Generac Power Systems Portable Generator 04389 3 04456 3 04390 3 User Manual
Installation and  
Owner’s Manual  
Air-cooled, Prepackaged  
Automatic Standby Generators  
Models:  
C
US  
04389-3 (6 kW NG, 7 kW LP)  
04456-3 (12 kW NG, 12 kW LP)  
04390-3 (13 kW NG, 15 kW LP)  
L
ISTED  
Not intended for use as Primary Power in place of utility or in  
life-support applications.  
DANGER  
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!  
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Table of Contents  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Introduction ........................Inside Front Cover  
Section 3 – Operation ....................................14  
3.1 Break-in Procedure .....................................14  
3.2 Using the Auto/Off/Manual Switch...............14  
3.3 Automatic Transfer Operation.....................15  
3.4 Sequence of Automatic Operation ...............15  
3.5 Manual Transfer Operation.........................16  
3.6 Setting the Exercise Timer ..........................17  
3.7 Protection Systems......................................17  
Read This Manual Thoroughly........................ IFC  
Contents.......................................................... IFC  
Operation and Maintenance ............................ IFC  
How to Obtain Service..................................... IFC  
Authorized Dealer Locator Number................... IFC  
Safety Rules ........................................................2  
Standards Index..................................................3  
Section 1 – General Information...................4  
1.1 Unpacking/Inspection....................................4  
1.2 Protection Systems........................................4  
Section 4 – Maintenance...............................18  
4.1 Fuses...........................................................18  
4.2 Checking the Engine Oil Level.....................18  
4.3 Changing the Engine Oil..............................19  
4.4 Changing the Oil Filter ................................19  
4.5 Changing the Engine Air Cleaner.................19  
4.6 Spark Plug(s) ..............................................20  
4.7 Battery Maintenance....................................20  
1.3 NEC Requirement for Arc Fault Circuit  
Interruption Breaker for Bedrooms ..............4  
1.4 The Generator...............................................5  
1.5 Specifications................................................6  
1.6 System Set LED ............................................7  
1.7 Fuel Requirements and Recommendations ...7  
1.8 Fuel Consumption.........................................7  
1.9 Reconfiguring the Fuel System ......................7  
1.10 Location ........................................................8  
1.11 Battery Installation........................................9  
1.12 The Battery ...................................................9  
4.8 Adjusting GH-410/GT-990/760  
Valve Clearance............................................21  
4.9 Cooling System ...........................................21  
4.10 Attention After Submersion.........................22  
4.11 Corrosion Protection...................................22  
4.12 Out of Service Procedure.............................22  
4.13 Service Schedule.........................................23  
Section 2 – Post Installation Start-up  
and Adjustments .......................10  
2.1 Before Initial Startup...................................10  
Section 5 – Troubleshooting........................ 24  
5.1 Troubleshooting Guide................................24  
2.2 Check Transfer Switch Operation ...............10  
2.3 Electrical Checks ........................................10  
2.4 Generator Tests Under Load.......................11  
2.5 Checking Automatic Operation....................11  
Section 6 – Notes ........................................... 25  
Section 7 – Electrical Data........................... 28  
Section 8 – Exploded Views and  
Parts Lists................................... 42  
Section 9 – Mounting Dimensions............. 63  
Section 10 – Warranty................................... 64  
2.6 Adjusting the Regulator  
(Natural Gas Only).......................................12  
2.7 Engine Governor Adjustment......................13  
2.8 Voltage Regulator Adjustment......................14  
1
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IMPORTANT SAFETY INSTRUCTIONS  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation  
be copied and posted near the unit’s installation site. Safety should be stressed to all opera-  
tors and potential operators of this equipment.  
WARNING:  
contains chemicals known to the state  
of California to cause cancer, birth  
defects or other reproductive harm.  
GENERAL HAZARDS  
The engine exhaust from this product  
• For safety reasons, the manufacturer recommends  
that the installation, initial start-up and main-  
tenance of this equipment is carried out by an  
Authorized Dealer.  
• The engine exhaust fumes contain carbon monox-  
ide, which can be DEADLY. This dangerous gas, if  
breathed in sufficient concentrations, can cause  
unconsciousness or even death. This exhaust  
system must be installed properly, in strict com-  
pliance with applicable codes and standards.  
Following installation, do nothing that might ren-  
der the system unsafe or in noncompliance with  
such codes and standards.  
• Keep hands, feet, clothing, etc., away from drive  
belts, fans, and other moving or hot parts. Never  
remove any drive belt or fan guard while the unit  
is operating.  
WARNING:  
This product contains or emits chemicals  
known to the state of California to cause  
cancer, birth defects or other reproductive harm.  
Study these SAFETY RULES carefully before install-  
ing, operating or servicing this equipment. Become  
familiar with this Owner’s Manual and with the  
unit. The generator can operate safely, efficiently and  
reliably only if it is properly installed, operated and  
maintained. Many accidents are caused by failing to  
follow simple and fundamental rules or precautions.  
The manufacturer cannot anticipate every possible  
circumstance that might involve a hazard. The warn-  
ings in this manual, and on tags and decals affixed  
to the unit are, therefore, not all-inclusive. If using  
a procedure, work method or operating technique  
the manufacturer does not specifically recommend,  
ensure that it is safe for others. Also make sure the  
procedure, work method or operating technique uti-  
lized does not render the generator unsafe.  
• Adequate, unobstructed flow of cooling and venti-  
lating air is critical to correct generator operation.  
Do not alter the installation or permit even partial  
blockage of ventilation provisions, as this can seri-  
ously affect safe operation of the generator. The  
generator MUST be installed outdoors.  
• When working on this equipment, remain alert  
at all times. Never work on the equipment when  
physically or mentally fatigued.  
• Inspect the generator regularly, and contact the  
nearest Authorized Dealer for parts needing repair  
or replacement.  
• Before performing any maintenance on the gen-  
erator, disconnect its battery cables to prevent  
accidental start up. Disconnect the cable from the  
battery post indicated by a NEGATIVE, NEG or (–)  
first. Reconnect that cable last.  
• Never use the generator or any of its parts as a  
step. Stepping on the unit can stress and break  
parts, and may result in dangerous operating con-  
ditions from leaking exhaust gases, fuel leakage,  
oil leakage, etc.  
DANGER  
Despite the safe design of this generator,  
operating this equipment imprudently, neglecting  
its maintenance or being careless can cause  
possible injury or death. Permit only responsible  
and capable persons to operate or maintain this  
equipment.  
Potentially lethal voltages are generated by  
these machines. Ensure all steps are taken to  
render the machine safe before attempting to  
work on the generator.  
Parts of the generator are rotating and/or hot  
during operation. Exercise care near running  
generators.  
2
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IMPORTANT SAFETY INSTRUCTIONS  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
• Keep a fire extinguisher near the generator at all  
times. Extinguishers rated “ABC” by the National  
Fire Protection Association are appropriate for  
use on the standby electric system. Keep the extin-  
guisher properly charged and be familiar with its  
use. Consult the local fire department with any  
questions pertaining to fire extinguishers.  
ELECTRICAL HAZARDS  
• All generators covered by this manual produce  
dangerous electrical voltages and can cause fatal  
electrical shock. Utility power delivers extremely  
high and dangerous voltages to the transfer switch  
as does the standby generator when it is in opera-  
tion. Avoid contact with bare wires, terminals,  
connections, etc., while the unit is running. Ensure  
all appropriate covers, guards and barriers are in  
place before operating the generator. If work must  
be done around an operating unit, stand on an  
insulated, dry surface to reduce shock hazard.  
• Do not handle any kind of electrical device while  
standing in water, while barefoot, or while hands or  
feet are wet. DANGEROUS ELECTRICAL SHOCK  
MAY RESULT.  
EXPLOSION HAZARDS  
• Do not smoke around the generator. Wipe up any  
fuel or oil spills immediately. Ensure that no com-  
bustible materials are left in the generator com-  
partment, or on or near the generator, as FIRE or  
EXPLOSION may result. Keep the area surround-  
ing the generator clean and free from debris.  
• Gaseous fluids such as natural gas and liquid pro-  
pane (LP) gas are extremely EXPLOSIVE. Install  
the fuel supply system according to applicable  
fuel-gas codes. Before placing the home standby  
electric system into service, fuel system lines must  
be properly purged and leak tested according to  
applicable code. After installation, inspect the fuel  
system periodically for leaks. No leakage is permit-  
ted.  
• The National Electrical Code (NEC) requires the  
frame and external electrically conductive parts of  
the generator to be connected to an approved earth  
ground. Local electrical codes also may require  
proper grounding of the generator electrical system.  
• After installing this home standby electrical sys-  
tem, the generator may crank and start at any  
time without warning. When this occurs, load cir-  
cuits are transferred to the STANDBY (generator)  
power source. To prevent possible injury if such a  
start and transfer occur, always set the generator’s  
Auto/Off/Manual switch to its OFF position before  
working on equipment and remove the 7.5A and  
15A fuses from the generator control panel.  
• In case of accident caused by electric shock, imme-  
diately shut down the source of electrical power. If  
this is not possible, attempt to free the victim from  
the live conductor. AVOID DIRECT CONTACT WITH  
THE VICTIM. Use a nonconducting implement,  
such as a dry rope or board, to free the victim from  
the live conductor. If the victim is unconscious,  
apply first aid and get immediate medical help.  
• Never wear jewelry when working on this equip-  
ment. Jewelry can conduct electricity resulting in  
electric shock, or may get caught in moving com-  
ponents causing injury.  
‹
STANDARDS INDEX  
In the absence of pertinent standards, codes, regu-  
lations and laws, the published information listed  
below may be used as installation guide for this  
equipment.  
1. NFPA No. 37, STATIONARY COMBUSTION  
ENGINES AND GAS TURBINES, available from  
the National Fire Protection Association, 470  
Atlantic Avenue, Boston, MA 02210.  
2. NFPA No. 76A, ESSENTIAL ELECTRICAL  
SYSTEMS FOR HEALTH CARE FACILITIES,  
available same as Item 1.  
3. NFPA No. 54, NATIONAL FUEL GAS CODE,  
available same as Item 1.  
4. NFPA No. 58, AMERICAN NATIONAL STANDARD  
FOR STORAGE AND HANDLING OF LIQUEFIED  
PETROLEUM GAS, available same as Item 1.  
5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL  
ELECTRIC CODE, available same as Item 1.  
6. Article X, NATIONAL BUILDING CODE, available  
from the American Insurance Association, 85  
John Street, New York, N.Y. 10038.  
FIRE HAZARDS  
• For fire safety, the generator must be installed  
and maintained properly. Installation always must  
comply with applicable codes, standards, laws  
and regulations. Adhere strictly to local, state and  
national electrical and building codes. Comply  
with regulations the Occupational Safety and  
Health Administration (OSHA) has established.  
Also, ensure that the generator is installed in  
accordance with the manufacturer’s instructions  
and recommendations. Following proper installa-  
tion, do nothing that might alter a safe installation  
and render the unit in noncompliance with the  
aforementioned codes, standards, laws and regula-  
tions.  
7. AGRICULTURAL WIRING HANDBOOK, avail-  
able from the Food and Energy Council, 909  
University Avenue, Columbia, MO 65201.  
8. ASAE  
EP-3634,  
INSTALLATION  
AND  
MAINTENANCEOFFARMSTANDBYELECTRICAL  
SYSTEMS, available from the American Society  
of Agricultural Engineers, 2950 Niles Road, St.  
Joseph, MI 49085.  
9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE  
LIQUIDS CODE, available same as Item 1.  
3
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Section 1 — General Information  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
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  
of the conditions describe in Section 1.3 are true.  
Only qualified electricians or contractors should  
attempt such installations, which must comply  
strictly with applicable codes, standards and  
regulations.  
1.3 NEC REQUIREMENT FOR ARC  
FAULT CIRCUIT INTERRUPTION  
1.1 UNPACKING/INSPECTION  
After unpacking, carefully inspect the contents for  
damage.  
BREAKER FOR BEDROOMS  
In 2001, the National Electric Code (NEC) intro-  
duced a requirement for new construction. This new  
requirement indicates the need for Arc Fault Circuit  
Interrupters to be used to protect the complete  
branch circuit that feeds a dwelling bedroom. The  
actual NEC requirement is indicated below.  
• This standby generator set has been factory sup-  
plied with a weather protective enclosure that is  
intended for outdoor installation only.  
• This UL listed standby generator set is packaged  
with an automatic transfer switch with built in  
load center. The combination transfer switch and  
load center is pre-wired with a two foot and 30 foot  
conduit. Circuit breakers for emergency circuit  
connections are included.  
‹
1.3.1 SECTION 210.12 ARC FAULT CIRCUIT  
INTERRUPTER PROTECTION  
1. Definition: An arc fault circuit interrupter is a  
device intended to provide protection from the  
effects of arc faults by recognizing characteristics  
unique to arcing and by functioning to de-ener-  
gize the circuit when an arc fault is detected.  
2. Dwelling Unit Bedrooms: All branch circuits that  
supply 125 volt, single-phase, 15 and 20 ampere  
outlets installed in dwelling unit bedrooms shall  
be protected by an arc fault circuit interrupter  
listed to provide protection of the entire branch  
circuit.  
Section 210.12 requires that AFCI protection be  
provided on branch circuits that supply outlets  
(receptacle, lighting, etc.) in dwelling bedrooms. The  
requirement is limited to 15 and 20 ampere, 125  
volt circuits. There is no prohibition against provid-  
ing AFCI protection on other circuits or in locations  
other than bedrooms. Because circuits are often  
shared between a bedroom and other areas such as  
closets and hallways, providing AFCI protection on  
the complete circuit would comply with 210.12.  
• This UL listed, 2-pole switch is rated at 100 AC  
amperes at 250 volts maximum. This transfer  
switch is for indoor use only.  
If this generator is used to power electrical load  
circuits normally powered by a utility power  
source, it is required by code to install a trans-  
fer switch. The transfer switch must effectively  
isolate the electrical system from the utility dis-  
tribution system when the generator is operat-  
ing (NEC 700, 701 & 702). Failure to isolate an  
electrical system by such means will result in  
damage to the generator and also may result in  
injury or death to utility power workers due to  
backfeed of electrical energy.  
If any loss or damage is noted at time of delivery, have  
the person(s) making the delivery note all damage  
on the freight bill or affix their signature under the  
consignor's memo of loss or damage.  
If during the installation of the home standby system  
the decision is made to provide back up power to a  
bedroom branch circuit, then the circuit breaker in  
the transfer switch should be replaced with an Arc  
Fault Circuit Interrupter.  
If a loss or damage is noted after delivery, separate  
the damaged materials and contact the carrier for  
claim procedures.  
“Concealed damage” is understood to mean damage  
to the contents of a package that is not in evidence at  
the time of delivery, but is discovered later.  
It is most important that breakers only be switched  
like for like. For instance, if replacing a 15A breaker,  
it MUST be replaced with a 15A AFCI breaker.  
Likewise, a 20A breaker MUST be replaced with a  
20A AFCI.  
1.2 PROTECTION SYSTEMS  
Unlike an automobile engine, the generator may have  
to run for long periods of time with no operator pres-  
ent to monitor engine conditions. For that reason, the  
engine is equipped with the following systems that  
protect it against potentially damaging conditions:  
These AFCI breakers are available at the nearest  
Home Depot or hardware store.  
Siemens Item #  
Q115AF  
Description  
15A Single Pole AFCI  
20A Single Pole AFCI  
1. Low Oil Pressure Sensor  
2. High Temperature Sensor  
3. Overcrank  
4. Overspeed  
Q120AF  
4
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Section 1 — General Information  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
1.4 THE GENERATOR  
Figure 1.1 – 7 kW, Single Cylinder GH-410 Engine  
Control  
Panel  
Oil  
Dipstick  
Data  
Decal  
GFCI  
Outlet  
Exhaust  
Enclosure  
Fuel  
Regulator  
Fuel  
Inlet  
Battery  
Compartment  
Oil Filter  
Figure 1.2 – 12 kW and 15 kW, V-twin GT-990/760 Engine  
Control  
Panel  
Oil  
Dipstick  
Data  
Decal  
GFCI  
Outlet  
Exhaust  
Enclosure  
Fuel  
Regulator  
Fuel  
Inlet  
Composite Base  
Battery  
Compartment  
Oil Filter  
5
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Section 1 — General Information  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
1.5 SPECIFICATIONS  
‹
1.5.1 GENERATOR  
Model 04389  
Model 04456  
Model 04390  
Rated Max. Continuous Power  
6,000 NG/7,000 LP  
12,000 NG/12,000 LP  
13,000 NG/15,000 LP  
Capacity (Watts*)  
Rated Voltage  
120/240  
120/240  
120/240  
Rated Max. Continuous Load  
Current (Amps)  
120 Volts**  
50.0 NG/58.3 LP  
100.0 NG/100.0 LP  
108.3 NG/125.0 LP  
240 Volts  
25.0 NG/29.2 LP  
50.0 NG/50.0 LP  
54.2 NG/62.5 LP  
Main Line Circuit Breaker  
Phase  
30 Amp  
50 Amp  
65 Amp  
1
1
1
Number of Rotor Poles  
Rated AC Frequency  
Power Factor  
2
2
2
60 Hz  
1
60 Hz  
1
60 Hz  
1
Recommended Air Filter  
Battery Requirement  
Part # 0C8127  
Group 26/26R  
12 Volts and  
Part # 0C8127  
Group 26/26R  
12 Volts and  
Part # 0C8127  
Group 26/26R  
12 Volts and  
350 Cold-cranking  
Amperes Minimum  
525 Cold-cranking  
Amperes Minimum  
525 Cold-cranking  
Amperes Minimum  
Weight  
375 Pounds  
470 Pounds  
487 Pounds  
Output Sound Level @  
23 ft (7m) at full load  
68 db (A)  
70.5 db (A)  
71.5 db (A)  
Normal Operating Range  
-20°F (-28.8°C) to 104°F (40°C)  
* Maximum wattage and current are subject to and limited by such factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc. Maximum power  
decreases about 3.5 percent for each 1,000 feet above sea level; and also will decrease about 1 percent for each 6° C (10° F) above 16° C (60° F) ambient temperature.  
** Load current values shown for 120 volts are maximum TOTAL values for two separate circuits. The maximum current in each circuit must not exceed the value stated for 240  
volts.  
‹
1.5.2 ENGINE  
Model 04389  
GH-410  
Model 04456  
GT-760  
Model 04390  
GT-990  
Type of Engine  
Number of Cylinders  
Rated Horsepower  
Displacement  
1
2
2
14.5 @ 3,600 rpm  
410cc  
26 @ 3,600 rpm  
763cc  
30 @ 3,600 rpm  
992cc  
Cylinder Block  
Aluminum w/Cast  
Iron Sleeve  
Aluminum w/Cast  
Iron Sleeve  
Aluminum w/Cast  
Iron Sleeve  
Valve Arrangement  
Ignition System  
Recommended Spark Plug  
Spark Plug Gap  
Compression Ratio  
Starter  
Overhead Valves  
Solid-state w/Magneto  
RC14YC  
0.76 mm (0.030 inch)  
8.6:1  
Overhead Valves  
Solid-state w/Magneto  
RC12YC  
0.508 mm (0.020 inch)  
9.5:1  
Overhead Valves  
Solid-state w/Magneto  
RC12YC  
0.508 mm (0.020 inch)  
9.5:1  
12 Vdc  
12 Vdc  
12Vdc  
Oil Capacity Including Filter  
Recommended Oil Filter  
Recommended Air Filter  
Operating RPM  
Approx. 1.5 Qts  
Part # 070185B  
Part # 0C8127  
3,600  
Approx. 1.7 Qts  
Part # 070185B  
Part # 0C8127  
3,600  
Approx. 1.7 Qts  
Part # 070185B  
Part # 0C8127  
3,600  
6
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Section 1 — General Information  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
1.6 SYSTEM SET LED  
DANGER  
The “System Set” LED is lit when all of the following  
conditions are true:  
Gaseous fuels such as natural gas and liquid  
propane (LP) gas are highly explosive. Even the  
slightest spark can ignite such fuels and cause  
an explosion. No leakage of fuel is permitted.  
Natural gas, which is lighter than air, tends to  
collect in high areas. LP gas is heavier than air  
and tends to settle in low areas.  
1. The AUTO/OFF/MANUAL switch is set to the  
AUTO position.  
2. The utility voltage being supplied to the unit is  
being sensed by the PCB. If the utility sense volt-  
age is not connected to the unit or if it is below  
168 volts AC, then the system set light will flash  
rapidly. This indicates that if the AUTO/OFF/  
MANUAL switch is placed in the Auto position,  
the generator will start.  
1.9 RECONFIGURING THE  
FUEL SYSTEM  
3. The “Not In Auto” dip switch is set to the OFF  
position on the control board.  
‹
1.9.1 7 KW, 410CC ENGINE  
To reconfigure the fuel system from NG to LP,  
follow these steps (Figure 1.3):  
4. No alarms are present, for example, low oil pres-  
sure, high temperature, etc.  
1.7 FUEL REQUIREMENTS  
NOTE:  
AND RECOMMENDATIONS  
The primary regulator for the propane supply is  
NOT INCLUDED with the generator. A fuel pres-  
sure of 10 to 12 inches of water column (0.36 to  
0.43 psi) to the fuel inlet of the generator MUST  
BE SUPPLIED.  
With LP gas, use only the vapor withdrawal  
system. This type of system uses the vapors formed  
above the liquid fuel in the storage tank.  
The engine has been fitted with a fuel carburetion  
system that meets the specifications of the 1997  
California Air Resources Board for tamper-proof  
dual fuel systems. The unit will run on natural gas or  
LP gas, but it has been factory set to run on natural  
gas. Should the primary fuel need to be changed to  
LP gas, the fuel system needs to be reconfigured. See  
Section 1.9 for instructions on reconfiguration of the  
fuel system.  
1. Turn off the main gas supply (if connected).  
2. Open the roof and remove the door.  
3. Remove the battery (if installed).  
4. Disconnect wire #0 and wire #14 from the gas  
solenoid on top of the demand regulator.  
5. Remove the carburetor fuel hose from the outlet  
port of the demand regulator.  
6. Remove the demand regulator by removing the  
fastener that retains the regulator mounting  
bracket.  
7. Remove the square headed steel pipe plug from  
outlet port #1 and the brass hose barb fitting  
from outlet port #2.  
Recommended fuels should have a Btu content of at  
least 1,000 Btus per cubic foot for natural gas; or at  
least 2,520 Btus per cubic foot for LP gas. Ask the  
fuel supplier for the Btu content of the fuel.  
Required fuel pressure for natural gas is 5 inches to  
7 inches water colum (0.18 to 0.25 psi); and for  
liquid propane, 10 inches to 12 inches of water  
column (0.36 to 0.43 psi).  
Figure 1.3 – Demand Regulator  
HOSE & PLUG  
SWITCHED SIDES  
NOTE:  
Any piping used to connect the generator to the  
fuel supply should be of adequate size to ensure  
the fuel pressure NEVER drops below 4 inches  
water colum for natural gas or 10 inches water  
column for liquid propane for all load ranges.  
FUEL HOSE  
PIPE  
PLUG  
FUEL HOSE  
BRASS HOSE  
FITTING  
BRASS HOSE  
FITTING  
OUTLET  
PORT  
ADJUSTMENT  
SCREW  
FUEL JET  
1.8 FUEL CONSUMPTION  
Model #  
Nat. Gas (*)  
LP Vapor (**)  
1/2 Load Full Load  
1/2 Load  
Full Load  
1.47/54  
2.08/76  
2.40/88  
04389  
04456  
04390  
66  
119  
215  
220  
0.82/30  
1.53/56  
1.58/58  
152  
156  
*Natural gas is in cubic feet per hour.  
**LP is in gallons per hour/cubic feet per hour.  
*** Values given are approximate.  
NG FUEL SYSTEM  
LP FUEL SYSTEM  
7
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Section 1 — General Information  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
8. Refit the brass hose barb fitting to outlet port #1  
13. To adjust the system to run on LP fuel, turn  
BOTH adjuster screws 1/2 TURN CLOCKWISE.  
The system should now be set for maximum  
power and best perfomance. DO NOT, UNDER  
ANY CIRCUMSTANCES, REMOVE THE SET  
PINS FROM THE REGULATOR HOUSING.  
THIS WILL VOID THE WARRANTY.  
14. It may be necessary to make minor adjustments  
to the preset adjustment screw settings to achieve  
maximum power, particularly at higher altitudes.  
If experiencing problems with the unit producing  
maximum power, follow the procedure in Section  
2.6 (Adjusting the Fuel Regulator).  
and the square headed steel pipe plug to outlet  
port #2.  
9. Reverse procedure steps 1-5 to reinstall demand  
regulator.  
10. Take the plastic plug supplied in the poly-bag  
with the generator and press it into the 3/4” hole  
on the bottom of the air cleaner base (Figure  
4.6).  
11. Reverse the procedure to convert back to natural  
gas.  
‹
1.9.2 12KW AND 15KW, V-TWIN ENGINES  
To reconfigure the fuel system from NG to LP, follow  
Figure 1.4 - Demand Regulator  
these steps:  
NOTE:  
OUTLET PORTS  
FUEL HOSE  
The primary regulator for the propane supply is  
NOT INCLUDED with the generator. A fuel pres-  
sure of 10 to 12 inches of water column (0.36 to  
0.43 psi) to the fuel inlet of the generator MUST  
BE SUPPLIED.  
BRASS HOSE  
FITTING  
IDLE CIRCUIT  
BRASS HOSE  
SMALL  
FUEL JET  
PORT  
FITTING  
1
NP  
REGULATOR  
HOUSING PORT  
ADJUSTER  
SCREWS  
1. Turn off the gas supply. (if connected)  
2. Open the roof and remove the door.  
3. Remove the battery. (if installed)  
4. Remove the engine air in baffle located on the left-  
hand side of the battery compartment. Two M6  
screws are located on top of the baffle and two  
M6 screws are located on the inside of the baffle  
towards the back.  
1.10 LOCATION  
5. Remove the small hose clamp and hose from the  
fuel regulator. It may be necessary to pry the hose  
off of the brass fitting using a screwdriver to gen-  
tly lift up the hose edge.  
‹
1.10.1 GENERATOR  
Install the generator set, in its protective enclosure,  
outdoors, where adequate cooling and ventilating air  
is always available. Consider these factors:  
6. Remove the small brass hose fitting from the  
regulator casting.  
• Install the unit where air inlet and outlet open-  
ings will not become obstructed by leaves, grass,  
snow, etc. If prevailing winds will cause blowing or  
drifting, consider using a windbreak to protect the  
unit.  
7. Place the small fuel jet, thread side first, into the  
threaded hole originally occupied by the brass  
hose fitting (Figure 1.4).  
8. Using a short No. 2 Phillips screw driver, thread  
the small fuel jet into the regulator casting. Do  
not over tighten.  
• 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. A good rule is to  
allow three feet of space on all sides.  
• Where strong prevailing winds blow from one  
direction, face the generator air inlet openings to  
the prevailing winds.  
9. Apply thread sealant to the threads of the hose  
fitting and replace it into the regulator body.  
10. Re-attach the small hose and hose clamp and  
tighten as necessary.  
11. Replace the engine air in baffle using the four M6  
screws.  
• Install the generator as close as possible to the fuel  
12. Identify both brass adjustment screws on the  
regulator.  
supply, to reduce the length of piping.  
• Install the generator as close as possible to  
the transfer switch. HOWEVER, REMEMBER  
THAT LAWS OR CODES MAY REGULATE THE  
DISTANCE.  
The genset must be installed on a level surface. The  
base frame must be level within two (2) inches all  
around.  
NOTE:  
One adjustment screw can be accessed from the  
front of the unit and the second can be accessed  
from the back of the unit enclosure by removing  
the plastic hole plug. The screw can be turned  
with a long flat blade screwdriver.  
8
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Section 1 — General Information  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
4. Connect the red battery cable (from starter con-  
‹
1.10.2 TRANSFER SWITCH  
tactor) to the battery post indicated by a positive,  
POS or (+).  
1.10.2.1 7 kW, 12 kW and 15 kW Units  
5. Connect the black battery cable (from frame  
ground) to the battery post indicated by a nega-  
tive, NEG or (—).  
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:  
NOTE:  
Damage will result if battery connections are made  
• 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 cor-  
rosive vapors.  
in reverse.  
NOTE:  
The generator is equipped with a battery trickle  
charger that is active when the unit is set up for  
automatic operation. With the battery installed  
and utility power source voltage available to the  
transfer switch, the battery receives a trickle  
charge while the engine is not running, to prevent  
self-discharge. The trickle charger is designed to  
help extend the life of the battery by maintain-  
ing the battery when the unit is not running. The  
trickle charge feature cannot be used to recharge  
a discharged battery.  
If the AUTO/OFF/MANUAL switch is not set to its  
OFF position, the generator can crank and start  
as soon as the battery cables are connected. If  
the utility power supply is not turned off, spark-  
ing can occur at the battery posts and cause an  
explosion.  
1.12 THE BATTERY  
DANGER  
Do not dispose of the battery in a fire. The  
battery is capable of exploding.  
1.11 BATTERY INSTALLATION  
Fill the battery with the proper electrolyte fluid if  
necessary and have the battery fully charged before  
installing it.  
A battery presents a risk of electrical shock  
and high short circuit current. The following pre-  
cautions are to be observed when working on  
batteries:  
Before installing and connecting the battery, complete  
the following steps:  
• Remove the 7.5A and 15A fuses from the genera-  
tor control panel.  
• Remove watches, rings or other metal objects;  
• Use tools with insulated handles;  
• Wear rubber gloves and boots;  
• Do not lay tools or metal parts on top of the  
battery; and  
1. Set the generator's AUTO/OFF/MANUAL switch to  
OFF.  
2. Turn off utility power supply to the transfer  
switch.  
3. Remove the 7.5A and 15A fuses from the genera-  
tor control panel.  
Battery cables were factory connected at the genera-  
tor (Figure 1.5). Connect cables to battery posts as  
follows:  
• Disconnect charging source prior to connecting or  
disconnecting battery terminals.  
Do not open or mutilate the battery. Released  
Figure 1.5 – Battery Cable Connections  
electrolyte has been known to be harmful to the  
skin and eyes, and to be toxic.  
The electrolyte is a dilute sulfuric acid that is  
harmful to the skin and eyes. It is electrically  
conductive and corrosive.  
The following procedures are to be observed:  
• Wear full eye protection and protective clothing;  
• Where electrolyte contacts the skin, wash it off  
immediately with water;  
• Where electrolyte contacts the eyes, flush  
thoroughly and immediately with water and seek  
medical attention; and  
9
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Section 2 — Post Installation Start-up and Adjustments  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
5. Check the engine crankcase oil level and, if neces-  
• Spilled electrolyte is to be washed down with an  
acid neutralizing agent. A common practice is to  
use a solution of 1 pound (500 grams) bicarbonate  
of soda to 1 gallon (4 liters) of water. The bicar-  
bonate of soda solution is to be added until the  
evidence of reaction (foaming) has ceased. The  
resulting liquid is to be flushed with water and the  
area dried.  
sary, fill to the dipstick FULL mark with the rec-  
ommended oil. Do not fill above the FULL mark.  
6. Check the fuel supply. Gaseous fuel lines must  
have been properly purged and leak tested in  
accordance with applicable fuel-gas codes. All  
fuel shutoff valves in the fuel supply lines must  
be open.  
Lead-acid batteries present a risk of fire because  
they generate hydrogen gas. The  
following procedures are to be followed:  
Never operate the engine with the oil level  
• DO NOT SMOKE when near the battery;  
• DO NOT cause flame or spark in battery area; and  
• Discharge static electricity from body before touch-  
ing the battery by first touching a grounded metal  
surface.  
below the “Add” mark on the dipstick. Doing  
this could damage the engine.  
2.2 CHECK TRANSFER SWITCH  
OPERATION  
Be sure the AUTO/OFF/MANUAL switch is set to  
Refer to Section 3.5, of the owner’s manual for man-  
ual operation procedures.  
the OFF position before connecting the battery  
cables. If the switch is set to AUTO or MANUAL,  
the generator can crank and start as soon as the  
battery cables are connected.  
DANGER  
Be sure the utility power supply is turned off  
Do not attempt manual transfer switch opera-  
tion until all power voltage supplies to the  
transfer switch have been positively turned off.  
Failure to turn off all power voltage supplies  
will result in extremely hazardous and possibly  
fatal electrical shock.  
and the 7.5A and 15A fuses are removed from  
the generator control panel, or sparking may  
occur at the battery posts as the cables are  
attached and cause an explosion.  
Servicing of the battery is to be performed or super-  
vised by personnel knowledgeable of batteries and  
the required precautions. Keep unauthorized person-  
nel away from batteries.  
2.3 ELECTRICAL CHECKS  
Complete electrical checks as follows:  
When replacing the battery, use the following type of  
battery: Group 26/26R 12-volt DC, negative ground  
battery with a rating of 350 cold-cranking amps mini-  
mum for 7 kW; 525 cold-cranking amps minimum  
for 12 and 15 kW at -17.8º C (0º F) minimum. When  
using a maintenance-free battery, it is not necessary  
to check the specific gravity or electrolyte level. Have  
these procedures performed at the intervals specified  
in the “Service Schedule.” A negative ground system  
is used. Battery connections are shown on the wiring  
diagrams. Make sure the battery is correctly connect-  
ed and terminals are tight. Observe battery polarity  
when connecting the battery to the generator set.  
1. Set the generator's main circuit breaker to its  
OFF (or open) position.  
2. Set the generator's Auto/Off/Manual switch to the  
OFF position.  
3. Turn OFF all loads connected to the transfer  
switch terminals T1 and T2.  
4. Turn on the utility power supply to the transfer  
switch using the means provided (such as a utility  
main line circuit breaker).  
DANGER  
The transfer switch is now electrically “hot.”  
Contact with “hot” parts will result in extremely  
2.1 BEFORE INITIAL START-UP  
hazardous and possibly fatal electrical shock.  
Proceed with caution.  
Before starting, complete the following:  
5. Use an accurate AC voltmeter to check utility  
power source voltage across transfer switch ter-  
minals N1 and N2. Nominal line-to-line voltage  
should be 240 volts AC.  
6. Check utility power source voltage across termi-  
nals N1 and the transfer switch neutral lug; then  
across terminal N2 and neutral. Nominal line-to-  
neutral voltage should be 120 volts AC.  
1. Set the generator’s main circuit breaker to its  
OFF (or open) position.  
2. Set the generator's AUTO/OFF/MANUAL switch to  
the OFF position.  
3. Turn OFF the utility power supply to the transfer  
switch using the means provided (such as the  
utility main line circuit breaker).  
4. Turn OFF all loads connected to the transfer  
switch terminals T1 and T2.  
10  
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Section 2 — Post Installation Start-up and Adjustments  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
7. When certain that utility supply voltage is compat-  
ible with transfer switch and load circuit ratings,  
turn OFF the utility power supply to the transfer  
switch.  
Do not attempt manual transfer switch opera-  
tion until all power voltage supplies to the  
transfer switch have been positively turned off.  
Failure to turn off all power voltage supplies  
will result in extremely hazardous and possibly  
fatal electrical shock.  
8. On the generator panel, set the AUTO/OFF/  
MANUAL switch to MANUAL. The engine should  
crank and start.  
9. Let the engine warm up for about five minutes to  
allow internal temperatures to stabilize. Then, set  
the generator’s main circuit breaker to its ON (or  
CLOSED) position.  
5. Manually set the transfer switch to the STANDBY  
position, i.e., load terminals connected to the  
generator's E1/E2 terminals. The transfer switch  
operating lever should be down.  
6. Set the generator's AUTO/OFF/MANUAL switch  
to MANUAL. The engine should crank and start  
immediately.  
DANGER  
Proceed with caution! Generator power voltage  
is now supplied to the transfer switch. Contact  
with live transfer switch parts will result in dan-  
gerous and possibly fatal electrical shock.  
7. Let the engine stabilize and warm up for a few  
minutes.  
10. Connect an accurate AC voltmeter and a fre-  
quency meter across transfer switch terminal  
lugs E1 and E2. Voltage should be 242-252 volts;  
frequency should read about 61-63 Hertz.  
11. Connect the AC voltmeter test leads across ter-  
minal lug E1 and neutral; then across E2 and  
neutral. In both cases, voltage reading should be  
121-126 volts AC.  
12. Set the generator’s main circuit breaker to its  
OFF (or open) position. Let the engine run at no-  
load for a few minutes to stabilize internal engine  
generator temperatures.  
8. Set the generator’s main circuit breaker to its ON  
(or closed) position. Loads are now powered by  
the standby generator.  
9. Turn ON electrical loads connected to transfer  
switch T1 and T2. Apply an electrical load equal  
to the full rated wattage/amperage capacity of the  
installed generator.  
10. Connect an accurate AC voltmeter and a frequen-  
cy meter across terminal lugs E1 and E2. Voltage  
should be greater than 230 volts; frequency  
should be greater than 58 Hertz.  
11. Let the generator run at full rated load for 20-30  
minutes. Listen for unusual noises, vibration or  
other indications of abnormal operation. Check  
for oil leaks, evidence of overheating, etc.  
12. When testing under load is complete, turn OFF  
electrical loads.  
13. Set the generator's AUTO/OFF/MANUAL switch to  
OFF. The engine should shut down.  
NOTE:  
It is important not to proceed until certain that  
generator AC voltage and frequency are correct  
and within the stated limits. Generally, if both AC  
frequency and voltage are high or low, the engine  
governor requires adjustment. If frequency is cor-  
rect, but voltage is high or low, the generator’s  
voltage regulator requires adjustment.  
13. Set the generator's main circuit breaker to its  
OFF (or OPEN) position.  
14. Let the engine run at no-load for a few minutes.  
15. Set the AUTO/OFF/MANUAL switch to OFF. The  
engine should shut down.  
2.5 CHECKING AUTOMATIC  
2.4 GENERATOR TESTS UNDER LOAD  
To test the generator set with electrical loads applied,  
proceed as follows:  
OPERATION  
To check the system for proper automatic operation,  
proceed as follows:  
1. Set generator’s main circuit breaker to its OFF  
(or OPEN) position.  
1. Set generator’s main circuit breaker to its OFF  
(or OPEN) position.  
2. Turn OFF all loads connected to the transfer  
switch terminals T1 and T2.  
2. Check that the AUTO/OFF/MANUAL switch is set  
3. Set the generator's AUTO/OFF/MANUAL switch to  
OFF.  
4. Turn OFF the utility power supply to the transfer  
switch, using the means provided (such as a util-  
ity main line circuit breaker).  
to OFF.  
3. Turn OFF the utility power supply to the transfer  
switch, using means provided (such as a utility  
main line circuit breaker).  
4. Manually set the transfer switch to the UTILITY  
position, i.e., load terminals connected to the util-  
ity power source side.  
11  
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Section 2 — Post Installation Start-up and Adjustments  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
5. Turn ON the utility power supply to the transfer  
5. The fuel regulator is fitted with one (7 kW), or two  
(12 & 15 kW) adjustment screws. While watch-  
ing the frequency meter, slowly turn the adjust-  
ment screws clockwise or counterclockwise one  
at a time until the highest frequency is read on  
the meter. Only limited adjustment is available  
because of the set pin. Under no circumstances  
should any of the pins be removed (Figures 2.1  
and 2.2).  
switch, using the means provided (such as a util-  
ity main line circuit breaker).  
6. Set the AUTO/OFF/MANUAL switch to AUTO. The  
system is now ready for automatic operation.  
7. Turn OFF the utility power supply to the transfer  
switch.  
With the AUTO/OFF/MANUAL switch at AUTO, the  
engine should crank and start when the utility source  
power is turned OFF. After starting, the transfer  
switch should connect load circuits to the standby  
side. Let the system go through its entire automatic  
sequence of operation.  
Figure 2.1 — Dual Fuel Regulators  
V-twin  
410  
With the generator running and loads powered by  
generator AC output, turn ON the utility power supply  
to the transfer switch. The following should occur:  
Adjustment  
Adjustment  
Screw  
(Both Sides)  
Set  
Pin  
• After about 13 seconds, the switch should transfer  
loads back to the utility power source.  
• About one minute after retransfer, the engine  
should shut down.  
Screw  
(One Side  
Only)  
Set Pin  
(Both Sides)  
2.6 ADJUSTING THE REGULATOR  
(NATURAL GAS ONLY)  
6. When the highest frequency is reached maximum  
power has been set. From this point turn both  
adjustment screws 1/4 turn counterclockwise.  
The regulator is now set.  
Although the generator has been factory set to pro-  
vide maximum power, it may be necessary in some  
areas to adjust this setting. Because natural gas has  
different BTU or power content across the country  
the engine may not perform as designed.  
Figure 2.2 — Placement of Regulator  
If experiencing engine problems at high or full load  
conditions follow these steps. It will require a fre-  
quency meter to perform this procedure.  
1. Turn off utility power to the main distribution  
panel in the house. This can be done by switching  
the service main breaker to the off or open posi-  
tion.  
2. Allow the generator to start. Before loading the  
generator, confirm that the No Load Frequency,  
with the roof open and door off, is set to 63-63.5  
Hz. Transfer load to emergency circuits.  
3. Turn on appliances, lights, pumps, etc., that are  
on the emergency circuits in an attempt to fully  
load the generator. Be cautious not to overload  
the generator. Use the following chart as a guide:  
Adjustment Screw  
Unit  
7 kW  
12 kW  
13 kW  
120 Volts  
50.0 amps  
100.0 amps  
108.3 amps  
240 Volts  
25.0 amps  
50.0 amps  
54.1 amps  
7. Turn utility power to the main distribution panel  
back on. This can be done by switching the ser-  
vice main breaker to the on or closed position.  
Allow the generator to shut down.  
4. When 3/4 load has been achieved. Connect a fre-  
quency meter to the output lugs of the generator’s  
main line circuit breaker.  
Do not make any unnecessary adjustments.  
Factory settings are correct for most applica-  
tions. However, when making adjustments, be  
careful to avoid overspeeding the engine.  
12  
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Section 2 — Post Installation Start-up and Adjustments  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
If this procedure or the equipment are not available,  
locate the nearest Dealer and they can perform the  
adjustments.  
‹
2.7.2 12 KW AND 15 KW UNITS  
1. Loosen governor clamp bolt (See Figure 2.4).  
2. Completely remove the idle spring.  
3. With governor arm at wide open throttle position,  
rotate governor shaft fully clockwise. Tighten  
clamp bolt to 84 inch-pounds.  
NOTE:  
A service fee may be charged for this adjustment.  
4. Start unit and apply full load. Use full load speed  
adjust screw (Figure 2.5) to adjust frequency to  
58 Hz.  
2.7 ENGINE GOVERNOR ADJUSTMENT  
If both AC frequency and voltage are correspondingly  
high or low, adjust the engine governor as follows:  
5. Remove load, stop engine, loosen the idle adjust  
screw and reconnect the idle spring.  
‹
2.7.1 7 KW UNITS  
6. Using a hand, push the governor arm to the  
closed throttle position. Make sure the idle spring  
does not stretch at all.  
1. Loosen the governor clamp bolt (Figures 2.3).  
2. Hold the governor lever at its wide open throttle  
position, and rotate the governor shaft clockwise  
as far as it will go. Then, tighten the governor  
lever clamp bolt to 70 inch-pounds (8 N-m).  
3. Start the generator; let it stabilize and warm up  
at no-load.  
Figure 2.4 — Engine Governor Adjustment  
V-twin Engines  
4. Connect a frequency meter across the generators  
AC output leads.  
Idle Spring  
Governor  
Shaft  
(Rotate  
Clockwise)  
5. Turn the primary adjust screw to obtain a fre-  
quency reading of 61.5 Hertz. Turn the secondary  
adjust screw to obtain a frequency of 62.5 Hz.  
6. When frequency is correct at no load, check the  
AC voltage reading. If voltage is incorrect, the volt-  
age regulator may require adjustment.  
Figure 2.3 — Engine Governor Adjustment  
Single Cylinder Engines  
SECONDARY  
ADJUST SCREW  
No Load Idle  
Adjustment Screw  
Governor Clamp Bolt  
Figure 2.5 — Full Load Speed Adjust Screw  
V-twin Engines  
GOVERNOR  
SHAFT  
Full Load Speed Adjust Screw  
GOVERNOR  
PRIMARY  
CLAMP  
BOLT  
ADJUST  
SCREW  
13  
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Section 3 — Operation  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
7. Restart the unit.  
3.1 BREAK-IN PROCEDURE  
8. Slowly turn the idle adjust screw to adjust the  
no-load idle frequency to 63-63.5 Hz (with door  
open).  
Once the unit has been installed and all electrical  
checks have been made, it is strongly recommended  
that the following “Break-in Procedure” be completed  
to ensure correct generator operation in the future.  
9. The governor is now set.  
1. Set the generator’s AUTO/OFF/MANUAL switch to  
AUTO.  
2. Turn OFF the utility power supply to the transfer  
switch using the means provided (such as a utility  
main line circuit breaker).  
‹
2.7.3 ADDITIONAL CORROSION  
PROTECTION  
Periodically spray all engine linkage parts and brack-  
ets with corrosion inhibiting spray such as WD-40 or  
a comparable product.  
3. The unit will start, and the transfer switch will  
transfer to standby.  
4. Using the transfer switch’s built-in emergency  
load center, turn on circuits to load the generator  
to approximately 25% rated load and run the unit  
for one hour.  
5. Run the unit for one hour at 50% rated load.  
6. Run the unit for one hour at 75% rated load.  
7. Run the unit for one hour at 100% rated load.  
8. Turn ON the utility power supply to the transfer  
switch, which will allow the transfer switch to  
transfer back to utility power. The unit will con-  
tinue to run for one minute and then shut down.  
9. Allow the unit to cool.  
2.8 VOLTAGE REGULATOR  
ADJUSTMENT  
With the frequency between 62-63 Hertz, slowly turn  
the slotted potentiometer (Figure 2.6) until line volt-  
age reads 247-252 volts.  
Figure 2.6 – Voltage Adjustment Potentiometer  
10. Set the generator’s main circuit breaker to its  
OFF (or OPEN) position.  
11. Set the generator's AUTO/OFF/MANUAL switch  
to OFF. Remove the 7.5A and 15A fuses from the  
generator control panel. Disconnect the battery  
cables as outlined in “General Hazards”.  
12. Drain the oil and remove the oil filter. Replace  
the oil filter according to Section 4.4, “Changing  
the Oil Filter”. Replace the oil with synthetic oil  
as recommended in Section 4.3, “Changing the  
Engine Oil”.  
13. Reconnect the battery cables as outlined in  
“General Hazards” (page 2) and insert the 7.5A  
and 15A fuses into the generator control panel.  
The generator is now ready for service.  
NOTE:  
The access panel on top of the control panel must  
be removed to adjust the voltage regulator.  
3.2 USING THE AUTO/OFF/MANUAL  
SWITCH (FIGURE 3.1)  
NOTE:  
The voltage regulator is housed above the gen-  
erator's control panel. The regulator maintains a  
voltage in direct proportion to frequency at a 2-to-  
1 ratio. For example, at 62 Hertz, line-to-neutral  
voltage will be 124 volts.  
‹
3.2.1 “AUTO” POSITION  
Selecting this switch position activates fully auto-  
matic system operation. It also allows personnel to  
start and exercise the engine every seven days with  
the setting of the exercise timer (see Section 3.6).  
This position also is used for remote starting, when  
it is set up.  
14  
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Section 3 — Operation  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
‹
3.2.2 “OFF” POSITION  
‹
3.3.1 12 VDC ACCESSORY OUTLET  
This switch position shuts down the engine. This  
position also prevents automatic operation.  
Your generator is equipped with a 12 VDC accessory  
outlet in the Generator Control Panel. (Figure 3.1)  
With the generator running or in standby mode, this  
outlet may be used to temporarily power low power  
accessories such as a work light, cell phone, radio or  
any other automotive style accessory. This outlet is  
capable of delivering a MAXIMUM of 7.5 Amps. If the  
accessory to be used through this circuit demands  
too much power, the fuse that protects this circuit  
will melt open and the circuit will not be functional.  
Figure 3.1 – Generator Control Panel  
EXTERNAL  
OUTLET FUSE  
GFCI  
CIRCUIT  
BREAKER  
7.5A  
AUTO  
OFF MAN.  
SYSTEM SET  
LOW OIL  
HIGH TEMP.  
OVER SPEED  
OVER CRANK  
SYST  
F
L
F
A
L
S
H
I
N
L
E
D
This 12 VDC outlet draws power from the gen-  
SET  
EXERCISE  
TIME  
N
O
S
E
N
S
E
4
S
H
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erator's starting battery and extended use of  
this outlet may drain the battery and the  
engine may not start. This outlet should NOT be  
used for battery charging.  
‹
3.2.3 “MANUAL” POSITION  
Set the switch to MANUAL to crank and start the  
engine. Transfer to standby power will not occur  
unless there is a utility failure.  
‹
3.3.2 120 VAC GFCI OUTLET  
Your generator is equipped with an external, 15 amp,  
120 volt, GFCI convenience outlet that is located in  
the right rear of the generator enclosure. (Figures  
1.1 and 1.2) When the generator is running, in the  
absence of utility power, this outlet may be used  
to power items outside your home such as lights  
or power tools. This outlet may also be used when  
utility power is present by running the generator in  
manual mode. This oultlet does not provide power if  
the generator is not running. This outlet is protected  
by a 15-amp circuit breaker located in the generator  
control panel. (Figure 3.1).  
With the switch set to AUTO, the engine may  
crank and start at any time without warning.  
Such automatic starting normally occurs when  
utility power source voltage drops below a pre-  
set level or during the normal exercise cycle. To  
prevent possible injury that might be caused  
by such sudden starts, always set the switch to  
OFF and remove the fuses before working on or  
around the generator or transfer switch. Then,  
place a “DO NOT OPERATE” tag on the genera-  
tor panel and on the transfer switch.  
3.4 SEQUENCE OF AUTOMATIC  
OPERATION  
3.3 AUTOMATIC TRANSFER  
The generator’s control panel houses a control logic  
circuit board. This board constantly monitors util-  
ity power source voltage. Should that voltage drop  
below a preset level, circuit board action will signal  
the engine to crank and start. After the engine starts,  
the circuit board signals the transfer switch to acti-  
vate and connect load circuits to the standby power  
supply (load terminal lugs T1/T2 connect to terminal  
lugs E1/E2).  
OPERATION  
To select automatic operation, do the following:  
1. Make sure the transfer switch main contacts are  
set to their UTILITY position, i.e., loads con-  
nected to the utility power source (Figure 3.2).  
2. Be sure that normal UTILITY power source volt-  
age is available to transfer switch terminal lugs  
N1 and N2.  
Upon restoration of utility source voltage above a  
preset level, generator circuit board action signals the  
transfer switch to transfer loads back to that power  
supply. After retransfer, the engine is signalled to shut  
down.  
3. Set the generator’s AUTO/OFF/MANUAL switch to  
AUTO.  
4. Set the generator’s main circuit breaker to its ON  
(or closed) position.  
With the preceding steps complete, the generator will  
start automatically when utility source voltage drops  
below a preset level. After the unit starts, loads are  
transferred to the standby power source. Refer to  
Section 3.4, “Sequence of Automatic Operation.”  
The actual sequence of operation is controlled by  
sensors and timers on a control logic circuit board,  
as follows:  
A.Utility Voltage Dropout Sensor  
• This sensor monitors utility source voltage.  
15  
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Section 3 — Operation  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
• If utility source voltage drops below about 60  
4. Use the manual transfer handle inside the trans-  
fer switch to move the main contacts to their  
“Standby” position, i.e., loads connected to the  
standby power source (Figure 3.2).  
percent of the nominal supply voltage, the sensor  
energizes a 15-second timer.  
• Once the timer has expired, the engine will crank  
and start.  
Figure 3.2 – Manual Transfer Switch Operation  
B.Engine Warm-up Time Delay  
• This mechanism lets the engine warm up for  
about 10 seconds before the load is transferred  
to the standby source.  
C.Standby Voltage Sensor  
• This sensor monitors generator AC output volt-  
age. When the voltage has reached 50 percent of  
the nominal rated voltage, transfer to standby  
can occur.  
D.Utility Voltage Pickup Sensor  
• This sensor monitors utility power supply volt-  
age. When that voltage is restored above 70 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.  
• 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.  
5. To crank and start the engine, set the AUTO/OFF/  
MANUAL switch to MANUAL.  
6. Let the engine stabilize and warm up for a few  
minutes.  
7. Set the generator’s main circuit breaker to its ON  
(or closed) position. The standby power source  
now powers the loads.  
• The timer will run for about one minute, and the  
generator will then shut down.  
‹
3.5.2 TRANSFER BACK TO UTILITY POWER  
SOURCE  
3.5 MANUAL TRANSFER OPERATION  
When utility power has been restored, transfer back  
to that source and shut down the generator. This can  
be accomplished as follows:  
‹
3.5.1 TRANSFER TO GENERATOR  
POWER SOURCE  
To start the generator and activate the transfer switch  
manually, proceed as follows:  
1. Set the generator’s main circuit breaker to its  
OFF (or open) position.  
2. Let the engine run for a minute or two at no-load  
to stabilize the internal temperatures.  
3. Set the generator’s AUTO/OFF/MANUAL switch to  
its OFF (or open) position. The engine should  
shut down.  
1. Set the generator’s AUTO/OFF/MANUAL switch to  
OFF.  
2. Set the generator’s main circuit breaker to its  
OFF (or open) position.  
3. Turn OFF the utility power supply to the transfer  
switch using the means provided (such as a utility  
main line circuit breaker).  
4. Check that utility power supply to the transfer  
switch is turned OFF.  
DANGER  
DANGER  
Do not attempt to activate the transfer switch  
manually until all power voltage supplies  
Do not attempt to activate the transfer switch  
manually until all power voltage supplies to the  
to the switch have been positively turned off.  
Failure to turn off all power voltage supplies  
may result in extremely hazardous and possibly  
fatal electrical shock.  
switch have been positively turned off. Failure  
to turn off all power voltage supplies may result  
in extremely hazardous and possibly fatal elec-  
trical shock.  
16  
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Section 3 — Operation  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
5. Use the manual transfer handle inside the trans-  
‹
3.7.2 HIGH TEMPERATURE SWITCH  
fer switch to move the main contacts back to their  
UTILITY position, i.e., loads connected to the util-  
ity power source (Figure 3.2).  
This switch’s contacts (Figure 3.3) close if the tem-  
perature should exceed approximately 140º C (284º  
F), initiating an engine shutdown. The generator will  
automatically restart and the LED on the generator  
control panel will reset once the temperature has  
returned to a safe operating level.  
6. Turn ON the utility power supply to the transfer  
switch using the means provided.  
7. Set the system to automatic operation as outlined  
in “Automatic Transfer Operation,” Section 3.3.  
Figure 3.3 – Low Oil Pressure and  
High Temperature Switches  
3.6 SETTING THE EXERCISE TIMER  
This generator is equipped with an exercise timer.  
Once it is set, the generator will start and exercise  
once every seven days, on the day of the week and at  
the time of day the following sequence is completed.  
During this exercise period, the unit runs for approx-  
imately 12 minutes and then shuts down. Transfer of  
loads to the generator output does not occur during  
the exercise cycle.  
Low Oil Switch  
High Temp Switch  
A switch on the control panel (see Figure 3.1) per-  
mits selection of the day and time for the system to  
exercise. At the chosen time, perform the following  
sequence to select the desired day and time of day the  
system will exercise.  
Oil  
Drain  
Hose  
1. Verify that the AUTO/OFF/MANUAL switch is set  
to AUTO.  
2. Hold down the “Set Exercise Time” switch until  
the generator starts (approximately 10 seconds)  
and then release.  
3. The generator will start and run for approximate-  
ly 12 minutes and then shut down on its own.  
The exerciser will then be set to run at that time  
of day every week.  
Oil Filter  
‹
3.7.3 OVERCRANK  
This feature prevents the generator from damaging  
itself when it continually attempts to start and anoth-  
er problem, such as no fuel supply, prevents it from  
starting. The unit will crank and rest for a preset  
time limit. Then, it will stop cranking, and the LED  
on the generator control panel will light indicating an  
overcrank failure. The AUTO/OFF/MANUAL switch  
will need to be set to OFF and then back to AUTO to  
reset the generator control board.  
NOTE:  
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.  
NOTE:  
If the fault is not repaired, the overcrank feature  
will continue to activate.  
The exerciser WILL NOT work if dip switch 2 on  
the controller printed circuit board (Remote Not  
Auto) is ON.  
3.7.3.1 Approximate Crank Cycle Times  
• 15 seconds ON  
• 7 seconds OFF  
• 7 seconds ON  
• 7 seconds OFF  
3.7 PROTECTION SYSTEMS  
‹
3.7.1 LOW OIL PRESSURE SWITCH  
This switch (Figure 3.3) has normally closed con-  
tacts that are held open by engine oil pressure dur-  
ing cranking and operating. Should oil pressure  
drop below the 8 psi range, switch contacts close,  
and the engine shuts down. The unit should not be  
restarted until oil is added. The AUTO/OFF/MANUAL  
switch must then be turned to OFF and then back to  
AUTO.  
• Repeat for 45 seconds  
Approximately 90 seconds total  
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Section 4 — Maintenance  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
3. Install the dipstick; then, remove it again. The oil  
‹
3.7.4 OVERSPEED  
level should be at the dipstick “Full” mark. If nec-  
essary, add oil to the “Full” mark only. DO NOT  
FILL ABOVE THE “FULL” MARK.  
This feature protects the generator from damage by  
shutting it down if it happens to run faster than the  
preset limit. This protection also prevents the gen-  
erator from supplying an output that could poten-  
tially damage appliances connected to the generator  
circuit. Contact the nearest Authorized Dealer if this  
failure occurs.  
Never operate the engine with the oil level  
below the “Add” mark on the dipstick. Doing  
this could damage the engine.  
4. Install the dipstick.  
4.1 FUSES  
5. Reset the AUTO/OFF/MANUAL switch to its origi-  
The generator panel's 15-amp fuse (Figure 4.1) pro-  
tects the DC control circuit and the battery charge  
circuit against overload. This fuse is wired in series  
with the battery output lead to the panel. If this fuse  
element has melted open, the engine will not be able  
to crank or start. The generator will also lose all bat-  
tery charge capabilities. Replace this fuse using only  
an identical 15-amp replacement fuse. To replace the  
fuse, push the fuse holder cap down and rotate it  
counterclockwise.  
nal position.  
Figure 4.2 — Oil Dipstick and Fill, 7 kW  
Oil Dipstick and Fill  
The generator panel's 7.5-amp fuse protects the  
12 VDC accessory socket. If the fuse element has  
melted open, the 12 VDC socket will not be able to  
provide power to any accessories. Replace this fuse  
using only an identical 7.5-amp replacement fuse. To  
replace the fuse, push the fuse holder cap down and  
rotate it counterclockwise.  
Figure 4.1 – Generator Control Panel  
EXTERNAL  
OUTLET FUSE  
GFCI  
Figure 4.3 — Oil Dipstick and Fill,  
12 kW and 15 kW  
CIRCUIT  
BREAKER  
7.5A  
AUTO  
OFF MAN.  
SYSTEM SET  
LOW OIL  
HIGH TEMP.  
OVER SPEED  
OVER CRANK  
SYST  
Oil Dipstick  
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EXERCISE  
TIME  
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Oil Fill  
4.2 CHECKING THE ENGINE  
OIL LEVEL  
For oil capacities, see “Specifications,” Section 1.5.  
For engine oil recommendations, see Section 4.3.1.  
To check the engine oil level, proceed as follows  
(Figures 4.2 and 4.3):  
1. Start the generator by moving the AUTO/OFF/  
MANUAL switch to the MANUAL position. Allow  
it to run for a short while and then shut it down  
by moving the switch to the OFF position.  
2. Remove the dipstick and wipe it dry with a clean  
cloth.  
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Section 4 — Maintenance  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
4.3 CHANGING THE ENGINE OIL  
4.4 CHANGING THE OIL FILTER  
Change the engine oil filter as follows:  
‹
4.3.1 ENGINE OIL RECOMMENDATIONS  
1. With the oil drained, remove the old oil filter by  
turning it counterclockwise.  
2. Apply a light coating of clean engine oil to the  
gasket of the new filter. See Section 1.5.1 for rec-  
ommended filter.  
Use oil of American Petroleum Institute (API) Service  
Class SG, SH or SJ. Use all season SAE 5W-30  
Synthetic oil. Organic break-in oil is required before  
using synthetic oil.  
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  
Section 4.3.1). See Section 1.5.2 for oil capaci-  
ties.  
NOTE:  
The unit is supplied with “break-in” oil. See the  
“Break-in Procedure,” Section 3.1, for the first  
required oil change.  
Any attempt to crank or start the engine before  
5. Start the engine and check for leaks.  
it has been properly serviced with the recom-  
mended oil may result in an engine failure.  
4.5 CHANGING THE ENGINE  
AIR CLEANER  
‹
4.3.2 OIL CHANGE PROCEDURE  
To change the oil, proceed as follows:  
‹
4.5.1 7 KW, 12 KW AND 15 KW  
GENERATORS  
1. Run the engine until it is thoroughly warmed up  
then shut OFF the engine.  
2. Immediately after the engine shuts OFF, pull the  
oil drain hose (Figure 4.4) free of its retaining  
clip. Remove the cap from the hose and drain the  
oil into a suitable container.  
See Figures 1.1 and 1.2, for the location of the air  
cleaner. Use the following procedure (Figure 4.6):  
1. Turn the two screws counterclockwise to loosen.  
2. Remove the cover and air filter.  
3. After the oil has drained, replace the cap onto the  
end of the oil drain hose. Retain the hose in the  
clip.  
4. Refill with the proper recommended oil (see  
Section 4.3.1). See Section 1.5.2 for oil capaci-  
ties.  
3. Wipe away dust or debris from inside of the air  
box and around edges.  
4. Install the new air cleaner into the air box.  
5. Install the cover. Turn the two cover screws clock-  
wise to tighten.  
See the “Service Schedule,” Section 4.13, for air  
cleaner maintenance. See Section 1.5.1 for air filter  
replacement part number.  
Figure 4.4 – Oil Drain Hose and Filter  
Low Oil Switch  
High Temp Switch  
Figure 4.6 — 7 kW, Engine Air Cleaner Location  
Fuel  
Regulator  
Air Cleaner  
Oil  
Drain  
Hose  
Oil Filter  
3/4" Hole  
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Section 4 — Maintenance  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Figure 4.7 — 12 kW and 15 kW Engine  
4.7 BATTERY MAINTENANCE  
Air Cleaner  
The battery should be inspected per the “Service  
Schedule,” Section 4.13. The following procedure  
should be followed for inspection:  
Screw  
1. Inspect the battery posts and cables for tightness  
and corrosion. Tighten and clean as necessary.  
2. Check the battery fluid level of unsealed batteries  
and, if necessary, fill with Distilled Water Only. Do  
not use tap water in batteries.  
3. Have the state of charge and condition checked.  
This should be done with an automotive-type bat-  
tery hydrometer.  
Cover  
Filter  
DANGER  
Do not dispose of the battery in a fire. The  
battery is capable of exploding.  
A battery presents a risk of electrical shock  
and high short circuit current. The following pre-  
cautions are to be observed when working on  
batteries:  
• Remove the 7.5A and 15A fuses from the genera-  
tor control panel.  
• Remove watches, rings or other metal objects;  
• Use tools with insulated handles;  
• Wear rubber gloves and boots;  
• Do not lay tools or metal parts on top of the  
battery; and  
4.6 SPARK PLUG(S)  
Reset the spark plug(s) gap or replace the spark  
plug(s) as necessary. See Section 4.13 for mainte-  
nance requirements.  
1. Clean the area around the base of the spark  
plug(s) to keep dirt and debris out of the engine.  
Clean by scraping or washing using a wire brush  
and commercial solvent. Do not blast the spark  
plug(s) to clean.  
• Disconnect charging source prior to connecting or  
disconnecting battery terminals.  
2. Remove the spark plug(s) and check the condi-  
tion. Replace the spark plug(s) if worn or if reuse  
is questionable. See Section 4.13 for recommend-  
ed inspection.  
3. Check the spark plug gap using a wire feeler  
gauge. Adjust the gap to 0.76 mm (0.030 inch)  
for 7 kW and 0.50 mm (0.020 inch) for 12/15 kW  
by carefully bending the ground electrode (Figure  
4.8).  
Do not open or mutilate the battery. Released  
electrolyte has been known to be harmful to the  
skin and eyes, and to be toxic.  
The electrolyte is a dilute sulfuric acid that is  
harmful to the skin and eyes. It is electrically  
conductive and corrosive. The following  
procedures are to be observed:  
• Wear full eye protection and protective clothing;  
• Where electrolyte contacts the skin, wash it off  
immediately with water;  
• Where electrolyte contacts the eyes, flush  
thoroughly and immediately with water and seek  
medical attention; and  
Figure 4.8 – Setting the Spark Plug Gap  
SET PLUG GAP AT 0.76 mm (.030 inch) - 7kW  
0.508 mm (.020 inch) - 12 & 15kW  
• Spilled electrolyte is to be washed down with an  
acid neutralizing agent. A common practice is to  
use a solution of 1 pound (500 grams) bicarbonate  
of soda to 1 gallon (4 liters) of water. The bicar-  
bonate of soda solution is to be added until the  
evidence of reaction (foaming) has ceased. The  
resulting liquid is to be flushed with water and the  
area dried.  
20  
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Section 4 — Maintenance  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
When valve clearance is correct, hold the pivot ball  
Lead-acid batteries present a risk of fire because  
they generate hydrogen gas. The  
following procedures are to be followed:  
stud in place with the allen wrench and tighten the  
rocker arm jam nut. Tighten the jam nut to 174  
in/lbs. torque. After tightening the jam nut, recheck  
valve clearance to make sure it did not change.  
• DO NOT SMOKE when near the battery;  
• DO NOT cause flame or spark in battery area; and  
• Discharge static electricity from body before touch-  
ing the battery by first touching a grounded metal  
surface.  
Figure 4.10 - Valve Clearance Adjustment  
Rocker  
Arm  
Pivot Ball  
Be sure the AUTO/OFF/MANUAL switch is set to  
Stud  
Jam Nut  
the OFF position before connecting the battery  
Valve  
Stem  
cables. If the switch is set to AUTO or MANUAL,  
the generator can crank and start as soon as the  
battery cables are connected.  
Be sure the utility power supply is turned off  
and the 7.5A and 15A fuses are removed from  
the generator control panel, or sparking may  
occur at the battery posts as the cables are  
attached and cause an explosion.  
4.8 ADJUSTING GH-410/GT-990/760  
• Install new valve cover gasket.  
• Re-attach the valve cover.  
NOTE:  
VALVE CLEARANCE  
After the first 6 months of operation, adjust the  
valve clearance in the engine.  
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.  
Important: If feeling uncomfortable about doing  
this procedure or the proper tools are not available,  
please contact the Authorized Dealer for service  
assistance. This is a very important step to insure  
longest life for the engine.  
• Re-attach the spark plug wire to the spark plug.  
• On GT-990, Repeat the process for the other cylin-  
der.  
To adjust valve clearance:  
4.9 COOLING SYSTEM  
• Make sure the engine is at room temperature.  
• Make sure that the spark plug wire is removed  
from the spark plug and out of the way.  
Air inlet and outlet openings in the generator com-  
partment must be open and unobstructed for con-  
tinued proper operation. This includes such obstruc-  
tions as high grass, weeds, brush, leaves and snow.  
• Remove the four screws attaching the valve cover  
with a #2 or #3 phillips screwdriver.  
• Make sure the piston is at Top Dead Center (TDC)  
of its compression stroke (both valves closed). To  
get the piston at TDC, remove the intake screen at  
the front of the engine to gain access to the flywheel  
nut. Use a large socket and socket wrench to rotate  
the nut and hence the engine. While watching the  
piston through the spark plug hole. The piston  
should move up and down. The piston is at TDC  
when it is up as high as it can go.  
Without sufficient cooling and ventilating air flow, the  
engine/generator quickly overheats, which causes it  
to quickly shut down. (See Figure 4.9 for vent loca-  
tions.)  
Figure 4.9 – Cooling Vent Locations  
• Loosen the rocker jam nut. Use an 10mm allen  
wrench to turn the pivot ball stud while checking  
clearance between the rocker arm and the valve  
stem with a feeler gauge. Correct clearance is  
0.002-0.004 inch (0.05-0.1 mm).  
NOTE:  
Hold the rocker arm jam nut in place as the pivot  
ball stud is turned.  
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Section 4 — Maintenance  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
7. Attach a tag to the engine indicating the viscosity  
and classification of the oil in the crankcase.  
8. Remove the spark plug(s) and spray fogging  
agent into the spark plug(s) threaded openings.  
Reinstall and tighten the spark plug(s).  
9. Remove the battery and store it in a cool, dry  
room on a wooden board. Never store the battery  
on any concrete or earthen floor.  
The exhaust from this product gets extremely  
hot and remains hot after shutdown. High grass,  
weeds, brush, leaves, etc. must remain clear of  
the exhaust. Such materials may ignite and burn  
from the heat of the exhaust system.  
10. Clean and wipe the entire generator.  
The maximum ambient temperature for the gen-  
erator is 40° C (104° F).  
‹
4.12.2 RETURN TO SERVICE  
To return the unit to service after storage, proceed  
as follows:  
4.10 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 and dry the generator.  
1. Verify that utility power is turned off and that the  
AUTO/OFF/MANUAL switch is set to OFF.  
2. Check the tag on the engine for oil viscosity and  
classification. Verify that the correct recommend-  
ed oil is used in the engine (see Section 4.3.1). 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,” Section 1.5, for type and  
size.  
4.11 CORROSION PROTECTION  
Periodically wash and wax the enclosure using auto-  
motive type products. Frequent washing is recom-  
mended in salt water/coastal areas. Spray engine  
linkages with a light oil such as WD-40.  
4. Clean and wipe the entire generator.  
5. Remove the 7.5A and 15A fuses from the genera-  
tor control panel. Reconnect the battery. Observe  
battery polarity. Damage may occur if the battery  
is connected incorrectly.  
4.12 OUT OF SERVICE PROCEDURE  
‹
4.12.1 REMOVAL FROM SERVICE  
If the generator cannot be exercised every seven days,  
and will be out of service longer than 90 days, pre-  
pare the generator for storage as follows:  
6. Open the fuel shutoff valve.  
7. Insert the 7.5A and 15A fuses into the generator  
control panel. Start the unit by moving the AUTO/  
OFF/MANUAL switch to MANUAL. Allow the unit  
to warm up thoroughly.  
1. Start the engine and let it warm up.  
2. Close the fuel shutoff valve in the fuel supply line  
and allow the unit to shut down.  
8. Stop the unit by setting the AUTO/OFF/MANUAL  
3. Once the unit has shut down, it will signal a low  
switch to OFF.  
oil fault.  
9. Turn on the utility power to the transfer switch.  
10. Set the AUTO/OFF/MANUAL switch to AUTO.  
11. The generator is now ready for service.  
NOTE:  
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 7.5A and 15A fuses from the genera-  
tor control panel. Disconnect the battery cables  
as outlined in “General Hazards” (page 2).  
6. While the engine is still warm from running,  
drain the oil completely. Refill the crankcase with  
oil. See ”Engine Oil Recommendations,” Section  
4.3.1.  
If the battery was dead or disconnected, the exer-  
cise timer must be reset.  
22  
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Section 4 — Maintenance  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
4.13 SERVICE SCHEDULE  
ATTENTION: It is recommended that all service work  
be performed by the nearest Authorized Dealer.  
SYSTEM/COMPONENT  
PROCEDURE  
FREQUENCY  
X = Action  
Inspect  
Change  
Clean  
W = Weekly  
M = Monthly  
Y = Yearly  
R = Replace as Necessary  
* = Notify Dealer  
if Repair is Needed.  
FUEL  
Fuel lines and connections*  
X
X
M
M
LUBRICATION  
Oil level  
Oil  
X
X
AFTER BREAK-IN,  
AND Y  
Oil filter  
AFTER BREAK-IN,  
AND Y  
COOLING  
Enclosure louvers  
BATTERY  
X
X
W
Remove corrosion,  
ensure dryness  
X
X
X
X
M
M
Clean and tighten  
battery terminals  
Check charge state  
X
X
R
R
EVERY 6 M  
EVERY 6 M  
Electrolyte level  
(unsealed batteries only)*  
ENGINE AND MOUNTING  
Air cleaner  
X
X
R
R
Y
Y
Spark plug(s)  
GENERAL CONDITION  
Vibration, Noise, Leakage,  
Temperature*  
X
M
Y
COMPLETE TUNE-UP*  
TO BE COMPLETED BY AN  
AUTHORIZED DEALER  
23  
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Section 5 — Troubleshooting  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
5.1 TROUBLESHOOTING GUIDE  
Problem  
Cause  
Correction  
The engine will not crank.  
1. Fuse blown.  
1. Replace 15A fuse in generator  
control panel.  
2. Loose, corroded or defective  
battery cables.  
2. Tighten, clean or replace  
as necessary.  
3. Defective starter contactor. (7 kW) 3. *  
4. Defective starter motor.  
5. Dead Battery.  
4. *  
5. Charge or replace battery.  
The engine cranks but  
will not start.  
1. Out of fuel.  
1. Replenish fuel.  
2. *  
3. *  
2. Defective fuel solenoid (FS).  
3. Open #14 wire from  
engine control board.  
4. Defective spark plug(s).  
5. Valve lash out of adjustment.  
4. Clean, re-gap or replace plug(s).  
5. Reset valve lash.  
The engine starts hard  
and runs rough.  
1. Air cleaner plugged  
or damaged.  
1. Check, replace air cleaner.  
2. Defective spark plug(s).  
3. Fuel Regulator not set.  
4. Fuel Pressure incorrect.  
2. Clean, re-gap or replace plug(s).  
3. Set Fuel Regulator.  
4. Confirm fuel pressure to regulator  
is 10-12” water column (0.36-0.43  
psi) for LP, and 5-7” water colum  
(0.18-0.25 psi) for natural gas.  
The Auto/Off/Manual switch  
is set to OFF, but the engine  
continues to run.  
1. Defective switch.  
1. *  
2. *  
2. Auto/Off/Manual switch  
wired incorrectly.  
3. Defective control board.  
3. *  
There is no AC output from  
the generator.  
1. Main line circuit breaker open. 1. Reset circuit breaker  
to ON (or closed).  
2. Generator internal failure.  
2. *  
There is no transfer to  
standby after utility  
source failure.  
1. Defective transfer switch coil.  
2. Defective transfer relay.  
3. Transfer relay circuit open.  
4. Defective control logic board.  
1. *  
2. *  
3. *  
4. *  
Unit consumes large  
amounts of oil.  
1. Break-in procedure  
1. *  
not followed (see Section 3.1).  
*Contact the nearest Authorized Dealer for assistance.  
24  
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Section 6 — Notes  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
25  
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Section 6 — Notes  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
26  
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Section 6 — Notes  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
27  
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Section 7 — Electrical Data  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Wiring Diagram – V-Twin – Drawing No. 0E9016  
ENGINE WIRING  
3
2
BATTERY  
CHARGER  
DIAGRAM KEY  
1
BA - BRUSH ASSEMBLY  
BCR - BATTERY CHARGE RELAY  
CB1 - MAIN OUTPUT BREAKER  
2
0
14  
1
13  
CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION  
CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL  
225B  
D
DSW - PCB MOUNTED DIP SWITCH  
-
DIODE  
224B  
FS - FUEL SOLENOID  
F1 - FUSE 15 AMP  
FS  
13  
0
13  
0
F2 - FUSE 7.5 AMP  
GRD - CONTROL PANEL GROUND  
14  
224B  
225B  
HTO - HIGH OIL TEMPERATURE SWITCH  
IC - INLINE CONNECTOR  
ICT - INTERCONNECTION TERMINALS  
0
IM1 - IGNITION MODULE, CYLINDER #1  
IM2 - IGNITION MODULE, CYLINDER #2  
LOP - LOW OIL PRESSURE SWITCH  
SC - STARTER CONTACTOR  
14  
0
0
SCR - STARTER CONTACTOR RELAY  
SP1, SP2 - SPARK PLUGS  
14  
SW1 - AUTO / OFF / MANUAL SWITCH  
SW2 - SET EXERCISE SWITCH  
SM - STARTER MOTOR  
14  
14  
TB - INSULATED TERMINAL BLOCK  
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)  
IC  
D
SP1  
14  
6
0
18  
0
0
IM1  
18  
85  
86  
4
3
D
2
1
13  
16  
13  
15  
13  
SP2  
IC  
IC  
85  
C1  
IM2  
86  
85  
16  
SCR  
16  
15 14  
18  
351  
85  
A
B
0
351  
86  
HTO  
0
56  
14  
18  
56  
86  
85  
18  
86  
1
2
4
5
56  
14  
4
86  
23  
LOP  
0
J1  
56  
CONTROL  
PRINTED CIRCUIT BOARD  
14  
66A  
239  
15A  
17  
RED  
BLACK  
DSW  
ON  
15  
13  
0
225  
224  
1 - 20 Vac Sense Transformer  
2 - Remote Not Auto  
3 - 50 Hz Operation  
4 - SPARE  
SM  
16  
-
+
12V  
BATTERY  
SC  
CUSTOMER SUPPLIED  
L.E.D - ALARM INDICATORS  
28  
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Section 7 — Electrical Data  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Wiring Diagram – V-Twin – Drawing No. 0E9016  
CONTROL PANEL BOX  
225  
224A  
224  
225A  
224A  
225A  
CLOSEST TO BEARING  
TX  
BCR  
BA  
CB2  
1
3
6
9
4
0
4
N1  
N2  
7
13  
0
STATOR  
162  
2
66  
A
B
77  
224B  
225B  
224B  
225B  
4
10  
9
2
66  
11  
11  
6
14  
0
2
6
8
14  
0
55  
4
22  
11  
6
5
66A  
11  
22  
22  
4
22  
4
77  
11  
13  
66  
0
77 66  
0
N2  
0
6
0
6
3
2
N1  
225  
162  
162  
0
44  
1
224  
VOLTAGE  
REGULATOR  
0
55  
C2  
0
66A  
0
0
0
0
33  
66A  
4
55  
0
0
22  
N2  
N1  
0
13  
15  
GRD  
0
0
351  
0
G
0
0
13  
194  
23  
194  
225  
23  
224  
194  
13  
15  
N2  
N1  
N2  
N1  
23  
351  
4
CB3  
L
11  
11  
44  
11  
66A  
15A  
N2  
22  
23  
23  
N
33  
194  
N1  
194  
0
0
G
EXTERNAL  
GFCI  
N
13  
13  
15  
OUTLET  
239  
66A  
239  
15A  
F2  
F1  
LOAD  
LINE  
1
3
2
4
15  
15A  
L
0
351  
17  
239  
15  
0
17  
SW1  
225  
224  
15  
15  
1a  
1
CB1  
15  
G
1b  
SW2  
0
240V GENERATOR  
OUTPUT TO TRANSFER  
SWITCH CONTACTOR  
15B  
AUTO  
MANUAL  
+
-
0
CUSTOMER  
CONNECTION  
12VDC ACCESSORY SOCKET  
29  
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Section 7 — Electrical Data  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Electrical Schematic – V-Twin – Drawing No. 0E9017  
11  
11  
22  
22  
225A  
3
225A  
2
224A  
1
224A  
225  
BATTERY  
CHARGER  
225B  
13  
224B  
13  
2
224  
0
1
7
9
7
6
BCR  
1
3
4
13  
11  
0
13  
77  
13  
C2-1  
0
77  
14  
BATTERY CHARGE  
WINDING  
66  
0
66  
C2-2  
22  
0
0
0
C2-4  
55  
HTO  
0
C2-11  
0
LOP  
11  
22  
ENGINE RUN  
WINDING  
(STATOR)  
BA  
FIELD  
SW2  
C1-4  
0
14  
13  
0
C2-3  
C1-3  
4
0
C2-10  
4
C2-9  
ELECTRONIC  
VOLTAGE  
REGULATOR  
15A  
4
66A  
0
85  
23  
6
86  
194  
162  
C1-6  
4
6
CB2  
0
351  
225  
14  
224  
C2-7  
C2-8  
66A  
2
(STATOR)  
1
2
3
4
5
J2  
239  
23  
DIAGRAM KEY  
4
1
66A  
J1  
194  
2
86  
BA - BRUSH ASSEMBLY  
BCR - BATTERY CHARGE RELAY  
CB1 - CIRCUIT BREAKER, MAIN OUTPUT  
CB2 - CIRCUIT BREAKER, ALT. EXCITATION  
3
5
7
23  
194  
56  
18  
CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL  
D - DIODE  
14  
15A  
66A  
239  
15A  
FS - FUEL SOLENOID  
F1 - FUSE 15 AMP  
F2 - FUSE 7.5 AMP  
CONTROL  
9
PRINTED CIRCUIT  
BOARD  
10  
HTO - HIGH OIL TEMPERATURE SWITCH  
IM1 - IGNITION MODULE, CYLINDER #1  
IM2 - IGNITION MODULE, CYLINDER #2  
17  
12  
14  
15  
0
LOP - LOW OIL PRESSURE SWITCH  
SC - STARTER CONTACTOR  
225  
224  
SCR - STARTER CONTACTOR RELAY  
SP1, SP2 - SPARK PLUGS  
16  
17  
SW1 - AUTO / OFF / MANUAL SWITCH  
SW2 - SET EXERCISE SWITCH  
SM - STARTER MOTOR  
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)  
30  
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Section 7 — Electrical Data  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Electrical Schematic – V-Twin – Drawing No. 0E9017  
11  
22  
C2-6  
C2-5  
TX  
240VAC  
UTILITY  
INPUT  
225A  
N2  
N1  
N2  
56VA  
1VA  
N2  
224A  
225  
N1  
12Vdc  
23  
TRANSFER  
RELAY  
COIL  
194  
224  
N1  
+
-
0
12VDC ACCESSORY SOCKET  
CUSTOMER  
CONNECTIONS  
194  
23  
11  
22  
15B  
13  
22  
N
17  
F1  
13  
0
15  
F2  
15B  
22  
15  
33  
0
15 15A  
120V  
SW1  
239  
POWER  
WINDING  
(STATOR)  
120V  
15A  
23  
15 15  
N
17  
15  
44  
CB1  
23  
11  
194  
13  
194  
11  
0
11  
239  
14  
239  
N
240V  
14  
15  
13  
CB3  
L
0
RED  
C2-1  
15  
SC  
SCR  
17  
15  
N
L
56  
18  
16  
16  
14  
C1-1  
BATTERY  
12V  
0
SC  
FS  
0
SM  
0
G
0
0
BLACK  
17  
15  
0
EXTERNAL  
GFCI  
OUTLET  
CUSTOMER  
SUPPLIED  
G
D
18  
G
IM1  
SP1  
SP2  
18  
C1-5  
IM2  
D
31  
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Section 7 — Electrical Data  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Wiring Diagram – Single Cylinder – Drawing No. 0E9014  
3
2
ENGINE WIRING  
BATTERY  
CHARGER  
(UTILITY)  
DIAGRAM KEY  
2
BA - BRUSH ASSEMBLY  
BCR - BATTERY CHARGE RELAY  
14  
0
13  
1
CB1 - MAIN OUTPUT BREAKER  
CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION  
CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL  
225B  
D
-
DIODE  
224B  
DSW - PCB MOUNTED DIP SWITCH  
FS - FUEL SOLENOID  
F1 - FUSE 15 AMP  
13  
13  
0
0
F2 - FUSE 7.5 AMP  
225B  
224B  
GRD - CONTROL PANEL GROUND  
HTO - HIGH OIL TEMPERATURE SWITCH  
IC - INLINE CONNECTOR  
0
ICT - INTERCONNECTION TERMINALS  
IM - IGNITION MODULE  
14  
LOP - LOW OIL PRESSURE SWITCH  
SC - STARTER CONTACTOR  
SP - SPARK PLUG  
14  
SW1 - AUTO / OFF / MANUAL SWITCH  
SW2 - SET EXERCISE SWITCH  
SM - STARTER MOTOR  
14  
TB - INSULATED TERMINAL BLOCK  
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)  
IC  
0
0
D
SP  
14  
0
6
5
0
4
IM  
18  
14  
85  
86  
4
85  
IC  
2
1
13  
13  
HTO  
0
C1  
13  
86  
4
IC  
56  
85  
18  
86  
56  
LOP  
351  
14  
18  
56  
13  
0
56  
351  
1
2
4
5
4
86  
23  
J1  
SC  
56  
18  
14  
CONTROL  
PRINTED CIRCUIT BOARD  
RED  
239  
BLACK  
DSW  
17  
15  
16  
0
225  
224  
1 - 20 Vac Sense Transformer  
2 - Remote Not Auto  
3 - 50 Hz Operation  
4 - SPARE  
-
+
12V  
BATTERY  
CUSTOMER SUPPLIED  
L.E.D - ALARM INDICATORS  
32  
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Section 7 — Electrical Data  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Wiring Diagram – Single Cylinder – Drawing No. 0E9014  
CONTROL PANEL BOX  
225  
224  
224A  
225A  
CLOSEST TO BEA  
224A  
225A  
4
TX  
BCR  
0
CB2  
162  
1
3
7
9
N1  
N2  
66  
13  
B
77  
2
224B  
225B  
0
225B  
224B  
4
10  
9
4
14  
0
2
66  
0
11  
6
14  
2
6
8
55  
66A  
4
7
22  
11  
6
11  
11  
22  
22  
4
22  
5
4
3
77  
11  
66  
13  
225  
4
0
0
44  
0
0
6
0
66A  
66  
N2  
6
2
162  
162  
N1  
77  
1
224  
55  
C2  
VOLTAGE  
REGULATOR  
66A  
4
22  
33  
0
0
66A  
4
0
4
44  
11  
0
0
0
55  
N2  
N1  
0
13  
225  
0
224  
GRD  
G
0
0
0
0
0
351  
194  
23  
N2  
N1  
351  
L
11  
CB3  
23  
13  
0
66A  
194  
13  
11  
N2  
11  
44  
N
22  
33  
23  
15A  
0
194  
N1  
G
EXTERNAL  
GFCI  
N
13  
0
13  
239  
66A  
F2  
F1  
LOAD  
LINE  
1
3
2
15A  
239  
L
15A  
17  
15  
0
4
5
351  
0
17  
SW1  
15  
15  
15  
G
1a  
1
15B  
15  
G
1b  
240V GENERATOR  
OUTPUT TO TRANSFER  
SWITCH CONTACTOR  
SW2  
MANUAL  
+
-
0
CUSTOMER  
CONNECTION  
12VDC ACCESSORY SOCKET  
33  
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Section 7 — Electrical Data  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Electrical Schematic – Single Cylinder – Drawing No. 0E9015  
11  
11  
22  
22  
225A  
3
2
0
225A  
224A  
1
224A  
225  
BATTERY  
CHARGER  
225B  
13  
224B  
11  
22  
0
13  
2
225A  
224  
1
9
9
7
7
BCR  
1
6
3
4
224A  
13  
77  
66  
0
14  
C2-1  
13  
BATTERY CHARGE  
WINDING  
77  
77  
66  
C2-2  
0
0
C2-4  
55  
HTO  
0
LOP  
11  
22  
4
ENGINE RUN  
WINDING  
(STATOR)  
BA  
FIELD  
SW2  
C1-4  
0
14  
C1-3  
0
C2-3  
ELECTRONIC  
VOLTAGE  
REGULATOR  
C2-10  
4
C2-9  
4
0
66A  
0
23  
6
194  
162  
C2-11  
6
6
CB2  
351  
23  
225  
14  
4
0
86  
194  
224  
85  
C2-7  
2
66A  
C2-8  
2
1
2
3
4
5
DPE WINDING  
(STATOR)  
239  
J2  
66A  
J1  
DIAGRAM KEY  
23  
4
194  
BA - BRUSH ASSEMBLY  
BCR - BATTERY CHARGE RELAY  
56  
6
7
8
9
18  
CB1 - CIRCUIT BREAKER, MAIN OUTPUT  
CB2 - CIRCUIT BREAKER, ALT. EXCITATION  
14  
CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL  
D - DIODE  
FS - FUEL SOLENOID  
CONTROL  
PRINTED CIRCUIT  
BOARD  
239  
15A  
F1 - FUSE 15 AMP  
F2 - FUSE 7.5 AMP  
17  
11  
12  
13  
14  
15  
HTO - HIGH OIL TEMPERATURE SWITCH  
HM - HOUR RUN METER  
0
225  
224  
IM - IGNITION MODULE  
LOP - LOW OIL PRESSURE SWITCH  
SC - STARTER CONTACTOR  
SP - SPARK PLUG  
16  
17  
SW1 - AUTO / OFF / MANUAL SWITCH  
SW2 - SET EXERCISE SWITCH  
SM - STARTER MOTOR  
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)  
34  
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Section 7 — Electrical Data  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Electrical Schematic – Single Cylinder – Drawing No. 0E9015  
11  
22  
11  
C2-6  
22  
C2-5  
TX  
240VAC  
UTILITY  
INPUT  
225A  
N2  
N1  
56VA  
1VA  
N2  
N2  
224A  
225  
N1  
12Vdc  
TRANSFER  
RELAY  
23  
194  
COIL  
224  
N1  
F1  
F2  
22  
+
15B  
15  
15  
15  
11  
CUSTOMER  
CONNECTIONS  
12VDC ACCESSORY  
SOCKET  
13  
23  
-
0
194  
22  
N
13  
13  
17  
NEUTRAL  
15  
22  
0
33  
0
13  
17  
15A  
120V  
120V  
POWER  
WINDING  
(STATOR)  
SW1  
N
15 15  
239  
44  
CB1  
23  
194  
239  
11  
11  
240V  
N
G
G
CB3  
15  
13  
RED  
L
C1-2  
15A 17 15  
SC  
14  
14  
56  
14  
56  
18  
N
L
G
C1-1  
BATTERY  
12V  
SM  
0
18  
SC  
0
FS  
0
15A  
17  
15  
0
C1-6  
0
BLACK  
G
EXTERNAL  
GFCI  
OUTLET  
CUSTOMER  
SUPPLIED  
18  
IM  
D
C1-5  
SP  
35  
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Section 7 — Electrical Data  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Wiring Diagram – 8 Circuit Load Center – Drawing No. 0E7687A  
36  
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Section 7 — Electrical Data  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Wiring Diagram – 8 Circuit Load Center – Drawing No. 0E7687A  
37  
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Section 7 — Electrical Data  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Wiring Diagram – 12 Circuit Load Center – Drawing No. 0E7687$  
38  
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Section 7 — Electrical Data  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Wiring Diagram – 12 Circuit Load Center – Drawing No. 0E7687$  
39  
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Section 7 — Electrical Data  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Electrical Schematic – 8 Circuit Load Center – Drawing No. 0E7815A  
E1  
N1A  
194  
23  
194  
23  
194  
23  
12Vdc TRANSER  
COIL  
194  
TR  
23  
A
B
7
7
9
9
E1  
TS TO  
GENERATOR  
CONTROL PANEL  
1
4
3
6
OPEN  
N2  
N1A  
F2  
N2  
126  
205  
240VAC  
OUTPUT  
N2A  
F1  
N1A  
N1A  
N1  
N1  
N1A  
E1  
E1  
BLACK  
RED  
TO GENERATOR  
OUTPUT  
CIRCUIT BREAKER  
E2  
E1  
E2  
NEUTRAL (WHITE)  
NEUTRAL (WHITE)  
RED (MAIN 2)  
NEUTRAL  
CONNECTION  
INSIDE SWITCH  
B
N2A  
240VAC TO  
MAIN DISTRIBUTION  
PANEL  
205  
B
N1A  
126  
N2A  
BLACK (MAIN 1)  
E1  
NO  
NC  
NC  
NO  
E2  
XB  
XA  
E2  
B
BLU  
VIO  
15A/120V CIRCUIT 6  
15A/120V CIRCUIT 5  
20A/120V CIRCUIT 2  
30A/240V CIRCUIT 1  
30A/240V CIRCUIT 3  
15A/120V CIRCUIT 4  
15A/120V CIRCUIT 7  
15A/120V CIRCUIT 8  
N2A  
T1  
T2  
YLW  
BRN  
ATS  
T1  
N2A  
CUSTOMER  
CIRCUIT  
CONNECTION  
B
E2  
T2  
BRN/WHT  
YLW/WHT  
GRY  
B
E2  
LEGEND  
ATS-AUTOMATIC TRANSFER SWITCH  
C1-UTILITY COIL & RECTIFIER  
C2-GENERATOR COIL & RECTIFIER  
F1,F2-5A, 600V FUSE  
PNK  
LC-CIRCUIT BREAKER (LOADS)  
TR-TRANSFER RELAY  
TS-TERMINAL STRIP  
LC  
XA,XB-LIMIT SWITCHES  
40  
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Section 7 — Electrical Data  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Electrical Schematic – 12 Circuit Load Center – Drawing No. 0E7815$  
E1  
N1A  
194  
23  
194  
23  
194  
23  
12Vdc TRANSER  
COIL  
194  
TR  
23  
A
B
7
7
9
9
E1  
TS TO  
GENERATOR  
CONTROL PANEL  
1
4
3
6
OPEN  
N2  
N1A  
F2  
N2  
126  
205  
240VAC  
OUTPUT  
N2A  
F1  
N1A  
N1A  
N1  
N1  
N1A  
E1  
E1  
BLACK  
RED  
TO GENERATOR  
OUTPUT  
CIRCUIT BREAKER  
E2  
E1  
E2  
NEUTRAL (WHITE)  
NEUTRAL (WHITE)  
RED (MAIN 2)  
NEUTRAL  
CONNECTION  
INSIDE SWITCH  
B
N2A  
240VAC TO  
MAIN DISTRIBUTION  
PANEL  
205  
B
N1A  
126  
N2A  
BLACK (MAIN 1)  
E1  
NO  
NC  
NC  
NO  
BLU/WHT  
ORG  
BLU  
20A/120V CIRCUIT 10  
15A/120V CIRCUIT 9  
20A/120V CIRCUIT 6  
15A/120V CIRCUIT 5  
20A/240V CIRCUIT 2  
30A/240V CIRCUIT 1  
30A/240V CIRCUIT 3  
20A/240V CIRCUIT 4  
15A/120V CIRCUIT 7  
20A/120V CIRCUIT 8  
15A/120V CIRCUIT 11  
15A/120V CIRCUIT 12  
E2  
E2  
B
VR2  
C2  
N2A  
VIO  
C1  
A
T1  
T2  
YEL  
ATS  
T1  
BRN  
N2A  
CUSTOMER  
CIRCUIT  
CONNECTION  
B
E2  
T2  
BRN/WHT  
YEL/WHT  
GRY  
B
E2  
LEGEND  
PNK  
ATS-AUTOMATIC TRANSFER SWITCH  
C1-UTILITY COIL & RECTIFIER  
C2-GENERATOR COIL & RECTIFIER  
F1,F2-5A, 600V FUSE  
LC-CIRCUIT BREAKER (LOADS)  
TR-TRANSFER RELAY  
TS-TERMINAL STRIP  
VIO/WHT  
ORG/WHT  
LC  
XA,XB-LIMIT SWITCHES  
41  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Enclosure – Drawing No. 0F0080-C  
PRE PACKAGED UNITS ONLY  
4
71  
40  
68  
69  
77  
80  
82  
41  
48  
46  
30  
17  
98  
99  
79  
80  
72  
1
86  
72  
52  
5
87  
29  
12  
60  
49  
16  
28  
55  
75  
97  
6
65  
47  
54  
31  
50  
9
44  
35  
46  
11  
49  
51  
25  
14  
8
74  
57  
35  
49  
27  
1
22  
56  
49  
5
93  
49  
91  
35  
26  
3
51  
39  
37  
42  
3
51  
21  
49  
43  
34  
33  
2
94  
10  
18  
52  
20  
4
15  
91  
71  
69  
35  
63  
92  
25  
68  
42  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Enclosure – Drawing No. 0F0080-C  
ITEM PART NO. QTY. DESCRIPTION  
ITEM PART NO. QTY. DESCRIPTION  
1
0C6140  
0D1901  
0C6735  
0F0063  
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
3
ASSEMBLY, ENCLOSURE BASE  
ASSEMBLY, ENCLOSURE BASE (7KW)  
SUPPORT, ROOF FOLDING  
ENCLOSURE, FRONT  
ENCLOSURE, EXHAUST SIDE  
ENCLOSURE, EXHAUST SIDE (7KW)  
ENCLOSURE, SIDE & BACK  
ENCLOSURE, SIDE & BACK (7KW)  
ENCLOSURE, ROOF  
PANEL, ALTERNATOR DIVIDER  
PANEL, ALTERNATOR DIVIDER (7KW)  
PANEL, MUFFLER BOX SIDE  
PANEL, MUFFLER BOX SIDE (7KW)  
COVER, MUFFLER BOX  
COVER, MUFFLER BOX (7KW)  
GASKET, DOOR SEAL  
FOAM, BACK ENCLOSURE  
47  
48  
49  
047411  
047411  
043116  
043116  
0D3700  
0D3700  
0D4662  
090388  
6
4
5
SCREW HHC M6-1.0 X 16 G8.8  
SCREW HHC M6-1.0 X 16 G8.8 (7KW)  
SCREW HHC M6-1.0 X 12 G8.8  
SCREW HHC M6-1.0 X 12 G8.8 (7KW)  
NUT, LOCKING FLANGE M6-1.0  
NUT, LOCKING FLANGE M6-1.0 (7KW)  
SCREW HHTT M8-1.2 X 20 BP  
SCREW TAPTITE M6-1.0 X 12 BP  
SCREW TAPTITE M6-1.0 X 12 BP (7KW)  
NUT LOCK TRIC M6 X 1.0 Y/ZNC  
GASKET, BATTERY SUPPORT BRACKET  
PLUG, PLASTIC 0.593  
LUG SLDLSS #2-#8X17/64 CU  
SCREW TAPTITE M6-1.0X25 BP  
L/WASH SPECIAL ¼  
BRACKET, BATTERY HOLD DOWN (7KW)  
CONTACTOR, STARTER (7KW)  
CABLE, #6 RED BATTERY 38.5"  
NUT HEX 1/4-20 STEEL (7KW)  
WASHER LOCK 5/16  
2
3
4
6
0C7062  
0C7062A  
0E8811  
0E8811A  
0E9873  
0C7065  
0C7065A  
0C8101A  
0C8861  
0C8101B  
0C8862  
0C8283  
0C8284A  
0C8284B  
0C8284C  
0C8285  
0C8899A  
0D1128  
0D1128A  
0E4244  
0D1605A  
0D1606  
0D5264  
0D1839  
0D1840  
0D2425  
0D2588  
0D2588A  
0D2676  
0D2677  
0D2979B  
0D2979B  
26  
24  
11  
36  
24  
2
1
1
1
1
2
1
1
1
2
6
7
8
1
1
1
1
2
2
1
2
2
11  
1
1
1
5
50  
51  
6
7
52  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
092120  
0D3167  
0A3328  
055414  
8
9
092079  
0A1658  
0C2937  
086729  
0388040AJ0  
022127  
022129  
022129  
074908  
0D2346  
0D2345  
023484F  
022142  
0A7836  
0A8475  
0912970069  
0912970070  
055450  
0E5968  
0D3701  
0D3472  
0C8742  
0C8911  
0D8442  
10  
11  
12  
13  
14  
15  
16  
FOAM, ROOF ENCLOSURE  
FOAM, FRONT ENCLOSURE  
BRACKET, BATTERY SUPPORT  
PAD, 24"X48" WITH MOUNTING HOLES  
PANEL, ENGINE DIVIDER  
PANEL, ENGINE DIVIDER (7KW)  
BAFFLE, INTAKE  
BAFFLE, INTAKE (7KW)  
HOUSING, FAN  
BAFFLE, EXHAUST (7KW)  
BRACKET, TOP SUPPORT  
BRACKET, BOTTOM SUPPORT  
DUCT, BASE AIR  
GASKET, FRONT DIVIDER  
GASKET, FRONT DIVIDER (7KW)  
COVER, FRONT EXHAUST ENCLOSURE  
COVER, BACK EXHAUST ENCLOSURE  
CLOTH, HARDWARE 266.7mm x 146mm  
CLOTH, HARDWARE 266.7mm x 146mm  
(7KW)  
CLOTH, HARDWARE 543mm x 146mm  
CLOTH, HARDWARE 266.7mm x 387.4mm  
CLOTH, HARDWARE (7KW)  
FOAM, FRONT INTAKE BAFFLE  
FOAM, FRONT INTAKE BAFFLE (7KW)  
FOAM, TOP INTAKE BAFFLE  
FOAM, BACK INTAKE BAFFLE  
FOAM, BACK INTAKE BAFFLE (7KW)  
FOAM, BACK ENCL. STRIP  
FOAM, EXHAUST SIDE ENCLOSURE END  
FOAM, EXHAUST SIDE ENCLSURE FRONT  
FOAM, EXHAUST FAN HOUSING  
WASHER, SELF LOCKING  
WASHER LOCK 5/16 (7KW)  
SCREW TAPTITE M5-0.8 X 10 BP  
HARNESS, ENGINE  
64  
65  
17  
HARNESS, ENGINE (7KW)  
66  
67  
68  
69  
70  
71  
72  
73  
74  
75  
76  
77  
78  
BUSHING, SNAP SB-1000-12  
SCREW HHC 5/16-18 X 3/4 G5 (7KW)  
RIVET,1/8" X 0.126" - 0.375" LSH POP  
L/WASH SPECIAL #10  
ASSEMBLY, ROOF / DOOR GROUND WIRE  
ASSEMBLY, ROOF / DOOR GROUND WIRE  
PLUG PLASTIC 1.375  
GASKET, EXTRUDED TRIM  
PLATE, "HOT"  
GROMMET 2.75 X 1/16  
EXTERNAL CONNECTION BOX  
POWER BLOCK  
HARNESS GENERATOR TO EXTERNAL  
CONNECTION BOX  
HARNESS GENERATOR TO EXTERNAL  
CONNECTION BOX (7KW)  
SCREW PPHM #10-32 X 1  
WASHER LOCK #10  
WASHER FLAT M5  
NUT HEX #10-32 STEEL  
FUEL LINE, 3/4"OUTDOOR (NOT SHOWN)  
WASHER SHAKPROOF EXT 1/4 STEEL  
NUT HEX M6-1.0 G8 YELLOW CHROME  
HINGE TYPE A WITH STUDS, SOCKET  
HINGE TYPE B WITH STUDS, SOCKET  
SCREW HHTR 1/4-20 X 3/4  
18  
19  
20  
21  
22  
23  
24  
25  
1
1
26  
27  
0D2979C  
0D2979D  
0D2979E  
0E4245  
0D3058A  
0E4245A  
0E4245B  
0D3058C  
0D3057D  
0D3059A  
0D3059B  
0D3059C  
0D7176  
1
1
1
1
1
1
1
1
1
1
1
1
24  
22  
1
1
2
1
1
1
1
4
1
18  
0D8652  
1
28  
79  
80  
81  
82  
83  
84  
85  
86  
87  
89  
90  
91  
92  
93  
94  
95  
96  
97  
98  
99  
036937  
022152  
051713  
022158  
0D3031  
026850  
049813  
0F0164A  
0F0165A  
0E2874  
043107  
022145  
045771  
0C3906  
0E4321  
0E1330A  
0E9692  
042907  
0F5241  
0F5943  
2
5
2
5
1
1
1
1
1
1
4
10  
4
2
1
1
1
2
1
1
29  
30  
31  
32  
33  
34  
35  
WASHER, SELF LOCKING (7KW)  
FOAM, FRONT EXHAUST ENCL COVER  
FOAM, BACK EXHAUST ENCL COVER  
DOOR, PAWL  
LATCH, QUARTER TURN LOCKING  
HINGE TYPE A WITH STUDS, PIN  
HINGE TYPE B WITH STUDS, PIN  
LATCH, QUARTER TURN NON-LOCKING  
WASHER NYLON .250"  
SCREW HHC M8-1.25 X 25  
WASHER FLAT 5/16  
NUT HEX M8-1.25  
SELF-ALIGN SCREW M6 HH  
PANEL, EXHAUST ALIGNMENT  
GROMMET, 38.1 CROSS SLIT WITH HOLE  
BRACKET, REGULATOR MOUNTING  
SCREW HHC M8-1.25 X 16mm  
PLATE, COVER  
36  
37  
38  
39  
40  
41  
42  
43  
44  
46  
0D3059D  
0D3059E  
0C7781A  
0D3037  
0F0164  
0F0165  
0D3037A  
0A2115  
022097  
WASHER LOCK M6-1/4"  
RIVET POP 0.125 X 0.337  
GASKET, COVER  
0F0710  
43  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Control Panel – Drawing No. 0E9162-J  
44  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Control Panel – Drawing No. 0E9162-J  
ITEM PART NO. QTY. DESCRIPTION  
ITEM PART NO. QTY. DESCRIPTION  
1
0E7886A  
0E7886E  
1
1
CIRCUIT BREAKER 30A X 2P 240V (7KW)  
CIRCUIT BREAKER 50A X 2P 240V  
(12KW)  
27  
28  
29  
30  
31  
32  
33  
074908  
049226  
082025  
0C3910  
022507  
0A9611  
046689  
4
6
6
1
2
1
1
SCREW TAPTITE, M5-0.8 x 10 BP  
WASHER LOCK M5  
NUT HEX LOCK M5-0.8 NYLON INSERT  
TRANSFORMER  
0E7886J  
1
CIRCUIT BREAKER 65A X 2P 240V  
(13/15KW)  
SCREW HHC 1/4"-20 x 1/2"  
FUSE 7.55A X AGC5  
2
3
4
5
6
7
0A1801  
083049  
0C2174  
075210A  
0D3062  
0D8615  
1
1
1
1
4
1
ASSEMBLY, BATTERY CHARGER ENGINE  
ASSEMBLY, POTTED REGULATOR  
RELAY, 12V 25A SPST  
BLOCK TERMINAL STRIP 20A 4 X 6 X  
1100V  
BLOCK 1 POSITION  
34  
35  
36  
37  
063617  
075475  
043180  
0E8812  
0E8895  
1
2
2
1
1
RELAY PANEL 12VDC DPDT 10A 240VAC  
SCREW PPHM M4-0.7 x 10mm  
WASHER FLAT M4  
HEX STAND-OFF #6-32 x 3/8"  
ASSEMBLY, HOME STANDBY  
CONTROLLER  
COVER, CONTROL PANEL COMPONENT  
COVER, CONTROL PANEL COMPONENT  
(7KW)  
0D8615A  
1
ASSEMBLY, HOME STANDBY  
CONTROLLER (7KW)  
HOLDER, FUSE  
8
9
032300  
022676  
0E4494  
0E7890  
2
1
1
1
38  
39  
40  
092036  
045770  
0E7866  
0E7867  
0D3700  
0912970069  
0E2874  
0A1658  
022473  
038750  
022097  
049813  
031879  
031879  
023897  
0E9056  
0E5840  
8
2
1
1
8
1
1
2
3
1
3
1
6
4
2
1
1
SCREW PPHMS/LW #6-32 x 1/4"  
SCREW HHC M5-0.8 x10mm  
COVER, CONTROL PANEL  
COVER, CONTROL PANEL (7KW)  
NUT FLANGE M6-1.0 NYLOK  
ASSEMBLY, ROOF/DOOR GROUND WIRE  
SCREW HHTR 1/4"-20 X 3/4"  
WASHER LOCK SPECIAL 1/4"  
WASHER FLAT 1/4"-M6  
FUSE, 15AMP X AGC15  
10  
11  
SWITCH, ROCKER DPDT ON-OFF-ON  
CIRCUIT BREAKER MOUNTING  
BRACKET  
41  
42  
43  
44  
45  
46  
47  
48  
49  
12  
13  
15  
17  
023484E  
075476  
0E6480  
0C1085  
0C1085  
054502  
053623  
1
4
6
6
4
1
1
SNAP BUSHING  
SCREW PPHM M4-0.7 x 16mm  
NUT HEX LOCK M4-0.7 NYLON INSERT  
SCREW PPHM M3-0.5 x 8mm  
SCREW PPHM M3-0.5 x 8mm (7KW)  
CIRCUIT BREAKER 3 X 1 ETA 46-500-P  
CIRCUIT BREAKER 2.5 X 1 ETA 46-500-P  
(7KW)  
SCREW HHC M6-1.0 x 30mm  
WASHER LOCK M6-1/4"  
NUT HEX M6-1.0  
19  
WASHER FLAT #4  
WASHER FLAT #4 (7KW)  
WASHER FLAT #10  
20  
0E7870  
0E7871  
075235  
0D5240  
0D9784  
0D9784  
1
1
4
1
6
4
CONTROL, PANEL BOTTOM  
CONTROL, PANEL BOTTOM (7KW)  
SCREW HHC M5-0.8 x 30mm  
SWITCH, SPST (ON)-ON N/O  
NUT HEX LOCK M3-0.5 NYLON INSERT  
NUT HEX LOCK M3-0.5 NYLON INSERT  
(7KW)  
50  
51  
52  
21  
22  
23  
SOCKET, 12VDC ACCESSORY  
CIRCUIT BREAKER 15A PUSH / PULL  
MAIN RESET  
53  
54  
55  
56  
57  
58  
59  
036903  
0E7833  
0E4261  
022985  
082625  
0E9171  
0F4793  
6
1
1
4
4
1
2
SCREW PPHM #6-32 X 5/8"  
PLATE, WEATHERPROOF GFCI  
OUTLET, 15A GFCI DUPLEX  
WASHER FLAT #6  
24  
26  
0D8502  
0E8956  
1
1
NEUTRAL CONNECTOR  
HARNESS, CONTROL PANEL (NOT  
SHOWN)  
NUT LOCK HEX #6-32 NYL INSERT  
GASKET, WEATHERPROOF GFCI  
SCREW PPHM M3-0.5 x 10mm  
0E8957  
1
HARNESS, CONTROL PANEL WIRE (NOT  
SHOWN) (7KW)  
45  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
7 kW, 8 Circuit Load Center Assembly – Drawing No. 0E7975-B  
31  
7
26  
9
6
11  
5
2
3A  
3
33  
22  
16  
29  
9
30  
27  
36  
15  
24  
12  
10  
13  
1
19  
25  
16  
3B  
22  
20  
17  
37  
21  
23  
14  
18  
32  
34  
8
4
35  
34  
46  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
7 kW, 8 Circuit Load Center Assembly – Drawing No. 0E7975-B  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
0D4801  
0D4800  
0C2237  
077220  
077220A  
082574  
084464  
074908  
024912  
0A1658  
063617  
0E7889A  
0A1495  
0A1661  
022473  
0D3094  
0D4684A  
0E7900  
0F4790  
022152  
064526  
0E6155  
063378  
0A2110  
074138  
036933  
077033  
048850  
028739  
0D4802  
0D3191  
0D3088  
073591  
073590A  
040213B  
0E7888C  
0A7215  
0E7888B  
0E7888A  
0D3320  
0E6193  
1
1
BOX GTS LOAD CENTER  
COVER, 8 POSITION GTS LOAD CENTER  
TRANSFER SWITCH HOME STANDBY 100A 2P 250V  
COIL UTILITY  
3
1
3A  
3B  
3C  
3D  
4
1
1
COIL STANDBY  
1
INSULATOR-SIDEWALL (NOT SHOWN)  
LIMIT SWITCH OPERATION (NOT SHOWN)  
SCREW TAPTITE M5-0.8 X 10 BP  
SCREW TAPTITE 1/4-20 X 5/8 BP  
LOCK WASHER, SPECIAL-1/4"  
RELAY PANEL 12VDC DPDT 10A@240VAC  
8 CIRCUIT LOAD CENTER 125A/240V  
SCREW HHTT M4-0.7 X 10  
1
8
5
1
6
1
7
1
8
1
9
4
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
2
RIVET POP 0.156" X 0.675"  
WASHER FLAT 1/4-M6  
1
1
HARNESS,GTS TO MAIN PANEL  
PLATE HARNESS ADAPTER  
SUBPLATE, LOAD CENTER  
1
1
10.5"  
6
U-CHANNEL  
WASHER LOCK #10  
2
SCREW HWHS #6-25 X 3/8  
ARM EXTENDER PIN  
HOLDER CABLE TIE  
1
4
4
SCREW SWAGE 1/4-20 X 1/2 ZINC  
LUG QUICK DISCONNECT NI-S 10X45 DEG BRASS / TIN  
SCREW PPHM #10-32 X 3/8"  
2
6
6
LUG SLDLSS 1/0-#14X9/16 AL/CU  
BLOCK TERMINAL 20A 5 X 6 X 1100V  
TIE WRAP UL 3.9" X .10" NAT'L  
HARNESS, GTS TO EXTERNAL CONNECTION BOX  
COVER, RELAY & TERM BLOCK  
WIRE HARNESS,GTS LOAD CENTER (NOT SHOWN FOR CLARITY)  
FUSE HOLDER  
1
4
1
1
1
2
2
FUSE 5A X BUSS  
4
PCB SUPPORT SNAP-IN 1-3/8"  
CIRCUIT BREAKER 20A X 1P  
SCREW SW 1/4-20X5/8 WITH WASHER  
CIRCUIT BREAKER 15A X 1P  
CIRCUIT BREAKER 30A X 2P  
COVER - HARNESS ENTRY  
1
4
5
1
1
1
BRACKET, ARM EXTENDER  
47  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
12 kW and 15 kW, 12 Circuit Load Center Assembly – Drawing No. 0E7973-F  
48  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
12 kW and 15 kW, 12 Circuit Load Center Assembly – Drawing No. 0E7973-F  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
0D3086  
0D3092  
0F5211  
0C2237  
077220  
077220A  
082574  
084464  
074908  
024912  
0A1658  
063617  
0E7889  
0A1495  
0A1661  
022473  
055450  
025034  
0D4684  
0E7900  
0F4790  
022152  
064526  
0E6155  
063378  
0D3094  
074138  
036933  
077033  
048850  
028739  
0A2110  
0D3191  
0D3088  
073591  
073590A  
040213B  
0E7888C  
0E7888  
0E7888B  
0E7888B  
0E7888A  
0D3320  
0D3093  
0D8597  
075475  
0A7215  
0E6193  
1
1
1
1
1
1
1
1
6
1
1
1
1
4
2
1
1
1
1
1
10.5"  
6
2
1
4
1
2
6
6
1
4
4
1
1
2
2
4
3
1
5
3
1
1
1
1
2
4
1
BOX GTS LOAD CENTER  
COVER, 12 CIRCUIT GTS LOAD CENTER  
COVER, 10 CIRCUIT GTS LOAD CENTER  
TRANSFER SWITCH HOME STANDBY 100A 2P 250V  
COIL UTILITY  
3
3A  
3B  
3C  
3D  
4
COIL STANDBY  
INSULATOR-SIDEWALL (NOT SHOWN)  
LIMIT SWITCH OPERATION (NOT SHOWN)  
SCREW HHTT M5-0.8 X 10  
5
SCREW HHTT 1/4-20 X 5/8  
6
LOCK WASHER, SPECIAL-1/4"  
RELAY PANEL 12VDC DPDT 10A@240VAC  
12 CIRCUIT LOAD CENTER 125A/240V  
SCREW HHTT M4-0.7 X 10  
7
8
9
10  
11  
12  
RIVET POP .156" X .675"  
WASHER FLAT 1/4-M6 ZINC  
PLUG PLASTIC 1.375  
PLUG STEEL 1.0625 (15KW)  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
HARNESS ADAPTER PLATE  
SUBPLATE, LOAD CENTER  
U-CHANNEL  
WASHER LOCK #10  
SCREW HWHS #6-25 X 3/8"  
ARM EXTENDER PIN  
HOLDER CABLE TIE  
HARNESS,GTS TO MAIN PANEL  
LUG QUICK DISCONNECT NI-S 10X45 DEG BRASS / TIN  
SCREW PPHM #10-32 X 3/8"  
LUG SLDLSS 1/0-#14X9/16 AL/CU  
BLOCK TERMINAL 20A 5 X 6 X 1100V  
TIE WRAP 3.9" X .10"  
SCREW SWAGE 1/4-20 X 1/2" ZINC  
COVER, RELAY & TERMINAL BLOCK  
WIRE HARNESS,GTS LOAD CENTER (NOT SHOWN FOR CLARITY)  
FUSE HOLDER  
FUSE 5A X BUSS  
PCB SUPPORT SNAP-IN 1-3/8"  
CIRCUIT BREAKER 20A 1P  
CIRCUIT BREAKER 20A 2P  
CIRCUIT BREAKER 15A 1P (12 CIRCUIT LOAD CENTER)  
CIRCUIT BREAKER 15A 1P (10 CIRCUIT LOAD CENTER)  
CIRCUIT BREAKER 30A 2P  
35  
36  
37  
COVER - HARNESS ENTRY  
HARNESS, GTS TO EXT CONN BOX  
HARNESS, GTS TO EXT CONN BOX (8.5KW)  
SCREW PPHM M4-0.7 X 10  
38  
39  
40  
SCREW SW 1/4"-20 X 5/8" WITH WASHER  
BRACKET, ARM EXTENDER  
49  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
GT-990/760 Engine – Drawing No. 0E8774-M Part 1  
50  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
GT-990/760 Engine – Drawing No. 0E8774-M Part 1  
ITEM PART NO. QTY. DESCRIPTION  
ITEM PART NO. QTY. DESCRIPTION  
1
0C5729  
1
ASSEMBLY, CRANKCASE HOUSING WITH  
SLEEVE  
37  
38  
39  
40  
41  
0C3971C  
0C5305  
0C3027  
0E9842  
0C5731  
1
1
1
1
1
ASSEMBLY, DIPSTICK WITH HANDLE  
TUBE, DIPSTICK  
2
3
0E9843  
090388  
1
3
1
1
3
1
4
1
4
2
2
2
1
1
2
1
1
1
1
1
1
SEAL, 38 I.D. CRANKSHAFT  
SCREW, TAPTITE M6-1.0 X 12 YC  
ASSEMBLY, BREATHER  
O-RING, OIL CLR 3/8 X 1/2  
SEAL, 42 I.D. CRANKSHAFT  
ASSEMBLY, HOUSING COVER WITH  
SLEEVE  
4
0C5372  
0C3005  
0E3372B  
0D8067A  
071983  
5
GASKET, BREATHER COVER  
SEPARATOR, OIL BREATHER  
ASSEMBLY, HEAD #1 G&S  
RETAINER, PISTON PIN 20  
ROCKER, COVER NO OIL FILL  
STUD M8-1.25/10MM X 30 G5 ZINC  
PISTON, HC  
6
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
64  
65  
66  
67  
68  
69  
70  
71  
72  
73  
0C3006  
080318  
093064  
0C8808  
0D2723B  
0C2979  
086515  
0D2274  
0D3867  
078672  
0C5371  
072694  
0D3998  
0C3027  
0D5313  
0D6024  
0C2976  
086516  
0C2229  
083897  
0D8067B  
0D9853D  
0C2978  
043790  
0D4010  
0D4011  
0D4012  
0D4013  
0D8675A  
0D8675B  
0D4015  
0D4016  
9
8
1
2
1
2
8
4
4
2
4
4
4
2
4
2
12  
2
2
4
1
4
2
1
1
1
1
1
1
1
1
1
SCREW, HHFC M10-1.5 X 55  
SCREW HHFC M6-1.0 X 25  
ASSEMBLY, OIL FILL CAP  
HOOK, LIFTING  
7
8
9
0C2981C  
045761A  
0E2985  
021533  
10  
11  
12  
13  
14  
15  
16A  
16B  
17  
18  
19  
20  
21  
ROCKER, COVER WITH OIL FILL  
GASKET, VALVE COVER  
KEEPER, VALVE SPRING  
RETAINER, VALVE SPRING  
SPRING, VALVE  
SET, PISTON RING 90MM  
PIN PISTON  
0E1466  
0D4041  
0C2983  
0C2985A  
0C2985B  
0D4042  
0A7811  
0C2977  
0C5943  
0E4357E  
ASSEMBLY, CAMSHAFT & GEAR  
SHAFT, GOVERNOR  
SEAL, VALVE STEM D7  
WASHER, VALVE SPRING  
STUD, ROCKER ARM PIVOT  
NUT HEX M8-1.0 G8 YEL CHR  
O-RING, 3/8" X 1/2"  
ROLLER BEARING, GOVERNOR PLATE  
ROLLER BEARING, GOVERNOR  
ASSEMBLY,GOVERNOR GEAR  
SPOOL, GOVERNOR MACHINED  
GASKET, CRANK CASE  
ROCKER ARM  
SEAL, OIL PASSAGE  
ASSEMBLY, CRANKSHAFT HORIZONTAL  
DIRECT DRIVE  
PLATE, PUSH ROD GUIDE  
SCREW HHFC M8-1.25 X 65  
VALVE, EXHAUST  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
0E3223  
0D2157  
0E6098  
0D4123A  
078699E  
0C3011  
0C3009  
0C3010  
093873  
0C5315  
0C5998  
0D1667  
0C2991  
0C2988  
0C2992  
2
2
1
1
2
2
2
2
2
1
1
1
2
1
1
ASSEMBLY, CONNECTING ROD  
SCREW SHC M6-1.0 X 50 G8.8  
SCREEN, OIL PICKUP  
VALVE, INTAKE  
TAPPET, SOLID  
ASSEMBLY, HEAD #2 G&S  
PUSHROD, 147  
GASKET, HEAD  
ASSEMBLY, OIL PUMP  
SLEEVE, SEAMED DOWEL 10 DIA.  
COVER, OIL RELIEF  
SPRING, OIL RELIEF  
BARBED ELBOW 90 3/8NPT X 3/8  
KIT GASKET  
KIT PISTON & RINGS  
BALL, 1/2D OIL RELIEF  
WASHER, LOCK RIB M6  
GEROTOR, OUTER  
CLAMP, OIL TUBE  
KIT BREATHER ASSEMBLY  
KIT GOVERNOR ASSEMBLY  
KIT HEAD ASSEMBLY CYLINDER 1  
KIT HEAD ASSEMBLY CYLINDER 2  
KIT OIL RELIEF  
ARM, GOVERNOR  
E-RING, GOVERNOR ARM  
THRUST WASHER, GOVERNOR  
BUSHING, GOVERNOR LOWER  
KIT GEAR COVER  
51  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
GT-990/760 Engine – Drawing No. 0E8774-M Part 2  
74  
138  
75  
139  
135  
122  
124  
125  
123, 145  
76  
77  
136  
137  
120  
125  
79  
124  
133  
143  
134  
78  
132  
131  
119  
142  
143  
116  
80  
115  
127  
114  
117  
121  
118  
128  
129  
81  
97  
98  
130  
126  
99  
82  
96  
95  
83  
100  
102  
84  
109  
103  
93  
105  
86  
85  
88  
94  
91  
104  
110  
97  
98  
99  
106  
112  
89  
90  
101  
89  
107  
108  
112  
92  
112  
113  
111  
52  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
GT-990/760 Engine – Drawing No. 0E8774-M Part 2  
ITEM PART NO. QTY. DESCRIPTION  
ITEM PART NO. QTY. DESCRIPTION  
74  
75  
76  
77  
78  
0C5136A  
0C3024  
0C3040  
0C8127  
0D8564A  
0D8564B  
0D2595  
0D4417  
0C3025  
0D3083  
0C7292  
070185B  
075281  
0F2094  
2
1
1
1
1
1
4
4
1
1
1
1
1
2
KNOB, AIR CLEANER  
COVER, AIRBOX NG/LP  
PRE-CLEANER,  
111  
112  
0D1131  
045756  
1
25  
GUARD, FAN  
SCREW TAPTITE M6-1X10 YELLOW  
CHROME  
ELEMENT, AIR CLEANER  
ASSEMBLY, MIXER/AIRBOX 990  
ASSEMBLY, MIXER/AIRBOX 760  
SCREW SHOULDER (8MM) M6-1.0 X 18  
WASHER,RUBBER 1/4" X 1/8" THICK  
SWITCH, OIL PRESS  
113  
114  
115  
116  
117  
118  
119  
120  
121  
122  
123  
0C9763  
0C3036A  
022145  
022129  
0C3018  
0C3019  
0D1142A  
0D1143  
0E6043  
0F1177  
0C3052  
4
1
1
1
1
1
1
1
2
1
1
NUT, GROMMET 1/4 PLUG  
HOSE, BREATHER  
WASHER FLAT 5/16-M8 ZINC  
WASHER LOCK M8-5/16  
WRAPPER, UPPER CYLINDER 1  
WRAPPER, LOWER CYLINDER 1  
WRAPPER, LOWER CYLINDER 2  
WRAPPER, UPPER CYLINDER 2  
SCREW TAPTITE M5-0.8 X 8 ZP  
ASSEMBLY, GROUND WIRE  
ASSY, IGNITION COIL GV-990 CYLINDER  
2
79  
80  
81  
82  
ASSEMBLY, OIL DRAIN HOSE  
NIPPLE, 3/4"-16 UNF  
OIL FILTER  
83  
84  
85  
86  
SWITCH, THERMAL 284F  
SCREW, M3-0.5 X 6 SEMS  
87  
88  
035461  
0F6301  
0C9806  
0C3026  
0C9764  
0C3043  
0C7694  
0C7693  
0C3041A  
070008  
070006  
040976  
0C3016A  
0E4997  
0C3725B  
0C3031  
0C3032  
0A5992  
051754  
0C3033  
0C3034  
0C8549A  
0C3022A  
2
4
2
1
4
2
1
1
2
4
4
4
1
1
1
1
1
2
2
1
1
1
1
BARBED STR 1/4NPT X 3/8  
CLAMP, HOSE OETIKER 16.5mm  
HOSE, 3/8" I.D. X 6" LONG  
COOLER, OIL  
124  
125  
126  
127  
128  
129  
1 30  
1 31  
1 32  
1 33  
1 34  
1 35  
1 36  
1 37  
1 38  
1 39  
022097  
092079  
0E4271  
0D4529  
022129  
061906  
082774  
0E5343  
0C8468  
0C3048  
0D3754  
0D3742  
0C8482  
0E0486  
0D3743  
0D3705  
4
4
1
2
2
2
1
1
1
1
1
1
1
1
1
1
WASHER LOCK M6-1/4  
89  
90  
SCREW TAPTITE M6-1.0 X 25 BP  
STARTER  
SPARKPLUG  
91  
92  
PLASTITE,1/4-15 X 3/4  
WASHER LOCK M8-5/16  
SCREW HHC M8-1.25 X 85 G8.8  
KEY, WOODRFF 4 X 19D  
NUT HEX LOCK M10-1.50  
SPRING, ANTI-LASH  
93  
94  
GASKET, MANIFOLD / PORT  
MANIFOLD CYLINDER 2  
MANIFOLD CYLINDER 1  
SLEEVE, RUBBER  
95  
96  
97  
98  
WASHER FLAT M8 SS  
ROD, GOVERNOR CONTROL  
ASSEMBLY, GOVERNOR LEVER  
SPRING, GOVERNOR  
WASHER LOCK M8 SSTL  
SCREW SHC M8-1.25 X 20 G12.9  
PLATE, BACKING WITH OIL COOLER  
GROUND WIRE CONNECTOR  
FLYWHEEL ASSEMBLY  
FAN, NYLON  
99  
100  
101  
102  
103  
104  
105  
106  
107  
108  
109  
110  
ASSEMBLY, GOVERNOR ADJUSTER  
SCREW SHC M10-1.5 X 75 G10.9  
SPRING, GOVERNOR IDLE  
ASSEMBLY, GOVERNOR ADJUSTER  
BRACKET  
PLATE, FAN  
WASHER SHAKEPROOF INT M8 SS  
SCREW HHC M8-1.25 X 12 G8.8  
WASHER, 25mm I.D.  
140  
142  
143  
144  
145  
0C2993  
045771  
0D6147  
0E8152  
0E7743  
1
1
7
1
1
SEAL, GOVERNOR SHAFT  
NUT HEX M8-1.25 G8  
SCREW HHFC M6-1.0 X 10mm  
O-RING 0.49" I.D. X 0.07" THICK  
ASSY, IGNITION COIL 270mm CYLINDER  
1
NUT,HEX M24  
SNORKEL, AIR INTAKE  
HOUSING, BLOWER NG COOLER  
53  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
7 kW Generator – Drawing No. 0D3504-E  
36  
45  
30  
47  
49  
50  
48  
34  
46  
44  
34  
43  
42  
41  
6
51  
35  
40  
34  
7
29  
1
31  
37  
18  
2
39  
3
26  
21  
53  
8
24  
25  
4
9
22  
32  
19  
30  
10  
10  
14  
20  
12  
17  
10  
28  
27  
38  
5
31  
16  
32  
31  
23  
11  
52  
33  
28  
15  
19  
17  
32  
13  
31  
28  
31  
32  
54  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
7 kW Generator – Drawing No. 0D3504-E  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
0C6934  
0C9935H  
0C9934H  
0C6043A  
0C8096  
0C9593  
0D3220  
0C8860  
031971  
0C3168  
056147  
0D1847  
0C7038C  
0D1647  
0D2558  
0C7038B  
0C7758  
0388050AE0  
0C2417A  
082121C  
066386  
029451  
049451  
022237  
022511  
022131  
039287  
022145  
049820  
090388  
022129  
022259  
059637  
048031K  
0C9592  
048031M  
040976  
0C2824  
025145  
090239  
0C6989  
0D1214  
0C8127  
0C3024  
0D2273  
055934N  
0F7065  
0C5136A  
074906  
022473  
0D4662  
0C8290  
066849  
1
ADAPTOR, ENGINE  
STATOR  
ROTOR  
1
3
1
4
1
CARRIER, REAR BEARING  
FAN, 8" CURVED BLADE  
MUFFLER  
5
1
6
1
7
1
TAIL PIPE, MUFFLER  
8
1
PANEL, MUFFLER BASE  
BEARING #6205-2RS-C3  
5/16 SPECIAL L/WASH  
9
1
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
3
1
BOLT ROTOR HHCS 5/16"-24 X 13-1/2" G5  
BOLT STATOR HHCS M8-1.25 x 305mm  
BRACKET, ALTERNATOR MOUNTING  
DUCT, ALTERNATOR AIR  
GASKET, ALTERNATOR AIR DUCT  
BRACKET, ENGINE MOUNTING  
RUBBER MOUNT  
4
1
1
1
1
4
1
CABLE, #6 40" BLACK BATTERY  
EARTH STRAP 3/8X 3/8  
1
1
CLIP-J VINYL COAT .625 ID  
ASSEMBLY BRUSH HOLDER  
TAPE ELEC UL FOAM 1/8 X 1/2  
WASHER FLAT .406ID X 1.62OD  
WASHER LOCK 3/8  
1
1.8 FT  
1
4
4
BOLT HHC 3/8-16 X 1-1/4 G5  
WASHER FLAT 3/8 ZINC  
SCREW HHC M8-1.25 X 45 G8.8  
WASHER FLAT 5/16 ZINC  
NUT LOCK HEX M8-1.25 NYL INSRT  
SCREW TAP M6-1.0X12 BP  
WASHER LOCK M8-5/16  
NUT HEX 5/16-18 STEEL  
SCREW TAPTITE 3/8-16X 3/4" BP  
BAND, HOSE CLAMP 35.05 DIA.  
BELLOWS  
4
4
12  
4
3
13  
8
2
3
1
2
HOSE CLAMP 3/4"  
2
SCREW SHC M8-1.25 X 20 G12.9  
SCREW TAPR #10-32 X 9/16  
U-BOLT 5/16"-18 X 1.25" W/ SADDLE  
GASKET, EXHAUST  
1
1
1
1
STINGER, ENGINE AIR IN  
BASE, AIR CLEANER  
1
1
ELEMENT, AIR CLEANER  
COVER, AIR CLEANER NG/LP  
TUBE, 1.25"O.D. x 20Ga. x 12.125" LONG  
CLAMP VINYL 1.31 X .281 Z  
HOSE LP 1/2" I.D.  
1
1
1
1.25 FT  
2
4
4
6
1
2
KNOB, AIR CLEANER  
SCREW TAPTITE M6-1 X 20 BP  
WASHER FLAT 1/4 ZINC  
SCREW HHTT M8-1.2 X 20 BP  
GASKET, PANEL  
SCREW HHTT M5-0.8 X 16  
55  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
12 kW and 15 kW Generator – Drawing No. 0D3417-L  
56  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
12 kW and 15 kW Generator – Drawing No. 0D3417-L  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
0C6934  
0C7930  
0D2359  
0C7944  
0D2356  
0C6043  
0D2336  
0D6634  
0D3220  
0C8101  
056482  
0C3168  
0D1838  
0D1846  
0C7038  
0D1609  
0D2559  
0C7038A  
0C7758  
0388050AD0  
0C2417A  
082121C  
066386  
029451  
049451  
022237  
022511  
022131  
051731  
022145  
049820  
045756  
022129  
022259  
059637  
0D4662  
0F7065  
048031M  
0F0462  
0C2824  
025145  
0C4138  
040173  
074995  
066849  
1
1
ADAPTOR, ENGINE  
STATOR 12KW  
STATOR 13KW / 15KW  
ROTOR 12KW  
ROTOR 13KW / 15KW  
3
1
4
5
1
CARRIER, REAR BEARING  
FAN, 12" CURVED BLADE  
MUFFLER  
1
6
1
7
1
TAIL PIPE, MUFFLER  
PANEL, MUFFLER BASE  
BEARING 1.1811-2.8346  
8
1
9
1
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
3
5/16 SPECIAL LOCK WASHER  
BOLT, HHCS 3/8"-24 x 15.50"  
BOLT, HHCS M8-1.25 x 345mm  
BRACKET, ALTERNATOR MOUNTING  
DUCT, ALTERNATOR AIR  
GASKET, ALTERNATOR AIR DUCT  
BRACKET, ENGINE MOUNTING  
RUBBER MOUNT  
1
4
1
1
1
1
4
1
CABLE, #6 48" BLACK BATTERY  
EARTH STRAP 3/8X 3/8  
1
1
CLIP-J, VYNL COAT 0.625" ID  
ASSEMBLY BRUSH HOLDER  
TAPE ELEC UL FOAM 1/8 X 1/2  
WASHER FLAT .406ID X 1.62OD  
WASHER LOCK 3/8  
1
2.6 FT  
1
5
4
SCREW HHC 3/8-16 X 1-1/4 G5  
WASHER FLAT 3/8 ZINC  
4
4
12  
SCREW HHC M8-1.25 X 50 G8.8  
WASHER FLAT 5/16 ZINC  
NUT LOCK HEX M8-1.25 NYL INSERT  
SCREW TAPTITE M6-1.0X10 BP  
WASHER LOCK M8-5/16  
4
2
10  
8
NUT HEX 5/16-18 STEEL  
SCREW TAPTITE 3/8-16 X 3/4 BP  
SCREW 5/16-18X3/4" HH THD ROLL  
HOSE RES 1/2 LP GAS  
2
4
3 FT  
4
HOSE CLAMP 3/4" I.D.  
4
NUT HEX W/TOOTH WSHR M8-1.25  
SCREW TAP-R #10-32 x 9/16  
U-BOLT 5/16"-18 X 1.25" WITH SADDLE  
GASKET, EXHAUST PORT  
CLAMP HOSE #5.5 0.62"-0.62"  
HOSE 1\4 ID LPG 350PSI UL21  
SCREW HHTT M5-0.8 X 16  
1
1
2
2
1.44 FT  
2
57  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
GN410 Engine – Drawing No. 0F3981-A Part 1  
58  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
GN410 Engine – Drawing No. 0F3981-A Part 1  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
0E3221  
0E1466  
021533  
0E2985  
071983  
0E8440  
0A7628  
078658  
078659  
088261E  
0E3812  
0E6519  
078645  
0A7811  
0A9877  
076701  
021713B  
078691  
0A5771  
0A5776  
076361  
0A8898D  
0D2274  
0C4391  
086025  
0E3341  
021714  
086516  
086517  
0D9853B  
083897  
077158  
0C3150  
072694  
083907  
072696  
078694  
021742  
0D6094  
076329  
0E0057  
0D4788  
074908  
086515  
078606  
0A1442  
078672  
089673  
0B2104  
078699C  
0A7627  
043790A  
088590  
078699B  
1
1
1
1
2
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
2
1
1
2
2
2
1
4
1
1
1
1
1
4
4
8
1
2
1
2
1
1
1
1
ASSEMBLY, CONNECTING ROD  
PIN, PISTON D20  
SET, PISTON RING 90MM  
3
4
PISTON, HC  
5
RETAINER, PISTON PIN 20  
ASSEMBLY, CRANKSHAFT GH410 SMALL TAPER  
ARM, GOVERNOR RC45  
6
7
8
PIN, "R" GOVERNOR ARM  
WASHER, GOVERNOR ARM THRUST  
CRANKCASE, SUBASSEMBLY WITH PLUGS GH410  
SEAL, 35 I.D. CRANKSHAFT  
ASSEMBLY, GOVERNOR GEAR  
C-RING, GOVERNOR GEAR RETAINER  
SPOOL, GOVERNOR- MACHINE  
ASSEMBLY, CAMSHAFT & GEAR  
GASKET , CRANKCASE  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
GASKET, HEAD 410  
COVER, OIL PRESSURE RELIEF  
SPRING, OIL RELIEF 360  
BALL, DIA 11/32 PRESSURE RELIEF  
WASHER, THRUST GOVERNOR GEAR  
ASSEMBLY, COVER, GEAR TOP CHECK / FILL  
RETAINER, VALVE SPRING  
VALVE SPRING LF  
SET,GEROTOR 12 THK  
BALANCER  
ASSEMBLY,CYLINDER HEAD SEATS & GUIDES  
VALVE, EXHAUST  
VALVE, INTAKE  
PUSH ROD 174.9  
TAPPET  
ASSEMBLY, SCREEN OIL PICK-UP  
GASKET, ROCKER COVER 410  
STUD, D20 PIVOT BALL  
ROCKER ARM  
NUT, JAM (ROCKER ARM)  
PLATE, PUSH ROD GUIDE  
SCREW, HHFL M10-1.5 X 105  
ASSEMBLY, ROCKER COVER BREATHER  
PLUG, OIL FILL PLASTIC  
O-RING 17.8 I.D. x 2.4  
PLUG, STANDARD PIPE 3/8 STEEL SQUARE HEAD  
SCREW, TAPTITE M5-0.8 X 10 BP  
KEEPER, VALVE SPRING  
SCREW & LOCKWASHER M6-1 X 12  
SCREW, HHFC M8-1.25 X 42  
SEAL, VALVE STEM D7  
WASHER, VALVE SPRING  
WASHER, LARGE SPRING  
DOWEL, SEAMED SLEEVE  
SHAFT, GOVERNOR RC55  
BARBED ELBOW 90 3/8NPT X 3/8 LOCKTITE  
DOWEL DIA 12 X 18L  
DOWEL, SLEEVE SEAMED 12 DIA.  
59  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
GN410 Engine – Drawing No. 0F3981-A Part 2  
60  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
GN410 Engine – Drawing No. 0F3981-A Part 2  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
0C1069  
0D2922  
0C8435  
0C9997  
088434  
045756  
0C4176A  
0D9004A  
059985  
022129  
0C2458A  
083512  
0D1401A  
091039  
0C9619  
049811  
022097  
040945  
086999  
0D5667A  
049821  
099236  
070185B  
082774  
091222E  
067198N  
067890  
0E7585  
072734  
072735  
0C3978  
0C6040  
0D9760  
092079  
0F3800  
083502  
082025  
0D3083  
0E7887C  
090072  
075281  
022145  
0F2094  
0C4373  
022717B  
0F3865  
0F3855  
039253  
0D3751  
0F3921  
0C8493  
0D8758  
5
1
1
1
1
11  
1
1
2
3
1
1
1
1
1
2
4
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
SCREW, TAPTITE M6-1.0X8 YELLOW CHROME  
HOUSING, BLOWER  
TUBE, DIPSTICK  
3
4
GUARD, FAN  
WRAPPER, BOTTOM  
5
6
SCREW, TAPTITE M6-1X10 YELLOW CHROME  
WRAPPER, TOP  
ASSY, STARTER  
7
8
9
SCREW, SHC M8-1.25 X 45 G12.9  
WASHER, LOCK M8-5/16  
BACKPLATE, L/F D/F  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
SCREW, TAPTITE M8-1.25 X 16 BP  
BREATHER TUBE  
GASKET, INTAKE ADAPTER  
ASSEMBLY, PLASTIC CARB  
WASHER, FLAT M6  
WASHER, LOCK M6-1/4  
SCREW, SHC M6-1.0 X 20 G12.9  
GASKET,OIL FILTR ADAPTER  
ADAPTER, OIL FILTER  
SCREW, SHC M8-1.25 X 30 G12.9  
SWITCH, OIL 8.0 PSI  
OIL FILTER  
KEY, WOODRFF 4 X 19D  
FLYWHEEL WITH RING GEAR 32DEG.  
WASHER,BELV-20 X 2.2  
NUT, HEX - FLYWHEEL  
SPARKPLUG  
ASSEMBLY,GOVERNOR LEVER 12 HP  
ROD,GOVERNOR CONTROL.  
SPRING, ANTI-LASH  
ASSEMBLY, WIRE  
ASSEMBLY, IGNITION COIL  
SCREW, TAPTITE M6-1.0 X 25 BP  
SPRING GOVERNOR  
BOLT, GOVERNOR ADJUST M5  
NUT HEX LOCK M5-0.8 NYINS ZINC  
ASSEMBLY, OIL DRAIN HOSE  
ASSEMBLY, CAP & DIPSTICK  
O-RING 9/16 X 3/4 X 3/32  
SWITCH, THERMAL  
WASHER FLAT 5/16 - M8  
SCREW, M3-0.5 X 6 SEMS  
SPACER, ENDFRAME  
GOMMET  
SPRING SECONDARY  
BRACKET SECONDARY GOVERNOR SPRING  
SCREW HHC M8-1.25 x 20  
SPRING, IDLE RETURNING  
BARREL GOVERNOR ADJUSTMENT  
SCREW SHC M5-0.8 x 30  
ENGINE LIFT HOOK  
61  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Gas Regulator – Drawing No. 0D8720-H  
10  
8
30  
9
2
12  
11  
21  
5
4
10  
28  
20  
3
25  
24  
1
22  
19  
7KW  
37  
23  
10  
16  
29  
26  
18  
15  
12  
14  
19  
11  
17  
32  
28  
13  
27  
31  
23  
24  
22  
12  
26  
20  
25  
15  
29  
18  
14  
11  
16  
17  
28  
13  
21  
ITEM PART NO. QTY. DESCRIPTION  
ITEM PART NO. QTY. DESCRIPTION  
1
2
0D5694  
0F5022  
0C4647  
0D4166  
0C6070  
0F4795  
0C5760J  
0C6606  
097934  
0C4645  
0C5761  
0C5968  
0C6066  
0C5759  
0C5764  
0C5764A  
070728  
0C6069  
0C5762  
045764  
1
1
CASTING, TWIN REGULATOR HOUSING  
SOLENOID COIL, 12VDC  
GASKET , SOLENOID  
22  
23  
24  
25  
26  
27  
0C6731  
0C6067  
0C4706  
0C6068  
0C4643A  
026073  
2
2
2
2
2
1
RIVET, POP .118 X .125  
SUPPORT, DIAPHRAGM  
3
1
DIAPHRAGM, TWIN REGULATOR  
CAP, DIAPHRAGM SUPPORT  
INLET, TWIN REGULATOR 11.11 DIA.  
PLUG, STANDARD PIPE 1/8” STEEL  
SQUARE HEAD  
4
1
PLUNGER, LP REGULATOR ASSEMBLY  
SPRING-SOLENOID, PLUNGER  
SCREW PPHM SEMS M4-0.7 X 10  
JET, GN 410 ENGINE LP (7KW)  
BARBED STRAIGHT 1/2NPT x 1/2  
O-RING, CHECK VALVE  
5
1
8
4
9
1
10  
11  
12  
13  
14  
15  
16  
17  
2*  
2*  
2*  
2
026073  
2
PLUG, STANDARD PIPE 1/8” STEEL  
SQUARE HEAD (7KW)  
ADJUSTER SCREW, TWIN REGULATOR  
LEVER, REGULATOR  
SUPPORT, INLET SEAL  
28  
29  
30  
0A4032  
0D3308  
024310  
2*  
4
PIN, LIMITED ADJUSTMENT  
WASHER, FLAT M3 X 10mm O.D.  
PLUG, STANDARD PIPE 1/2” STEEL  
SQUARE HEAD (7KW)  
2
1
2
SEAL, INLET  
PIN, PIVOT ARM  
SPRING, REGULATOR  
2
31  
32  
028414A  
0D5698A  
1
1
BARBED STRAIGHT 1/8”NPT X 1/4”  
JET IDLE PRIMER PHILLIPS HD (V-TWIN  
ONLY)  
2
2
SPRING, REGULATOR (7KW)  
SCREW, PFHMS M3-0.5 x 5  
GASKET, DIAPHRAGM  
18  
19  
20  
21  
4
37  
0D3973  
1
PLUG, EXPANSION 16mm  
2
2
16  
COVER, TWIN REGULATOR  
SCREW, TAPTITE M4X8 BP  
* A QUANTITY OF 1 IS TO BE USED ON 7KW HOME STANDBY  
62  
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Section 9 — Mounting Dimensions  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Drawing No. 0D3739-C  
1
2
T
0
/
 4
 0
    H
    O
M
1
2
 0
/
 4
 0
    H
    O
M
v
1
2
 0
/
 4
 0
   H
   O
 M
1
2
T
0
/
 4
 0
    H
    O
M
v
1
2
 0
/
 4
 0
   H
   O
 M
1
2
T
0
/
 4
 0
    H
    O
M
F
C B H O M -  
F
C B H O M -  
F
C B H O M -  
F
C B H O M -  
F
C B H O M -  
F
C B H O M -  
CBHOM-F  
CBHOM-F  
CBHOM-F  
OM  
CBHOM-F  
CBHOM-F  
OM  
CBHOM-F  
T
1
2
0
2
HOM  
T
1
2
0
2
HOM  
TY  
120/  
P
E
H
T
1
2
0
2
H
OM  
 v
TY  
120/  
P
E
H
T
1
2
0
2
H
OM  
 v
63  
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Section 10 – Warranty  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
NOTE: This Emission Control Warranty Statement pertains to this product only IF the generator size is 15 kW or below.  
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT  
YOUR WARRANTY RIGHTS AND OBLIGATIONS  
The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission  
Control System Warranty on your new engine.* In California, new utility, and lawn and garden equipment engines must be  
designed, built and equipped to meet the state’s stringent anti-smog standards. Generac will warrant the emission control  
system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved 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  
GENERAC POWER SYSTEMS, INC.  
P.O. BOX 297  
WHITEWATER, WI 53190  
Part 1  
ATTENTION WARRANTY DEPARTMENT  
GENERAC POWER SYSTEMS, INC.  
211 MURPHY DRIVE  
EAGLE, WI 53119  
64  
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Section 10 – Warranty  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
EMISSION CONTROL SYSTEM WARRANTY  
Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines:  
(a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on the  
date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue  
for 24 consecutive months thereafter.  
(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or  
equipment and to each subsequent purchaser/owner that each of its engines is ...  
(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its  
authority, and  
(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a  
warranted emissions-related part to fail to be identical in all material respects to the part as described in the engine  
manufacturer’s application for certification.  
(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:  
(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s  
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall  
be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the  
ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.  
(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual  
shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or  
replace as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS  
Warranty shall be warranted for the remainder of the ECS Warranty Period.  
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s  
Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part  
fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection  
(4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the  
remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.  
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no  
charge to the owner at a Generac Authorized Warranty Service Facility.  
(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsible  
for diagnostic costs if the repair is deemed warrantable.  
(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused  
by a failure under warranty of any emission-related part covered by the ECS Warranty.  
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient  
to meet the expected demand for such emission-related parts.  
(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS  
Warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce Generac  
ECS Warranty obligations.  
(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac  
engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim.  
Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of  
such an unapproved, add-on, modified, counterfeit and/or “grey market” part.  
EMISSION RELATED PARTS INCLUDE THE FOLLOWING:  
1) Fuel Metering System:  
3) Ignition System including:  
a) Spark plug  
b) Ignition module  
1.2) LPG/Natural Gas carburetion assembly and its internal com-  
ponents.  
a) Fuel controller (if so equipped)  
4) Catalytic Muffler Assembly (if so equipped) including:  
a) Muffler gasket  
b) Exhaust manifold  
b) Mixer and its gaskets (if so equipped)  
c) Carburetor and its gaskets (if so equipped)  
d) Primary gas regulator (if so equipped)  
e) LP liquid vaporizer (if so equipped)  
5) Crankcase Breather Assembly including:  
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  
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Section 10 – Warranty  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
®
GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR GUARDIAN  
"PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"  
For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Guardian generator will  
be free from defects in material and workmanship for the items and period set forth below. Generac will, at its option, repair or replace  
any part which, upon examination, inspection and testing by Generac or a Guardian Authorized Warranty Service Dealer, is found to  
be defective. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Guardian Authorized  
Warranty Service Dealer. All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by  
the purchaser/owner. This warranty applies only to Generac Guardian prepackaged emergency automatic standby generators sold and  
rated for use in "Standby" applications.  
WARRANTY SCHEDULE  
YEARS ONE and TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed (proof of purchase and main-  
tenance is required):  
Engine - All Components  
Alternator - All Components  
Transfer System - All Components  
Steel enclosures are warranted against rusting for the first year of ownership only. Damage caused after receipt of generator is the  
responsibility of the owner and is not covered by this warranty. Nicks, scrapes, dents or scratches to the painted enclosure should be  
repaired promptly by the owner.  
All warranty expense allowances are subject to the conditions defined in Guardian's Warranty Policies, Procedures and Flat Rate  
Manual.  
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:  
• Guardian generators that utilize non-Guardian/Generac replacement parts.  
• Guardian generators utilizing non-Guardian/Generac automatic transfer switches.  
•
Repairs or diagnostics performed by individuals other than Guardian/Generac authorized dealers not authorized in writing by  
Generac Power Systems.  
•
Any Guardian generators used as rental or trailer mounted applications.  
• Units used for prime power in place of existing utility power where utility power is present or in place of utility power where utility  
power service does not normally exist.  
• Costs of normal maintenance, adjustments, installation and start-up.  
•
Steel enclosures that are rusting due to the improper installation, location in a harsh or saltwater environment or scratched where  
integrity of paint applied is compromised.  
• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.  
• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all  
mechanical devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty will not  
cover repair when normal use has exhausted the life of a part(s) or engine.  
• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire,  
freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.  
• Damage related to rodent and/or insect infestation.  
• Products that are modified or altered in a manner not authorized by Generac in writing.  
•
Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or  
replacement of the defective part(s).  
• Failure due to misapplication.  
• Telephone, cellular phone, facsimile, internet access or other communication expenses.  
• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty  
period.  
• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.  
•
Rental equipment used while warranty repairs are being performed.  
• Costs incurred for equipment used for removal and/or reinstallation of generator, (i.e.; cranes, hoists, lifts, etc.)  
• Overnight freight costs for replacement part(s).  
• Overtime labor.  
•
Starting batteries, fuses, light bulbs and engine fluids.  
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES  
NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not  
allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.  
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT  
SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A  
DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential  
damages, so the above limitation may not apply to you.  
This warranty gives you specific legal rights. You also have other rights from state to state.  
GENERAC® POWER SYSTEMS, INC.  
P.O. BOX 297 • WHITEWATER, WI 53190  
Revision (02/01/05)  
Part No. 0F3982  
Revision D (10/05/05)  
Printed in U.S.A.  
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