Generac Power Systems Guardian 005240 Installation instructions

www.generac.com or 1-888-GENERAC
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
Installation and
Owner's Manual
7, 10, 13 and 16kW Air-cooled, Automatic Standby Generators
nNot intended for use in critical life support applications.
nOnly qualified electricians or contrac- tors should attempt installation! Deadly
exhaust fumes. Outdoor installation only!
L I S T E D
CU
S

Introduction............................................................. 1
Read This Manual Thoroughly ...............................................1
Contents ...............................................................................1
Operation and Maintenance ...................................................1
How to Obtain Service...........................................................1
Authorized Dealer Locator Number.............................................1
Safety Rules ........................................................... 2
Standards Index ....................................................................3
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
Post Installation Start-up and Adjustments .......... 11
2.1 Before Initial Startup.....................................................11
2.2 Check Transfer Switch Operation..................................12
2.3 Electrical Checks..........................................................12
2.4 Generator Tests Under Load .........................................12
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.......................................14
Operation ..............................................................15
3.1 Using the AUTO/OFF/MANUAL Switch ..........................15
3.2 Automatic Transfer Operation .......................................15
3.3 Sequence of Automatic Operation.................................16
3.4 Manual Transfer Operation............................................16
3.5 Setting the Exercise Timer ............................................17
3.6 Protection Systems ......................................................17
Maintenance .........................................................18
4.1 Fuses...........................................................................18
4.2 Checking the Engine Oil Level.......................................19
4.3 Changing the Engine Oil ...............................................19
4.4 Changing the Engine Air Cleaner...................................20
4.5 Spark Plug(s)...............................................................21
4.6 Battery Maintenance.....................................................21
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 ....................................................23
4.11 Out of Service Procedure..............................................23
4.12 Service Schedule .........................................................25
Troubleshooting .................................................... 26
5.1 Troubleshooting Guide..................................................26
Notes ....................................................................27
Mounting Dimensions ...........................................30
Warranty............................................................... 32
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

1
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
Dealer for starting, operating and servicing procedures.
Throughout this publication, and on tags and decals affixed to the
generator, DANGER, WARNING, CAUTION and NOTE blocks are
used to alert personnel to special instructions about a particular
operation that may be hazardous if performed incorrectly or care-
lessly. Observe them carefully. Their definitions are as follows:
INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF
NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.
Indicates a hazardous situation or action which, if not
avoided, could result in death or serious injury.
Indicates a hazardous situation or action which, if not
avoided, could result in minor or moderate injury.
NOTE:
Notes contain additional information important to a procedure
and will be found within the regular text body of this manual.
These safety warnings cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the special
instructions while performing the action or service are essential to
preventing accidents.
Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTION blocks. The type of information each
indicates is as follows:
nThis symbol points out important safety information that,
if not followed, could endanger personal safety and/or
property of others.

This symbol points out potential explosion hazard.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock hazard.
The operator is responsible for proper and safe use of the equip-
ment. The manufacturer strongly recommends that the operator
read this Owner’s Manual and thoroughly understand all instruc-
tions before using this equipment. The manufacturer also strongly
recommends instructing other users to properly start and operate
the unit. This prepares them if they need to operate the equipment
in an emergency.
CONTENTS
This manual contains pertinent owner’s information, including
warranty, electrical diagrams, exploded views and lists of repair
parts, for these different models:
05240 & 05280 – 6 kW NG, 7 kW LP, single-cylinder GH-410•
Engine
05241 & 05281 – 9.0 kW NG, 10 kW LP, V-twin GT-530•
Engine
05242 & 05282 – 13 kW NG, 13 kW LP, V-twin 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 a
Dealer. Normal maintenance service and replacement of parts
are the responsibility of the owner/operator and, as such, are not
considered defects in materials or workmanship within the terms
of the warranty. Individual operating habits and usage contribute to
the need for maintenance service.
Proper maintenance and care of the generator ensures a minimum
number of problems and keep operating expenses at a minimum.
See a Dealer for service aids and accessories.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs, contact a Dealer
for assistance. Service technicians are factory-trained and are
capable of handling all service needs.
When contacting a Dealer about parts and service, always supply
the complete model number and serial number of the unit as given
on its data decal, which is located on the generator. See section “The
Generator” for decal location.
Model No. _________________ Serial No.______________
CALIFORNIA PROPOSITION 65 WARNING
Engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects
and other reproductive harm.
CALIFORNIA PROPOSITION 65 WARNING
This product contains or emits chemicals known to the
State of California to cause cancer, birth defects and
other reproductive harm.
Introduction

2
SAFETY RULES
n
Save These Instructions – The manufacturer
suggests that these rules for safe operation
be copied and posted near the unit’s instal-
lation site. Safety should be stressed to all
operators and potential operators of this
equipment.
Study these SAFETY RULES carefully before installing, operating
or servicing this equipment. Become familiar with this Owner’s
Manual and with the unit. The generator can operate safely, effi-
ciently and reliably only if it is properly installed, operated and
maintained. Many accidents are caused by failing to follow simple
and fundamental rules or precautions.
The manufacturer cannot anticipate every possible circumstance
that might involve a hazard. The warnings in this manual, and on
tags and decals affixed to the unit are, therefore, not all-inclusive. If
using a procedure, work method or operating technique the manu-
facturer does not specifically recommend, ensure that it is safe for
others. Also make sure the procedure, work method or operating
technique utilized does not render the generator unsafe.
n
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
install, operate and 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.
n
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
n
Installation must always comply with appli-
cable codes, standards, laws and regula-
tions.
n
A running generator gives off carbon mon-
oxide, an odorless, colorless poison gas.
Breathing in carbon monoxide can cause
headaches, fatigue, diziness, nausea, vomit-
ting, confusion, fainting, siezures or death.
GENERAL HAZARDS
For safety reasons, the manufacturer recommends that this•
equipment be installed, serviced and repaired by a Service
Dealer or other competent, qualified electrician or installation
technician who is familiar with applicable codes, standards
and regulations. The operator also must comply with all such
codes, standards and regulations.
The engine exhaust fumes contain carbon monoxide, which•
can be DEADLY. This dangerous gas, if breathed in sufficient
concentrations, can cause unconsciousness or even death.
Do NOT alter or add to the exhaust system or do anything that
might render the system unsafe or in noncompliance with appli-
cable codes and standards.
Install a battery operated carbon monoxide alarm indoors,•
according to manufacturer’s instructions/recommendations.
Adequate, unobstructed flow of cooling and ventilating air is•
critical to correct generator operation. Do not alter the instal-
lation or permit even partial blockage of ventilation provisions,
as this can seriously affect safe operation of the generator. The
generator MUST be installed and operated outdoors only.
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.
When working on this equipment, remain alert at all times.•
Never work on the equipment when physically or mentally
fatigued.
Inspect the generator regularly, and contact the nearest Dealer•
for parts needing repair or replacement.
Before performing any maintenance on the generator, discon-•
nect 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 dan-
gerous operating conditions from leaking exhaust gases, fuel
leakage, oil leakage, etc.
ELECTRICAL HAZARDS
All generators covered by this manual produce dangerous•
electrical voltages and can cause fatal electrical shock. Utility
power delivers extremely high and dangerous voltages to the
transfer switch as does the standby generator when it is in
operation. Avoid contact with bare wires, terminals, connec-
tions, etc., while the unit is running. Ensure all appropriate
covers, guards and barriers are in place, secured and/or locked
before operating the generator. If work must be done around
an operating unit, stand on an insulated, dry surface to reduce
shock hazard.
Do not handle any kind of electrical device while stand-•
ing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
Safety Rules

3
The National Electrical Code (NEC) requires the frame and external•
electrically conductive parts of the generator to be connected to
an approved earth ground. Local electrical codes also may require
proper grounding of the generator electrical system.
After installing this home standby electrical system, the genera-•
tor may crank and start at any time without warning. When this
occurs, load circuits are transferred to the STANDBY (genera-
tor) power source. To prevent possible injury if such a start and
transfer occur, always set the generator’s AUTO/OFF/MANUAL
switch to its OFF position before working on equipment and
remove the 15A fuse from the generator control panel.
In case of accident caused by electric shock, immediately shut•
down the source of electrical power. If this is not possible,
attempt to free the victim from the live conductor. AVOID DIRECT
CONTACT WITH THE VICTIM. Use a nonconducting implement,
such as a dry rope or board, to free the victim from the live
conductor. If the victim is unconscious, apply first aid and get
immediate medical help.
Never wear jewelry when working on this equipment. Jewelry•
can conduct electricity resulting in electric shock, or may get
caught in moving components causing injury.
FIRE HAZARDS
For fire safety, the generator must be installed and maintained•
properly. Installation must always comply with applicable
codes, standards, laws and regulations. Adhere strictly
to local, state and national electrical and building codes.
Comply with regulations the Occupational Safety and Health
Administration (OSHA) has established. Also, ensure that the
generator is installed in accordance with the manufacturer’s
instructions and recommendations. Following proper installa-
tion, do nothing that might alter a safe installation and render
the unit in noncompliance with the aforementioned codes,
standards, laws and regulations.
Keep a fire extinguisher near the generator at all times.•
Extinguishers rated “ABC” by the National Fire Protection
Association are appropriate for use on the standby electric
system. Keep the extinguisher properly charged and be familiar
with its use. Consult the local fire department with any ques-
tions pertaining to fire extinguishers.
EXPLOSION HAZARDS
Do not smoke around the generator. Wipe up any fuel or oil•
spills immediately. Ensure that no combustible materials are left
in the generator compartment, or on or near the generator, as
FIRE or EXPLOSION may result. Keep the area surrounding the
generator clean and free from debris.
Gaseous fluids such as natural gas and liquid propane (LP)•
gas are extremely EXPLOSIVE. Install the fuel supply system
according to applicable fuel-gas codes. Before placing the
home standby electric system into service, fuel system lines
must be properly purged and leak tested according to applica-
ble code. After installation, inspect the fuel system periodically
for leaks. No leakage is permitted.
STANDARDS INDEX
In the absence of pertinent standards, codes, regulations and laws,
the published information listed below may be used as installation
guide for this equipment.
1. NFPA No. 37, STATIONARY COMBUSTION ENGINES AND GAS
TURBINES, available from the National Fire Protection Association,
470 Atlantic Avenue, Boston, MA 02210.
2. NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH
CARE FACILITIES, available same as Item 1.
3. NFPA No. 54, NATIONAL FUEL GAS CODE, available same as Item
1.
4. NFPA No. 58, AMERICAN NATIONAL STANDARD FOR STORAGE
AND HANDLING OF LIQUEFIED PETROLEUM GAS, available same
as Item 1.
5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL ELECTRIC CODE,
available same as Item 1.
6. Article X, NATIONAL BUILDING CODE, available from the American
Insurance Association, 85 John Street, New York, N.Y. 10038.
7. AGRICULTURAL WIRING HANDBOOK, available from the Food and
Energy Council, 909 University Avenue, Columbia, MO 65201.
8. ASAE EP-3634, INSTALLATION AND MAINTENANCE OF FARM
STANDBY ELECTRICAL SYSTEMS, available from the American
Society of Agricultural Engineers, 2950 Niles Road, St. Joseph, MI
49085.
9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE,
available same as Item 1.
n
Only qualified electricians or contractors
should attempt such installations, which must
comply strictly with applicable codes, stan-
dards and regulations.
Safety Rules

n
Only qualified electricians or contractors
should attempt such installations, which must
comply strictly with applicable codes, stan-
dards and regulations.
1.1 UNPACKING/INSPECTION
After unpacking, carefully inspect the contents for damage.
This standby generator set is ready for installation with a factory•
supplied and pre-mounted base pad and has a weather protec-
tive enclosure that is intended for outdoor installation only.
This UL listed standby generator set is packaged with an auto-•
matic 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 connec-
tions 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 trans-
fer switch. The transfer switch must effectively
isolate the electrical system from the utility
distribution system when the generator is oper-
ating (NEC 700, 701 & 702). Failure to isolate an
electrical system by such means will result in
damage to the generator and also may result in
injury or death to utility power workers due to
backfeed of electrical energy.
If any loss or damage is noted at time of delivery, have the
person(s) making the delivery note all damage on the freight bill
or affix their signature under the consignor's memo of loss or
damage.
If a loss or damage is noted after delivery, separate the damaged
materials and contact the carrier for claim procedures.
“Concealed damage” is understood to mean damage to the con-
tents of a package that is not in evidence at the time of delivery,
but is discovered later.
1.2 PROTECTION SYSTEMS
Unlike an automobile engine, the generator may have to run for
long periods of time with no operator present to monitor engine
conditions. For that reason, the engine is equipped with the fol-
lowing systems that protect it against potentially damaging condi-
tions:
1. Low Oil Pressure Sensor 4. Overspeed
2. High Temperature Sensor 5. RPM Sensor
3. Overcrank 6. Low Battery
There are LED readouts on the control panel to notify personnel
that one of these faults has occurred. There is also a System
Set LED that is lit when all of the conditions described in section
"System Set LED" are true. (See the "Protection Systems" section
for details.)
1.3 NEC REQUIREMENT FOR ARC
FAULT CIRCUIT INTERRUPTION
BREAKER FOR BEDROOMS
In 2001, the National Electric Code (NEC) introduced a requirement
for new construction. This new requirement indicates the need for
Arc Fault Circuit Interrupters to be used to protect the complete
branch circuit that feeds a dwelling bedroom. The actual NEC
requirement is indicated below.
1.3.1 SECTION 210.12 ARC FAULT CIRCUIT
INTERRUPTER PROTECTION
1. Definition: An arc fault circuit interrupter is a device intended
to provide protection from the effects of arc faults by recog-
nizing characteristics unique to arcing and by functioning to
de-energize the circuit when an arc fault is detected.
2. Dwelling Unit Bedrooms: All branch circuits that supply 125
volt, single-phase, 15 and 20 ampere outlets installed in
dwelling unit bedrooms shall be protected by an arc fault cir-
cuit 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 dwell-
ing bedrooms. The requirement is limited to 15 and 20 ampere,
125 volt circuits. There is no prohibition against providing AFCI
protection on other circuits or in locations other than bedrooms.
Because circuits are often shared between a bedroom and other
areas such as closets and hallways, providing AFCI protection on
the complete circuit would comply with 210.12.
If during the installation of the home standby system the decision
is made to provide back up power to a bedroom branch circuit,
then the circuit breaker in the transfer switch should be replaced
with an Arc Fault Circuit Interrupter.
It is most important that breakers only be switched like for like.
For instance, if replacing a 15A breaker, it MUST be replaced with
a 15A AFCI breaker. Likewise, a 20A breaker MUST be replaced
with a 20A AFCI.
These AFCI breakers are available at the nearest hardware store.
Siemens Item # Description
Q115AF 15A Single Pole AFCI
Q120AF 20A Single Pole AFCI
4
General Information

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
General Information

6
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 62.5 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 RC14YC RC14YC
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 # 070185F Part # 070185F Part # 070185F Part # 070185F
Recommended Air Filter Part # 0C8127 Part # 0E9581 Part # 0C8127 Part # 0C8127
Operating RPM 3,600 3,600 3,600 3,600
General Information

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 voltage is not connected to the
unit or if it is below approximately 150-160 volts AC, then
the system set light will flash rapidly. This indicates that if the
AUTO/OFF/ MANUAL switch is placed in the Auto position, the
generator will start.
3. No alarms are present, for example, low oil pressure, high
temperature, etc.
1.7 FUEL REQUIREMENTS
AND RECOMMENDATIONS
With LP gas, use only the vapor withdrawal system. This type of
system uses the vapors formed above the liquid fuel in the storage
tank.
The engine has been fitted with a fuel carburetion system that
meets the specifications of the 1997 California Air Resources
Board for tamper-proof dual fuel systems. The unit will run on
natural gas or LP gas, but it has been factory set to run on natural
gas. Should the primary fuel need to be changed to LP gas, the
fuel system needs to be reconfigured. See the Reconfiguring the
Fuel System section for instructions on reconfiguration of the fuel
system.
Recommended fuels should have a Btu content of at least 1,000
Btus per cubic foot for natural gas; or at least 2,520 Btus per
cubic foot for LP gas. Ask the fuel supplier for the Btu content of
the fuel.
Required fuel pressure for natural gas is 5 inches to 7 inches
water column (0.18 to 0.25 psi); and for liquid propane, 10
inches to 12 inches of water column (0.36 to 0.43 psi).
NOTE:
All pipe sizing, construction and layout must comply with NFPA
54 for natural gas applications and NFPA 58 for liquid propane
applications. Once the generator is installed, verify that the fuel
pressure NEVER drops below four (4) inches water column for
natural gas or 10 inches water column for liquid propane.
Prior to installation of the generator, the installer should consult
local fuel suppliers or the fire marshall to check codes and regula-
tions for proper installation. Local codes will mandate correct rout-
ing of gaseous fuel line piping around gardens, shrubs and other
landscaping to prevent any damage.
Special considerations should be given when installing the unit
where local conditions include flooding, tornados, hurricanes,
earthquakes and unstable ground for the flexibility and strength of
piping and their connections.
Use an approved pipe sealant or joint compound on all threaded
fitting.
All installed gaseous fuel piping must be purged and leak tested
prior to initial start-up in accordance with local codes, standards
and regulations.
1.8 FUEL CONSUMPTION
Unit Nat. Gas (*) LP Vapor (**)
1/2 Load Full Load 1/2 Load Full Load
6/7 kW 66 119 0.82/30 1.47/54
9/10 kW 102 156 1.25/46 1.93/70
13/13 kW 156 220 1.55/57 2.18/80
15/16 kW 173 245 1.59/59 2.51/92
*Natural gas is in cubic feet per hour.
**LP is in gallons per hour/cubic feet per hour.
*** Values given are approximate.
1.8.1 BTU FLOW REQUIREMENTS - NATURAL GAS
BTU flow required for each unit based on 1000 BTU per cubic
foot.
6kW — 119,000 BTU/Hour•
9kW — 156,000 BTU/Hour•
13kW — 220,000 BTU/Hour•
15kW — 245,000 BTU/Hour•

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 eas-
ily accessible. Local codes determine the proper location.
General Information

1.9 RECONFIGURING THE
FUEL SYSTEM
1.9.1 7 KW, 410CC ENGINE
To reconfigure the fuel system from NG to LP, follow these steps
(Figure 1.4):
NOTE:
The primary regulator for the propane supply is NOT INCLUDED
with the generator. A fuel pressure of 10 to 12 inches of water
column (0.36 to 0.43 psi) to the fuel inlet of the generator MUST
BE SUPPLIED.
1. Turn off the main gas supply (if connected).
2. Open the roof and remove the door.
3. Remove the battery (if installed).
4. Disconnect wire #0 and wire #14 from the gas solenoid on
top of the demand regulator.
5. Remove the carburetor fuel hose from the outlet port of the
demand regulator.
6. Remove the demand regulator by removing the fastener that
retains the regulator mounting bracket.
7. Remove the square headed steel pipe plug from outlet port
#1 and the brass hose barb fitting from outlet port #2.
8. Refit the brass hose barb fitting to outlet port #1 and the
square headed steel pipe plug to outlet port #2.
Figure 1.4 – Demand Regulator
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 genera-
tor and press it into the 3/4” hole on the bottom of the air
cleaner base (Figure 4.6).
11. Reverse the procedure to convert back to natural gas.
12. Check for gas leakage at the pipe plug, hose connection and
fittings.
1.9.2 10, 13 AND 16KW, V-TWIN ENGINES
To reconfigure the fuel system from NG to LP, follow these steps:
NOTE:
The primary regulator for the propane supply is NOT INCLUDED
with the generator. A fuel pressure of 10 to 12 inches of water
column (0.36 to 0.43 psi) to the fuel inlet of the generator MUST
BE SUPPLIED.
1. Open the roof.
2. For 10kW units: Loosen clamp and slide back the air inlet
hose.
• Slide fuel selector on carburetor out towards the back of the
enclosure (Figures 1.5 and 1.6).
• Return the inlet hose and tighten clamp securely.
For 13 and 16kW units: remove the air cleaner cover.
• Slide the selector lever out towards the back of the enclosure
(Figures 1.7 and 1.8).
• Return the air cleaner cover and tighten the two thumb
screws.
3. Close the roof.
4. Reverse the procedure to convert back to natural gas.
Figure 1.5 - 10kW, GT-530 (Inlet Hose Slid Back)
8
General Information

9
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
n
The engine exhaust fumes contain carbon
monoxide, which can be DEADLY. This dan-
gerous gas, if breathed in sufficient concen-
trations, can cause unconsciousness or even
death. This exhaust system must be installed
properly, in strict compliance with applicable
codes and standards. Following installation,
do nothing that might render the system
unsafe or in noncompliance with such codes
and standards.
• Operate the generator outdoors ONLY.
• Keep exhaust gases from entering a confined
area through windows, doors, ventilation or
other openings (Figure 1.9).
Install the generator set, in its protective enclosure, outdoors,
where adequate cooling and ventilating air is always available
(Figure 1.9). Consider these factors:
The installation of the generator• must comply strictly with
NFPA 37, NFPA 54, NFPA 58, and NFPA 70 standards (http://
www.nfpa.org/).
Install the unit where air inlet and outlet openings will not•
become obstructed by leaves, grass, snow, etc.. If prevailing
winds will cause blowing or drifting, consider using a wind-
break 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 mainte-•
nance 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 run-off,•
landscape irrigation, water sprinklers or sump pump discharge
does not flood the unit or spray the enclosure, including any air
inlet or outlet openings.
Figure 1.9 – Generator Clearances
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
General Information

10
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.
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.
1.10.2 TRANSFER SWITCH
1.10.2.1 7, 10, 13, and 16 kW Units (if equipped)
The transfer switch shipped with this generator is enclosed in a
NEMA 1 enclosure. This type of enclosure is intended for indoor
use only. Follow these rules:
Install the transfer switch indoors on a firm, sturdy supporting•
structure.
To prevent switch distortion, level the switch if necessary. This•
can be done by placing washers between the switch enclosure
and mounting surface.
Never install the switch where water or any corrosive substance•
might drip onto the enclosure.
Protect the switch at all times against excessive moisture, dust,•
dirt, lint, construction grit and corrosive vapors.

If the AUTO/OFF/MANUAL switch is not set
to its OFF position, the generator can crank
and start as soon as the battery cables are
connected. If the utility power supply is not
turned off, sparking can occur at the battery
posts and cause an explosion.
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 follow-
ing steps:
1. Set the generator's AUTO/OFF/MANUAL switch to OFF.
2. Turn off utility power supply to the transfer switch.
3. Remove the 15A fuse from the generator control panel.
Battery cables were factory connected at the generator (Figure
1.10). Connect cables to battery posts as follows:
4. Connect the red battery cable (from starter contactor) to the
battery post indicated by a positive, POS or (+).
5. Connect the black battery cable (from frame ground) to the
battery post indicated by a negative, NEG or (—).
NOTE:
Dielectric grease should be used on battery posts to aid in the
prevention of corrosion.
NOTE:
Damage will result if battery connections are made in reverse.
Figure 1.10 – Battery Cable Connections
NOTE:
In areas where temperatures regularly fall below 10° F (-12° C)
it is recommended that a pad type battery heater be installed to
aid in cold climate starting (see Specifications).
NOTE:
The generator is equipped with a battery trickle charger that
is active when the unit is set up for automatic operation. With
the battery installed and utility power source voltage available
to the transfer switch, the battery receives a trickle charge
while the engine is not running, to prevent self-discharge. The
trickle charger is designed to help extend the life of the battery
by maintaining the battery when the unit is not running. The
trickle charge feature cannot be used to recharge a discharged
battery.
General Information

11
1.13 THE BATTERY

Do not dispose of the battery in a fire. The
battery is capable of exploding.

A battery presents a risk of electrical shock
and high short circuit current. The following
precautions are to be observed when work-
ing on batteries:
• Remove the 15A fuse from the generator con-
trol 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.
n
Do not open or mutilate the battery.
Released electrolyte has been known to
be harmful to the skin and eyes, and to be
toxic.
n
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 bicarbonate of soda solution is to
be added until the evidence of reaction (foam-
ing) has ceased. The resulting liquid is to be
flushed with water and the area dried.

Lead-acid batteries present a risk of fire
because they generate hydrogen gas. The
following procedures are to be followed:
• DO NOT SMOKE when near the battery;
• DO NOT cause flame or spark in battery area;
and
• Discharge static electricity from body before
touching the battery by first touching a ground-
ed metal surface.
n
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 con-
nected.

Be sure the utility power supply is turned off
and the 15A fuse is removed from the gener-
ator control panel, or sparking may occur at
the battery posts as the cables are attached
and cause an explosion.
Servicing of the battery is to be performed or supervised by per-
sonnel knowledgeable of batteries and the required precautions.
Keep unauthorized personnel away from batteries.
See the Specifications section for the correct size and rating when
replacing the battery. When using a maintenance-free battery, it
is not necessary to check the specific gravity or electrolyte level.
Have these procedures performed at the intervals specified in the
“Service Schedule.” A negative ground system is used. Battery
connections are shown on the wiring diagrams. Make sure the bat-
tery is correctly connected and terminals are tight. Observe battery
polarity when connecting the battery to the generator set.
2.1 BEFORE INITIAL START-UP
NOTE:
These units have been run and tested at the factory prior to
being shipped and do not require any type of break-in.
Before starting, complete the following:
1. Set the generator’s main circuit breaker to its OFF (or OPEN)
position.
2. Set the generator's AUTO/OFF/MANUAL switch to the OFF
position.
3. Turn OFF all breakers on the load center of the transfer box (T1
and T2).
4. Turn OFF all loads connected to the transfer switch terminals
T1 and T2.
5. Check the engine crankcase oil level and, if necessary, fill to
the dipstick FULL mark with the recommended oil. Do not fill
above the FULL mark.
6. Check the fuel supply. Gaseous fuel lines must have been
properly purged and leak tested in accordance with applicable
fuel-gas codes. All fuel shutoff valves in the fuel supply lines
must be open.
During initial start up, after installation, it is normal for the genera-
tor to exceed the normal number of start attempts and experience
an “over crank” fault. This is due to accumulated air in the fuel
system during shipment.
NOTE:
This procedure applies to 13kW and 16kW units only and should
be performed by trained personnel.
n
Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
this could damage the engine.
Post Installation Start-up and Adjustments

12
2.2 CHECK TRANSFER SWITCH
OPERATION
Refer to the "Manual Transfer Operation" section, of the owner’s
manual for procedures.

Do not attempt manual transfer switch opera-
tion until all power voltage supplies to the
transfer switch have been positively turned
off. Failure to turn off all power voltage sup-
plies 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 break-
er).

The transfer switch is now electrically
“hot.” Contact with “hot” parts will result in
extremely hazardous and possibly fatal elec-
trical shock. Proceed with caution.
5. Use an accurate AC voltmeter to check utility power source
voltage across transfer switch terminals N1 and N2. Nominal
line-to-line voltage should be 240 volts AC.
6. Check utility power source voltage across terminals N1 and
the transfer switch neutral lug; then across terminal N2 and
neutral. Nominal line-to-neutral voltage should be 120 volts
AC.
7. When certain that utility supply voltage is compatible with
transfer switch and load circuit ratings, turn OFF the utility
power supply to the transfer switch.
8. On the generator panel, set the AUTO/OFF/ MANUAL switch to
MANUAL. The engine should crank and start.
9. Let the engine warm up for about five minutes to allow inter-
nal temperatures to stabilize. Then, set the generator’s main
circuit breaker to its ON (or CLOSED) position.

Proceed with caution! Generator power volt-
age is now supplied to the transfer switch.
Contact with live transfer switch parts will
result in dangerous and possibly fatal electri-
cal shock.
10. Connect an accurate AC voltmeter and a frequency meter
across transfer switch terminal lugs E1 and E2. 7kW voltage
should be 242-252 volts at a frequency of 61-63 Hertz. 10,
13, and 16kW voltage should be 247-249 volts at a frequency
of 57.5-59.5 Hertz.
11. Connect the AC voltmeter test leads across terminal lugs E1
and neutral; then across E2 and neutral. In both cases, volt-
age 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.
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) posi-
tion.
2. Turn OFF all breakers on the load center of the transfer box (T1
and T2).
3. Set the generator's AUTO/OFF/MANUAL switch to OFF.
4. Turn OFF the utility power supply to the transfer switch,
using the means provided (such as a utility main line circuit
breaker).

Do not attempt manual transfer switch opera-
tion until all power voltage supplies to the
transfer switch have been positively turned
off. Failure to turn off all power voltage sup-
plies 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).
Post Installation Start-up and Adjustments

13
10. Connect an accurate AC voltmeter and a frequency meter
across terminal lugs E1 and E2.
• 7kW voltage should be greater than 230 volts and frequency
should be greater than 58 Hz.
• 10, 13 & 16kW voltage should be greater than 240 volts and
frequency should be greater than 60 Hz.
11. Let the generator run at full rated load for 20-30 minutes.
Listen for unusual noises, vibration or other indications of
abnormal operation. Check for oil leaks, evidence of overheat-
ing, 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) posi-
tion.
2. Check that the AUTO/OFF/MANUAL switch is set to OFF.
3. Turn OFF the utility power supply to the transfer switch, using
means provided (such as a utility main line circuit breaker).
4. Manually set the transfer switch to the UTILITY position, i.e.,
load terminals connected to the utility power source side.
5. Turn ON the utility power supply to the transfer switch,
using the means provided (such as a utility main line circuit
breaker).
6. Set the generator's main circuit breaker to its ON (or CLOSED))
position.
7. Set the AUTO/OFF/MANUAL switch to AUTO. The system is
now ready for automatic operation.
8. Turn OFF the utility power supply to the transfer switch.
With the AUTO/OFF/MANUAL switch at AUTO, the engine should
crank and start when the utility source power is turned OFF after a
10 second delay. After starting, the transfer switch should connect
load circuits to the standby side after a 15 second delay. Let the
system go through its entire automatic sequence of operation.
With the generator running and loads powered by generator AC
output, turn ON the utility power supply to the transfer switch. The
following should occur:
After about 15 seconds, the switch should transfer loads back•
to the utility power source.
About one minute after retransfer, the engine should shut•
down.
2.6 ADJUSTING THE FUEL
REGULATOR - 7KW (NATURAL
GAS ONLY)
NOTE:
All V-twin engine units DO NOT require a fuel regulator adjust-
ment due to the fuel system design.
Although the generator has been factory set to provide maximum
power, it may be necessary in some areas to adjust this setting. If
experiencing engine problems at high or full load conditions, fol-
low these steps. It will require a frequency meter to perform this
procedure.
1. Turn off utility power to the main distribution panel in the
house. This can be done by switching the service main
breaker to the off or open position.
2. Allow the generator to start. Before loading the generator,
confirm that the No Load Frequency, with the roof open and
door off, is set to 63-63.5 Hz. Transfer load to emergency
circuits.
3. Turn on appliances, lights, pumps, etc., that are on the emer-
gency 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 frequency meter
to the output lugs of the generator’s main line circuit breaker.
5. The fuel regulator is fitted with one adjustment screw. While
watching the frequency meter, slowly turn the adjustment
screw clockwise or counterclockwise until the highest fre-
quency is read on the meter. Only limited adjustment is avail-
able because of the set pin. Under no circumstances should
any of the pins be removed (Figure 2.3).
Figure 2.3 — 7kW Fuel Regulator
410cc Engine
Adjustment
Screw
(One Side
Only)
Set
Pin
ngine
6. When the highest frequency is reached maximum power has
been set. From this point turn the adjustment screw 1/4 turn
counterclockwise. The regulator is now set.
7. Turn utility power to the main distribution panel back on. This
can be done by switching the service main breaker to the on
or closed position. Allow the generator to shut down.
Post Installation Start-up and Adjustments

14
n
Do not make any unnecessary adjustments.
Factory settings are correct for most appli-
cations. However, when making adjustments,
be careful to avoid overspeeding the engine.
If this procedure or the test equipment is not available, locate the
nearest Dealer and they can perform the adjustments.
NOTE:
A service fee may be charged for this adjustment.
2.7 ENGINE GOVERNOR
ADJUSTMENT
If both AC frequency and voltage are correspondingly high or low,
adjust the engine governor as follows:
2.7.1 7 KW UNITS
n
The engine must be OFF to perform steps 1
and 2.
1. Loosen the governor clamp bolt (Figure 2.4).
2. Hold the governor lever at its wide open throttle position
(clockwise), and rotate the governor shaft clockwise as far
as it will go. Then, tighten the governor lever clamp bolt to 70
inch-pounds (8 N-m).
Figure 2.4 — Engine Governor Adjustment Single
Cylinder Engines
GOVERNOR
SHAFT
PRIMARY
ADJUST
SCREW
GOVERNOR
CLAMP
BOLT
SECONDARY
ADJUST SCREW
3. Start the generator; let it stabilize and warm up at no-load.
4. Connect a frequency meter across the generators AC output
leads.
5. Turn the primary adjust screw to obtain a frequency reading
of 61.5 Hertz. Turn the secondary adjust screw to obtain a
frequency of 62.5 Hz.
6. When frequency is correct at no load, check the AC voltage
reading. If voltage is incorrect, the voltage regulator may
require adjustment (See the Voltage Regulator Adjustment
section).
2.7.2 13 KW AND 16 KW UNITS
NOTE:
All V-twin units DO NOT require an engine governor adjustment
due to their design.
2.7.3 ADDITIONAL CORROSION
PROTECTION
Periodically spray all engine linkage parts and brackets with corro-
sion 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 2.5) 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 247-
249 volts.
NOTE:
The access panel on top of the control panel must be removed
to adjust the voltage regulator.
NOTE:
The voltage regulator is housed above the generator's control
panel. The regulator maintains a voltage in direct proportion to
frequency at a 2-to-1 ratio. For example, at 62 Hertz, line-to-
neutral voltage will be 124 volts.
Unit 120 Volts 240 Volts
7 kW 50.0 amps 25.0 amps
Post Installation Start-up and Adjustments

15
Figure 2.5 – Voltage Adjustment Potentiometer
Tu r n t o
adjust voltage.
3.1 USING THE AUTO/OFF/
MANUAL SWITCH (FIGURE 3.1)
3.1.1 “AUTO” POSITION
Selecting this switch position activates fully automatic system
operation. It also allows the unit to automatically start and exercise
the engine every seven days with the setting of the exercise timer
(see the Setting the Exercise Timer section).
3.1.2 “OFF” POSITION
This switch position shuts down the engine. This position also
prevents automatic operation.
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.
n
With the switch set to AUTO, the engine may
crank and start at any time without warning.
Such automatic starting normally occurs
when utility power source voltage drops
below a preset level or during the normal
exercise cycle. To prevent possible injury
that might be caused by such sudden starts,
always set the switch to OFF and remove the
fuses before working on or around the gen-
erator or transfer switch. Then, place a “DO
NOT OPERATE” tag on the generator panel
and on the transfer switch.
3.1.4 CHOKE OPERATION
1. 990 engines have an electric choke in the air box that is auto-
matically controlled by the electronic control board.
2. 530 engines have an electric choke on the divider panel air
inlet hose that is automatically controlled by the electronic
control board.
3. 410 engines do not have a choke.
3.2 AUTOMATIC TRANSFER
OPERATION
To select automatic operation, do the following:
1. Make sure the transfer switch main contacts are set to their
UTILITY position, i.e., loads connected to the utility power
source (Figure 3.2).
2. Be sure that normal UTILITY power source voltage is avail-
able 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 auto-
matically 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.
Operation

16
3.3 SEQUENCE OF AUTOMATIC
OPERATION
The generator’s control panel houses a control logic circuit board.
This board constantly monitors utility power source voltage.
Should that voltage drop below a preset level, circuit board action
will signal the engine to crank and start. After the engine starts,
the circuit board signals the transfer switch to activate and con-
nect 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 trans-
fer loads back to that power supply. After retransfer, the engine is
signalled to shut down.
The actual sequence of operation is controlled by sensors and
timers on a control logic circuit board, as follows:
A. Utility Voltage Dropout Sensor
• This sensor monitors utility source voltage.
• If utility source voltage drops below about 65 percent of the
nominal supply voltage, the sensor energizes a 10 second
timer.
• Once the timer has expired, the engine will crank and start if
utility is still low.
B. Engine Warm-up Time Delay
• This mechanism lets the engine warm up for about five
(5) seconds before the load is transferred to the standby
source.
C. Standby Voltage Sensor
• This sensor monitors generator AC output voltage. When the
voltage has reached 50 percent of the nominal rated voltage,
transfer to standby can occur.
D. Utility Voltage Pickup Sensor
• This sensor monitors utility power supply voltage. When that
voltage is restored above 75 percent of the nominal source
voltage, a retransfer time delay starts timing.
E. Retransfer Time Delay
• This timer runs for about 15 seconds.
• At end of a 15-second delay, circuit board action de-energizes
transfer relay in the transfer switch if utility is still present.
• Retransfer to utility power source then occurs.
F. Engine Cool-down Timer
• When the load is transferred back to utility power source, the
engine cool-down timer starts timing.
• The timer will run for about one minute, and the generator will
then shut down.
3.4 MANUAL TRANSFER
OPERATION
3.4.1 TRANSFER TO GENERATOR
POWER SOURCE
To start the generator and activate the transfer switch manually,
proceed as follows:
1. Set the generator’s AUTO/OFF/MANUAL switch to OFF.
2. Set the generator’s main circuit breaker to its OFF (or OPEN)
position.
3. Turn OFF the utility power supply to the transfer switch
using the means provided (such as a utility main line circuit
breaker).

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 pos-
sibly fatal electrical shock.
4. Use the manual transfer handle inside the transfer switch to
move the main contacts to their STANDBY position, i.e., loads
connected to the standby power source (Figure 3.2).
5. To crank and start the engine, set the AUTO/OFF/MANUAL
switch to MANUAL.
6. Let the engine stabilize and warm up for a few minutes.
7. Set the generator’s main circuit breaker to its ON (or CLOSED)
position. The standby power source now powers the loads.
Figure 3.2 – Manual Transfer Switch Operation
Operation

17
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 fol-
lows:
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.

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 pos-
sibly fatal electrical shock.
5. Use the manual transfer handle inside the transfer switch to
move the main contacts back to their UTILITY position, i.e.,
loads connected to the utility power source (Figure 3.2).
6. Turn ON the utility power supply to the transfer switch using
the means provided.
7. Set the system to automatic operation as outlined in Automatic
Transfer Operation section.
3.5 SETTING THE EXERCISE TIMER
This generator is equipped with an exercise timer. Once it is set,
the generator will start and exercise once every seven days, on the
day of the week and at the time of day the following sequence is
completed. During this exercise period, the unit runs for approxi-
mately 12 minutes and then shuts down. Transfer of loads to the
generator output does not occur during the exercise cycle unless
utility power is lost.
A switch on the control panel (see Figure 3.1) permits selection of
the day and time for the system to exercise. At the chosen time,
perform the following sequence to select the desired day and time
of day the system will exercise. Remember seasonal time changes
affect the exercise time settings.
1. Verify that the AUTO/OFF/MANUAL switch is set to AUTO.
2. Press and hold the "Set Exercise Time" switch for several
seconds, then release. All the red LED's will flash for approxi-
mately 10 seconds and then stop.
3. Once the red LED's stop flashing, the generator will start and
run for approximately 12 minutes and then shut down. The
exerciser is now set to run at this time of day each week.
Example: If the "Set Exercise Time" switch is pressed on
Saturday afternoon at 2:00 p.m., the generator will start and
exercise for approximately 12 minutes every Saturday at 2:00
p.m..
NOTE:
The exerciser will only work in the AUTO mode and will not work
unless this procedure is performed. The exerciser will need to
be reset every time the 12-volt battery is disconnected and then
reconnected, and when the 15A fuse is removed.
The 16kW unit has a low speed exercise option. Dip switch 1 on
the control board is factory set to OFF. This allows the engine to
run at a slower speed during weekly exercise periods for quieter
operation. If this Dip switch is set to ON, the generator will exercise
at it's normal speed.
This DIP switch position is only read at board power up. If the DIP
switch position is changed, power to the board must be cycled for
the micro controller to recognize the new DIP switch position.
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 follow-
ing:
• 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 opera-
tion.
3.6 PROTECTION SYSTEMS
3.6.1 LOW OIL PRESSURE SWITCH
This switch (Figure 3.3) has normally closed contacts that are held
open by engine oil pressure during cranking and operating. Should
oil pressure drop below the 8 psi range, switch contacts close, and
the engine shuts down. The unit should not be restarted until oil is
added. The AUTO/OFF/MANUAL switch must then be turned to OFF
and then back to AUTO.
3.6.2 HIGH TEMPERATURE SWITCH
This switch’s contacts (Figure 3.3) close if the temperature should
exceed approximately 144º C (293º F), initiating an engine shut-
down. 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.
Operation

18
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 another problem, such as no fuel
supply, prevents it from starting. The unit will crank and rest for
a preset time limit. Then, it will stop cranking, and the LED on the
generator control panel will light indicating an overcrank failure.
The AUTO/OFF/MANUAL switch will need to be set to OFF and then
back to AUTO to reset the generator control board.
NOTE:
If the fault is not repaired, the overcrank feature will continue
to activate.
3.7.3.1 Approximate Crank Cycle Times
7kW Units:
15 seconds ON•
7 seconds OFF•
7 seconds ON•
7 seconds OFF•
7 seconds ON•
7 seconds OFF•
7 seconds ON•
7 seconds OFF•
7 seconds ON•
7 seconds OFF•
7 seconds ON•
If the unit fails to start, the overcrank alarm LED will be illumi-
nated.
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 illumi-
nated.
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 protec-
tion also prevents the generator from supplying an output that
could potentially damage appliances connected to the generator
circuit. Contact the nearest Authorized Dealer if this failure
occurs.
3.6.5 RPM SENSOR FAILURE
During cranking, if the board does not see a valid RPM signal
within three (3) seconds, it will shut down and latch out on RPM
sensor loss.
During running, if the RPM signal is lost for one full second the
board will shut down the engine, wait 15 seconds, then re-crank
the engine.
If an RPM signal is not detected within the first three (3) sec-•
onds of cranking, the control board will shut the engine down
and latch out on RPM sensor loss.
If the RPM signal is detected the engine will start and run nor-•
mally. If the RPM signal is subsequently lost again, the control
board will try one more re-crank attempt before latching out and
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 bat-
tery condition. Low battery voltage is a non-latching alarm which
will automatically clear if the battery voltage rises above 11.0 volts.
Battery voltage is NOT monitored during the crank cycle.
4.1 FUSES
The 15-amp fuse on the generator panel protects the DC control
circuit against overload (Figure 4.1). This fuse is wired in series
with the battery output lead to the panel. If this fuse element has
melted open, the engine will not be able to crank or start. Replace
this fuse using only an identical 15-amp replacement fuse. To
replace the fuse, push the fuse holder cap down and rotate it
counterclockwise. Whenever the fuse is removed or replaced, the
exercise timer needs to be reset.
Figure 4.1 – Generator Control Panel
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
Maintenance