3

1

2

13

15B

18

85

239

56

225

14

4

23

14

14

56

15A

239

15

194 4

F1

22 11

0

225

86 85

14

0

225B

23

225B

224B

194

0

86

2

14

56

13

4

6

224B

85

18

86

0

13

15

18

18

85

23

224

0

0

11

22

39

Section 8 — Electrical Data

Air-cooled Generators

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

WINDING

22

22

225A

56VA

225A

224A

224

225

225

14

224A

1VA

14

TX

0

0

23

224B

225B

194

0

1

7

2

56

14

0

0

4

6

0

0

0

BCR

6

7

3

9

4

9

22

0

FS

62

0

0

11

56

13

BCR - BATTERY CHARGE RELAY

CB - CIRCUIT BREAKER, MAIN OUTPUT

IM - IGNITION MODULE

HTO - HIGH OIL TEMPERATURE SWITCH

F1 - FUSE 15 AMP

FS - FUEL SOLENOID

11

DIAGRAM KEY

BA - BRUSH ASSEMBLY

33 CB

44

23194 N2 N1

11

33 44

0

SC SM

SC

33

22

44

BATTERY

12V

RED

0

0

11

85

18

86

HTO LOP

18 IM

ENGINE AND

ALTERNATOR

SP

FIELD

BA

0

SW1 - SWITCH, AUTO / OFF / MANUAL

TX - TRANSFORMER, 16 Vac 56 VA &

SW2 - SWITCH, SET EXERCISE

16 Vac 1 VA (DUAL SEC.)

SPST, N.C., ON-(OFF)

LOP - LOW OIL PRESSURE SWITCH

SP - SPARK PLUG

DPDT, ON-OFF-ON

SC - STARTER CONTACTER

DPE

POWER

WINDING 22

33

STATOR

CHARGE

WINDING

BATTERY

77 66

224A 225A

13

66

77

4

224

N2

N1

7766

11

22

0

7766

WINDING

POWER

4

2

11

44

6

16

SM - STARTER MOTOR

NEUTRAL

CONTACTOR

OUTPUT TO

TRANSFER SWITCH

240VAC GENERATOR 12Vdc

COIL

RELAY

TRANSFER UTILITY

INPUT

240VAC

40

Section 8 — Electrical Data

Air-cooled Generators

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

41

Section 8 — Electrical Data

Air-cooled Generators

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

42

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

Enclosure – Drawing No. 0F9431-B

SHEET METAL PAINT/MATERIAL CODE LEGEND

The following exploded views contain part numbers of various sheet metal components. Only the base part number is listed. When ordering sheet metal, the correct

color and material information must be included as a suffi x at the end of the part number as shown below.

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

S = Steel N = Tan Roof 0F6522 S = Steel N = Tan 0F6522SN

A = Aluminum G = Gray Door 0F6555 A = Aluminum G = Gray 0F6555AG

B = Black Divider 0F6558 S = Steel B = Black 0F6558SB

43

ITEM PART NO. QTY. DESCRIPTION

1 0F9653 1 PAD, 24 X 48” WITH MOUNTING HOLES

2 045771 4 NUT HEX M8-1.25

3 022129 4 WASHER LOCK 5/16

022129 5 WASHER LOCK 5/16 (7KW)

4 022145 8 WASHER FLAT 5/16

5 043107 4 SCREW HHC M8-1.25 X 25

6 090388 15 SCREW TAPTITE M6-1.0 X 12

7 0D3700 24 NUT, LOCKING FLANGE M6-1.0 (7KW)

8 0D4662 14 SCREW HHTR 5/16-18 X 3/4" (7KW)

0D4662 13 SCREW HHTR 5/16-18 X 3/4"

9 0F8871 1 SCROLL, FAN (7KW, 10KW)

0F8080 1 SCROLL, FAN

10 0F8246 1 PANEL, ALTERNATOR DIVIDER (7KW)

0F8915 1 PANEL, ALTERNATOR DIVIDER (10KW)

0F6558 1 PANEL, ALTERNATOR DIVIDER

11 092120 4 NUT LOCK TRIC M6 X 1.0

12 0F7825 1 FOAM, MUFFLER BOX FRONT

13 0F7824 1 FOAM, MUFFLER BOX END

14 0F6549 1 ENCLOSURE, EXHAUST SIDE

15 0F7824A 1 FOAM, MUFFLER BOX END

16 0D1840 2 BRACKET, BOTTOM SUPPORT

17 047411 6 SCREW HHC M6-1.0 X 16 G8.8 (7KW)

047411 8 SCREW HHC M6-1.0 X 16 G8.8

18 0F0710 12 RIVET POP 0.125” X 0.337”

19 0A2115 4 WASHER NYLON M6-1/4”

20 0C6735 2 SUPPORT, ROOF FOLDING

21 0D2979D 2 CLOTH HARDWARE 266.7mm X 387.4mm

22 0D7176 34 WASHER, SELF LOCKING

23 0F7827 2 FOAM, EXHAUST ENCLOSURE COVER

24 0F6570 1 COVER, BACK EXHAUST ENCLOSURE

25 0F6571 1 COVER, FRONT EXHAUST ENCLOSURE

26 0D2979B 1 CLOTH, HARDWARE 266.7mm X 146mm

27 0D2979C 1 CLOTH, HARDWARE 543mm X 146mm

28 022097 4 WASHER LOCK M6-1/4 (7KW)

022097 3 WASHER LOCK M6-1/4

29 022473 2 WASHER FLAT M6-1/4

30 0F7826 1 FOAM, MUFFLER BOX BACK

31 0F0165A 1 HINGE TYPE B WITH STUDS, SOCKET

32 0F6550 1 ENCLOSURE, SIDE & BACK

33 0F0164A 1 HINGE TYPE A WITH STUDS, SOCKET

34 0E1330A 1 GROMMET, 38.1 CROSS SLIT WITH HOLE

35 021267A 2 PLUG PLASTIC 1.5 BLIND GROMMET

36 0E5968 11 GASKET, EXTRUDED TRIM

37 0F0165 1 HINGE TYPE B WITH STUDS, PIN

38 0F0164 1 HINGE TYPE A WITH STUDS, PIN

39 0C1085 1 SCREW PPHM M3-0.5 X 8

40 0A8475 1 L/WASH SPECIAL #10

41 0G0400 1 WIRE ASSEMBLY, GROUND

42 0F6552 1 ENCLOSURE, ROOF

43 0F9379 1 FOAM, ROOF ENCLOSURE

44 0D1839 2 BRACKET, TOP SUPPORT

45 0F8210 1 REGULATOR ASSEMBLY (7KW)

0F8209 1 REGULATOR ASSEMBLY (10KW)

0F9078 1 REGUALTOR ASSEMBLY

46 0F5458 4 SCREW PLASTITE HI-LOW #10 X 3/8

47 0F5438 1 HARNESS, ENGINE (7KW)

0F5434 1 HARNESS ENG V-T HSB

ITEM PART NO. QTY. DESCRIPTION

48 0F8263 1 PANEL, ENGINE DIVIDER (7KW)

0F7886 1 PANEL, ENGINE DIVIDER (10KW)

0F7885 1 PANEL, ENGINE DIVIDER

49 023484H 1 BUSHING SNAP SB-1500-18

50 0D3058A 1 FOAM, FRONT INTAKE BAFFLE (7KW)

0E4245 1 FOAM, FRONT INTAKE BAFFLE

51 0D3058C 1 FOAM, BACK INTAKE BAFFLE (7KW)

52 0D1605A 1 BAFFLE, INTAKE (7KW)

0F7798 1 BAFFLE, INTAKE

53 0F8380 1 FOAM, TOP INTAKE BAFFLE

54 0D3472 1 GROMMET OVAL 31.75 X 50.8

55 0C8285 1 BRACKET, BATTERY SUPPORT

56 0D3167 1 GASKET, BATTERY SUPPORT BRACKET

57 0E1330 1 GROMMET, 38.1 DIA. CROSS SLIT

58 043116 3 SCREW HHC, M6-1.0 X 12 G8.8(7KW)

043116 1 SCREW HHC M6-1.0 X 12 G8.8

59 086729 1 CONTACTOR, STARTER (7KW)

60 0F8039 1 MOUNTING CLIP

61 022127 1 NUT HEX 1/4-20 (7KW)

62 0388040AJ0 1 CABLE, #6 RED BATTERY 38.5”

63 0F8847 1 GASKET, FRONT DIVIDER

0F8434 1 GASKET, FRONT DIVIDER (10KW)

64 0F9968 1 FUEL LINE, 1/2” OUTDOOR (NOT SHOWN)

65 0C2937 1 BRACKET, BATTERY HOLD DOWN (7KW)

66 049813 1 NUT HEX M6-1.0 G8

67 0A1658 1 LOCK WASHER SPECIAL 1/4

68 0G0617 1 EXTERNAL CONNECTION BOX

69 092079 1 SCREW TAPTITE M6-1.0 X 25 BP

70 055414 1 LUG SLDLSS #2-#8 X 17/64 CU

71 0F8234 1 ASSEMBLY, ENCLOSURE BASE (7KW)

0F7711 1 ASSEMBLY, ENCLOSURE BASE

72 0F8257 1 FOAM, FRONT ENCLOSURE

73 0C3906 2 SELF-ALIGN SCREW M6 HH

74 0F6555 1 ENCLOSURE, FRONT

75 0F8555 1 GASKET, DOOR SEAL

76 0D3037 1 LATCH, QUARTER TURN LOCKING

77 0D3037A 1 LATCH, QUARTER TURN NON-LOCKING

78 0F9143 2 PAWL, DOOR

79 0F8261 1 FOAM, BACK ENCLOSURE

80 0F5440 1 HARNESS GENERATOR TO EXTERNAL

CONNECTION BOX (7KW)

0F9328 1 HARNESS GENERATOR TO EXTERNAL

CONNECTION BOX (10KW)

0F5478 1 HARNESS GENERATOR TO EXTERNAL

CONNECTION BOX

81 051713 2 WASHER FLAT M5

82 022152 5 WASHER LOCK #10

83 036937 2 SCREW PPHM#10-32 X 1

84 022158 5 NUT HEX #10-32

85 0C8911 1 POWER BLOCK

86 026850 1 WASHER SHAKEPROOF EXT 1/4 STEEL

87 031879 2 WASHER FLAT #4

88 0D9784 1 NUT HEX LOCK M3-0.5

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

Enclosure – Drawing No. 0F9431-B

44

32

44

19

29

3

17 27

29

8,9

37

22

10

27

15

43

44

20

6

13 17

35

21

5

34

15

25

23

36

30

12

26

7

32 28

2

39

17

23

4

25

18

13

17

14

16

40

15

33

24

31

44

38

32 44

43

1

41

31

11

42

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

Control Panel – Drawing No. 0F9695-B

45

ITEM PART NO. QTY. DESCRIPTION

1 0E7886A 1 CIRCUIT BREAKER 30A X 2P 240V (7KW)

0E7886D 1 CIRCUIT BREAKER 45A X 2P 240V (10KW)

0E7886K 1 CIRCUIT BREAKER 55A X 2P 240V (13KW)

0E7886J 1 CIRCUIT BREAKER 65A X 2P 240V (16KW)

2 0A1801 1 ASSEMBLY, BATTERY CHARGER ENGINE

3 0F9719 1 ASSEMBLY, POTTED REGULATOR

4 0C2174 1 RELAY, 12V 25A SPST (NON 7KW)

5 075210A 1 BLOCK TERMINAL 1 POSITION

6 038750 1 SCREW HHC M6-1.0 x 30mm

7 0F8992 1 ASSEMBLY, HOME STANDBY CONTROLLER

0F1504 1 ASSEMBLY, HOME STANDBY CONTROLLER (7KW)

8 032300 1 HOLDER, FUSE

9 022676 1 FUSE, 15 AMP X AGC15

10 0E4494 1 SWITCH, ROCKER DPDT ON-OFF-ON

11 0E7890 1 CIRCUIT BREAKER MOUNTING BRACKET

12 023484E 1 SNAP BUSHING

13 075476 4 SCREW PPHM M4-0.7 x 16mm

14 043182 2 M3 LOCK WASHER (NON 7KW)

15 0E6480 6 NUT HEX LOCK M4-0.7 NYLON INSERT

16 0D4804A 1 CURRENT TRANSFORMER, IDLE CONTROL (NON 7KW)

17 0C1085 12 SCREW PPHM M3-0.5 x 8mm

0C1085 8 SCREW PPHM M3-0.5 x 8mm (7KW)

18 058000H 2 M3-0.5 TRIC NUT (NON 7KW)

19 023897 2 WASHER FLAT #10

20 0F8040 1 CONTROL, PANEL BOTTOM

0F9282 1 CONTROL, PANEL BOTTOM (7KW)

21 075235 4 SCREW HHC M5-0.8 x 30mm

22 0E3928 1 SWITCH, SPST

23 0D9784 4 NUT HEX LOCK M3-0.5 NYLON INSERT

0D9784 2 NUT HEX LOCK M3-0.5 NYLON INSERT (7KW)

24 0D8502 1 NEUTRAL BLOCK

25 031879 4 WASHER FLAT #4

031879 2 WASHER FLAT #4 (7KW)

26 0F5433 1 HARNESS, CONTROL PANEL WIRE (NOT SHOWN)

0F5437 1 HARNESS, CONTROL PANEL WIRE (NOT SHOWN) (7KW)

27 074908 4 SCREW HHTT, M5-0.8 x 10 BP

28 049813 1 NUT HEX M6-1.0

29 082025 6 NUT HEX LOCK M5-0.8 NYLON INSERT

30 0G0627 1 XFMR 240/16V 1VA&56VA W/PTC

31 022507 2 SCREW HHC 1/4”-20 x 1/2”

32 022097 3 WASHER LOCK M6-1/4”

33 046689 1 TERMINAL STRIP 4 POSITION

34 063617 1 RELAY PANEL 12VDC DPDT 10A 240VAC

35 075475 2 SCREW PPHM M4-0.7 x 10mm

36 043180 2 WASHER FLAT M4

37 0F8041 1 COVER, CONTROL PANEL COMPONENT

0F9283 1 COVER, CONTROL PANEL COMPONENT (7KW)

38 045770 2 SCREW HHC M5-0.8 x10mm

39 0E7866 1 COVER, CONTROL PANEL

0E7867 1 COVER, CONTROL PANEL (7KW)

40 0D3700 8 NUT FLANGE M6-1.0 NYLOK

41 0G0400 1 WIRE ASSEMBLY, GROUND

42 0E2874 1 SCREW HHTR 1/4"-20 X 3/4"

43 0A1658 2 WASHER LOCK SPECIAL 1/4”

44 022473 4 WASHER FLAT 1/4”-M6

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

Control Panel – Drawing No. 0F9695-B

46

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

Transfer Switch Assembly – Drawing No. 0F9774-A

47

ITEM PART NO. QTY. DESCRIPTION

1 0F8278 1 BOX LOAD CENTER

2 0D4800 1 COVER, 8 CIRCUIT LOAD CENTER

0F5211 1 COVER, 10 CIRCUIT LOAD CENTER

0D3092 1 COVER, 12 CIRCUIT LOAD CENTER

0F8312 1 COVER, 16 CIRCUIT LOAD CENTER

3 0C2237 1 TRANSFER SWITCH HOME STANDBY

100A 2P 250V

3A 077220 1 COIL UTILITY

3B 077220A 1 COIL STANDBY

3C 082574 1 INSULATOR-SIDEWALL (NOT SHOWN)

3D 084464 1 LIMIT SWITCH OPERATION (NOT

SHOWN)

4 074908 6 SCREW HHTT M5-0.8 X 10

5 024912 1 SCREW HHTT 1/4-20 X 5/8

6 0A1658 1 LOCK WASHER, SPECIAL-1/4”

7 063617 1 RELAY PANEL 12VDC DPDT 10A@240VAC

8 0E7889A 1 8 CIRCUIT LOAD CENTER

0E7889 1 12 CIRCUIT LOAD CENTER (ALSO USED

FOR 10 CIRCUIT)

0F9213 1 16 CIRCUIT LOAD CENTER

9 0A1495 4 SCREW HHTT M4-0.7 X 10

10 0A1661 2 RIVET POP .156” X .675”

11 022473 1 WASHER FLAT 1/4-M6 ZINC

12 081108 1 PLUG PLASTIC

0F9199 1 PLUG PLASTIC

13 0D4684 1 HARNESS ADAPTER PLATE

0D4684A 1 8 CIRCUIT HARNESS ADAPTER PLATE

14 0F8279 1 SUBPLATE, LOAD CENTER

15 0F4790 10.5” U-CHANNEL

16 022152 6 WASHER LOCK #10

17 064526 2 SCREW HWHS #6-25 X 3/8”

18 0E6155 1 ARM EXTENDER PIN

19 063378 4 HOLDER CABLE TIE

20 0G0979 1 HARNESS, 8 CIRCUIT LOAD CENTER TO

MAIN PANEL

0G0980 1 HARNESS, 10 CIRCUIT LOAD CENTER

TO MAIN PANEL

0G0981 1 HARNESS, 12 CIRCUIT LOAD CENTER

TO MAIN PANEL

0G0982 1 HARNESS, 16 CIRCUIT LOAD CENTER

TO MAIN PANEL

ITEM PART NO. QTY. DESCRIPTION

21 074138 2 LUG QUICK DISCONNECT NI-S 10X45

DEG BRASS / TIN

22 036933 6 SCREW PPHM #10-32 X 3/8”

23 077033 6 LUG SLDLSS 1/0-#14X9/16 AL/CU

24 048850 1 BLOCK TERMINAL 20A 5 X 6 X 1100V

25 028739 4 TIE WRAP 3.9" X .10"

26 0A2110 4 SCREW SWAGE 1/4-20 X 1/2" ZINC

27 0D3191 1 COVER, RELAY & TERMINAL BLOCK

28 0D3088 1 WIRE HARNESS, LOAD CENTER (NOT

SHOWN)

29 073591 2 FUSE HOLDER

30 073590A 2 FUSE 5A

31 040213B 4 SUPPORT SNAP-IN 1-3/8"

8 10 12 16 CIRCUIT

32 0E7888 A/R CIR BRK 20A 2P 1 1

33 0E7888A A/R CIR BRK 30A 2P 1 1 1

34 0E7888B A/R CIR BRK 15A 1P 5 3 5 5

35 0E7888C A/R CIR BRK 20A 1P 1 3 3 5

36 0E7888D A/R CIR BRK 40A 2P 1 1

37 0E7888E A/R CIR BRK 50A 2P 1

38 0D3320 1 COVER - HARNESS ENTRY

39 0F5439 1 HARNESS, 8 CIRCUIT LOAD CENTER TO

EXT CONN BOX

0F9327 1 HARNESS, 10 CIRCUIT LOAD CENTER

TO EXT CONN BOX

0F6720 1 HARNESS, 12 CIRCUIT LOAD CENTER

TO EXT CONN BOX

0F6720 1 HARNESS, 16 CIRCUIT LOAD CENTER

TO EXT CONN BOX

40 075475 2 SCREW PPHM M4-0.7 X 10

41 0A7215 4 SCREW SW 1/4"-20 X 5/8” WITH WASHER

42 0E6193 1 BRACKET, ARM EXTENDER

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

Transfer Switch Assembly – Drawing No. 0F9774-A

48

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

49

ITEM PART NO. QTY. DESCRIPTION

1 0C5729 1 ASSEMBLY, CRANKCASE HOUSING WITH

SLEEVE

2 0E9843 1 SEAL, 38 I.D. CRANKSHAFT

3 090388 3 SCREW, TAPTITE M6-1.0 X 12 YC

4 0C5372 1 ASSEMBLY, BREATHER

5 0C3005 1 GASKET, BREATHER COVER

6 0E3372B 1 SEPARATOR, OIL BREATHER

7 0D8067A 1 ASSEMBLY, HEAD #1 G&S

8 071983 4 RETAINER, PISTON PIN 20

9 0C2981F 1 ROCKER, COVER NO OIL FILL

11 0E2985 2 PISTON, HC

12 021533 2 SET, PISTON RING 90MM

13 0E1466 2 PIN PISTON

14 0D4041 1 ASSEMBLY, CAMSHAFT & GEAR

15 0C2977 1 GASKET, CRANK CASE

16 0C5943 1 SEAL, OIL PASSAGE

17 0E4357E 1 ASSEMBLY, CRANKSHAFT HORIZONTAL

DIRECT DRIVE

18 0E3223 2 ASSEMBLY, CONNECTING ROD

19 0D2157 2 SCREW SHC M6-1.0 X 50 G8.8

20 0E6098 1 SCREEN, OIL PICKUP

21 0D4123A 1 ASSEMBLY, OIL PUMP

22 0E8152 1 O-RING .49 ID X .07 THICK

23 0C3011 2 COVER, OIL RELIEF

24 0C3009 2 SPRING, OIL RELIEF

25 0C3010 2 BALL, 1/2D OIL RELIEF

26 093873 2 WASHER, LOCK RIB M6

27 0F5458 1 SCREW, PLASTITE HI-LOW #10

28 0C3027 3 O-RING, 3/8” X 1/2”

29 0C5998 1 CLAMP, OIL TUBE

30 0D4497 1 PLUG-CRANKCASE

31 0F2664C 1 ASSEMBLY, DIPSTICK WITH HANDLE

32 0C5305 1 TUBE, DIPSTICK

33 0D6147 7 SCREW HHFC M6-1.0 X 10mm

ITEM PART NO. QTY. DESCRIPTION

34 043790 1 BARBED ELBOW 90 3/8NPT X 3/8

35 0E9842 1 SEAL, 42 I.D. CRANKSHAFT

36 0C5731 1 ASSEMBLY, HOUSING COVER WITH

SLEEVE

37 0C3006 10 SCREW, HHFC M10-1.5 X 55

38 080318 8 SCREW HHFC M6-1.0 X 25

39 093064 1 ASSEMBLY, OIL FILL CAP

40 0C8808 2 HOOK, LIFTING

41 0D2723D 1 ROCKER, COVER WITH OIL FILL

42 0C2979 2 GASKET, VALVE COVER

43 086515 8 KEEPER, VALVE SPRING

44 0D2274 4 RETAINER, VALVE SPRING

45 0D3867 4 SPRING, VALVE

46 078672 2 SEAL, VALVE STEM D7

47 0C5371 4 WASHER, VALVE SPRING

48 072694 4 STUD, ROCKER ARM PIVOT

49 0D5313 4 ROCKER ARM

50 0D3998 4 NUT HEX M8-1.0 G8 YEL CHR

51 0D6024 2 PLATE, PUSH ROD GUIDE

52 0C2976 12 SCREW HHFC M8-1.25 X 65

53 086516 2 VALVE, EXHAUST

54 0C2229 2 VALVE, INTAKE

55 083897 4 TAPPET, SOLID

56 0D8067B 1 ASSEMBLY, HEAD #2 G&S

57 0D9853D 4 PUSHROD, 147

58 0C2978 2 GASKET, HEAD

59 0D4010 1 KIT GASKET

60 0D4012 1 KIT BREATHER ASSEMBLY

61 0D8675A 1 KIT HEAD ASSEMBLY CYLINDER 1

62 0D8675B 1 KIT HEAD ASSEMBLY CYLINDER 2

63 0D4015 1 KIT OIL RELIEF

64 078699C 2 SLEEVE DOWEL PIN 14 DIA.

65 078699B 4 SLEEVE DOWEL PIN 12 DIA.

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

50

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

51

ITEM PART NO. QTY. DESCRIPTION

64 022145 1 WASHER FLAT M8 – 5/16

65 0C5136A 2 KNOB, AIR CLEANER

66 0C3024 1 COVER, AIRBOX NG/LP

67 0C3040 1 PRE-CLEANER,

68 0C8127 1 ELEMENT, AIR CLEANER

69 0F9255 1 ASSEMBLY, MIXER/AIRBOX 990

70 0E9582 4 SCREW SHLDR(8MM) M6-1.0 X 21

71 0D4417 4 WASHER,RUBBER 1/4" X 1/8" THICK

72 0G0767A 2 SPARKPLUG,GT990 HSB

73 0E6043 2 SCREW TAPTITE M5 – 0.8 X 8

74 0D1142A 1 WRAPPER, LOWER CYLINDER 2

75 0C3025 1 SWITCH, OIL PRESS

76 0C7292 1 NIPPLE, ¾”-16 UNF

77 070185B 1 OIL FILTER

78 0D3083 1 ASSY, OIL DRAIN HOSE

79 0F2094 2 SCREW M3 – 0.5 X 6 SEMS

80 075281 1 SWITCH, THERMAL 284F

81 035461 2 BARBED STRAIGHT 1/4NPT X 3/8

82 0F6301 4 CLAMP, HOSE OETIKER 16.5MM

83 0G0286 2 HOSE, 3/8” I.D. X 6” LG

84 0E9506 1 COOLER, OIL

85 0C9764 4 SCREW PLASTITE 1/4-15 X 3/4

86 0C3043 2 GASKET, MANIFOLD / PORT

87 0C7694 1 MANIFOLD CYLINDER 2

88 070008 4 WASHER FLAT M8 SS

89 070006 4 WASHER LOCK M8 SSTL

90 040976 4 SCREW SHC M8 – 1.25 X 20 G12.9

91 045756 17 SCREW TAPTITE M6 – 1X10 YELLOW

CHROME

92 0E4997 1 ASSY,GROUND WIRE CONNECTOR

93 0C3033 1 WASHER, 25MM I.D.

94 0C3034 1 NUT, HEX M24

95 0C9763 4 NUT, GROMMET 1/4 PLUG

96 0D1131 1 GUARD, FAN

97 0F1169K 1 HOUSING, BLOWER NG COOLER

98 051754 2 SCREW HHC M8 – 1.25 X 12 G8.8

99 0A5992 2 WASHER SHAKEPROOF INT M8 SS

100 0C3032 1 PLATE, FAN

101 0C3031 1 FAN, NYLON

102 0C3725E 1 FLYWHEEL ASSEMBLY

103 0F1170A 1 PLATE, BACKING WITH OIL COOLER

104 0C7693 1 MANIFOLD CYLINDER 1

105 0C3041A 2 SLEEVE, RUBBER

106 082774 1 KEY, WOODRUFF 4 X 19D

107 0C3036A 1 HOSE BREATHER

108 0C3019 1 WRAPPER, LOWER CYLINDER 1

109 0C3018 1 WRAPPER, UPPER CYLINDER 1

ITEM PART NO. QTY. DESCRIPTION

110 0D1143 1 WRAPPER, UPPER CYLINDER 2

111 0E9323 1 STARTER MOTOR HEAR REDUCED 1KW

112 061906 2 SCREW HHC M8 – 1.25 X 85 G8.8

113 022129 3 WASHER LOCK M8 – 5/16

114 0F1177 1 ASSEMBLY, GROUND WIRE

115 022097 6 WASHER LOCK M6 – 1/4

116 092079 4 SCREW TAPTITE M6 – 1.0 X 25 BP

117 0G0798A 1 ASSY, IGN COIL W/DIODE, CYLINDER 1

118 0G0798B 1 ASSY, IGN COIL W/DIODE, CYLINDER 2

119 0E9568 1 ASSY, THROTTLE SHAFT

120 0E9565 2 THROTTLE VALVE

121 074027 4 SCREW PPHM M3 – 0.5 X 5

122 0C3044 1 COVER, DUST, MIX/AIRBOX

123 0C4756 1 SPRING, IDLE ADJUST

124 075477 1 SCREW PPHM M5 – 0.58 X 20

125 043116 2 SCREW HHC M6 – 1.0 X 12

126 0E1644 1 SCREW BHSC M6-1.0 X 12 SS

127 0E9572 1 BRACKET, STEPPER MOTOR

128 0D9784 1 NUT HEX LOCK M3 – 0.5 NYLON INSERT

129 0E5108 1 ASSY, CONTROLLER

130 0D6342 1 BALL STUD, 10MM

131 0E9570 1 ASSY, THROTTLE ROD

132 0E9577 1 BELLOWS, INTAKE

133 0E5846 1 EXPANSION PLUG

134 0E9419 3 #10 O-RING

135 0C4760 1 PLUG, MANIFOLD

136 0F9253 1 ASSY, AIR BOX BASE

137 0E9553 1 PIN, FUEL SELECTOR

138 0E9554 1 PIN, FUEL SEL STOP

139 0E9348 1 SOLENOID COVER

140 0E9599 1 LINKAGE, CHOKE

141 0E9595 4 SCREW PPPH HI-LO #6 X 1/2

142 090987 1 SCREW PHTT M3 – 0.5 X 8

143 0E9403 1 RETAINER, CHOKE RETURN SPRING

144 0E9571 1 SPRING, CHOKE RETURN

145 0E9380 1 WASHER, BELLEVILLE SPRING

146 0A6345 1 SCREW PPHM M2 – 0.4 X 8

147 0E9598 1 CHOKE ARM

148 0E9593 1 SCREW SHOULDER M3 – 0.5 X 6

149 0E9564 1 VALVE, CHOKE

150 0E9575 1 SHAFT, CHOKE

151 0E9357 1 SEAL, GOVERNOR ARM

152 0A7094 2 SCREW PHM #4 – 40 X 1/4

153 0E9574 1 BRACKET, SOLENOID

154 0F9273 1 SOLENOID, 6VDC

155 0F5467 1 NUT HEX M8 – 1.25 YELLOW ZINC

156 0E9557 1 SPRING, CHOKE VALVE ADJUST

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

52

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

53

ITEM PART NO. QTY. DESCRIPTION

1 0E9428B 1 CRANKCASE

2 0E3812 2 SEAL D 35 X 48.2

3 0C8566 2 SCREW HHFC M6 – 1.0 X 20

4 0E9367A 1 ASSY, BREATHER

5 0E9366 1 GASKET BREATHER ASSY

6 0E9304 1 CYLINDER HEAD 1

7 0E9334C 1 COVER, ROCKER PLAIN

8 076390 4 PISTON PIN RETAINER RING

9 076389 2 PISTON PIN

10 088057 2 PISTON

11 088411 2 PISTON RING SET

12 0E9322A 2 ASSY CONNECTING ROD

13 0E9407A 1 ASSY, CAM & GEAR

14 0E9350 1 GASKET CRANKCASE

15 0E9318E 1 ASSY CRANKSHAFT W/PLUG

16 043116 3 SCREW HHC M6 – 1.0 X 12

17 093873 3 WASHER LOCK M6 RIBBED

18 0G0272 1 ASSY GEROTOR

19 0E9482 1 SPRING OIL PRESSURE RELIEF

20 0A5776 1 BALL 11/32 DIA PRESSURE RELIEF

21 0C5315A 1 GEROTOR OUTER 9MM THICK

22 0C5314A 1 GEROTOR INNER 9MM THICK

23 0E9473 1 GEAR COVER

24 073144 9 SCREW HHFC M8 – 1.25 X 45

25 0C3027 2 O-RING 3/8 X 1/2

26 0E9358 1 SCREEN OIL PICK-UP

27 093064 1 ASSY, OIL FILL CAP

28 0E9334A 1 COVER, ROCKER, W/ FILL

29 0E9352 2 GASKET, VALVE COVER

30 0C3592 8 KEEPER, VALVE SPRING

31 0C3733 4 VALVE RETAINER

32 0C4390 4 SPRING VALVE

33 088156 2 SEAL, VALVE STEM

34 084186 4 WASHER, VALVE SPRING

35 0E9368 2 SPARKPLUG

36 077168 12 SCREW HHC M8 – 1.25 X 56

37 0E9305 1 CYLINDER HEAD 2

38 0C3590 2 VALVE EXHAUST

39 0E9351 2 GASKET CYLINDER HEAD

40 0C3591 2 VALVE INTAKE

41 083235 4 TAPPET, SOLID

42 0E9455E 4 PUSHROD, ALUMINUM

43 0E9353A 2 PLATE, PUSH ROD GUIDE

44 076307 4 NUT JAM (ROCKER ARM)

45 077160 4 ROCKER ARM

46 077161 4 STUD ROCKER ARM PIVOT

47 0G0273 1 GASKET KIT

48 0G0274 1 BREATHER KIT

49 0G0275 1 KIT HEAD ASSY CYLINDER #1

50 0G0276 1 KIT HEAD ASSEMBLY CYLINDER #2

51 0E9502 1 SEPERATOR, OIL, GT530

52 080318 12 SCREW HHFC M6 – 1.0 X 25

53 0E3372C 1 SEPARATOR, OIL BREATHER GT530

54 078699B 6 SLEEVE DOWEL PIN 12 DIA.

55 0C5943 1 SEAL, OIL PASSAGE

56 043790 1 BARBED EL 90 3/8 NPT X 3/8

57 0D4788 1 PLUG STD PIPE 3/8 STEEL SQ HD

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

54

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

55

ITEM PART NO. QTY. DESCRIPTION

58 022097 3 WASHER LOCK M6-1/4

59 0E9561 1 INTAKE ADAPTER

60 0E9472 1 GASKET, AIRBOX TO CARB/MIXER

61 0E9471 1 GASKET, MANIFOLD TO CARB/MIXER

62 078643B 4 BOLT, CARB MOUNT M6 – 1.0 X 85

63 0D9784 1 NUT HEX LOCK M3 – 0.5

64 0E9584 1 ASSY, CONTROLLER

65 0D6342 1 BALL STUD, 10 MM

66 0E9587 1 ASSY, THROTTLE ROD

67 0C9997 1 GUARD, FAN

68 0E9319 2 GASKET INTAKE

69 0E9597 1 BREATHER HOSE

70 040976 4 SCREW SHC M8 – 1.25 X 20 G12.9

71 022129 2 WASHER LOCK M8 – 5/16

72 061906 2 SCREW HHC M8 – 1.25 X 85

73 0E9323 1 STARTER MOTOR

74 0E9507 6 SCREW HHFC M8 – 1.25 X 14

75 0E9362 2 LIFTING HOOK

76 0E9337 1 WRAPPER OUTER CYLINDER 1

77 0E9339 1 WRAPPER INNER CYLINDER 1

78 0E9402 1 TUBE, DIPSTICK

79 0F2664H 1 ASSY, DIPSTICK /TEXT

80 0E9336F 1 BLOWER HOUSING

81 0D6147 6 SCREW HHFC M6-1.0 X 10 G8.8

82 0E5139 3 SCREW HHFC M6-1.0 X 8 G8.8

83 0E9432 1 WRAPPER INNER CYLINDER 2

84 0E9338 1 WRAPPER OUTER CYLINDER 2

85 0E9370 1 GASKET, OIL FILTER ADAPTER

86 0E9505A 1 ASSY, DIRECT OIL COOLER ADAPTER

87 0F5458 2 SCREW PLASTITE HI-LOW #10X3/8

ITEM PART NO. QTY. DESCRIPTION

88 045757 3 SCREW HHC M6 – 1.0 X 25

89 070185B 1 OIL FILTER

90 094090 1 THERMAL SWITCH

91 0F2094 2 SCREW PPHM M3-0.5 X 6 SEMS

92 0D3083 1 ASSEMBLY, OIL DRAIN HOSE

93 0A8584 1 OIL PRESSURE SWITCH

94 082774 1 KEY, WOODRUFF 4 X 19D

95 0E7209 1 ASSY, GROUNDING WIRE

96 0E9514B 1 ASSY IGNITION COIL CYLINDER 1

0E9514C 1 ASSY IGNITION COIL CYLINDER 2

97 026850 4 WASHER SHAKEPROOF EXT 1/4

98 0E9443 1 ASSY, MIXER DUAL FUEL

99 0F6301 4 CLAMP, HOSE OETIKER 16.5MM

100 0G0286 1 HOSE 3/8”ID X 6” SAE J30R9

101 0G0479 1 HOSE 3/8”ID X 7.25 SAE J30R9

102 0E9340 1 BACKING PLATE

103 0E9525C 1 ASSY, FLYWHEEL & RING GEAR

104 0E9486 1 FAN, FLYWHEEL, 20 FIN, 218.8 OD

105 0A5992 2 WASHER LOCK INT M8

106 048571 2 SCREW HHC M8 – 1.25 X 10

107 067890 1 NUT HEX M20 – 1.5

108 067198N 1 WASHER BELV – 20 X 2.2

109 0C3032 1 PLATE, FAN

110 0E4997 1 ASSY, GROUND WIRE CONNECTOR

111 0E9406 1 OIL COOLER

112 0G1705 14 SCREW HHFC M6 – 1.0 X 14

113 0E9450 1 CENTER BAFFLE

114 0E9376 1 INTAKE MANIFOLD

115 0E9550 1 FRONT COVER

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

56

32

23

34

35

36

45

39

33

20

19

18

43 44

46

11

49

29

37

27 28

30

31 17

52

47

48

24 38

26

22 40

41

25

25

50

15

53

14

21

12

51

13

54

16

1

6

1

2

11

10

42

57

9

8

3

4

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

57

ITEM PART NO. QTY. DESCRIPTION

1 0E3221 1 ASSEMBLY, CONNECTING ROD

2 0E1466 1 PIN, PISTON D20

3 021533 1 SET, PISTON RING 90MM

4 0E2985 1 PISTON, HC

5 071983 2 RETAINER, PISTON PIN 20

6 0E8440 1 ASSEMBLY, CRANKSHAFT GH410 SMALL TAPER

7 0A7628 1 ARM, GOVERNOR RC45

8 078658 1 PIN, “R” GOVERNOR ARM

9 078659 2 WASHER, GOVERNOR ARM THRUST

10 088261E 1 CRANKCASE, SUBASSEMBLY WITH PLUGS GH410

11 0E3812 2 SEAL, 35 I.D. CRANKSHAFT

12 0E6519 1 ASSEMBLY, GOVERNOR GEAR

13 078645 1 C-RING, GOVERNOR GEAR RETAINER

14 0A7811 1 SPOOL, GOVERNOR- MACHINE

15 0A9877 1 ASSEMBLY, CAMSHAFT & GEAR

16 076701 1 GASKET , CRANKCASE

17 021713B 1 GASKET, HEAD 410

18 078691 1 COVER, OIL PRESSURE RELIEF

19 0A5771 1 SPRING, OIL RELIEF 360

20 0A5776 1 BALL, DIA 11/32 PRESSURE RELIEF

21 076361 1 WASHER, THRUST GOVERNOR GEAR

22 0A8898D 1 ASSEMBLY, COVER, GEAR TOP CHECK / FILL

23 0D2274 2 RETAINER, VALVE SPRING

24 0C4391 2 VALVE SPRING LF

25 086025 1 SET,GEROTOR 12 THK

26 0E3341 1 BALANCER

27 021714 1 ASSEMBLY,CYLINDER HEAD SEATS & GUIDES

28 086516 1 VALVE, EXHAUST

29 086517 1 VALVE, INTAKE

30 0D9853B 2 PUSH ROD 174.9

31 083897 2 TAPPET

32 077158 1 ASSEMBLY, SCREEN OIL PICK-UP

33 0C3150 1 GASKET, ROCKER COVER 410

34 072694 2 STUD, D20 PIVOT BALL

35 083907 2 ROCKER ARM

36 072696 2 NUT, JAM (ROCKER ARM)

37 078694 1 PLATE, PUSH ROD GUIDE

38 021742 4 SCREW, HHFL M10-1.5 X 105

39 0D6094 1 ASSEMBLY, ROCKER COVER BREATHER

40 076329 1 PLUG, OIL FILL PLASTIC

41 0E0057 1 O-RING 17.8 I.D. x 2.4

42 0D4788 1 PLUG, STANDARD PIPE 3/8 STEEL SQUARE HEAD

43 074908 1 SCREW, TAPTITE M5-0.8 X 10 BP

44 086515 4 KEEPER, VALVE SPRING

45 078606 4 SCREW & LOCKWASHER M6-1 X 12

46 0A1442 8 SCREW, HHFC M8-1.25 X 42

47 078672 1 SEAL, VALVE STEM D7

48 089673 2 WASHER, VALVE SPRING

49 0B2104 1 WASHER, LARGE SPRING

50 078699C 2 DOWEL, SEAMED SLEEVE

51 0A7627 1 SHAFT, GOVERNOR RC55

52 043790A 1 BARBED ELBOW 90 3/8NPT X 3/8 LOCKTITE

53 088590 1 DOWEL DIA 12 X 18L

54 078699B 1 DOWEL, SLEEVE SEAMED 12 DIA.

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

58

19

20

41

7

12

6

6

6

21

43

23

15

16

14

18

17

31

30 27

2

45

38

22

6

5

40

3

39

28

13

11

47

44

29

8

6

24

10

51

9

50

46

49

18

25

32

34

26

18

1

35

34

33

48

52

10

42

4

6

36

37

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

59

ITEM PART NO. QTY. DESCRIPTION

1 0C1069 5 SCREW, TAPTITE M6-1.0X8 YELLOW CHROME

2 0D2922 1 HOUSING, BLOWER

3 0F8426 1 TUBE, DIPSTICK

4 0C9997 1 GUARD, FAN

5 088434 1 WRAPPER, BOTTOM

6 045756 11 SCREW, TAPTITE M6-1X10 YELLOW CHROME

7 0C4176A 1 WRAPPER, TOP

8 0D9004A 1 ASSY, STARTER

9 059985 2 SCREW, SHC M8-1.25 X 45 G12.9

10 022129 3 WASHER, LOCK M8-5/16

11 0C2458A 1 BACKPLATE, L/F D/F

12 083512 1 SCREW, TAPTITE M8-1.25 X 16 BP

13 0D1401A 1 BREATHER TUBE

14 091039 1 GASKET, INTAKE ADAPTER

15 0C9619 1 ASSEMBLY, PLASTIC CARB

16 049811 2 WASHER, FLAT M6

17 022097 4 WASHER, LOCK M6-1/4

18 040945 2 SCREW, SHC M6-1.0 X 20 G12.9

19 086999 1 GASKET,OIL FILTR ADAPTER

20 0D5667A 1 ADAPTER, OIL FILTER

21 049821 2 SCREW, SHC M8-1.25 X 30 G12.9

22 099236 1 SWITCH, OIL 8.0 PSI

23 070185B 1 OIL FILTER

24 082774 1 KEY, WOODRFF 4 X 19D

25 091222E 1 FLYWHEEL WITH RING GEAR 32DEG.

26 067198N 1 WASHER,BELV-20 X 2.2

27 067890 1 NUT, HEX - FLYWHEEL

28 0E7585 1 SPARKPLUG

29 072734 1 ASSEMBLY,GOVERNOR LEVER 12 HP

30 072735 1 ROD,GOVERNOR CONTROL.

31 0C3978 1 SPRING, ANTI-LASH

32 0C6040 1 ASSEMBLY, WIRE

33 0D9760 1 ASSEMBLY, IGNITION COIL

34 092079 2 SCREW, TAPTITE M6-1.0 X 25 BP

35 0F3800 1 SPRING GOVERNOR

36 083502 1 BOLT, GOVERNOR ADJUST M5

37 082025 1 NUT HEX LOCK M5-0.8 NYINS ZINC

38 0D3083 1 ASSEMBLY, OIL DRAIN HOSE

39 0E7887C 1 ASSEMBLY, CAP & DIPSTICK

40 090072 1 O-RING 9/16 X 3/4 X 3/32

41 075281 1 SWITCH, THERMAL

42 022145 1 WASHER FLAT 5/16 - M8

43 0F2094 2 SCREW, M3-0.5 X 6 SEMS

44 0C4373 1 SPACER, ENDFRAME

45 022717B 1 GOMMET

46 0F3865 1 SPRING SECONDARY

47 0F3855 1 BRACKET SECONDARY GOVERNOR SPRING

48 039253 1 SCREW HHC M8-1.25 x 20

49 0D3751 1 SPRING, IDLE RETURNING

50 0F3921 1 BARREL GOVERNOR ADJUSTMENT

51 0C8493 1 SCREW SHC M5-0.8 x 30

52 0D8758 1 ENGINE LIFT HOOK

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

60

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

61

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

ITEM PART NO. QTY. DESCRIPTION

1 0F8186 1 ADAPTOR, ENGINE

2 0F5540H 1 STATOR

3 0C9934H 1 ROTOR

4 0F7774A 1 CARRIER, REAR BEARING

5 0C8096 1 FAN, 8” CURVED BLADE

6 0F6591 1 MUFFLER

7 0F8078 1 TAIL PIPE, MUFFLER

9 056482 1 BEARING

10 0C3168 3 5/16 SPECIAL L/WASH

11 056147 1 BOLT ROTOR HHCS 5/16”-24 X 13-1/2” G5

12 0D1847 4 BOLT STATOR IHHCS M8-1.25 x 305mm

13 0C7038C 1 BRACKET, ALTERNATOR MOUNTING

14 0F9445 1 DUCT, ALTERNATOR AIR

15 0F9497 1 GASKET, ALTERNATOR AIR DUCT

16 0C7038B 1 BRACKET, ENGINE MOUNTING

17 0C7758 4 RUBBER MOUNT

18 0388050AE0 1 CABLE, #6 40” BLACK BATTERY

19 0C2417A 1 EARTH STRAP 3/8X 3/8

20 0F6528 1 EXHAUST FLEX

21 066386 1 ASSEMBLY BRUSH HOLDER

22 029451 1.8 FT TAPE ELEC UL FOAM 1/8 X 1/2

23 049451 1 WASHER FLAT .406ID X 1.62OD

24 022237 4 WASHER LOCK 3/8

25 022511 4 BOLT HHC 3/8-16 X 1-1/4 G5

26 022131 4 WASHER FLAT 3/8

27 039287 4 SCREW HHC M8-1.25 X 45 G8.8

28 022145 18 WASHER FLAT 5/16

29 049820 4 NUT LOCK HEX M8-1.25 NYL INSRT

30 090388 8 SCREW TAP M6-1.0X12

31 022129 17 WASHER LOCK M8-5/16

32 022259 8 NUT HEX 5/16-18

33 059637 2 SCREW TAPTITE 3/8-16X 3/4”

34 048031K 3 BAND, HOSE CLAMP 35.05 DIA.

35 0C9592 1 BELLOWS

36 048031M 2 HOSE CLAMP 3/4"

37 040976 2 SCREW SHC M8-1.25 X 20 G12.9

38 0G0414 1 PLATE “HOT”

39 028237 3 U-BOLT 5/16”-18 X 1.38” W/ SADDLE

40 090239 1 GASKET, EXHAUST

41 0C6989 1 STINGER, ENGINE AIR IN

42 0D1214 1 BASE, AIR CLEANER

43 0C8127 1 ELEMENT, AIR CLEANER

44 0C3024 1 COVER, AIR CLEANER NG/LP

45 0D2273 1 TUBE, 1.25"O.D. x 20Ga. x 12.125" LONG

46 055934N 1 CLAMP VINYL 1.31 X .281 Z

47 0F7065 1.25 FT HOSE LP 1/2" I.D.

48 0C5136A 2 KNOB, AIR CLEANER

49 039253 2 SCREW HHC M8-1.25 X 20 G8.8

50 022473 4 WASHER FLAT 1/4

52 066849 2 SCREW HHTT M5-0.8 X 16

53 0F6551 1 FLEX COVER

54 0F8079 1 BRACKET MUFFLER ACCESS

55 0F0710 2 RIVET POP 0.125” X 0.337”

56 0F8256 1 EXHAUST MANIFOLD

57 045771 4 NUT HEX M8-1.25 NY INS

58 0G0676 2 SCREW THTT M6-1.0 X 10

59 074906 4 SCREW HHTT M6-1.0 X 20

62

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

63

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

ITEM PART NO. QTY. DESCRIPTION

1 0F8186 1 ADATOR, ENGINE

2 0F6694 1 STATOR (16KW)

0F5538 1 STATOR (13KW)

0F7548 1 STATOR (10KW)

3 0F9795 1 ROTOR (16KW)

0F5539 1 ROTOR (13KW)

0F7549 1 ROTOR (10KW)

4 0F7774 1 CARRIER, REAR BEARING

5 0E9579 1 FAN, 12” CURVED BLADE

0F8998 1 FAN, 12” CURVED BLADE (10KW)

6 0F6591 1 MUFFLER

7 0F8078 1 TAIL PIPE, MUFFLER

8 0F7797 1 FLEX BASE

0F8141 1 FLEX BASE (10KW)

9 056482 1 BEARING

10 0C3168 3 5/16 SPECIAL LOCK WASHER

11 0D1838 1 BOLT, IHHCS 3/8”-24 X 15.50”

12 0D1846 4 BOLT, IHHCS M8-1.25 X 345mm

13 0C7038 1 BRACKET, ALTERNATOR MOUNTING

14 0F9396 1 DUCT, ALTERNATOR AIR

15 0D2559 1 GASKET, ALTERNATOR AIR DUCT

16 0C7038A 1 BRACKET, ENGINE MOUNTING

0F4179 1 PLATE, MOUNTING ENG 530HSB

17 0C7758 4 RUBBER MOUNT

18 0388050AD0 1 CABLE, #6 48” BLACK BATTERY

19 0C2417A 1 EARTH STRAP 3/8 X 3/8

20 0F6528 1 EXHAUST FLEX

21 066386 1 ASSEMBLY BRUSH HOLDER

22 029451 2.6 FT TAPE ELEC UL FOAM 1/8 X 1/2

23 049451 1 WASHER FLAT .406ID X 1.62OD

24 022237 5 WASHER LOCK 3/8

25 022511 4 SCREW HHC 3/8 X 16 X 1-1/4

26 022131 4 WASHER FLAT 3/8 ZINC

27 051731 4 SCREW HHC M8-1.25 X 50

28 022145 18 WASHER FLAT 5/16 ZINC

29 049820 4 NUT LOCK HEX M8-1.25 NYL INSERT

30 0G0676 2 SCREW THTT M6-1.0 X 10

31 022129 18 WASHER LOCK M8-5/16

32 022259 8 NUT LOCK HEX 5/16-18

33 059637 2 SCREW TAPTITE 3/8-16 X ¾

ITEM PART NO. QTY. DESCRIPTION

34 0D4662 3 SCREW 5/16-18 X 3/4”

35 0F7065 3 FT HOSE RES ½ LP GAS

36 048031M 4 HOSE CLAMP ¾” I.D.

38 0G0414 1 PLATE, “HOT”

39 0D5823 3 U-BOLT 5/16”-18 X 1.62” WITH SADDLE

40 0E9369 2 GASKET, EXHAUST PORT (10KW)

0C4138 2 GASKET, EXHAUST PORT

41 040173 2 CLAMP HOSE #5.5 0.62”-0.62” (10KW)

42 074995 1.44 FT HOSE ¼ ID LPG 350PSI UL21 (10KW)

43 066849 2 SCREW HHTT M5-0.8 X 16

44 0F7799 1 EXHAUST MANIFOLD

0F8115 1 EXHAUST MANIFOLD (10KW)

45 0F7796 1 FLEX COVER

0F8204 1 FLEX COVER (10KW)

46 0F9385 1 FLEX COVER EXTENSION (10KW)

47 090388 13 SCREW TAPTITE M6-1.0 X 12

48 045771 4 NUT HEX M8-1.25

49 039253 2 SCREW HHC M8-1.25 X 20

50 0F0710 5 RIVET POP 0.125” X 0.337” (10KW)

0F0710 2 RIVET POP 0.125” X 0.337”

51 0F8079 1 BRACKET MUFFLER ACCESS

52 0F9273 1 SOLENOID, 6 VOLTS DC (10KW)

53 0E9592 2 SCREW PPHM $4-40 X 3/8 SEMS (10KW)

54 0E9588 1 LINKAGE, CHOKE (10KW)

55 077091 1 COTTER PIN (10KW)

56 0E9581 1 AIR CLEANER GTH530 HSB (10KW)

57 0E9594 3 SCREW PPPH HI-LO #14-15 X ½ (10KW)

58 0E9590 1 ASSEMBLY, CHOKE SHAFT (10KW)

59 0E9542 1 VALVE, CHOKE (10KW)

60 0D1683 2 SCREW PFHM M3-0.5 X 5 (10KW)

61 077075 1 BOOT, CHOKE SOLENOID (10KW)

62 0E9595 2 SCREW PPPH HI-LO #6/1/2 W/ #5HD

(10KW)

63 0E9589 1 CHOKE HSG (10KW)

64 0E9591 1 SPRING-CHOKE RETURN (10KW)

65 0E9549 1 HOSE, INTAKE GTH530 HSB (10KW)

66 035685 1 CLAMP HOSE #28 1.32-2.25

67 099502 2 CLAMP HOSE #24 B1.06-2.00

68 0C8565 4 SCREW SHC M8-1.25 X 18 G8.8

64

7KW

17

20

10

25

21

24

19

23

22

35 7

26

36

33

29

32

18

14

15

16

13

34 27

37

5

36

10

37

6

4

3

2

8

10

17

1

26

15

14

13

16

31

22

19

9

30

21

25

20

24

29 18

23

11

12

28

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

65

ITEM PART NO. QTY. DESCRIPTION

1 0D5694 1 CASTING, TWIN REGULATOR HOUSING (7KW)

0F9285 1 CASTING, TWIN REGULATOR HOUSING

2 0F5022 1 SOLENOID COIL, 12VDC

3 0C4647 1 GASKET , SOLENOID

4 0D4166 1 PLUNGER, LP REGULATOR ASSEMBLY

5 0F8822 1 REGULATOR BRACKET

6 022145 2 WASHER FLAT 5/16-M8

7 022129 2 WASHER LOCK 5/16-M8

8 0F4795 4 SCREW PPHM SEMS M4-0.7 X 10

9 0C5760P 1 FUEL JET GASEOUS REGULATOR (7KW)

10 0C6606 1 BARBED STRAIGHT ½ NPT x ½ (7KW)

0C6606 2 BARBED STRAIGHT ½ NPT x ½

11 097934 1 O-RING (7KW)

12 0C4645 1 ADJUSTER SCREW, TWIN REGULATOR (7KW)

13 0C5761 2 LEVER, REGULATOR

14 0C5968 2 SUPPORT, INLET SEAL

15 0C6066 2 SEAL, INLET

16 0C5759 2 PIN, PIVOT ARM

17 0C5764A 2 SPRING, REGULATOR (7KW)

0C5764 2 SPRING, REGULATOR

18 070728 4 SCREW, PFHMS M3-0.5 x 5

19 0C6069 2 GASKET, DIAPHRAGM

20 0C5762 2 COVER, TWIN REGULATOR (7KW)

0F9189 2 COVER, TWIN REGULATOR

21 045764 16 SCREW, TAPTITE M4X8 BP

22 0C6731 2 RIVET, POP .118 X .125

23 0C6067 2 SUPPORT, DIAPHRAGM

24 0C4706 2 DIAPHRAGM, TWIN REGULATOR

25 0C6068 2 CAP, DIAPHRAGM SUPPORT

26 0C4643A 2 INLET, TWIN REGULATOR 11.11 DIA.

27 072683A 2 PLUG STD PIPE 1/8 SOCKET HEAD (7KW)

072683A 1 PLUG STD PIPE 1/8 SOCKET HEAD

28 0A4032 1 PIN, LIMITED ADJUSTMENT (7KW)

29 0D3308 4 WASHER, FLAT M3 X 10mm O.D.

30 024310 1 PLUG, STANDARD PIPE 1/2” STEEL SQUARE HEAD (7KW)

31 0D3973 1 PLUG, EXPANSION 16mm (7KW)

32 042907 2 SCREW HHC M8-1.25 X 16

33 028414A 1 BARBED STRAIGHT 1/8”NPT X ¼” (10KW)

34 035578A 1 NIPPLE CLOSE 1/8NPT (10KW)

35 0G0247 1 SOLENOID, LP/NG DC12V (10KW)

36 0F9773B 1 SOLENOID WIRE, #0 (10KW)

37 0F9773A 1 SOLENOID WIRE, #14 (10KW)

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

66

16

13

34

5

11

6

7

17

26

14

15

3

9

7

35

4

6

33

3

2

12

27

32

30

28

8

1

31

8

10

27

18

19

22

23

29

21

25

24

20

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

67

ITEM PART NO. QTY. DESCRIPTION

1 0F9285 1 CASTING, TWIN REGULATOR HOUSING

2 0F5022 1 SOLENOID COIL, 12VDC

3 0C4647 2 GASKET , SOLENOID

4 0D4166 1 PLUNGER, LP REGULATOR ASSEMBLY

5 0F8096 1 BRKT REGULATOR MOUNTING 990

6 022145 4 WASHER FLAT 5/16-M8

7 022129 4 WASHER LOCK 5/16-M8

8 0F4795 8 SCREW PPHM SEMS M4-0.7 X 10

9 045771 2 NUT HEX M8-1.25

10 0C6606 2 BARBED STRAIGHT ½ NPT x ½

11 042907 2 SCREW HHC M8-1.25 X 16

12 026915A 1 NIPPLE CLOSE ¾ X 1.375 WITH VIBRA SEAL

13 0C5761 2 LEVER, REGULATOR

14 0C5968 2 SUPPORT, INLET SEAL

15 0C6066 2 SEAL, INLET

16 0C5759 2 PIN, PIVOT ARM

17 0C5764 2 SPRING, REGULATOR

18 070728 4 SCREW, PFHMS M3-0.5 x 5

19 0C6069 2 GASKET, DIAPHRAGM

20 0F9189 2 COVER, TWIN REGULATOR

21 045764 16 SCREW, TAPTITE M4X8 BP

22 0C6731 2 RIVET, POP .118 X .125

23 0C6067 2 SUPPORT, DIAPHRAGM

24 0C4706 2 DIAPHRAGM, TWIN REGULATOR

25 0C6068 2 CAP, DIAPHRAGM SUPPORT

26 0C4643A 2 INLET, TWIN REGULATOR 11.11 DIA.

27 072683A 3 PLUG STD PIPE 1/8 SOCKET HEAD

28 049226 4 WASHER, LOCK, M5

29 0D3308 4 WASHER, FLAT M3 X 10mm O.D.

30 051713 4 WASHER, FLAT, M5

31 0F8979 1 SOLENOID COVER PLATE

32 051716 4 NUT HEX M5-0.8

33 0E9533 1 SOLENOID ADAPTER

34 0E9534 1 ASSY, FUEL SYSTEM PLENUM

35 0E9535 1 PLENUM GASKET

Section 9 — Exploded Views and Parts Lists

Air-cooled Generators

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

68

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 modifica-

tion or improper maintenance of your engine.

Your emission control system may include parts such as the carburetor, ignition system and exhaust system. Generac will

repair your engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.

MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted. If, dur-

ing 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 unap-

proved modifications, or the use of counterfeit and/or “grey market” parts not made, supplied or approved by Generac.

You are responsible for contacting a Generac Authorized Warranty Service Facility as soon 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 ser-

vice, evidence must be presented showing the date of the sale to the original purchaser/owner.

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

the following addresses:

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

ATTENTION WARRANTY DEPARTMENT ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC. GENERAC POWER SYSTEMS, INC.

P.O. BOX 297 211 MURPHY DRIVE

WHITEWATER, WI 53190 EAGLE, WI 53119

Part 1

Section 10 – Warranty

Air-cooled Generators

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

69

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:

* 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

1) Fuel Metering System:

1.2) LPG/Natural Gas carburetion assembly and its internal com-

ponents.

a) Fuel controller (if so equipped)

b) Mixer and its gaskets (if so equipped)

c) Carburetor and its gaskets (if so equipped)

d) Primary gas regulator (if so equipped)

e) LP liquid vaporizer (if so equipped)

2) Air Induction System including:

a) Intake pipe/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

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

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 main-

tenance 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 Revision (02/01/05)