Generac Power Systems

Installation
and
Owner’s Manual
7, 10, 13, 16 & 18kW Air-cooled,
Automatic Standby Generators
C US
LISTED
 Not intended for use as Primary Power in place of utility or in

life-support applications. 
DANGER
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
INTRODUCTION
Thank you for purchasing this compact, high per-  This
ard.
symbol points out potential explosion haz-
formance, air-cooled, engine-driven generator. It is
designed to automatically supply electrical power to
operate critical loads during a utility power failure.
 This symbol points out potential fire hazard.
This unit is factory installed in an all-weather, metal  This symbol points out potential electrical shock
hazard.
enclosure that is intended exclusively for outdoor
installation. This generator will operate using either The operator is responsible for proper and safe use
vapor withdrawn liquid propane (LP) or natural gas of the equipment. The manufacturer strongly recom-
(NG). mends that the operator read this Owner's Manual
and thoroughly understand all instructions before
NOTE: using this equipment. The manufacturer also strong-
This generator is suitable for supplying typical ly recommends instructing other users to properly
residential loads such as Induction Motors (sump start and operate the unit. This prepares them if they
pumps, refrigerators, air conditions, furnaces, need to operate the equipment in an emergency.
etc.), Electronic Components (computer, monitor,
TV, etc.), Lighting Loads and Microwaves. CONTENTS
This manual contains pertinent owner’s information,
READ THIS MANUAL THOROUGHLY including warranty, electrical diagrams, exploded
If any portion of this manual is not understood, views and lists of repair parts, for these different
contact the nearest Authorized Dealer for starting, models:
operating and servicing procedures. • 6 kW NG, 7 kW LP, single-cylinder GH-410 Engine
• 9 kW NG, 10 kW LP, V-twin GT-530 Engine
Throughout this publication, and on tags and decals
affixed to the generator, DANGER, WARNING, • 13 kW NG, 13 kW LP, V-twin GT-990 Engine
CAUTION and NOTE blocks are used to alert person- • 15 kW NG, 16 kW LP, V-twin GT-990 Engine
nel to special instructions about a particular opera- • 16 kW NG, 18 kW LP, V-twin GT-990 Engine
tion that may be hazardous if performed incorrectly
or carelessly. Observe them carefully. Their defini- OPERATION AND MAINTENANCE
tions are as follows:
It is the operator's responsibility to perform all safety
checks, to make sure that all maintenance for safe
DANGER operation is performed promptly, and to have the
After this heading, read instructions that, if not equipment checked periodically by an Authorized
strictly complied with, will result in serious person- Dealer. Normal maintenance service and replacement
al injury, including death, in addition to property of parts are the responsibility of the owner/operator
damage. 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.
After this heading, read instructions that, if not
strictly complied with, may result in serious person- Proper maintenance and care of the generator ensures
al injury or property damage. a minimum number of problems and keep operating
expenses at a minimum. See an Authorized Dealer
for service aids and accessories.
After this heading, read instructions that, if not HOW TO OBTAIN SERVICE
strictly complied with, could result in damage to
equipment and/or property. When the generator requires servicing or repairs,
NOTE: contact an Authorized Dealer for assistance. Service
technicians are factory-trained and are capable of
After this heading, read explanatory statements handling all service needs.
that require special emphasis.
When contacting an Authorized Dealer about parts
These safety warnings cannot eliminate the haz- and service, always supply the complete model num-
ards that they indicate. Common sense and strict ber and serial number of the unit as given on its data
compliance with the special instructions while decal, which is located on the generator. See section
performing the service are essential to preventing "The Generator" for decal location.
accidents.
Model No. ____________ Serial No. ______________
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.
Table of Contents
Air-cooled Generators
Introduction ........................Inside Front Cover Section 3 – Operation ....................................15

Read This Manual Thoroughly ........................ IFC 3.1 Using the AUTO/OFF/MANUAL Switch ........ 15
Contents .......................................................... IFC 3.2 Automatic Transfer Operation ..................... 15
Operation and Maintenance ............................ IFC 3.3 Sequence of Automatic Operation ............... 15
How to Obtain Service..................................... IFC 3.4 Manual Transfer Operation ......................... 16
3.5 Setting the Exercise Timer .......................... 17
Safety Rules ........................................................2 3.6 Protection Systems ...................................... 17
Standards Index .................................................. 3
Section 4 – Maintenance ...............................18
Section 1 – General Information ...................4 4.1 Fuses ........................................................... 18
1.1 Unpacking/Inspection .................................... 4 4.2 Checking the Engine Oil Level ..................... 19
1.2 Protection Systems ........................................ 4 4.3 Changing the Engine Oil .............................. 19
1.3 NEC Requirement for Arc Fault Circuit 4.4 Changing the Engine Air Cleaner................. 20
Interruption Breaker for Bedrooms .............. 4 4.5 Spark Plug(s) .............................................. 21
1.4 The Generator ............................................... 5 4.6 Battery Maintenance .................................... 21
1.5 Specifications ................................................ 6 4.7 Adjusting GH-410/GT-530/990
1.6 System Set LED ............................................ 7 Valve Clearance............................................ 22
1.7 Fuel Requirements and Recommendations ... 7 4.8 Cooling System ........................................... 23
1.8 Fuel Consumption ......................................... 7 4.9 Attention After Submersion ......................... 23
1.9 Reconfiguring the Fuel System ...................... 8 4.10 Corrosion Protection ................................... 23
1.10 Location ........................................................ 9 4.11 Out of Service Procedure............................. 23
1.11 Battery Requirements.................................. 10 4.12 Service Schedule ......................................... 25
1.12 Battery Installation ...................................... 10
1.13 The Battery ................................................. 11 Section 5 – Troubleshooting ........................ 26
5.1 Troubleshooting Guide ................................ 26
Section 2 – Post Installation Start-up
and Adjustments .......................12 Section 6 – Electrical Data ............................27
2.1 Before Initial Startup................................... 12 Section 7 – Exploded Views and
2.2 Check Transfer Switch Operation ............... 12 Parts Lists ................................... 38
2.3 Electrical Checks ........................................ 12 Section 8 – Mounting Dimensions ............. 60
2.4 Generator Tests Under Load ....................... 13 Section 9 – Notes ........................................... 62
2.5 Checking Automatic Operation .................... 13 Section 10 – Warranty ................................... 64
2.6 Engine Governor Adjustment ...................... 14
2.7 Voltage Regulator Adjustment...................... 14
1
IMPORTANT SAFETY INSTRUCTIONS
 
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.

• WARNING:   GENERAL HAZARDS 
• The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth • For safety reasons, the manufacturer recommends
defects or other reproductive harm. that the installation, initial start-up and main-
tenance of this equipment is carried out by an
Authorized Dealer.

• WARNING:  • The engine exhaust fumes contain carbon monox-
ide, which can be DEADLY. This dangerous gas, if
• This product contains or emits chemicals breathed in sufficient concentrations, can cause
known to the state of California to cause unconsciousness or even death. This exhaust
cancer, birth defects or other reproductive harm. system must be installed properly, in strict com-
pliance with applicable codes and standards.
Study these SAFETY RULES carefully before install- Following installation, do nothing that might ren-
ing, operating or servicing this equipment. Become der the system unsafe or in noncompliance with
familiar with this Owner’s Manual and with the such codes and standards.
unit. The generator can operate safely, efficiently and • Keep hands, feet, clothing, etc., away from drive
reliably only if it is properly installed, operated and belts, fans, and other moving or hot parts. Never
maintained. Many accidents are caused by failing to remove any drive belt or fan guard while the unit
follow simple and fundamental rules or precautions. is operating.
The manufacturer cannot anticipate every possible • Adequate, unobstructed flow of cooling and venti-
circumstance that might involve a hazard. The warn- lating air is critical to correct generator operation.
ings in this manual, and on tags and decals affixed Do not alter the installation or permit even partial
to the unit are, therefore, not all-inclusive. If using blockage of ventilation provisions, as this can seri-
a procedure, work method or operating technique ously affect safe operation of the generator. The
the manufacturer does not specifically recommend, generator MUST be installed outdoors.
ensure that it is safe for others. Also make sure the • When working on this equipment, remain alert
procedure, work method or operating technique uti- at all times. Never work on the equipment when
lized does not render the generator unsafe. physically or mentally fatigued.
• Inspect the generator regularly, and contact the
DANGER nearest Authorized Dealer for parts needing repair
or replacement.
 Despite the safe design of this generator,
operating this equipment imprudently, neglecting • Before performing any maintenance on the gen-
its maintenance or being careless can cause erator, disconnect its battery cables to prevent
possible injury or death. Permit only responsible accidental start up. Disconnect the cable from the
and capable persons to operate or maintain this battery post indicated by a NEGATIVE, NEG or
equipment. (–) first, then remove the POSITIVE, POS or (+)
cable. When reconnecting the cables, connect the
 Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
POSITIVE cable first, the NEGATIVE cable last.
• Never use the generator or any of its parts as a
render the machine safe before attempting to step. Stepping on the unit can stress and break
work on the generator. parts, and may result in dangerous operating con-
 Parts of the generator are rotating and/or hot ditions from leaking exhaust gases, fuel leakage,
during operation. Exercise care near running oil leakage, etc.
generators.
2
IMPORTANT SAFETY INSTRUCTIONS
• Keep a fire extinguisher near the generator at all

 ELECTRICAL HAZARDS  times. Extinguishers rated “ABC” by the National
Fire Protection Association are appropriate for
• All generators covered by this manual produce
dangerous electrical voltages and can cause fatal use on the standby electric system. Keep the extin-
electrical shock. Utility power delivers extremely guisher properly charged and be familiar with its
high and dangerous voltages to the transfer switch use. Consult the local fire department with any
as does the standby generator when it is in opera- questions pertaining to fire extinguishers.
 EXPLOSION HAZARDS 
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 • Do not smoke around the generator. Wipe up any
generator. If work must be done around an oper- fuel or oil spills immediately. Ensure that no com-
ating unit, stand on an insulated, dry surface to bustible materials are left in the generator com-
reduce shock hazard. partment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surround-
• Do not handle any kind of electrical device while ing the generator clean and free from debris.
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK • Gaseous fluids such as natural gas and liquid pro-
MAY RESULT. pane (LP) gas are extremely EXPLOSIVE. Install
the fuel supply system according to applicable
• The National Electrical Code (NEC) requires the fuel-gas codes. Before placing the home standby
frame and external electrically conductive parts of electric system into service, fuel system lines must
the generator to be connected to an approved earth be properly purged and leak tested according to
ground. Local electrical codes also may require applicable code. After installation, inspect the fuel
proper grounding of the generator electrical system. system periodically for leaks. No leakage is permit-
• After installing this home standby electrical sys- ted.
tem, the generator may crank and start at any
time without warning. When this occurs, load cir- STANDARDS INDEX
cuits are transferred to the STANDBY (generator)
power source. To prevent possible injury if such a In the absence of pertinent standards, codes, regu-
start and transfer occur, always set the generator’s lations and laws, the published information listed
AUTO/OFF/MANUAL switch to its OFF position below may be used as installation guide for this
before working on equipment and remove the 15A equipment.
fuse from the generator control panel. 1. NFPA No. 37, STATIONARY COMBUSTION
• In case of accident caused by electric shock, imme- ENGINES AND GAS TURBINES, available from
diately shut down the source of electrical power. If the National Fire Protection Association, 470
this is not possible, attempt to free the victim from Atlantic Avenue, Boston, MA 02210.
the live conductor. AVOID DIRECT CONTACT WITH 2. NFPA No. 76A, ESSENTIAL ELECTRICAL
THE VICTIM. Use a nonconducting implement, SYSTEMS FOR HEALTH CARE FACILITIES,
such as a dry rope or board, to free the victim from available same as Item 1.
the live conductor. If the victim is unconscious, 3. NFPA No. 54, NATIONAL FUEL GAS CODE,
apply first aid and get immediate medical help. available same as Item 1.
• Never wear jewelry when working on this equip- 4. NFPA No. 58, AMERICAN NATIONAL STANDARD
ment. Jewelry can conduct electricity resulting in FOR STORAGE AND HANDLING OF LIQUEFIED
electric shock, or may get caught in moving com- PETROLEUM GAS, available same as Item 1.
ponents causing injury. 5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL
 FIRE HAZARDS 
ELECTRIC CODE, available same as Item 1.
6. Article X, NATIONAL BUILDING CODE, available
• For fire safety, the generator must be installed and from the American Insurance Association, 85
maintained properly. Installation must always John Street, New York, N.Y. 10038.
comply with applicable codes, standards, laws 7. AGRICULTURAL WIRING HANDBOOK, avail-
and regulations. Adhere strictly to local, state able from the Food and Energy Council, 909
and national electrical and building codes. Comply University Avenue, Columbia, MO 65201.
with regulations the Occupational Safety and 8. ASAE EP-3634, INSTALLATION AND
Health Administration (OSHA) has established. MAINTENANCE OF FARM STANDBY ELECTRICAL
Also, ensure that the generator is installed in SYSTEMS, available from the American Society
accordance with the manufacturer’s instructions of Agricultural Engineers, 2950 Niles Road, St.
and recommendations. Following proper installa- Joseph, MI 49085.
tion, do nothing that might alter a safe installation 9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
and render the unit in noncompliance with the LIQUIDS CODE, available same as Item 1.
aforementioned codes, standards, laws and regu-
lations.
3
Section 1 — General Information
There are LED readouts on the control panel to notify

DANGER personnel that one of these faults has occurred.
There is also a System Set LED that is lit when all
 Only qualified electricians or contractors should
attempt such installations, which must comply
of the conditions described in section "System Set
LED" are true. (See the "Protection Systems" section
strictly with applicable codes, standards and regu- for details.)
lations.
1.1 UNPACKING/INSPECTION 1.3 NEC REQUIREMENT FOR ARC

After unpacking, carefully inspect the contents for FAULT CIRCUIT INTERRUPTION
damage. BREAKER FOR BEDROOMS
• This standby generator set is ready for installa- In 2001, the National Electric Code (NEC) intro-
tion with a factory supplied and pre-mounted base duced a requirement for new construction. This new
pad and has a weather protective enclosure that is requirement indicates the need for Arc Fault Circuit
intended for outdoor installation only. Interrupters to be used to protect the complete
• This UL listed standby generator set is packaged branch circuit that feeds a dwelling bedroom. The
with an automatic transfer switch with built in actual NEC requirement is indicated below.
load center. The combination transfer switch and
load center is pre-wired with a two foot and 30 foot 1.3.1 SECTION 210.12 ARC FAULT CIRCUIT
conduit. Circuit breakers for emergency circuit INTERRUPTER PROTECTION
connections are included (if equipped).
1. Definition: An arc fault circuit interrupter is a
• This UL listed, 2-pole switch is rated at 100 AC device intended to provide protection from the
amperes at 250 volts maximum. This transfer effects of arc faults by recognizing characteristics
switch is for indoor use only (if equipped). 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
 Ifcircuits
this generator is used to power electrical load
normally powered by a utility power
supply 125 volt, single-phase, 15 and 20 ampere
outlets installed in dwelling unit bedrooms shall
source, it is required by code to install a transfer be protected by an arc fault circuit interrupter
switch. The transfer switch must effectively isolate listed to provide protection of the entire branch
the electrical system from the utility distribution circuit.
system when the generator is operating (NEC 700, Section 210.12 requires that AFCI protection be
701 & 702). Failure to isolate an electrical system provided on branch circuits that supply outlets
by such means will result in damage to the gen- (receptacle, lighting, etc.) in dwelling bedrooms. The
erator and also may result in injury or death to requirement is limited to 15 and 20 ampere, 125
utility power workers due to backfeed of electrical volt circuits. There is no prohibition against provid-
energy. ing AFCI protection on other circuits or in locations
If any loss or damage is noted at time of delivery, have other than bedrooms. Because circuits are often
the person(s) making the delivery note all damage shared between a bedroom and other areas such as
on the freight bill or affix their signature under the closets and hallways, providing AFCI protection on
consignor's memo of loss or damage. the complete circuit would comply with 210.12.
If a loss or damage is noted after delivery, separate If during the installation of the home standby system
the damaged materials and contact the carrier for the decision is made to provide back up power to a
claim procedures. bedroom branch circuit, then the circuit breaker in
the transfer switch should be replaced with an Arc
“Concealed damage” is understood to mean damage
Fault Circuit Interrupter.
to the contents of a package that is not in evidence at
the time of delivery, but is discovered later. It is most important that breakers only be switched
like for like. For instance, if replacing a 15A breaker,
1.2 PROTECTION SYSTEMS it MUST be replaced with a 15A AFCI breaker.
Unlike an automobile engine, the generator may have Likewise, a 20A breaker MUST be replaced with a
to run for long periods of time with no operator pres- 20A AFCI.
ent to monitor engine conditions. For that reason, the
These AFCI breakers are available at the nearest
engine is equipped with the following systems that
hardware store.
protect it against potentially damaging conditions:
Siemens Item # Description
1. Low Oil Pressure Sensor 4. Overspeed
2. High Temperature Sensor 5. RPM Sensor Q115AF 15A Single Pole AFCI
3. Overcrank 6. Low Battery Q120AF 20A Single Pole AFCI
4
1.4 THE GENERATOR

Figure 1.1 – 7kW, Single Cylinder, GH-410 Engine Figure 1.2 – 10kW, V-twin, GT-530 Engine
Control Panel de
Data Label Panel contrrol
Oil Varilla medidora Etiqueta de datos
(see sample)
Dipstick de aceite (consulte la muestra)
Exhaust Air Filter Cerramiento Filtro de aire

Enclosure Cover para los gases
de escape Entrada de
Fuel combustible
Inlet (parte trasera)
(back)
Regulador
Fuel de combustible
Regulator
Base compuesta Filtro de aceite Compartimiento de la batería
Composite Base Oil Filter Battery Compartment
Figure 1.3 – 13, 16 and 18kW, V-twin, GT-990 Engine
Data Label Sample
Data Label
(see sample)
Air Filter Control

Oil Cover Panel
Dipstick
Exhaust
Enclosure
Fuel
Inlet
(Back)
Fuel
Regulator
Composite Base Oil Filter Battery Compartment
5
1.5 SPECIFICATIONS
1.5.1 GENERATOR
Model 7 kW 10 kW 13 kW 16 kW 18 kW
Rated Max. Continuous Power 7,000 NG 9,000 NG 13,000 NG 15,000 NG 16,000 NG
Capacity (Watts*) 6,000 LP 10,000 LP 13,000 LP 16,000 LP 18,000 LP
Rated Voltage 120/240
Rated Max. Continuous Load Current (Amps)

120 Volts** (NG/LP) 50.0/58.3 75.0/83.3 108.3/108.3 125/133.3 133.3/150
240 Volts (NG/LP) 25.0/29.2 37.5/41.7 54.1/54.1 62.5/66.6 66.6/75
Main Line Circuit Breaker 30 Amp 45 Amp 55 Amp 65 Amp 80 Amp
Circuits*** - - - 1 -
50A, 240V
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
Number or Rotor Poles 2
Rated AC Frequency 60 Hz
Power Factor 1
Battery Requirement Group 26, 12 Volts and 350 Group 26, 12 Volts and 525
Cold-cranking Amperes Minimum Cold-cranking Amperes Minimum
Weight (unit only in pounds) 336 375 425.5 445/414 421
Enclosure Steel Steel/Aluminum Aluminum
Normal Operating Range -20°F (-28.8°C) to 104°F (40°C) -20°F (-28.8°C) to
77°F (25°C)
* Maximum wattage and current are subject to and limited by such factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc. Maximum power decreases about 3.5 per-
cent 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 7 kW 10 kW 13/16/18 kW
Type of Engine GH-410 GT-530 GT-990
Number of Cylinders 1 2 2
Rated Horsepower @3,600 rpm 14.8 18 27 (13kW) / 30 (16kW) / 31.5 (18kW)
Displacement 410cc 530cc 992cc
Cylinder Block Aluminum w/Cast Iron Sleeve
Valve Arrangement Overhead Valves
Ignition System Solid-state w/Magneto
Recommended Spark Plug RC14YC BPR6HS RC14YC
Spark Plug Gap 0.76 mm (0.030 inch) 0.76 mm (0.030 inch) 1.02 mm (0.040 inch)
Compression Ratio 8.6:1 9.5:1 9.5:1
Starter 12 VDC
Oil Capacity Including Filter Approx. 1.5 Qts Approx. 1.7 Qts Approx. 1.7 Qts
Recommended Oil Filter Part # 070185F
Recommended Air Filter Part # 0G3332 Part # 0E9581 Part # 0C8127
Operating RPM 3,600
6
1.6 SYSTEM SET LED Special considerations should be given when install-
ing the unit where local conditions include flooding,
The “System Set” LED is lit when all of the following
conditions are true: tornados, hurricanes, earthquakes and unstable
ground for the flexibility and strength of piping and
1. The AUTO/OFF/MANUAL switch is set to the their connections.
AUTO position.
Use an approved pipe sealant or joint compound on
2. The utility voltage being supplied to the unit is
all threaded fitting.
being sensed by the PCB. If the utility sense volt-
age is not connected to the unit or if it is below All installed gaseous fuel piping must be purged and
approximately 150-160 volts AC, then the system leak tested prior to initial start-up in accordance with
set light will flash rapidly. This indicates that if local codes, standards and regulations.
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-
1.8 FUEL CONSUMPTION
sure, high temperature, etc. Nat. Gas LP Vapor
Unit
1/2 Load Full Load 1/2 Load Full Load
1.7 FUEL REQUIREMENTS 6/7 kW 66 119 0.82/30 1.47/54
AND RECOMMENDATIONS 9/10 kW 102 156 1.25/46 1.93/70
With LP gas, use only the vapor withdrawal sys-
tem. This type of system uses the vapors formed 13/13 kW 156 220 1.55/57 2.18/80
above the liquid fuel in the storage tank. 15/16 kW 173 245 1.59/59 2.51/92
The engine has been fitted with a fuel carburetion 16/18 kW 184 262 1.83/66.4 2.85/103.5
system that meets the specifications of the 1997 *Natural gas is in cubic feet per hour.
California Air Resources Board for tamper-proof dual **LP is in gallons per hour/cubic feet per hour.
*** Values given are approximate.
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 1.8.1 BTU FLOW REQUIREMENTS -
gas, the fuel system needs to be reconfigured. See the NATURAL GAS
Reconfiguring the Fuel System section for instruc-
tions on reconfiguration of the fuel system. BTU flow required for each unit based on 1000 BTU
per cubic foot.
Recommended fuels should have a Btu content of at
least 1,000 Btus per cubic foot for natural gas; or at • 6kW — 119,000 BTU/Hour
least 2,520 Btus per cubic foot for LP gas. Ask the • 9kW — 156,000 BTU/Hour
fuel supplier for the Btu content of the fuel. • 13kW — 220,000 BTU/Hour
Required fuel pressure for natural gas is 5 inches • 15kW — 245,000 BTU/Hour
to 7 inches water column (0.18 to 0.25 psi); and • 16kW — 262,000 BTU/Hour
for liquid propane, 10 inches to 12 inches of water
column (0.36 to 0.43 psi). The primary regulator DANGER
for the propane supply is NOT INCLUDED with the
generator.  Gaseous fuels such as natural gas and liquid
propane (LP) gas are highly explosive. Even the
NOTE: slightest spark can ignite such fuels and cause
All pipe sizing, construction and layout must com- an explosion. No leakage of fuel is permitted.
ply with NFPA 54 for natural gas applications and Natural gas, which is lighter than air, tends to
NFPA 58 for liquid propane applications. Once the collect in high areas. LP gas is heavier than air
generator is installed, verify that the fuel pressure and tends to settle in low areas.
NEVER drops below four (4) inches water column NOTE:
for natural gas or 10 inches water column for liq- A minimum of one approved manual shut-off valve
uid propane. must be installed in the gaseous fuel supply line.
Prior to installation of the generator, the installer The valve must be easily accessible. Local codes
should consult local fuel suppliers or the fire mar- determine the proper location.
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.
7
1.9 RECONFIGURING THE NOTE:

Use an approved pipe sealant or joint compound
FUEL SYSTEM on all threaded fittings to reduce the possibility
1.9.1 7 KW, 410CC ENGINE of leakage.
To reconfigure the fuel system from NG to LP, follow 9. Reverse procedure steps 1-6 to reinstall demand
these steps (Figure 1.4): regulator.
10. Take the plastic plug supplied in the poly-bag
NOTE: with the generator and press it into the 3/4” hole
The primary regulator for the propane supply is on the bottom of the air cleaner base (Figure
NOT INCLUDED with the generator. A fuel pres- 4.6).
sure of 10 to 12 inches of water column (0.36 to 11. Reverse the procedure to convert back to natural
0.43 psi) to the fuel inlet of the generator MUST gas.
BE SUPPLIED. 12. Check for gas leakage at the pipe plug, hose con-
1. Turn off the main gas supply (if connected). nection and fittings.
2. Open the roof and remove the door.
3. Remove the battery (if installed). 1.9.2 10, 13, 16, AND 18KW, V-TWIN
4. Disconnect wire #0 and wire #14 from the gas ENGINES
solenoid on top of the demand regulator. To reconfigure the fuel system from NG to LP, follow
5. Remove the carburetor fuel hose from the outlet these steps:
port of the demand regulator. NOTE:
6. Remove the demand regulator by removing the The primary regulator for the propane supply is
fastener that retains the regulator mounting NOT INCLUDED with the generator. A fuel pres-
bracket. sure of 10 to 12 inches of water column (0.36 to
7. Remove the square headed steel pipe plug from 0.43 psi) to the fuel inlet of the generator MUST
outlet port #1 and the brass hose barb fitting BE SUPPLIED.
from outlet port #2.
8. Refit the brass hose barb fitting to outlet port #1 1. Open the roof.
and the square headed steel pipe plug to outlet 2. For 10kW units: Loosen clamp and slide back
port #2. the air inlet hose.
• Slide fuel selector on carburetor out towards the
Figure 1.4 – Demand Regulator back of the enclosure (Figures 1.5 and 1.6).
• Return the inlet hose and tighten clamp securely.
HOSE & PLUG
SWITCHED SIDES
For 13, 16 and 18kW units: remove the air cleaner
FUEL HOSE cover.
• Slide the selector lever out towards the back of
FUEL HOSE
PIPE
PLUG
the enclosure (Figures 1.7 and 1.8).
BRASS HOSE BRASS HOSE
FITTING FITTING • Return the air cleaner cover and tighten the two
OUTLET
PORT
thumb screws.
ADJUSTMENT
SCREW
FUEL JET
Figure 1.5 - 10kW, GT-530 (Inlet Hose Slid Back)
Fuel Selection
Lever - "In"
NG FUEL SYSTEM LP FUEL SYSTEM Position for
Natural Gas
Fuel
STATIC
PRESSURE
TAP
RUNNING
PRESSURE
TAP
8
3. Close the roof. 1.10 LOCATION

4. Reverse the procedure to convert back to natural
gas. 1.10.1 GENERATOR
Figure 1.6 - 10kW, GT-530 (Inlet Hose Slid Back) 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:
Fuel Selection • The installation of the generator must comply
Lever - "Out" strictly with NFPA 37, NFPA 54, NFPA 58, and
Position for NFPA 70 standards.
Liquid Propane • Install the unit where air inlet and outlet open-
(Vapor) Fuel 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
Figure 1.7 - 13, 16, & 18kW, GT-990 installed in accordance with current applicable
NFPA 37 and NFPA 70 standards; as well as any
(Airbox Cover Removed) other federal, state and local codes for minimum
distances from other structures. DO NOT install
Fuel Selection Lever - "In" Position for Natural Gas Fuel under wooden decks or structures unless there is
at least four (4) feet of clearance above the genera-
tor, three (3) feet of clearance on sides and front,
and 18 inches of clearance at back of unit.
• Install the unit where rain gutter down spouts,
roof 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
Figure 1.8 - 13, 16, & 18kW, GT-990 the prevailing winds.
(Airbox Cover Removed) Figure 1.9 – Generator Clearances
Fuel Selection Lever - "Out" Position for Liquid Propane
(Vapor) Fuel
9
• 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
 IfOFF
the AUTO/OFF/MANUAL switch is not set to its
position, the generator can crank and start
LOCATION. as soon as the battery cables are connected. If
• The genset must be installed on a level surface. the utility power supply is not turned off, spark-
The base frame must be level within two (2) inches ing can occur at the battery posts and cause an
all around. explosion.
• The generator is typically placed on pea gravel or
crushed stone. Check local codes if a concrete slab 1.11 BATTERY REQUIREMENTS
is required. If a concrete base slab is required, all See the Specifications section for correct battery size
federal, state and local codes should be followed. and rating.
Special attention should be given to the concrete
base slab which should exceed the length and 1.12 BATTERY INSTALLATION
width of the generator by a minimum of six (6) Fill the battery with the proper electrolyte fluid if
inches (0.152 meters) on all sides. necessary and have the battery fully charged before
installing it.
Before installing and connecting the battery, complete
 The engine exhaust fumes contain carbon mon-
oxide, which can be DEADLY. This dangerous
the following steps:
1. Set the generator's AUTO/OFF/MANUAL switch to
gas, if breathed in sufficient concentrations, OFF.
can cause unconsciousness or even death. This 2. Turn off utility power supply to the transfer
exhaust system must be installed properly, in switch.
strict compliance with applicable codes and stan- 3. Remove the 15A fuse from the generator control
dards. Following installation, do nothing that panel.
might render the system unsafe or in noncompli- Battery cables were factory connected at the genera-
ance with such codes and standards. tor (Figure 1.10). Connect cables to battery posts as
• Operate the generator outdoors ONLY. follows:
• Keep exhaust gases from entering a confined area
through windows, doors, ventilation or other 4. Connect the red battery cable (from starter con-
openings (Figure 1.9). tactor) to the battery post indicated by a positive,
POS or (+).
1.10.2 TRANSFER SWITCH 5. Connect the black battery cable (from frame
ground) to the battery post indicated by a nega-
1.10.2.1 7, 10, 13, 16 and 18 kW Units tive, NEG or (—).
(if equipped) Figure 1.10 – Battery Cable Connections
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.
10
NOTE: The following procedures are to be observed:

Dielectric grease should be used on battery posts • Wear full eye protection and protective clothing;
to aid in the prevention of corrosion. • Where electrolyte contacts the skin, wash it off
immediately with water;
NOTE: • Where electrolyte contacts the eyes, flush thor-
Damage will result if battery connections are made oughly and immediately with water and seek
in reverse. medical attention; and
• Spilled electrolyte is to be washed down with an
NOTE: acid neutralizing agent. A common practice is to
In areas where temperatures regularly fall below use a solution of 1 pound (500 grams) bicarbonate
10° F (-12° C) it is recommended that a pad type of soda to 1 gallon (4 liters) of water. The bicar-
battery heater be installed to aid in cold climate bonate of soda solution is to be added until the
starting. evidence of reaction (foaming) has ceased. The
NOTE: resulting liquid is to be flushed with water and the
area dried.
The generator is equipped with a battery trickle
charger that is active when the unit is set up for  Lead-acid batteries present a risk of fire because
they generate hydrogen gas. The following
automatic operation. With the battery installed
procedures are to be followed:
and utility power source voltage available to the
transfer switch, the battery receives a trickle • DO NOT SMOKE when near the battery;
charge while the engine is not running, to prevent • DO NOT cause flame or spark in battery area; and
self-discharge. The trickle charger is designed to • Discharge static electricity from body before touch-
help extend the life of the battery by maintain- ing the battery by first touching a grounded metal
ing the battery when the unit is not running. The surface.
trickle charge feature cannot be used to recharge
a discharged battery.
 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
1.13 THE BATTERY battery cables are connected.
DANGER  Be sure the utility power supply is turned off

and the 15A fuse is removed from the generator
 Do not dispose of the battery in a fire. The
battery is capable of exploding.
control panel, or sparking may occur at the bat-
tery posts as the cables are attached and cause
an explosion.
 Aandbattery presents a risk of electrical shock
high short circuit current. The following pre- Servicing of the battery is to be performed or super-
cautions are to be observed when working on vised by personnel knowledgeable of batteries and
batteries: the required precautions. Keep unauthorized person-
nel away from batteries.
• Remove the 15A fuse from the generator control
panel. See the Specifications section for the correct size
• Remove watches, rings or other metal objects; and rating when replacing the battery. When using a
• Use tools with insulated handles; maintenance-free battery, it is not necessary to check
• Wear rubber gloves and boots; the specific gravity or electrolyte level. Have these
• Do not lay tools or metal parts on top of the procedures performed at the intervals specified in
battery; and the “Service Schedule.” A negative ground system is
• Disconnect charging source prior to connecting or used. Battery connections are shown on the wiring
disconnecting battery terminals. diagrams. Make sure the battery is correctly connect-
ed and terminals are tight. Observe battery polarity
when connecting the battery to the generator set.
 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.
11
Section 2 — Post Installation Start-up and Adjustments
2.1 BEFORE INITIAL START-UP 2.3 ELECTRICAL CHECKS

NOTE: Complete electrical checks as follows:
These units have been run and tested at the fac- 1. Set the generator's main circuit breaker to its
tory prior to being shipped and do not require any OFF (or OPEN) position.
type of break-in. 2. Set the generator's AUTO/OFF/MANUAL switch to
Before starting, complete the following: the OFF position.
3. Turn OFF all breakers on the load center of the
1. Set the generator’s main circuit breaker to its transfer box (T1 and T2).
OFF (or OPEN) position.
4. Turn on the utility power supply to the transfer
2. Set the generator's AUTO/OFF/MANUAL switch to switch using the means provided (such as a utility
the OFF position. main line circuit breaker).
3. Turn OFF all breakers on the load center of the
transfer box (T1 and T2). DANGER
4. Turn OFF all loads connected to the transfer
switch terminals T1 and T2.
5. Check the engine crankcase oil level and, if neces-
 The transfer switch is now electrically “hot.”
Contact with “hot” parts will result in extremely
sary, fill to the dipstick FULL mark with the rec- hazardous and possibly fatal electrical shock.
ommended oil. Do not fill above the FULL mark. Proceed with caution.
6. Check the fuel supply. Gaseous fuel lines must 5. Use an accurate AC voltmeter to check utility
have been properly purged and leak tested in power source voltage across transfer switch ter-
accordance with applicable fuel-gas codes. All minals N1 and N2. Nominal line-to-line voltage
fuel shutoff valves in the fuel supply lines must should be 240 volts AC.
be open. 6. Check utility power source voltage across termi-
During initial start up only, the generator may exceed nals N1 and the transfer switch neutral lug; then
the normal number of start attempts and experience across terminal N2 and neutral. Nominal line-to-
an “over crank” fault (See the "Overcrank" section). neutral voltage should be 120 volts AC.
This is due to accumulated air in the fuel system dur- 7. When certain that utility supply voltage is compat-
ing installation. Reset the control board and restart ible with transfer switch and load circuit ratings,
up to two more times, if necessary. If unit fails to turn OFF the utility power supply to the transfer
start, contact the local dealer for assistance. switch.
8. On the generator panel, set the AUTO/OFF/
MANUAL switch to MANUAL. The engine should
crank and start.
 Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
9. Let the engine warm up for about five minutes to
allow internal temperatures to stabilize. Then, set
this could damage the engine. the generator’s main circuit breaker to its ON (or
CLOSED) position.
2.2 CHECK TRANSFER SWITCH
DANGER
OPERATION
Refer to the "Manual Transfer Operation" section, of
the owner’s manual for procedures.
 Proceed with caution! Generator power voltage
is now supplied to the transfer switch. Contact
with live transfer switch parts will result in dan-
DANGER gerous and possibly fatal electrical shock.
10. Connect an accurate AC voltmeter and a frequen-
 Do not attempt manual transfer switch opera-
tion until all power voltage supplies to the
cy meter across transfer switch terminal lugs E1
and E2. 7kW voltage should be 242-252 volts at
transfer switch have been positively turned off. a frequency of 61-63 Hertz. 10, 13, 16 and 18kW
Failure to turn off all power voltage supplies voltage should be 247-249 volts at a frequency of
will result in extremely hazardous and possibly 57.5-59.5 Hertz.
fatal electrical shock. 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, 16 and 18kW).
12
12. Set the generator’s main circuit breaker to its • 10, 13, 16 and 18kW voltage should be greater
OFF (or OPEN) position. Let the engine run at no- than 240 volts and frequency should be greater
load for a few minutes to stabilize internal engine than 60 Hz.
generator temperatures. 11. Let the generator run at full rated load for 20-30
13. Set the generator's AUTO/OFF/MANUAL switch to minutes. Listen for unusual noises, vibration or
OFF. The engine should shut down. other indications of abnormal operation. Check
NOTE: for oil leaks, evidence of overheating, etc.
It is important not to proceed until certain that 12. When testing under load is complete, turn OFF
generator AC voltage and frequency are correct electrical loads.
and within the stated limits. Generally, if both AC 13. Set the generator's main circuit breaker to its
frequency and voltage are high or low, the engine OFF (or OPEN) position.
governor requires adjustment* (*GH410 only). If 14. Let the engine run at no-load for a few minutes.
frequency is correct, but voltage is high or low, the 15. Set the AUTO/OFF/MANUAL switch to OFF. The
generator’s voltage regulator requires adjustment. engine should shut down.
2.4 GENERATOR TESTS UNDER LOAD 2.5 CHECKING AUTOMATIC

To test the generator set with electrical loads applied,
proceed as follows:
OPERATION
To check the system for proper automatic operation,
1. Set generator’s main circuit breaker to its OFF proceed as follows:
(or OPEN) position. 1. Set generator’s main circuit breaker to its OFF
2. Turn OFF all breakers on the load center of the (or OPEN) position.
transfer box (T1 and T2). 2. Check that the AUTO/OFF/MANUAL switch is set
3. Set the generator's AUTO/OFF/MANUAL switch to to OFF.
OFF. 3. Turn OFF the utility power supply to the transfer
4. Turn OFF the utility power supply to the transfer switch, using means provided (such as a utility
switch, using the means provided (such as a util- main line circuit breaker).
ity 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.
 Do not attempt manual transfer switch opera-
tion until all power voltage supplies to the
5. Turn ON the utility power supply to the transfer
switch, using the means provided (such as a util-
transfer switch have been positively turned off. ity main line circuit breaker).
Failure to turn off all power voltage supplies 6. Set the generator's main circuit breaker to its ON
will result in extremely hazardous and possibly (or CLOSED) position.
fatal electrical shock. 7. Set the AUTO/OFF/MANUAL switch to AUTO. The
5. Manually set the transfer switch to the STANDBY system is now ready for automatic operation.
position, i.e., load terminals connected to the 8. Turn OFF the utility power supply to the transfer
generator's E1/E2 terminals. The transfer switch switch.
operating lever should be down. With the AUTO/OFF/MANUAL switch at AUTO, the
6. Set the generator's AUTO/OFF/MANUAL switch engine should crank and start when the utility source
to MANUAL. The engine should crank and start power is turned OFF after a 10 second delay. After
immediately. starting, the transfer switch should connect load cir-
7. Let the engine stabilize and warm up for a few cuits to the standby side after a 15 second delay. Let
minutes. the system go through its entire automatic sequence
8. Set the generator’s main circuit breaker to its ON of operation.
(or closed) position. Loads are now powered by With the generator running and loads powered by
the standby generator. generator AC output, turn ON the utility power supply
9. Turn ON the load center of the transfer switch to the transfer switch. The following should occur:
(T1 and T2).
• After about 15 seconds, the switch should transfer
10. Connect an accurate AC voltmeter and a frequen- loads back to the utility power source.
cy meter across terminal lugs E1 and E2.
• About one minute after retransfer, the engine
• 7kW voltage should be greater than 230 volts and should shut down.
frequency should be greater than 58 Hz.
13
2.6 ENGINE GOVERNOR ADJUSTMENT 2.6.2 13, 16 & 18 KW UNITS

If both AC frequency and voltage are correspondingly NOTE:
high or low, adjust the engine governor as follows:
All V-twin units DO NOT require an engine gover-
nor adjustment due to their design.
2.6.1 7 KW UNITS
2.6.3 ADDITIONAL CORROSION
PROTECTION
 The
2.
engine must be OFF to perform steps 1 and
Periodically spray all engine linkage parts and brack-
ets with corrosion inhibiting spray such as WD-40 or
1. Loosen the governor clamp bolt (Figure 2.1). a comparable product.
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 2.7 VOLTAGE REGULATOR
the governor lever clamp bolt to 70 inch-pounds
(8 N-m). ADJUSTMENT
Figure 2.1 — Engine Governor Adjustment 2.7.1 7KW UNITS
Single Cylinder Engines With the frequency between 62-63 Hertz at no-load,
slowly turn the slotted potentiometer (Figure 2.2)
until line voltage reads 248-252 volts.
SECONDARY
ADJUST SCREW
Figure 2.2 – Voltage Adjustment Potentiometer
GOVERNOR
SHAFT
GOVERNOR PRIMARY
CLAMP ADJUST Turn to
BOLT SCREW adjust voltage.
2.7.2 10, 13, 16 & 18 KW UNITS

With the frequency between 58-59 Hertz at no-load,
3. Start the generator; let it stabilize and warm up
slowly turn the slotted potentiometer (Figure 2.3)
at no-load.
until line voltage reads 247-249 volts.
4. Connect a frequency meter across the generators
AC output leads. NOTE:
5. Turn the primary adjust screw to obtain a fre- The access panel on top of the control panel must
quency reading of 61.5 Hertz. Turn the secondary be removed to adjust the voltage regulator.
adjust screw to obtain a frequency of 62.5 Hz.
NOTE:
6. When frequency is correct at no load, check the
AC voltage reading. If voltage is incorrect, the volt- The voltage regulator is housed above the gen-
age regulator may require adjustment (See the erator's control panel. The regulator maintains a
Voltage Regulator Adjustment section). 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.
14
Section 3 — Operation
3.1 USING THE AUTO/OFF/MANUAL 3.2 AUTOMATIC TRANSFER

SWITCH (FIGURE 3.1) OPERATION
To select automatic operation, do the following:
3.1.1 “AUTO” POSITION 1. Make sure the transfer switch main contacts are
Selecting this switch position activates fully automatic set to their UTILITY position, i.e., loads con-
system operation. It also allows the unit to automati- nected to the utility power source (Figure 3.2).
cally start and exercise the engine every seven days 2. Be sure that normal UTILITY power source volt-
with the setting of the exercise timer (see the Setting age is available to transfer switch terminal lugs
the Exercise Timer section). N1 and N2 (Refer to the Electrical Data section).
3. Set the generator’s AUTO/OFF/MANUAL switch to
3.1.2 “OFF” POSITION AUTO.
This switch position shuts down the engine. This 4. Set the generator’s main circuit breaker to its ON
position also prevents automatic operation. (or CLOSED) position.
With the preceding steps complete, the generator will
Figure 3.1 – Generator Control Panel 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
CONTROL AND INFORMATION CENTER
Sequence of Automatic Operation section.
SYSTEM SET
3.3 SEQUENCE OF AUTOMATIC

LOW BATTERY
LOW OIL
AUTO. OFF MAN.
HIGH TEMP
SYSTEM FUSE OVER SPEED
NO RPM SENSE IF FLASHING
OVER CRANK
OPERATION
The generator’s control panel houses a control logic
15A SET
FLASHING GREEN LED=
NO UTILITY SENSE
circuit board. This board constantly monitors util-
EXERCISE
ASSY: 0F8418/0F8419
TIME
5 FLASHING RED LEDS=
EXERCISER NOT SET 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,
3.1.3 “MANUAL” POSITION the circuit board signals the transfer switch to acti-
Set the switch to MANUAL to crank and start the vate and connect load circuits to the standby power
engine. Transfer to standby power will not occur supply (load terminal lugs T1/T2 connect to terminal
unless there is a utility failure. 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
 With the switch set to AUTO, the engine may
crank and start at any time without warning.
Hz.
Such automatic starting normally occurs when Upon restoration of utility source voltage above a
utility power source voltage drops below a pre- preset level, generator circuit board action signals the
set level or during the normal exercise cycle. To transfer switch to transfer loads back to that power
prevent possible injury that might be caused supply. After retransfer, the engine is signalled to shut
by such sudden starts, always set the switch to down.
OFF and remove the fuses before working on or The actual sequence of operation is controlled by
around the generator or transfer switch. Then, sensors and timers on a control logic circuit board,
place a “DO NOT OPERATE” tag on the genera-
as follows:
tor panel and on the transfer switch.
A. Utility Voltage Dropout Sensor
3.1.4 CHOKE OPERATION • This sensor monitors utility source voltage.
• If utility source voltage drops below about 65
1. 990 engines have an electric choke in the air box
that is automatically controlled by the electronic percent of the nominal supply voltage, the sensor
control board. energizes a 10 second timer.
2. 530 engines have an electric choke on the divider • Once the timer has expired, the engine will crank
panel air inlet hose that is automatically con- and start if utility is still low.
trolled by the electronic control board. B. Engine Warm-up Time Delay
3. 410 engines have a choke behind the air box that • This mechanism lets the engine warm up for
is automatically controlled by the electronic con- about five (5) seconds before the load is trans-
trol board. ferred to the standby source.
15
C. Standby Voltage Sensor 7. Set the generator’s main circuit breaker to its ON
• This sensor monitors generator AC output volt- (or CLOSED) position. The standby power source
age. When the voltage has reached 50 percent of now powers the loads.
the nominal rated voltage, transfer to standby
can occur. Figure 3.2 – Manual Transfer Switch Operation
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

3.4.2 TRANSFER BACK TO UTILITY POWER
3.4.1 TRANSFER TO GENERATOR SOURCE
POWER SOURCE When utility power has been restored, transfer back
To start the generator and activate the transfer switch to that source and shut down the generator. This can
manually, proceed as follows: be accomplished as follows:
1. Set the generator’s AUTO/OFF/MANUAL switch to 1. Set the generator’s main circuit breaker to its
OFF. OFF (or OPEN) position.
2. Set the generator’s main circuit breaker to its 2. Let the engine run for a minute or two at no-load
OFF (or OPEN) position. to stabilize the internal temperatures.
3. Turn OFF the utility power supply to the transfer 3. Set the generator’s AUTO/OFF/MANUAL switch
switch using the means provided (such as a utility to its OFF (or OPEN) position. The engine should
main line circuit breaker). shut down.
4. Check that utility power supply to the transfer
DANGER switch is turned OFF.
 Do not attempt to activate the transfer switch

manually until all power voltage supplies to the
DANGER
switch have been positively turned off. Failure
to turn off all power voltage supplies may result
 Do not attempt to activate the transfer switch
manually until all power voltage supplies to the
in extremely hazardous and possibly fatal elec- switch have been positively turned off. Failure
trical shock. to turn off all power voltage supplies may result
4. Use the manual transfer handle inside the trans- in extremely hazardous and possibly fatal elec-
fer switch to move the main contacts to their trical shock.
STANDBY position, i.e., loads connected to the 5. Use the manual transfer handle inside the trans-
standby power source (Figure 3.2). fer switch to move the main contacts back to their
5. To crank and start the engine, set the AUTO/OFF/ UTILITY position, i.e., loads connected to the util-
MANUAL switch to MANUAL. ity power source (Figure 3.2).
6. Let the engine stabilize and warm up for a few 6. Turn ON the utility power supply to the transfer
minutes. switch using the means provided.
7. Set the system to automatic operation as outlined
in Automatic Transfer Operation section.
16
3.5 SETTING THE EXERCISE TIMER • If utility is still lost after 10 seconds, run the
engine up to 3600 RPM and transfer the load.
This generator is equipped with an exercise timer.
Once it is set, the generator will start and exercise At this time the controller will exit the exercise
once every seven days, on the day of the week and at routine and assume full automatic operation.
the time of day the following sequence is completed.
During this exercise period, the unit runs for approx- 3.6 PROTECTION SYSTEMS
imately 12 minutes and then shuts down. Transfer of
loads to the generator output does not occur during 3.6.1 LOW OIL PRESSURE SWITCH
the exercise cycle unless utility power is lost. This switch (Figure 3.3) has normally closed con-
A switch on the control panel (see Figure 3.1) per- tacts that are held open by engine oil pressure dur-
mits selection of the day and time for the system to ing cranking and operating. Should oil pressure
exercise. At the chosen time, perform the following drop below the 8 psi range, switch contacts close,
sequence to select the desired day and time of day and the engine shuts down. The unit should not be
the system will exercise. Remember seasonal time restarted until oil is added. The AUTO/OFF/MANUAL
changes affect the exercise time settings. switch must then be turned to OFF and then back to
AUTO.
1. Verify that the AUTO/OFF/MANUAL switch is set
to AUTO.
2. Press and hold the "Set Exercise Time" switch for 3.6.2 HIGH TEMPERATURE SWITCH
several seconds, then release. All the red LED's This switch’s contacts (Figure 3.3) close if the tem-
will flash for approximately 10 seconds and then perature should exceed approximately 144º C (293º
stop. F), initiating an engine shutdown. The generator will
3. Once the red LED's stop flashing, the generator automatically restart and the LED on the generator
will start and run for approximately 12 minutes control panel will reset once the temperature has
and then shut down. The exerciser is now set to returned to a safe operating level.
run at this time of day each week.
Example: If the "Set Exercise Time" switch is Figure 3.3 – Low Oil Pressure and
pressed on Saturday afternoon at 2:00 p.m., the High Temperature Switches
generator will start and exercise for approximate-
ly 12 minutes every Saturday at 2:00 p.m.. Low Oil Switch High Temp Switch
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 16 and 18kW units have a low speed exercise Loos
en
option. Dip switch 1 on the control board is factory
set to OFF. This allows the engine to run at a slower Oil Filter
speed during weekly exercise periods for quieter
operation. If this Dip switch is set to ON, the genera- Oil
tor will exercise at it's normal speed. Drain
This DIP switch position is only read at board power Hose
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.
3.6.3 OVERCRANK
Low speed exercise will be handled as follows:
This feature prevents the generator from damaging
1. The standard start sequence will be initiated. itself when it continually attempts to start and anoth-
2. The unit will run at 2,400 RPM. er problem, such as no fuel supply, prevents it from
3. If utility is lost during exercise, the controller will starting. The unit will crank and rest for a preset
do the following: time limit. Then, it will stop cranking, and the LED
• Wait 10 seconds for utility to return. on the generator control panel will light indicating an
• If utility returns within 10 seconds, continue to overcrank failure. The AUTO/OFF/MANUAL switch
exercise at 2,400 RPM. will need to be set to OFF and then back to AUTO to
reset the generator control board.
17
Section 4 — Maintenance
NOTE: • If an RPM signal is not detected within the first

If the fault is not repaired, the overcrank feature three (3) seconds of cranking, the control board
will continue to activate. will shut the engine down and latch out on RPM
sensor loss.
3.7.3.1 Approximate Crank Cycle Times • If the RPM signal is detected, the engine will start
and run normally. If the RPM signal is subsequent-
7kW Units: ly lost again, the control board will try one more
• 15 seconds ON re-crank attempt before latching out and flashing
• 7 seconds OFF the over speed LED.
• 7 seconds ON
• 7 seconds OFF 7 KW Operation
• 7 seconds ON During cranking, if the control board does not see a
• 7 seconds OFF valid RPM signal within three (3) seconds, it will shut
• 7 seconds ON down and latch out on RPM sensor loss.
• 7 seconds OFF The control board will continue the standard crank/
• 7 seconds ON reset sequence. At the end of the crank/reset cycle,
• 7 seconds OFF the control board will latch out on over crank (if RPM
• 7 seconds ON are never seen). The control board will not energize
If the unit fails to start, the overcrank alarm LED will fuel solenoid until it sees RPM.
be illuminated.
In the event the control board sees RPM during
10, 13, 16 & 18kW Units: crank, and then RPM are lost during crank, the con-
• 16 seconds ON trol board will shut down the engine (turn off fuel and
• 7 seconds OFF ground magneto). The control board will wait two
(2) seconds and then continue the crank sequence
• 16 seconds ON
with the next crank cycle (if additional crank cycles
• 7 seconds OFF exist).
• 7 seconds ON
• 7 seconds OFF 3.6.6 LOW BATTERY
• 7 seconds ON The microprocessor will continually monitor the
• 7 seconds OFF battery voltage and turn on the Low Battery LED if
• 7 seconds ON the battery voltage falls below 11.0 volts for one (1)
• 7 seconds OFF minute. No other action is taken on a low battery
If the unit fails to start, the overcrank alarm LED will condition. Low battery voltage is a non-latching alarm
be illuminated. which will automatically clear if the battery voltage
rises above 11.0 volts. Battery voltage is NOT moni-
tored during the crank cycle.
3.6.4 OVERSPEED
This feature protects the generator from damage by 4.1 FUSES
shutting it down if it happens to run faster than the The 15-amp fuse on the generator panel protects the
preset limit. This protection also prevents the genera- DC control circuit against overload (Figure 4.1). This
tor from supplying an output that could potentially fuse is wired in series with the battery output lead
damage appliances connected to the generator cir- to the panel. If this fuse element has melted open,
cuit. Contact the nearest Authorized Dealer if this the engine will not be able to crank or start. Replace
failure occurs. this fuse using only an identical 15-amp replacement
fuse. To replace the fuse, push the fuse holder cap
3.6.5 RPM SENSOR FAILURE down and rotate it counterclockwise. Whenever the
fuse is removed or replaced, the exercise timer needs
10, 13, 16 & 18kW Operation to be reset.
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, than re-crank the engine.
18
Figure 4.1 – Generator Control Panel Figure 4.3 — Oil Dipstick and Fill, 10kW
CONTROL AND INFORMATION CENTER Oil Dipstick

SYSTEM SET
LOW BATTERY
LOW OIL
AUTO. OFF MAN.
HIGH TEMP
SYSTEM FUSE OVER SPEED
NO RPM SENSE IF FLASHING
OVER CRANK
FLASHING GREEN LED=

15A SET NO UTILITY SENSE
EXERCISE 5 FLASHING RED LEDS=
ASSY: 0F8418/0F8419
TIME EXERCISER NOT SET
4.2 CHECKING THE ENGINE

OIL LEVEL
For oil capacities, see the Specifications section. Oil Fill
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. Figure 4.4 — Oil Dipstick and Fill,
2. Remove the dipstick and wipe it dry with a clean 13, 16 & 18kW
cloth.
3. Completely insert the dipstick; then, remove it
again. The oil level should be at the dipstick “Full” Oil Dipstick
mark. If necessary, add oil to the “Full” mark
only. DO NOT FILL ABOVE THE “FULL” MARK.
Figure 4.2 — Oil Dipstick and Fill, 7kW
Oil Dipstick and Fill 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

All oil should meet minimum American Petroleum
Institute (API) Service Class SJ, SL or better. Use
no special additives. Select the oil's viscosity grade
 Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
according to the expected operating temperature
(also see chart).
this could damage the engine. • Above 40° F, use SAE 30
4. Install the dipstick. • Below 40° F and down to 10° F, use 10W-30
5. Reset the AUTO/OFF/MANUAL switch to its origi- • Below 10° F, use synthetic 5W-30
nal position.
19
Figure 4.5 – Oil Drain Hose and Filter

Low Oil Switch High Temp Switch
SA
AEE 3 0
10 W
W-3
-30
Synthetic 5W-30
Loos
en
Oil Filter
Oil
Drain
Hose
 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. 4.4 CHANGING THE ENGINE
4.3.3 OIL & OIL FILTER CHANGE PROCEDURE
AIR CLEANER
To change the oil, proceed as follows: 4.4.1 7, 13, AND 16KW GENERATORS
1. Start the engine by moving the AUTO/OFF/ See Figures 1.1 and 1.2, for the location of the air
MANUAL switch to MANUAL and run until it cleaner. Use the following procedures (Figure 4.6,
is thoroughly warmed up. Then shut OFF the 7kW; Figure 4.8, 13/16kW):
engine by moving the switch to the OFF position. 1. Lift the roof and remove the door.
2. Immediately after the engine shuts OFF, pull the 2. Turn the two screws counterclockwise to loosen.
oil drain hose (Figure 4.5) free of its retaining
3. Remove the cover and air filter.
clip. Remove the cap from the hose and drain the
oil into a suitable container. 4. Wipe away dust or debris from inside of the air
box and around edges.
3. After the oil has drained, replace the cap onto the
end of the oil drain hose. Retain the hose in the 5. Install the new air cleaner into the air box.
clip. 6. Install the cover. Turn the two cover screws clock-
Change the engine oil filter as follows: wise to tighten.
See the Service Schedule section for air cleaner main-
1. With the oil drained, remove the old oil filter by tenance. See the Specifications section for air filter
turning it counterclockwise. replacement part number.
2. Apply a light coating of clean engine oil to the gas-
ket of the new filter. See the Specifications section
Figure 4.6 — 7 kW, Engine Air Cleaner Location
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 Air
Specifications section for oil capacities. Cleaner
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 3/4”
AUTO position. Hole
20
4.4.2 10KW GENERATORS 4.5 SPARK PLUG(S)

See Figure 1.2 for the location of the air cleaner. Use Reset the spark plug(s) gap or replace the spark
the following procedure (Figure 4.7): plug(s) as necessary. See the Service Schedule section
for maintenance requirements.
1. Lift the roof and remove the door.
2. Turn the worm gear clamp screw counterclock- 1. Clean the area around the base of the spark
wise to loosen. plug(s) to keep dirt and debris out of the engine.
3. Pull the old filter off the divider panel hub. 2. Remove the spark plug(s) and check the condi-
tion. Replace the spark plug(s) if worn or if reuse
4. Wipe away dust or debris from the panel hub.
is questionable. See the Service Schedule section
5. Install the new air cleaner onto the hub. for recommended inspection. Clean by scraping
6. Turn the worm gear clamp screw clockwise to or washing using a wire brush and commercial
tighten. solvent. Do not blast the spark plug(s) to clean.
7. Replace door and roof. 3. Check the spark plug gap using a wire feeler
gauge. Adjust the gap to 0.76 mm (0.030 inch)
Figure 4.7 — 10kW Engine Air Cleaner for 7 and 10kW; and 1.02 mm (0.040 inch) for
13, 16 and 18kW by carefully bending the ground
electrode (Figure 4.9).
Control Figure 4.9 – Setting the Spark Plug Gap
Panel SET PLUG GAP AT 0.76 mm (.030 inch) - 7 & 10kW;

1.02 mm (.040 inch) - 13, 16 & 18kW
Air Filter
Figure 4.8 — 13, 16 & 18kW

Engine Air Cleaner 4.6 BATTERY MAINTENANCE
The battery should be inspected per the "Service
Schedule" section. The following procedure should be
Screw 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.
Cover This should be done with an automotive-type bat-
tery hydrometer.
Filter DANGER
 Do not dispose of the battery in a fire. The
battery is capable of exploding.
 Aandbattery presents a risk of electrical shock

high short circuit current. The following pre-
cautions are to be observed when working on
batteries:
21
• Remove the 15A fuse from the generator control

panel.
4.7 ADJUSTING GH-410/GT-530/990
• Remove watches, rings or other metal objects; VALVE CLEARANCE
• Use tools with insulated handles; After the first six (6) months of operation, check
• Wear rubber gloves and boots; the valve clearance in the engine, adjust if neces-
• Do not lay tools or metal parts on top of the sary.
battery; and
Important: If feeling uncomfortable about doing
• Disconnect charging source prior to connecting or
this procedure or the proper tools are not available,
disconnecting battery terminals.
please contact the Authorized Dealer for service
assistance. This is a very important step to insure
longest life for the engine.
 Do not open or mutilate the battery. Released
electrolyte has been known to be harmful to the
To check valve clearance:
skin and eyes, and to be toxic. • The engine should be cool before checking. If
valve clearance is 0.002" - 0.004" (0.05 - 0.1mm),
 The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
adjustment is not needed.
• Remove spark plug wires and position wires away
conductive and corrosive. The following from plugs.
procedures are to be observed: • Remove spark plugs.
• Wear full eye protection and protective clothing; • Make sure the piston is at Top Dead Center (TDC)
• Where electrolyte contacts the skin, wash it off of its compression stroke (both valves closed). To
immediately with water; get the piston at TDC, remove the intake screen at
• Where electrolyte contacts the eyes, flush thor- the front of the engine to gain access to the flywheel
oughly and immediately with water and seek nut. Use a large socket and socket wrench to rotate
medical attention; and the nut and hence the engine in a clockwise direc-
• Spilled electrolyte is to be washed down with an tion. While watching the piston through the spark
acid neutralizing agent. A common practice is to plug hole. The piston should move up and down.
use a solution of 1 pound (500 grams) bicarbonate The piston is at TDC when it is at its highest point
of soda to 1 gallon (4 liters) of water. The bicar- of travel (Figure 4.10).
bonate of soda solution is to be added until the To adjust valve clearance (if necessary):
evidence of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water and the • Make sure the engine is at 60° to 80° F.
area dried. • Make sure that the spark plug wire is removed
from the spark plug and out of the way.
 Lead-acid batteries present a risk of fire because
they generate hydrogen gas. The • Remove the four screws attaching the valve cover.
following procedures are to be followed: • Loosen the rocker jam nut. Use an 10mm allen
wrench to turn the pivot ball stud while checking
• DO NOT SMOKE when near the battery; clearance between the rocker arm and the valve
• DO NOT cause flame or spark in battery area; and stem with a feeler gauge. Correct clearance is
• Discharge static electricity from body before touch- 0.002-0.004 inch (0.05-0.1 mm).
ing the battery by first touching a grounded metal NOTE:
surface.
Hold the rocker arm jam nut in place as the pivot
 Be sure the AUTO/OFF/MANUAL switch is set to
the OFF position before connecting the battery
ball stud is turned.
cables. If the switch is set to AUTO or MANUAL, When valve clearance is correct, hold the pivot ball
the generator can crank and start as soon as the stud in place with the allen wrench and tighten the
battery cables are connected. rocker arm jam nut. Tighten the jam nut to 174
in/lbs. torque. After tightening the jam nut, recheck
 Be sure the utility power supply is turned off
and the 15A fuse is removed from the generator
valve clearance to make sure it did not change.
control panel, or sparking may occur at the bat- • Install new valve cover gasket.
tery posts as the cables are attached and cause • Re-attach the valve cover.
an explosion. 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.
• Install spark plugs.
22
• Re-attach the spark plug wire to the spark plug.

• On the GT-530 and GT-990, repeat the process for
the other cylinder.
Figure 4.10 - Valve Clearance Adjustment

 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
Rocker from the heat of the exhaust system.
Pivot Ball Arm
Stud
Jam Nut
Valve
Stem  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.
4.10 CORROSION PROTECTION

4.8 COOLING SYSTEM Periodically wash and wax the enclosure using auto-
motive type products. Frequent washing is recom-
Air inlet and outlet openings in the generator com-
partment must be open and unobstructed for con- mended in salt water/coastal areas. Spray engine
tinued proper operation. This includes such obstruc- linkages with a light oil such as WD-40.
tions as high grass, weeds, brush, leaves and snow.
Without sufficient cooling and ventilating air flow, the 4.11 OUT OF SERVICE PROCEDURE
engine/generator quickly overheats, which causes it
to quickly shut down. (See Figure 4.11 for vent loca- 4.11.1 REMOVAL FROM SERVICE
tions.)
If the generator cannot be exercised every seven days,
Make sure the doors and roof are in place dur- and will be out of service longer than 90 days, pre-
ing operation as running the generator with them pare the generator for storage as follows:
removed can effect cooling air movement.
1. Start the engine and let it warm up.
Figure 4.11 – Cooling Vent Locations 2. Close the fuel shutoff valve in the fuel supply line
and allow the unit to shut down.
Air 3. Once the unit has shut down, it will signal a low
Outlet Air Intake 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".
23
7. Attach a tag to the engine indicating the viscosity 4. Clean and wipe the entire generator.
and classification of the oil in the crankcase. 5. Make sure the 15A fuse is removed from the
8. Remove the spark plug(s) and spray fogging generator control panel. Reconnect the battery.
agent into the spark plug(s) threaded openings. Observe battery polarity. Damage may occur if the
Reinstall and tighten the spark plug(s). battery is connected incorrectly.
9. Remove the battery and store it in a cool, dry 6. Open the fuel shutoff valve.
room on a wooden board. Never store the battery 7. Insert the 15A fuse into the generator control
on any concrete or earthen floor. panel. Start the unit by moving the AUTO/OFF/
10. Clean and wipe the entire generator. MANUAL switch to MANUAL. Allow the unit to
warm up thoroughly.
4.11.2 RETURN TO SERVICE 8. Stop the unit by setting the AUTO/OFF/MANUAL
To return the unit to service after storage, proceed switch to OFF.
as follows: 9. Turn on the utility power to the transfer switch.
10. Set the AUTO/OFF/MANUAL switch to AUTO.
1. Verify that utility power is turned off and that the
11. The generator is now ready for service.
AUTO/OFF/MANUAL switch is set to OFF.
NOTE:
2. Check the tag on the engine for oil viscosity and
classification. Verify that the correct recommend- If the battery was dead or disconnected, the exer-
ed oil is used in the engine (see the Engine Oil cise timer must be reset.
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.
24
4.12 SERVICE SCHEDULE
ATTENTION: It is recommended that all service work

be performed by the nearest Dealer.
SYSTEM/COMPONENT PROCEDURE FREQUENCY

X = Action W = Weekly
R = Replace as Necessary M = Monthly
Inspect Change Clean
* = Notify Dealer if Repair is Y = Yearly
Needed.
FUEL
Fuel lines and connections* X M
LUBRICATION
Oil level X M or 24 hours of
continuous operation.
Oil X 2Y or 200 hours
of operation.**
Oil filter X 2Y or 200 hours
of operation.**
COOLING
Enclosure louvers X X W
BATTERY
Remove corrosion, ensure X X M
dryness
Clean and tighten battery X X M
terminals
Check charge state X R EVERY 3 M
Electrolyte level X R EVERY 3 M
(unsealed batteries only)*
ENGINE AND MOUNTING
Air cleaner X R 2Y or 200 hours
Spark plug(s) X R 2Y or 200 hours
GENERAL CONDITION
Vibration, Noise, Leakage, X M
Temperature*
COMPLETE TUNE-UP* TO BE COMPLETED BY A DEALER 2Y or 200 hours
* Contact the nearest dealer for assistance if necessary.
** Change oil and filter after first eight (8) hours of operation and then every 200 hours thereafter, or 2 years, which-
ever occurs first. Change sooner when operating under a heavy load or in a dusty or dirty environment or in high
ambient temperatures.
25
Section 5 — Troubleshooting
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. *
3. Improper type or viscosity of oil. 3. See "Engine Oil Recommendations".
4. Damaged gasket, seal or hose. 4. Check for oil leaks.
*Contact the nearest Authorized Dealer for assistance.
26
Section 6 — Electrical Data
Electrical Schematic – 8, 10, 12 and 16 Circuit Load Center – Drawing No. 0F9775
E1
N1A 194 194 194
12Vdc TRANSER
194 COIL
A 23 23 23
7 7 9 9
E1 TR
TS TO
1 4 3 6
B OPEN GENERATOR
N1A CONTROL PANEL
23 F2
126 205 N2 N2
N2A 240VAC
F1 OUTPUT
N1A N1A N1 N1
N1A
E1 E1 BLACK
E2 RED TO GENERATOR
OUTPUT
E1 CIRCUIT BREAKER
E2 NEUTRAL (WHITE)
NEUTRAL
CONNECTION
INSIDE SWITCH
B NEUTRAL (WHITE)
N2A 240VAC TO
205 RED (MAIN 2) MAIN DISTRIBUTION
B PANEL
126 N1A
N2A BLACK (MAIN 1)
E1
NO NC NC NO
E2 CIRCUIT 14
XA XB E2 CIRCUIT 13
COM COM
B CIRCUIT 10
VR1 VR2
N2A
A C1 C2 CIRCUIT 9
T1 T2
ATS CIRCUIT 6
N2A CIRCUIT 5
10 CIRCUIT LOAD CENTER

B E2
CIRCUIT 2
T1 CIRCUIT 1
T2 CIRCUIT 3
B E2 CIRCUIT 4
CIRCUIT 7
LEGEND CIRCUIT 8
ATS-AUTOMATIC TRANSFER SWITCH
C1-UTILITY COIL & RECTIFIER CIRCUIT 11
C2-GENERATOR COIL & RECTIFIER
F1,F2-5A, 600V FUSE
CIRCUIT 12
LC-CIRCUIT BREAKER (LOADS)
TR-TRANSFER RELAY
TS-TERMINAL STRIP CIRCUIT 15
XA,XB-LIMIT SWITCHES
CIRCUIT 16
LC
27
Wiring Diagram – 10, 13, 16 & 18kW, V-Twin – Drawing No. 0F7822-A
28
Wiring Diagram – 10, 13, 16 & 18kW, V-Twin – Drawing No. 0F7822-A
29
Electrical Schematic – 10, 13, 16 & 18kW, V-Twin – Drawing No. 0F7823-A
30
Electrical Schematic – 10, 13, 16 & 18kW, V-Twin – Drawing No. 0F7823-A
31
Wiring Diagram – 7kW, Single Cylinder – Drawing No. 0F7820-A
32
Wiring Diagram – 7kW, Single Cylinder – Drawing No. 0F7820-A
33
Electrical Schematic – 7kW, Single Cylinder – Drawing No. 0F7821-A
34
Electrical Schematic – 7kW, Single Cylinder – Drawing No. 0F7821-A
35
Wiring Diagram – 8, 10, 12 and 16 Circuit Load Center – Drawing No. 0F9070-B
36
Wiring Diagram – 8, 10, 12 and 16 Circuit Load Center – Drawing No. 0F9070-B
37
Section 7 — Exploded Views and Parts Lists
Enclosure – Drawing No. 0G5050-E
SHEET METAL PAINT/MATERIAL CODE LEGEND

The following exploded views contain part numbers of various sheet metal components. Only the base part number is listed. When ordering sheet metal, the correct
color and material information must be included as a suffix at the end of the part number as shown below.
Material Color Example: Desc. Part No. Material Color Order As"
S = Steel N = Tan Roof 0F6522 S = Steel N = Tan 0F6522SN
A = Aluminum G = Gray Door 0F6555 A = Aluminum G = Gray 0F6555AG
B = Black Divider 0F6558 S = Steel B = Black 0F6558SB
38
Enclosure – Drawing No. 0G5050-E
ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION
1 0F9653 1 PAD, 24 X 48” WITH MOUNTING HOLES 0F7886 1 PANEL, ENGINE DIVIDER (10KW)
2 045771 4 NUT HEX M8-1.25 0F7885 1 PANEL, ENGINE DIVIDER
3 022129 4 WASHER LOCK 5/16 49 023484H 1 BUSHING SNAP SB-1500-18
022129 5 WASHER LOCK 5/16 (7KW) 50 0D3058A 1 FOAM, FRONT INTAKE BAFFLE (7KW)
4 022145 8 WASHER FLAT 5/16 0E4245 1 FOAM, FRONT INTAKE BAFFLE
5 043107 4 SCREW HHC M8-1.25 X 25 51 0D3058C 1 FOAM, BACK INTAKE BAFFLE (7KW)
6 090388 15 SCREW TAPTITE M6-1.0 X 12 52 0D1605A 1 BAFFLE, INTAKE (7KW)
7 0D3700 24 NUT, LOCKING FLANGE M6-1.0 0F7798 1 BAFFLE, INTAKE
0D3700* 14 NUT, LOCKING FLANGE M6-1.0 53 0F8380 1 FOAM, TOP INTAKE BAFFLE
022097* 10 WASHER LOCK M6-1/4 54 0D3472 1 GROMMET OVAL 31.75 X 50.8
022473* 10 WASHER FLAT 1/4-M6 ZINC 55 0C8285 1 BRACKET, BATTERY SUPPORT
049813* 10 NUT HEX M6 X 1.0 56 0D3167 1 GASKET, BATTERY SUPPORT BRACKET
8 0D4662 14 SCREW HHTR 5/16-18 X 3/4” (7KW) 57 0E1330 1 GROMMET, 38.1 DIA. CROSS SLIT
0D4662 13 SCREW HHTR 5/16-18 X 3/4” 58 043116 3 SCREW HHC, M6-1.0 X 12 G8.8(7KW)
9 0F8871 1 SCROLL, FAN (7KW, 10KW) 043116 1 SCREW HHC M6-1.0 X 12 G8.8
0F8080 1 SCROLL, FAN 59 086729 1 CONTACTOR, STARTER (7KW)
10 0F8246 1 PANEL, ALTERNATOR DIVIDER (7KW) 60 0F8039 1 MOUNTING CLIP
0F8915 1 PANEL, ALTERNATOR DIVIDER (10KW) 61 022127 1 NUT HEX 1/4-20 (7KW)
0F6558 1 PANEL, ALTERNATOR DIVIDER 62 0388040AJ0 1 CABLE, #6 RED BATTERY 38.5”
11 092120 4 NUT LOCK TRIC M6 X 1.0 63 0F8847 1 GASKET, FRONT DIVIDER
12 0F7825 1 FOAM, MUFFLER BOX FRONT 0F8434 1 GASKET, FRONT DIVIDER (10KW)
13 0F7824 1 FOAM, MUFFLER BOX END 64 0F9968 1 FUEL LINE, 1/2” OUTDOOR (NOT SHOWN)
14 0F6549 1 ENCLOSURE, EXHAUST SIDE 65 0C2937 1 BRACKET, BATTERY HOLD DOWN (7KW)
15 0F7824A 1 FOAM, MUFFLER BOX END 66 049813 1 NUT HEX M6-1.0 G8
16 0D1840 2 BRACKET, BOTTOM SUPPORT 67 0A1658 1 LOCK WASHER SPECIAL 1/4
17 047411 6 SCREW HHC M6-1.0 X 16 G8.8 (7KW) 68 0G0617 1 EXTERNAL CONNECTION BOX
047411 8 SCREW HHC M6-1.0 X 16 G8.8 69 092079 1 SCREW TAPTITE M6-1.0 X 25 BP
18 0F0710 12 RIVET POP 0.125” X 0.337” 70 055414 1 LUG SLDLSS #2-#8 X 17/64 CU
19 0A2115 4 WASHER NYLON M6-1/4” 71 0F8234 1 ASSEMBLY, ENCLOSURE BASE (7KW)
20 0C6735 2 SUPPORT, ROOF FOLDING 0F7711 1 ASSEMBLY, ENCLOSURE BASE
21 0D2979D 2 CLOTH HARDWARE 266.7mm X 387.4mm 72 0F8257 1 FOAM, FRONT ENCLOSURE
22 0D7176 34 WASHER, SELF LOCKING 73 0C3906 2 SELF-ALIGN SCREW M6 HH
23 0F7827 2 FOAM, EXHAUST ENCLOSURE COVER 74 0F6555 1 ENCLOSURE, FRONT
24 0F6570 1 COVER, BACK EXHAUST ENCLOSURE 75 0F8555 1 GASKET, DOOR SEAL
25 0F6571 1 COVER, FRONT EXHAUST ENCLOSURE 76 0D3037 1 LATCH, QUARTER TURN LOCKING
26 0D2979B 1 CLOTH, HARDWARE 266.7mm X 146mm 77 0D3037A 1 LATCH, QUARTER TURN NON-LOCKING
27 0D2979C 1 CLOTH, HARDWARE 543mm X 146mm 78 0F9143 2 PAWL, DOOR
28 022097 4 WASHER LOCK M6-1/4 (7KW) 79 0F8261 1 FOAM, BACK ENCLOSURE
022097 3 WASHER LOCK M6-1/4 80 0F5440 1 HARNESS GENERATOR TO EXTERNAL
29 022473 2 WASHER FLAT M6-1/4 CONNECTION BOX (7KW)
30 0F7826 1 FOAM, MUFFLER BOX BACK 0F9328 1 HARNESS GENERATOR TO EXTERNAL
31 0F0165A 1 HINGE TYPE B WITH STUDS, SOCKET CONNECTION BOX (10KW)
32 0F6550 1 ENCLOSURE, SIDE & BACK (7KW ONLY) 0F5478 1 HARNESS GENERATOR TO EXTERNAL
0G5705 1 ENCLOSURE, SIDE & BACK CONNECTION BOX
33 0F0164A 1 HINGE TYPE A WITH STUDS, SOCKET 81 051713 2 WASHER FLAT M5
34 0E1330A 1 GROMMET, 38.1 CROSS SLIT WITH HOLE 82 022152 5 WASHER LOCK #10
35 021267A 2 PLUG PLASTIC 1.5 BLIND GROMMET 83 036937 2 SCREW PPHM#10-32 X 1
36 0E5968 11 GASKET, EXTRUDED TRIM 84 022158 5 NUT HEX #10-32
37 0F0165 1 HINGE TYPE B WITH STUDS, PIN 85 0C8911 1 POWER BLOCK
38 0F0164 1 HINGE TYPE A WITH STUDS, PIN 86 026850 1 WASHER SHAKEPROOF EXT 1/4 STEEL
40 0A8475 1 L/WASH SPECIAL #10 89 0G3540 1 WASHER FLAT .125ID X .375OD
41 0G0400 1 WIRE ASSEMBLY, GROUND 90 0G3539 1 RIVET POP .122 X 0.465 STEEL
42 0F6552 1 ENCLOSURE, ROOF 91 0G5900 1 COVER PLATE, RF MONITOR
43 0F9379 1 FOAM, ROOF ENCLOSURE (10,13,16,18KW)
44 0D1839 2 BRACKET, TOP SUPPORT 92 0G5862 1 GASKET, RF COVER PLATE (10,13,16,18KW)
45 0F8210 1 REGULATOR ASSEMBLY (7KW) 93 0E6480 3 NUT HEX LOCK M4-0.7 NY INS
0F8209 1 REGULATOR ASSEMBLY (10KW) (10,13,16,18KW)
0F9078 1 REGUALTOR ASSEMBLY 94 051787 3 SCREW HHC M4-0.7 X 16 C8.8
46 0F5458 4 SCREW PLASTITE HI-LOW #10 X 3/8 (10,13,16,18KW)
47 0F5438 1 HARNESS, ENGINE (7KW) 95 043180 6 WASHER FLAT M4 (10,13,16,18KW)
0F5434 1 HARNESS ENG V-T HSB
48 0G5451 1 PANEL, ENGINE DIVIDER (7KW) *ITEM 7 FOR MODELS WITH ALUMINUM ENCLOSURE
39
Control Panel – Drawing No. 0F9695-G
40
Control Panel – Drawing No. 0F9695-G
1 0E7886A 1 CIRCUIT BREAKER 30A X 2P 240V (7KW) 24 0D8502 1 NEUTRAL BLOCK

0E7886D 1 CIRCUIT BREAKER 45A X 2P 240V 25 031879 4 WASHER FLAT #4
(10KW) 031879 2 WASHER FLAT #4 (7KW)
0E7886E 1 CIRCUIT BREAKER 50A X 2P 240V 26 0F5433 1 HARNESS, CONTROL PANEL WIRE (NOT
(12KW) SHOWN)
0E7886K 1 CIRCUIT BREAKER 55A X 2P 240V 0F5437 1 HARNESS, CONTROL PANEL WIRE (NOT
(13KW) SHOWN) (7KW)
0E7886J 1 CIRCUIT BREAKER 65A X 2P 240V 27 074908 4 SCREW HHTT, M5-0.8 x 10 BP
(16KW) 28 049813 4 NUT HEX M6-1.0
0E7886L 1 CIRCUIT BREAKER 80A X 2P 240V 29 082025 6 NUT HEX LOCK M5-0.8 NYLON INSERT
(18KW) 30 0G0627 1 XFMR 240/16V 1VA&56VA W/PTC
2 0A1801 1 ASSEMBLY, BATTERY CHARGER ENGINE 31 022507 2 SCREW HHC 1/4”-20 x 1/2”
3 0F9719 1 ASSEMBLY, POTTED REGULATOR 32 022097 4 WASHER LOCK M6-1/4”
4 0C2174 1 RELAY, 12V 25A SPST (NON 7KW) 33 046689 1 TERMINAL STRIP 4 POSITION
5 075210A 1 BLOCK TERMINAL 1 POSITION 34 063617 1 RELAY PANEL 12VDC DPDT 10A 240VAC
7 0F8992 1 ASSY, HOME STANDBY CONTROLLER 35 075475 2 SCREW PPHM M4-0.7 x 10mm
0F1504 1 ASSY, HOME STANDBY CONTROLLER 36 043180 2 WASHER FLAT M4
(7KW) 37 0F8041 1 COVER, CONTROL PANEL COMPONENT
0G5715 1 ASSY, HOME STANDBY CONTROLLER 0F9283 1 COVER, CONTROL PANEL COMPONENT
(18KW) (7KW)
8 032300 1 HOLDER, FUSE 38 045770 2 SCREW HHC M5-0.8 x10mm
9 022676 1 FUSE, 15 AMP X AGC15 39 0E7866 1 COVER, CONTROL PANEL
10 0E4494 1 SWITCH, ROCKER DPDT ON-OFF-ON 0E7867 1 COVER, CONTROL PANEL (7KW)
11 0E7890 1 CIRCUIT BREAKER MOUNTING BRACKET 40 0D3700 8 NUT FLANGE M6-1.0 NYLOK
12 023484E 1 SNAP BUSHING 022097* 8 WASHER LOCK M6-1/4
13 075476 4 SCREW PPHM M4-0.7 x 16mm 022473* 8 WASHER FLAT 1/4-M6
14 043182 2 M3 LOCK WASHER (NON 7KW) 049813* 8 NUT HEX M6 X 1.0
15 0E6480 6 NUT HEX LOCK M4-0.7 NYLON INSERT 41 0G0400 1 WIRE ASSEMBLY, GROUND
16 0D4804A CURRENT TRANSFORMER, IDLE 43 0A1658 2 WASHER LOCK SPECIAL 1/4”
CONTROL (NON 7KW) 44 022473 6 WASHER FLAT 1/4”-M6
0D4804A 2 CURRENT TRANSFORMER, IDLE 45 0E3969 2 SCREW PPH M3-0.5 X 30mm (18KW)
CONTROL (18KW) 46 0G5454 2 SPACER (18KW)
17 0C1085 12 SCREW PPHM M3-0.5 x 8mm 47 0G5449A 1 JUMPER WIRE, RED (18KW, NOT
0C1085 8 SCREW PPHM M3-0.5 x 8mm (7KW) SHOWN)
18 058000H 2 M3-0.5 TRIC NUT (NON 7KW) 48 0G5449B 1 JUMPER WIRE, BLACK (18KW, NOT
19 023897 2 WASHER FLAT #10 SHOWN)
20 0F8040 1 CONTROL, PANEL BOTTOM 49 0D5303 2 WASHER FLAT .25” ID X 1"OD ZINC
0F9282 1 CONTROL, PANEL BOTTOM (7KW) 50 0G6131 2 SCREW HHC M6-1.0 x 30mm
21 075235 4 SCREW HHC M5-0.8 x 30mm
22 0E3928 1 SWITCH, SPST *ITEM 40 FOR MODELS WITH ALUMINUM ENCLOSURE
23 0D9784 4 NUT HEX LOCK M3-0.5 NYLON INSERT
0D9784 2 NUT HEX LOCK M3-0.5 NYLON INSERT
(7KW)
41
Transfer Switch Assembly – Drawing No. 0F9774-C
42
Transfer Switch Assembly – Drawing No. 0F9774-C
1 0F8278 1 BOX LOAD CENTER 21 074138 2 LUG QUICK DISCONNECT NI-S 10X45
2 0D4800 1 COVER, 8 CIRCUIT LOAD CENTER DEG BRASS / TIN
0F5211 1 COVER, 10 CIRCUIT LOAD CENTER 22 036933 6 SCREW PPHM #10-32 X 3/8”
0D3092 1 COVER, 12 CIRCUIT LOAD CENTER 23 077033 6 LUG SLDLSS 1/0-#14X9/16 AL/CU
0F8312 1 COVER, 16 CIRCUIT LOAD CENTER 24 048850 1 BLOCK TERMINAL 20A 5 X 6 X 1100V
3 0C2237 1 TRANSFER SWITCH HOME STANDBY 25 028739 4 TIE WRAP 3.9" X .10"
100A 2P 250V 26 0A2110 4 SCREW SWAGE 1/4-20 X 1/2" ZINC
3A 077220 1 COIL UTILITY 27 0D3191 1 COVER, RELAY & TERMINAL BLOCK
3B 077220A 1 COIL STANDBY 28 0D3088 1 WIRE HARNESS, LOAD CENTER (NOT
3C 082574 1 INSULATOR-SIDEWALL (NOT SHOWN) SHOWN)
3D 084464 1 LIMIT SWITCH OPERATION (NOT 29 073591 2 FUSE HOLDER
SHOWN) 30 073590A 2 FUSE 5A
4 074908 6 SCREW HHTT M5-0.8 X 10 31 040213B 4 SUPPORT SNAP-IN 1-3/8"
5 024912 1 SCREW HHTT 1/4-20 X 5/8 8 10 12 16 CIRCUIT
6 0A1658 1 LOCK WASHER, SPECIAL-1/4” 32 0E7888 A/R CIR BRK 20A 2P 1 1
7 063617 1 RELAY PANEL 12VDC DPDT 10A@240VAC 33 0E7888A A/R CIR BRK 30A 2P 1 1 1
8 0E7889A 1 8 CIRCUIT LOAD CENTER 34 0E7888B A/R CIR BRK 15A 1P 5 3 5 5
0E7889 1 12 CIRCUIT LOAD CENTER (ALSO USED 35 0E7888C A/R CIR BRK 20A 1P 1 3 3 5
FOR 10 CIRCUIT) 36 0E7888D A/R CIR BRK 40A 2P 1 1
0F9213 1 16 CIRCUIT LOAD CENTER 37 0E7888E A/R CIR BRK 50A 2P 1
9 0A1495 4 SCREW HHTT M4-0.7 X 10 38 0D3320 1 COVER - HARNESS ENTRY
10 0A1661 2 RIVET POP .156” X .675” 39 0F5439 1 HARNESS, 8 CIRCUIT LOAD CENTER TO
11 022473 1 WASHER FLAT 1/4-M6 ZINC EXT CONN BOX
12 081108 1 PLUG PLASTIC 0F9327 1 HARNESS, 10 CIRCUIT LOAD CENTER
13 0D4684 1 HARNESS ADAPTER PLATE TO EXT CONN BOX
0D4684A 1 8 CIRCUIT HARNESS ADAPTER PLATE 0F6720 1 HARNESS, 12 CIRCUIT LOAD CENTER
14 0F8279 1 SUBPLATE, LOAD CENTER TO EXT CONN BOX
15 0F4790 10.5” U-CHANNEL 0F6720 1 HARNESS, 16 CIRCUIT LOAD CENTER
16 022152 6 WASHER LOCK #10 TO EXT CONN BOX
17 064526 2 SCREW HWHS #6-25 X 3/8” 40 074908 2 SCREW HHTT M5-0.8 X 10 (8 CIRCUIT)
18 0E6155 1 ARM EXTENDER PIN 066849 2 SCREW HHTT M5-0.8 X 16 (10, 12, 16
19 063378 4 HOLDER CABLE TIE CIRCUIT)
20 0G0979 1 HARNESS, 8 CIRCUIT LOAD CENTER TO 41 0A7215 4 SCREW SW 1/4"-20 X 5/8” WITH WASHER
MAIN PANEL 42 0E6193 1 BRACKET, ARM EXTENDER
0G0980 1 HARNESS, 10 CIRCUIT LOAD CENTER
TO MAIN PANEL
TO MAIN PANEL
TO MAIN PANEL
43
13, 16 & 18kW, GT-990 Engine – Drawing No. 0G3071-Q - Part 1
44
1 0C5729 1 ASSY, C’CASE WITH SLEEVE 32 0C5305 1 TUBE, DIPSTICK

(13,14,16,17Kw) 33 0D6147 5 SCREW HHFC M6-1.0 X 10mm
0G8548 1 ASSY, CRANKCASE WITH SLEEVE (20Kw) 34 043790A 1 BARBED ELBOW 90 3/8NPT X 3/8 VS
2 0E9843A 1 SEAL, 38 I.D. CRANKSHAFT GREEN 35 0E9842A 1 SEAL, 42 I.D. CRANKSHAFT GREEN
3 0G0919 5 SCREW, HHFCS M6-1.0 X 12 G8.8 36 0F8054 1 GEARCOVER / ADAPTOR GTH-990
4 0C5372 1 ASSEMBLY, BREATHER 37 0C3006 10 SCREW, HHFC M10-1.5 X 55
5 0C3005 1 GASKET, BREATHER COVER 38 080318 8 SCREW HHFC M6-1.0 X 25
6 0E3372B 1 SEPARATOR, OIL BREATHER 39 093064 1 ASSEMBLY, OIL FILL CAP
7 0D8067A 1 ASSEMBLY, HEAD #1 G&S (13,14,16,17Kw) 40 0G1839 2 LIFT HOOK GT990/760
0G4400A 1 ASSY,HEAD #1 (20 Kw) 41 0D2723D 1 ROCKER, COVER WITH OIL FILL
8 071983 4 RETAINER, PISTON PIN 20 42 0C2979 2 GASKET, VALVE COVER
9 0C2981F 1 ROCKER, COVER NO OIL FILL 43 086515 8 KEEPER, VALVE SPRING
11 0G2751 2 PISTON, FLAT TOP DIA 90 COATED 44 0D2274 4 RETAINER, VALVE SPRING
12 0G2565 2 RING SET, PISTON DIA 90 45 0D3867 4 SPRING, VALVE
13 0E1466 2 PIN, PISTON (13,14,16,17Kw) 46 078672 2 SEAL, VALVE STEM D7
0G7940 2 PIN, PISTON (20Kw) 47 0C5371 4 WASHER, VALVE SPRING
14 0D4041 1 ASSY, CAMSHAFT & GEAR 48 072694 4 STUD, ROCKER ARM PIVOT
(13,14,16,17Kw) 49 0D5313 4 ROCKER ARM
0G7974 1 ASSY, CAMSHAFT & GEAR (20Kw) 50 0D3998 4 NUT HEX M8-1.0 G8 YEL CHR
15 0C2977 1 GASKET, CRANK CASE 51 0D6024 2 PLATE, PUSH ROD GUIDE
16 0C5943 1 SEAL, OIL PASSAGE 52 0C2976 12 SCREW HHFC M8-1.25 X 65
17 0E4357E 1 ASSY, CRANK & GEAR (13,14,16,17Kw) 53 086516 2 VALVE, EXHAUST
0G5001E 1 ASSY,C’SHAFT 0.D. 41 (20Kw) 54 0C2229 2 VALVE, INTAKE
18 0E3223 2 ASSY,CONNECTING ROD (13,14,16,17Kw) 55 083897 4 TAPPET, SOLID
0G4998 2 ASSY,CONNECTING ROD (20Kw) 56 0D8067B 1 ASSEMBLY, HEAD #2 G&S (13,14,16,17Kw)
19 0G6431 2 SCREW SHC SEMS M6-1.0 X 50 G8.8 0G4400B 1 ASSY, HEAD #2 (20Kw)
20 0E6098 1 SCREEN, OIL PICKUP 57 0D9853D 4 PUSHROD, 147
21 0D4123B 1 ASSEMBLY, OIL PUMP W/O O-RING 58 0C2978 2 GASKET, HEAD
22 0E8152 1 O-RING .49 ID X .07 THICK 59 0D4010 1 KIT GASKET
23 0C3011 2 COVER, OIL RELIEF 60 0D4012 1 KIT BREATHER ASSEMBLY
24 0C3009 2 SPRING, OIL RELIEF 61 0D8675A 1 KIT HEAD ASSEMBLY CYLINDER 1
25 0C3010 2 BALL, 1/2D OIL RELIEF 62 0D8675B 1 KIT HEAD ASSEMBLY CYLINDER 2
27 0F5458 1 SCREW, PLASTITE HI-LOW #10 63 0D4015 1 KIT OIL RELIEF
28 0C3027 1 O-RING, 3/8” X 1/2” 64 078699C 2 SLEEVE DOWEL PIN 14 DIA.
29 0C5998 1 CLAMP, OIL TUBE 65 078699B 4 SLEEVE DOWEL PIN 12 DIA.
31 0F2664C 1 ASSEMBLY, DIPSTICK WITH HANDLE
45
46
64 022145 1 WASHER FLAT M8 – 5/16 108 0G7604 1 WRAPPER, LOWER CYLINDER 1 ZINC
65 0C5136A 2 KNOB, AIR CLEANER (13,14,16,17Kw) 109 0G7603 1 WRAPPER, UPPER CYLINDER 1 ZINC
0C5136D 2 KNOB,AIR CLEANER (20Kw) 110 0G7605 1 WRAPPER, UPPER CYLINDER 2 ZINC
66 0C3024 1 COVER, AIRBOX NG/LP (13,14,16,17Kw) 111 0E9323 1 STARTER MOTOR HEAR REDUCED 1KW
0G5895 1 COVER, AIRBOX NG/LP (20Kw) 112 061906 2 SCREW HHC M8 – 1.25 X 85 G8.8
68 0C8127 1 ELEMENT, AIR CLEANER (13,14,16,17Kw) 113 022129 3 WASHER LOCK M8 – 5/16
0G5894 1 ELEMENT, AIR CLEANER (20Kw) 114 0F1177 1 ASSEMBLY, GROUND WIRE
69 0F9255 1 ASSY, MIXER / AIRBOX 990 (13, 16Kw) 115 022097 2 WASHER LOCK M6 – 1/4
0G8297 1 ASSY, MIXER / AIRBOX 990 (14, 17 Kw) 116 0G3110 4 SCREW TAPTITE M6 – 1.0 X 20 ZINC
0G8448 1 ASSY, MIXER / AIRBOX 999 (20Kw) 117 0G3224A 1 ASSY, IGN COIL W/DIODE, CYLINDER 1
70 0E9582 4 SCREW SHLDR(8MM) M6-1.0 X 21 118 0G3224B 1 ASSY, IGN COIL W/DIODE, CYLINDER 2
71 0D4417 4 WASHER,RUBBER 1/4" X 1/8" THICK 119 0E9568 1 ASSY, THROTTLE SHAFT
72 0E7585A 2 SPARKPLUG, RCY14 .040”GAP 120 0E9565 2 THROTTLE VALVE
(13,14,16,17Kw) 121 074027 4 SCREW PPHM M3 – 0.5 X 5
0G0767A 2 SPARKPLUG, RC12 .040” GAP (20Kw) 122 0C3044 1 COVER, DUST, MIX/AIRBOX
73 0E6043 2 SCREW TAPTITE M5 – 0.8 X 8 123 0C4756 1 SPRING, IDLE ADJUST
74 0G7606 1 WRAPPER, LOWER CYLINDER 2 ZINC 124 075477 1 SCREW PPHM M5 – 0.58 X 20
75 0C3025 1 SWITCH, OIL PRESS 125 043116 2 SCREW HHC M6 – 1.0 X 12
76 0F0452D 1 HOSE 3/8" 300PSI 6.5" LG OIL 126 0E1644 1 SCREW BHSC M6-1.0 X 12 SS
77 070185F 1 OIL FILTER, 90mm 127 0E9572 1 BRACKET, STEPPER MOTOR
78 0D3083 1 ASSY, OIL DRAIN HOSE 129 0G6453 1 ASSY,CONTROLLER GTH990 HSB
79 0F2094 2 SCREW M3 – 0.5 X 6 SEMS 131 0E9570 1 ASSY, THROTTLE ROD
80 094090 1 SWITCH, THERMAL 293F 132 0E9577 1 BELLOWS, INTAKE
81 035461 2 BARBED STRAIGHT 1/4NPT X 3/8 133 0E5846 1 EXPANSION PLUG
82 0G3662B 5 CLAMP, HOSE OETIKER STEPLESS 134 0E9419 3 #10 O-RING
18.5mm 135 0C4760 1 PLUG, MANIFOLD
83 0F0452C 1 HOSE 3/8" 300PSI 6" LG OIL 136 0F9253 1 ASSY, AIR BOX BASE
84 0E9506 1 COOLER, OIL 137 0G5970 1 PIN, FUEL SELECTOR (13, 16Kw) NO
85 0C9764 4 SCREW PLASTITE 1/4-15 X 3/4 STRIPES
86 0C3043 2 GASKET, MANIFOLD / PORT 0G8239 1 PIN,FUEL SELECTOR (14,17Kw) 2
87 0C7694A 1 MANIFOLD CYLINDER 2 STRIPES
88 045756 4 SCREW, HHTT M6-1 x 10 LONG 0G8450 1 PIN, FUEL SELECTOR (20Kw) 3 STRIPES
89 082025 1 NUT, HEX LOCK M5-0.8 ZINC 138 0E9554 1 PIN, FUEL SEL STOP
90 0G3730 4 SCREW SHC M8 – 1.25 X 20 SEMS 139 0E9348 1 SOLENOID COVER
91 090388 13 SCREW TAPTITE M6–1X12 CLEAR ZINC 140 0E9599 1 LINKAGE, CHOKE
92 0E4997 1 ASSY,GROUND WIRE CONNECTOR 141 0E9595 4 SCREW PPPH HI-LO #6 X 1/2
93 0C3033 1 WASHER, 25MM I.D. 142 090987 1 SCREW PHTT M3 – 0.5 X 8
94 0C3034 1 NUT, HEX M24 143 0E9403 1 RETAINER, CHOKE RETURN SPRING
95 0C9763 4 NUT, GROMMET 1/4 PLUG 144 0E9571 1 SPRING, CHOKE RETURN
96 0D1131 1 GUARD, FAN 145 0E9380 1 WASHER, BELLEVILLE SPRING
97 0F1169K 1 HOUSING, BLOWER NG COOLER 146 0A6345 1 SCREW PPHM M2 – 0.4 X 8
98 051754 2 SCREW HHC M8 – 1.25 X 12 G8.8 147 0E9598 1 CHOKE ARM
99 0A5992 2 WASHER SHAKEPROOF INT M8 SS 148 0E9593 1 SCREW SHOULDER M3 – 0.5 X 6
100 0C3032 1 PLATE, FAN 149 0E9564 1 VALVE, CHOKE
101 0C3031 1 FAN, NYLON 150 0E9575 1 SHAFT, CHOKE
102 0C3725B 1 ASSY, FLYWHEEL (13,14,16,17Kw) 151 0E9357 1 SEAL, GOVERNOR ARM
0C3725D 1 ASSY, FLYWHEEL (20Kw) 152 0A7094 2 SCREW PHM #4 – 40 X 1/4
103 0G4928A 1 PLATE, BACKING WITH OIL COOLER 153 0E9574 1 BRACKET, SOLENOID
ZINC 154 0F9273 1 SOLENOID, 6VDC
104 0C7693A 1 MANIFOLD CYLINDER 1 155 0F5467 1 NUT HEX M8 – 1.25 YELLOW ZINC
105 0C3041A 2 SLEEVE, RUBBER 156 0E9557 1 SPRING, CHOKE VALVE ADJUST
106 082774 1 KEY, WOODRUFF 4 X 19D 157 0E1644 1 SCREW, BHSC M6-1.0 x 12
107 0C3036A 1 HOSE BREATHER
47
10kW, GT-530 Engine – Drawing No. 0F9429-R - Part 1
48
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 8 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
49
50
58 022097 3 WASHER LOCK M6-1/4 88 045757 3 SCREW HHC M6 – 1.0 X 25

59 0E9561 1 INTAKE ADAPTER 89 070185F 1 OIL FILTER
60 0E9472 1 GASKET, AIRBOX TO CARB/MIXER 90 094090 1 THERMAL SWITCH
61 0E9471 1 GASKET, MANIFOLD TO CARB/MIXER 91 0F2094 2 SCREW PPHM M3-0.5 X 6 SEMS
62 078643B 4 BOLT, CARB MOUNT M6 – 1.0 X 85 92 0G4403 1 ASSY OIL DRAIN HOSE
63 0D9784 1 NUT HEX LOCK M3 – 0.5 93 0D9235 1 OIL PRESSURE SWITCH HOBBS 5PSI
64 0E9584 1 ASSY, CONTROLLER 94 082774 1 KEY, WOODRUFF 4 X 19D
65 0D6342 1 BALL STUD, 10 MM 95 0F1177 1 ASSY, GROUNDING WIRE
66 0E9587 1 ASSY, THROTTLE ROD 96 0G3251A 1 ASSY IGNITION COIL CYLINDER 1
67 0C9997 1 GUARD, FAN 0G3251B 1 ASSY IGNITION COIL CYLINDER 2
68 0E9319 2 GASKET INTAKE 97
69 0E9597 1 BREATHER HOSE 98 0E9443 1 ASSY, MIXER DUAL FUEL
70 040976 4 SCREW SHC M8 – 1.25 X 20 G12.9 99 0G3662B 4 CLAMP, HOSE OETIKER STEPLESS
71 022129 2 WASHER LOCK M8 – 5/16 18.5mm
72 061906 2 SCREW HHC M8 – 1.25 X 85 100 0G0286 1 HOSE 3/8”ID X 6” SAE J30R9
73 0E9323 1 STARTER MOTOR 101 0G0479 1 HOSE 3/8”ID X 7.25 SAE J30R9
74 0E9507 6 SCREW HHFC M8 – 1.25 X 14 102 0G4985 1 BACKING PLATE, GT-530 ZINC
75 0E9362 2 LIFTING HOOK 103 0E9525C 1 ASSY, FLYWHEEL & RING GEAR
76 0G7608 1 WRAPPER OUTER CYLINDER 1 CLEAR 104 0E9486 1 FAN, FLYWHEEL, 20 FIN, 218.8 OD
ZINC 105 0A5992 2 WASHER LOCK INT M8
77 0G7610 1 WRAPPER INNER CYLINDER 1 CLEAR 106 051754 2 SCREW HHC M8 – 1.25 X 12
ZINC 107 067890 1 NUT HEX M20 – 1.5
78 0G3378 1 TUBE, DIPSTICK GTH 530 108 067198N 1 WASHER BELV – 20 X 2.2
79 0F2664H 1 ASSY, DIPSTICK /TEXT 109 0C3032 1 PLATE, FAN
80 0E9336F 1 BLOWER HOUSING 110 0E4997 1 ASSY, GROUND WIRE CONNECTOR
81 0D6147 6 SCREW HHFC M6-1.0 X 10 G8.8 111 0E9406 1 OIL COOLER
82 0E5139 3 SCREW HHFC M6-1.0 X 8 G8.8 112 0G1705 13 SCREW HHFC M6 – 1.0 X 14
83 0G7611 1 WRAPPER INNER CYLINDER 2 CLEAR 113 0E9450 1 CENTER BAFFLE
ZINC 114 0E9376 1 INTAKE MANIFOLD
84 0G7609 1 WRAPPER OUTER CYLINDER 2 CLEAR 115 0E9550 1 FRONT COVER
ZINC 116 028916 1 ELBOW - 1/8” NPT
85 0E9370 1 GASKET, OIL FILTER ADAPTER 117 0C8563 2 SCREW, HHFC M6-1.0 x 12
86 0E9505A 1 ASSY, DIRECT OIL COOLER ADAPTER 118 0G0919 4 SCREW, HHFCS M6-1 x 12 CLEAR ZINC
87 0F5458 2 SCREW PLASTITE HI-LOW #10X3/8 119 0G6432 4 SCREW, HHC M6-1 x 25 SEMS
51
7kW, GH-410 Engine – Drawing No. 0G4423-E - Part 1
52
1 0E3221 1 ASSEMBLY, CONNECTING ROD

2 0E1466 1 PIN, PISTON DIA 20
3 0G2565 1 RING SET, PISTON DIA 90
4 0G2751 1 PISTON, FLAT TOP DIA 90 COATED
5 071983 2 RETAINER, PISTON PIN
6 0E8440 1 ASSEMBLY, CRANKSHAFT
7 0A7628 1 ARM, GOVERNOR RC45
8 078658 1 PIN, “R” GOVERNOR ARM
9 078659 2 WASHER, GOVERNOR ARM THRUST
10 0F8446C 1 CRANKCASE, MACHINED GH-410
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-MACHINED
15 0G3358 1 ASSEMBLY, CAMSHAFT & GEAR 410HSB
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 LF
21 076361 1 WASHER, THRUST GOVERNOR GEAR
22 0G4233C 1 ASSY GEAR COVER GH410 TOP CHK ONLY
23 0D2274 2 RETAINER, VALVE SPRING
24 0C4391 2 SPRING, VALVE L-71.7N
25 086025 1 SET, GEROTOR 12 THICK
26 0E3341 1 BALANCER, MACHINED
27 021714 1 ASSEMBLY, CYLINDER HEAD W/GUIDES & SEATS
28 086516 1 VALVE, EXHAUST
29 086517 1 VALVE, INTAKE
30 0D9853B 2 PUSH, ROD
31 083897 2 TAPPET
32 077158 1 ASSEMBLY, OIL PICK-UP SCREEN
33 0C3150 1 GASKET, ROCKER COVER 410
34 072694 2 STUD, D20 PIVOT BALL
35 083907 2 ARM, SOLID ROCKER
36 0D3998 2 NUT, HEX M8-1.0 G8 YELLOW CHROME
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 0G4194 1 ASSY, PISTON HC GH410 COATED (I/N’S:1-5)
41 0G5792 1 WASHER LOCK M5 RIBBED
42 0D4788 1 PLUG, STD PIPE 3/8 STEEL SQ HEAD
43 045770 1 SCREW, HHC M5-0.8 X 10 G8.8
44 086515 4 KEEPER, VALVE SPRING
45 078606 4 SCREW, SHC M6-1.0 X 12 W/LOCK WASHER
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 078699B 2 SLEEVE, DOWEL PIN 12mm DIA.
51 078699C 2 SLEEVE, DOWEL PIN 14mm DIA.
52 043790A 1 BARBED EL 90 3/8NPT X 3/8 VS
53
54
1 0C1069 5 SCREW, TAPTITE M6-1.0X8 YELLOW CHROME

2 0D2922 1 HOUSING, BLOWER
3 0G1220 1 TUBE 410GH OIL FILL/CHECK
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 0G7967 1 SCREW HHTT 5/16-18X1/2" CLEAR
13 0D1401A 1 BREATHER TUBE
14 091039 1 GASKET, INTAKE ADAPTER
15 0C9619 1 ASSEMBLY, PLASTIC CARB
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 0D9235 1 SWITCH, OIL 5 PSI
23 070185F 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 0G3249 1 ASSEMBLY, IGNITION COIL ADVANCE W/DIODE
34 0G3111 2 SCREW, TAPTITE M6-1.0 X 25 ZINC
35 0F3800 1 SPRING GOVERNOR
36 083502 1 BOLT, GOVERNOR ADJUST M5
37 082025 1 NUT HEX LOCK M5-0.8 NYINS ZINC
38 0G4403 1 ASSY OIL DRAIN HOSE
39 0C8434D 1 DIPSTICK, GTH410
40 090072 1 O-RING 9/16 X 3/4 X 3/32
41 094090 1 SWITCH, THERMAL 293F
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 GROMMET
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
53 0D6147 1 SCREW HHFCS M6-1.0X10 G8.8
54 0G3662 1 CLAMP,HOSE OETIKER STEPLESS 17
55 036916 2 SCREW, PPHM #8-32 X 1/4
55
Generator – Drawing No. 0F9422-C
56
Generator – Drawing No. 0F9422-C
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 0D5823 3 U-BOLT 5/16”-18 X 1.62” 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
57
10, 13, 16 & 18kW, V-twin Generators – Drawing No. 0G5051-B
58
10, 13, 16 & 18kW, V-twin Generators – Drawing No. 0G5051-B
1 040976 4 SCREW SHC M8-1.25 X 20mm 33 059637 2 SCREW TAPTITE 3/8-16 X ¾

2 0G2824C 1 STATOR (16KW) 34 0E9591 1 SPRING-CHOKE RETURN (10KW)
0G2822C 1 STATOR (13KW & 10KW) 35 0F7065 3 FT HOSE RES ½ LP GAS
0G5277C 1 STATOR (18 KW) 36 048031M 4 HOSE CLAMP ¾” I.D.
3 0G2825C 1 ROTOR (16KW) 37 0E9589 1 CHOKE HSG (10KW)
0G2823C 1 ROTOR (13KW & 10KW) 38 0G0414 1 PLATE, “HOT”
0G5278C 1 ROTOR (18 KW) 39 0D5823 3 U-BOLT 5/16”-18 X 1.62” WITH SADDLE
4 0F7774 1 CARRIER, REAR BEARING 40 0E9369 2 GASKET, EXHAUST PORT (10KW)
5 0E9579 1 FAN, 12” CURVED BLADE 0C4138 2 GASKET, EXHAUST PORT
0F8998 1 FAN, 12” CURVED BLADE (10KW) 41 040173 2 CLAMP HOSE #5.5 0.62”-0.62” (10KW)
6 0F6591 1 MUFFLER 42 074995 1.44 FT HOSE ¼ ID LPG 350PSI UL21 (10KW)
7 0F8078 1 TAIL PIPE, MUFFLER 43 066849 2 SCREW HHTT M5-0.8 X 16
8 099502 2 CLAMP HOSE #24 B1.06-2.00 (10KW) 44 0F7799 1 EXHAUST MANIFOLD
9 056482 1 BEARING 0F8115 1 EXHAUST MANIFOLD (10KW)
10 0C3168 3 5/16 SPECIAL LOCK WASHER 45 0G30430GS0R 1 FLEX COVER
11 0D1838 1 BOLT, IHHCS 3/8”-24 X 15.50” 0G30440GS0R 1 FLEX COVER (10KW)
12 0D1846 4 BOLT, IHHCS M8-1.25 X 345mm 46 0E9595 2 SCREW PPPH HI-LO #6/1/2 W/ #5HD
13 0C7038 1 BRACKET, ALTERNATOR MOUNTING (10KW)
14 0F9396 1 DUCT, ALTERNATOR AIR 47 090388 7 SCREW TAPTITE M6-1.0 X 12
15 0D2559 1 GASKET, ALTERNATOR AIR DUCT 48 045771 4 NUT HEX M8-1.25
16 0C7038A 1 BRACKET, ENGINE MOUNTING 49 039253 2 SCREW HHC M8-1.25 X 20
0F4179 1 PLATE, MOUNTING ENG 530HSB 50 0F0710 2 RIVET POP 0.125” X 0.337”
17 0C7758 4 RUBBER MOUNT 51 0F8079 1 BRACKET MUFFLER ACCESS
18 0388050AD0 1 CABLE, #6 48” BLACK BATTERY 52 0F9273 1 SOLENOID, 6 VOLTS DC (10KW)
19 0C2417A 1 EARTH STRAP 3/8 X 3/8 53 0E9592 2 SCREW PPHM $4-40 X 3/8 SEMS (10KW)
20 0F6528 1 EXHAUST FLEX 54 0E9588 1 LINKAGE, CHOKE (10KW)
21 066386 1 ASSEMBLY BRUSH HOLDER 55 077091 1 COTTER PIN (10KW)
22 029451 2.6 FT TAPE ELEC UL FOAM 1/8 X 1/2 56 0E9581 1 AIR CLEANER GTH530 HSB (10KW)
23 049451 1 WASHER FLAT .406ID X 1.62OD 57 0E9594 3 SCREW PPPH HI-LO #14-15 X ½ (10KW)
24 022237 5 WASHER LOCK 3/8 (10KW) 58 0E9590 1 ASSEMBLY, CHOKE SHAFT (10KW)
022237 1 WASHER LOCK 3/8 59 0E9542 1 VALVE, CHOKE (10KW)
25 035685 1 CLAMP HOSE #28 1.32-2.25 (10KW) 60 0D1683 2 SCREW PFHM M3-0.5 X 5 (10KW)
26 0E9549 1 HOSE, INTAKE GTH530 HSB (10KW) 61 077075 1 BOOT, CHOKE SOLENOID (10KW)
27 051731 4 SCREW HHC M8-1.25 X 50 62 0F8186 1 ADAPTOR, ENGINE (10KW)
28 022145 18 WASHER FLAT 5/16 ZINC 63 0G2387 1 PLUG, GEAR COVER (13 & 16KW)
29 049820 4 NUT LOCK HEX M8-1.25 NYL INSERT 64 022511 4 SCREW HHC 3/8 X 16 X 1-1/4 (10KW)
30 0G0676 2 SCREW THTT M6-1.0 X 10 65 022131 4 WASHER FLAT 3/8 ZINC (10KW)
31 022129 18 WASHER LOCK M8-5/16 66 0G4750 1 PLUG, GEARCOVER ADAPTOR-SMALL (13
32 022259 8 NUT LOCK HEX 5/16-18 & 16KW)
59
Section 8 — Mounting Dimensions
Drawing No. 0F9424-D
60
Section 8 — Mounting Dimensions
Drawing No. 0F9424-D
61
Section 9 — Notes
62
Section 9 — Notes
63
Section 10 – Warranty
NOTE: This Emission Control Warranty Statement pertains to this product only IF the generator size is 15 kW or below.
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission
Control System Warranty on your new engine.* In California, new utility, and lawn and garden equipment engines must be
designed, built and equipped to meet the state’s stringent anti-smog standards. Generac will warrant the emission control
system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved 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
64
Section 10 – Warranty
EMISSION CONTROL SYSTEM WARRANTY

Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines:
(a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on the
date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue
for 24 consecutive months thereafter.
(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or
equipment and to each subsequent purchaser/owner that each of its engines is ...
(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its
authority, and
(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a
warranted emissions-related part to fail to be identical in all material respects to the part as described in the engine
manufacturer’s application for certification.
(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:
(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall
be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the
ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.
(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual
shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or
replace as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS
Warranty shall be warranted for the remainder of the ECS Warranty Period.
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part
fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection
(4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the
remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no
charge to the owner at a Generac Authorized Warranty Service Facility.
(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsible
for diagnostic costs if the repair is deemed warrantable.
(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused
by a failure under warranty of any emission-related part covered by the ECS Warranty.
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient
to meet the expected demand for such emission-related parts.
(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS
Warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce Generac
ECS Warranty obligations.
(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac
engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim.
Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of
such an unapproved, add-on, modified, counterfeit and/or “grey market” part.
EMISSION RELATED PARTS INCLUDE THE FOLLOWING:

1) Fuel Metering System: 3) Ignition System including:
1.2) LPG/Natural Gas carburetion assembly and its internal com- a) Spark plug
ponents. b) Ignition module
a) Fuel controller (if so equipped) 4) Catalytic Muffler Assembly (if so equipped) including:
b) Mixer and its gaskets (if so equipped) a) Muffler gasket
c) Carburetor and its gaskets (if so equipped) b) Exhaust manifold
d) Primary gas regulator (if so equipped) 5) Crankcase Breather Assembly including:
e) LP liquid vaporizer (if so equipped) a) Breather connection tube
2) Air Induction System including:
a) Intake pipe/manifold
b) Air cleaner
*Generac engine types covered by this warranty statement include the following:
1) Prepackaged Standby Generator
2) Auxiliary Power Unit (APU) Generator
3) Standby Generator
Part 2
65
GENERAC® POWER SYSTEMS, INC.
P.O. BOX 297 • WHITEWATER, WI 53190
Part No. 0G4869 Revision E (04/01/08) Catalog No. OMASPB07-3 Printed in U.S.A.

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Installation

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

 This symbol points out important safety infor-

Introduction ........................Inside Front Cover Section 3 – Operation ....................................15

• Keep a fire extinguisher near the generator at all

There are LED readouts on the control panel to notify

1.1 UNPACKING/INSPECTION 1.3 NEC REQUIREMENT FOR ARC

1.4 THE GENERATOR

Exhaust Air Filter Cerramiento Filtro de aire

Base compuesta Filtro de aceite Compartimiento de la batería

Composite Base Oil Filter Battery Compartment

Figure 1.3 – 13, 16 and 18kW, V-twin, GT-990 Engine

Data Label Sample

Air Filter Control

Composite Base Oil Filter Battery Compartment

Rated Max. Continuous Load Current (Amps)

1.9 RECONFIGURING THE NOTE:

3. Close the roof. 1.10 LOCATION

• Install the generator as close as possible to the fuel

NOTE: The following procedures are to be observed:

DANGER  Be sure the utility power supply is turned off

 Do not open or mutilate the battery. Released

 The electrolyte is a dilute sulfuric acid that is

2.1 BEFORE INITIAL START-UP 2.3 ELECTRICAL CHECKS

2.4 GENERATOR TESTS UNDER LOAD 2.5 CHECKING AUTOMATIC

2.6 ENGINE GOVERNOR ADJUSTMENT  2.6.2 13, 16 & 18 KW UNITS

 2.7.2 10, 13, 16 & 18 KW UNITS

3.1 USING THE AUTO/OFF/MANUAL 3.2 AUTOMATIC TRANSFER

3.3 SEQUENCE OF AUTOMATIC

3.4 MANUAL TRANSFER OPERATION

 Do not attempt to activate the transfer switch

NOTE: • If an RPM signal is not detected within the first

CONTROL AND INFORMATION CENTER Oil Dipstick

FLASHING GREEN LED=

4.2 CHECKING THE ENGINE

Figure 4.2 — Oil Dipstick and Fill, 7kW

Oil Dipstick and Fill Oil Fill

4.3 CHANGING THE ENGINE OIL

 4.3.2 ENGINE OIL RECOMMENDATIONS

Figure 4.5 – Oil Drain Hose and Filter

 Any attempt to crank or start the engine before

 4.4.2 10KW GENERATORS 4.5 SPARK PLUG(S)

Control Figure 4.9 – Setting the Spark Plug Gap

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

Figure 4.8 — 13, 16 & 18kW

 Aandbattery presents a risk of electrical shock

• Remove the 15A fuse from the generator control

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

Figure 4.10 - Valve Clearance Adjustment

4.9 ATTENTION AFTER SUBMERSION

4.10 CORROSION PROTECTION

4.12 SERVICE SCHEDULE

ATTENTION: It is recommended that all service work

SYSTEM/COMPONENT PROCEDURE FREQUENCY

5.1 TROUBLESHOOTING GUIDE

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

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

*Contact the nearest Authorized Dealer for assistance.

12 CIRCUIT LOAD CENTER

16 CIRCUIT LOAD CENTER

2.6 ENGINE GOVERNOR ADJUSTMENT 2.6.2 13, 16 & 18 KW UNITS

2.7.2 10, 13, 16 & 18 KW UNITS

4.3.2 ENGINE OIL RECOMMENDATIONS

4.4.2 10KW GENERATORS 4.5 SPARK PLUG(S)