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Home My WebLink About46707-Z �oN;g�FFOlkcpGy Town of Southold 9/15/2024 o P.O.Box 1179 co x 53095 Main Rd goy �a i Southold,New York 11971 CERTIFICATE OF OCCUPANCY No: 45549 Date: 9/15/2024 THIS CERTIFIES that the building GENERATOR Location of Property: 19000 Route 25,Mattituck SCTM#: 473889 See/Block/Lot: 115.-6-7 Subdivision: Filed Map No. Lot No. conforms substantially to the Application for Building Permit heretofore filed in this office dated 7/20/2021 pursuant to which Building Permit No. 46707 dated 8/18/2021 was issued, and conforms to all of the requirements of the applicable provisions of the law. The occupancy for which this certificate is issued is: "as built"accessory generator as applied for. The certificate is issued to WeWo Group LLC of the aforesaid building. SUFFOLK COUNTY DEPARTMENT OF HEALTH APPROVAL ELECTRICAL CERTIFICATE NO. 46707 9/l/2021 PLUMBERS CERTIFICATION DATED Aut on d i ature TOWN OF SOUTHOLD BUILDING DEPARTMENT :x TOWN CLERK'S OFFICE SOUTHOLD, NY BUILDING PERMIT (THIS PERMIT MUST BE KEPT ON THE PREMISES WITH ONE SET OF APPROVED PLANS AND SPECIFICATIONS UNTIL FULL COMPLETION OF THE WORK AUTHORIZED) Permit#: 46707 Date: 8/18/2021 Permission is hereby granted to: WeWo Group LLC 15900 Main Rd Mattituck, NY 11952 To: legalize "as built" generator as applied for. At premises located at: 19000 Route 25, Mattituck SCTM #473889 Sec/Block/Lot# 115.-6-7 Pursuant to application dated 7/20/2021 and approved by the Building Inspector. To expire on 2/17/2023. Fees: AS BUILT-ACCESSORY $200.00 ELECTRIC $170.00 CO-RESIDENTIAL $50.00 Total: $420.00 uilding Inspector OF SOUr�ol Town Hall Annex ~ Telephone(631)765-1802 54375 Main Road Fax(631)765-9502 P.O.Box 1179 Q sean.devlinA-town.southold.n us Southold,NY 11971-0959 y MUNT`I,�� BUILDING DEPARTMENT TOWN OF SOUTHOLD CERTIFICATE OF ELECTRICAL COMPLIANCE SITE LOCATION Issued To: WeWo Group LLC Address: 19000 Route 25 city:Mattituck st: NY zip: 11952 Building Permit#: 46707 Section: 115 Block: 6 Lot: 7 WAS EXAMINED AND FOUND TO BE IN COMPLIANCE WITH THE NATIONAL ELECTRIC CODE Contractor: DBA: Glenn's Electric License No: 4770ME SITE DETAILS Office Use Only Residential X Indoor X Basement Service Commerical Outdoor X 1 st Floor Pool New Renovation 2nd Floor Hot Tub Addition Survey Attic Garage INVENTORY Service 1 ph Heat Duplec Recpt Ceiling Fixtures Bath Exhaust Fan Service 3 ph Hot Water GFCI Recpt Wall Fixtures Smoke Detectors Main Panel A/C Condenser Single Recpt Recessed Fixtures CO2 Detectors Sub Panel A/C Blower Range Recpt Ceiling Fan Combo Smoke/CO Transformer UC Lights Dryer Recpt Emergency Fixture Time Clocks Disconnect 100A Switches El 4'LED Exit Fixtures Pump Other Equipment: 17kW Guardian Generator w/200A Whole House Transfer Switch Notes: Generator •Inspector Signature: � Date: September 1, 2021 S.Devlin-Cert Electrical Compliance Form �o��Of SOUIy�� 4707 0 7 I • `^' � # # TOWN OFSOUTHOLD BUILDING DEPT: �ycou 765-1802 T I NISPECTION [ ] FOUNDATION 1ST [ ] ROUGH PLBG. [ ] FOUNDATION 2ND [ ]ANSULATION/CAULKING [ ] FRAMING/STRAPPING [ ] FINAL [ ] FIREPLACE & CHIMNEY [ ] FIRE SAFETY INSPECTION [ ] FIRE RESISTANT CONSTRUCTION [ ] FIRE RESISTANT PENETRATION [ ] ELECTRICAL (ROUGH) ELECTRICAL (FINAL) [ ] CODE VIOLATION [ ] PRE C/O REMARKS: tcmf` i2 DATE INSPECTOR � ` FIELD:INSPECTI01`1 REPOAT DATE77 afit. S FOUNDATLON(1ST) FOU (DATION (2NA) ^� X rn ROUGH FRAMING:'& yJII,1 PLUMBING: C�1 41 INSULATION.PER N.Y. STATESARGY CODS N. FINAL'. Gh-d Q °)' o " � 0 o� fFot��o TOWN OF SOUTHOLD-BUILDING DEPARTMENT Town Hall Annex 54375 Main Road P. O.Box 1179 Southold,NY 11971-0959 Telephone(631) 765-1802 Fax(631)765-9502 https://www.southoldtomm.gov Date Received APPLICATION'FOR BUILDING PERMIT jr Office Use Only D D PERMIT NO. BuildingInspector:pklyki JUt 2 0 2021 Applications arid:#orrris must.be filled out in their entirety:;Incomplete applications will not.be accepted.Where the Applicant is not the.owner an -BUMDI G DEPT' owner's Authorization form(PageIl.shall be completed::,- TOW�4 ()y,O�JTHOLD Date: Z OWNERS)°OF PROPERTY::, Name: �e�0 L LC SCTM#1000- 1 f1,.5 Cp - Project Address:` -��O Q�.✓1— �_ _ G1 .1C..�_-.N T -�_��1_rJ_ __ Phone#: '°"1 oZga "1 �0� Email: 4r� 0.rl_ -C_�L1fl�_C+, Mailing Address CONTACT PERSON:_ Name: Mailing Address: Phone#: — �- —�� Email: DESIGN"PROFESSIONAL INFORMATION: Name: Mailing Address: Phone#: Email: CO NTRACTOR,INFORMATION:; = Name: CD (8_LAD 00_A_Mailing Address e- p K J 4 ( Phone#: " - ��9- LA9 l 9 Email: O��o�INZ C@.rNl0.i��C_Or►'�._ DESCRIPTION OF PROPOSED CONSTRUCTION` ❑New Struc6�' &rwiro_4-o& e ❑Addition ❑Alteration ❑Repair ❑Demolition Estiima^tEd Cos of P ject: Wher _ $ y��'� Will the lot be re-graded? ❑Yes k9N0 Will excess fill be removed from premises? ❑Yes 00 1 AT,0 Existing use of property: eZ6-t Intended use of property: Zone or use district in which premises is situated: Are there any covenants and restrictions with respect to this property? E]Yes ®.No IF YES, PROVIDE A COPY. 'B6x.�Aft6��,ROb�dlhg:�..Thpowrier/6ontrai&d��/`d'6 lgnL r f S f -Check' S 0 i6hallsirb�06nisible i)rall;dt'ain:'a-gid"and storm'water.Iti66iiip'r64idid.byL,."Lt., Chapter,136,of the-Town,Co'c"APPLICATION IS HEREBY,MADE to the Building De aitmentforthe,issuanidi of Bull ding PpFrnit pursuant to the Building 0rdinance of the Town of SoUjhola"S6fjoik;L-Cqunty,,New'Y'or- and_other applicaW 6�4s,Ordlhaini:6 or-Regu at!qns;�.9T.t k -f he construction ofb6ild!ngs idditionsialterations or forr"qva or de molitiona"gfiere inaescrli..e 7 applicant.,, , -alf applicable 6"j;ordi housing code and rigulatiohsandtoad it44ihbrked-lnspectors at enents punisfiable -i elaS' A kidemeanor.'pursuant,to Section M.45 of the,NbW Yo&Stjie Penal LaW. , j� Application Submitted By(print name): ElAuthorized Agent P!ca !�ner _� Ia� �__ __ Q--S ___ — Signature of Applicant: Date: qw- STATE OF NEW YORK) SS: COUNTYOF C, being duly sworn,deposes and says that(s)he is the applicant (Name of inQidual signing contract)above named, /l/n (S)he is the LAJ 2 n C-Ir"" (Contractor,Agent,Corporate Officer,etc.) of said owner or owners,and is duly authorized to perform or have performed the said work and to make and file this application;that all statements contained in this application are true to the best of his/her knowledge and belief,and that the work will be performed in the manner set forth in the application file therewith. Sworn before me this day of 20� a Ak Not Public PROPERTY OWNER AUTHORIZATION EVELYN K GOLZ NOTARY PUBLIC-STATE OF NEW YORK (Where the applicant is not the owner) No.01GO6205435 bualified*in Suffolk County, My Commission Expires M*41*,-20� residing at Aune all goa do hereby authorize to apply on my behalf to the Town of Southold Building Department for approval as described herein. Owner's Signature Date Print Owner's Name 2 Fot/e G BUILDING DEPARTMENT-Electrical Inspector TOWN OF SOUTHOLD o yam. Town Hall Annex- 54375 Main Road - PO Box 1179 o� . Southold, New York 11971-0959 Telephone (631) 765-1802 - FAX (631) 765-9502 rogerrCEDsoutholdtownny.gov - seand(aD-southoldtownny.gov APPLICATION FOR ELECTRICAL INSPECTION ELECTRICIAN INF RMATION (All Information Required) Date: 2 Company Name: �r eArI t(��-ri C. 5 Name: (f;-(e__n 7:5-a C_o to S License No.: email: Phone No: 3( _&5Sj ❑I request an email copy of Certificate of Compliance Address.: JOB SITE INFORMATION (All Information Required) Name: WCV-.,)c7 L�L✓C_ — a� Address: L 9 oC9O �A Q (L Cross Street: Phone No.: /r7 )_� BIdg.Permit#: (r��d7 email: r a-n c� o_o�.Cc) Tax Map District: 1000 Section: Block: (S) Lot: BRIEF DESCRIPTION OF WORK (Please Print Clearly Geaecc4o I L vo y0 � �yvev- 2_ Check All That Apply: Is job ready for inspection?: YES ❑NO ❑Rough In ❑Final Do you need a Temp Certificate?: ❑YES [310 Issued On Temp Informatio (All information required) Service Size - Ph ❑3 Ph Size: A #Meters Old Meter# [I1Vew Service ❑ Service Reconnect ❑ Underground ❑Overhead # Underground Laterals ❑1 ❑2 ❑H Frame[-]Pole Work done on Service? ❑Y ❑.N Additional Information: PAYMENT DUE WITH APPLICATION 10 Electrical Inspection Form 2020.xisx 0IX 0 r REF - _ BUILDING DEPARTMENT-Electrical Inspector QS.,_ ..:.:,,< ►aG,:. TOWN OF SOUTHOLD Town Hall Annex- 54375 Main Road - PO Box 1179 Southold, New York 11971-0959 Telephone (631) 765-1802 - FAX (631) 765-9502 ... rogerr(a)_southoldtownny.aov -- seand(a-southoldtownhy.aov APPLICATION FOR ELECTRICAL INSPECTION ELECTRICIAN INF IMATION (AII Information Required) Date: anp Y 2X11'1S Com Name: t(,6 �- r t C. Name: �o C_o 14 S License No.: L(11(7—H F email: Phone No: 3( _&5Sj ❑I request an email copy of Certificate of Compliance Address.: JOB SITE INFORMATION (All Information Required) Name: 1/��,1/�D Address: L ©c9p t �� -,��r� �J (l Cross Street: ;J Phone No.: Bldg.'Permit#: jl (i70- 7 email: v,i,odr can c� �-Can-� Tax Map District: 1 00 0 Section: IBlock: Lot: BRIEF DESCRIPTION OF WORK(Please Print Clearl,Y) ,�crl� .-�-o'r" -T— Check All That Apply: Is job ready for inspection?: (YES ❑NO ❑Rough In ❑Final Do you need a Temp Certificate?: []YES E<O Issued On Temp Informatio (All information required) Service Size Ph ❑3 Ph Size: A #Meters Old Meter# lew Service ❑ Service Reconnect ❑ Underground []Overhead # Underground Laterals ❑1 2 ❑H Frame❑Pole Work done on Service? ❑Y ❑N Additional Information: PAYMENT DUE WITH APPLICATION Electrical Inspection Form 2020.xlsx (1)UNAUTHORIZED ALTERATION OR ADDITION TO THIS SURVEY IS A VIOLATION OF SECTION 72D9 OF THE NEW YORK STAlt EDUCATION LAW.(2)DISTANCES SHOWN HEREON FROM PROPERTY LINES TO EXISTING STRUCTURES ARE FOR A SPECIFIC PURPO`.E AND ARE NOT TO BE USED TO ESTABLISH PROPERTY LINES OR FOR ERECTION OF FENCES.(3)COPIES OF THIS SURVEY MAP NOT BEARING THE LAND SURVEYOR'S INKED SEAL OR EMBOSSED SEAL SHALL NOT BE CONSIDERED 10 BE A VALID TRUE COPY.(4)CERTIFICATION INDICATED HEREON SHALL RUN ONLY TO THE PERSON FOR WHOM THE SURVEY IS PREPARED AND ON MS BEHALF TO TIE TITLE COMPANY,GOVERNMENTAL AGENCY AND LENDING INSTITUTION USTED HEREON,AND TO THE ASSIGNEES OF THE LENDING NSTITUTION CERTIFICATIONS ARE NOT TRANSFERABLE TO ADDITIONAL INSTITUTIONS OR SUBSEQUENT OWNERS. (5,THE LOCATION OF WELLS(W),SEPTIC TANKS(ST)h CESSPOOLS(CP)SHQNI HEREON ARE FROM FIELD OBSERVATIONS AND OR DATA OBTAINED FROM OTHERS. N 400 Ostrander Avenue, Riverhead, New York IILIOI tel. 631.727.2303 fax. 631.727.0144 odmin@youngengineering.com 4� Q. Howard W. Young, Land Surveyor �• Thomas G. Wolpert, Professional Engineer R Douglas E. Adams, Professional Engineer w > E MAIN ROAD (N.-,r.5. RTE. 2�) Robert G. Tast, Architect Robert 5tromski, Architect CMF ELECTRIC METER R WATER MAIN W o R o.o'N ° II I 58Q 03 00 W 0.0'E DI NSci �� 2a1.53 EOP 68.8 ' N87°3a'20"W S CMF CMF CMF 161.30' w �l ,W ETER CMF SITE DATA 9i ROOF OVER STOCKADE Z a w j' WOOD PORCH w 3 FENCE d) U; o DWI I �� 0 i FEN a� I AREA = 7.5262 ACRES I L 6 V a 91 2 15.9't I II o = FRAME LPE 6QaGARAGE° ISTONE ID ®ST T 41 P2 2 STORY w `O L �— O L L 0 I' FRAME HOUSE 0 O s� w AME OW z !(1 (V 6 4 Q Y w SHED DW N c LEGEND Q o z STON V FRAM N z WALL LU GARAG 41 GAR 5.6'W FEN ON 2 PIPE FOUND _ _ _ _ _ _ DI = DRAINAGE INLET CHAIN LINK FE 0.2 s EOP = EDGE OF PAVEMENT m FENCE 0. CMF 0.2 W to 0.1'N 586°18'10�IE RO = ROOF OVER w O.O'W ?I.33' `III = UTILITY POLE a1 CMF = 0 4 W o 3'S , p GMF = MONUMENT SET 5AN I TAR) MEASUREMENTS z o.2 E 6 0 ■ = MONUMENT FOUND 41 0?LU < '� Z = STAKE SET A B > _m ST 26' 24' ' To 9.2'w 1— JQ K u- =LAWN UP STAKE FOUND m NNo LPI 34' 551 6 w W V LP2 41' 50, CMF If1 0.2'N Fpp O.O'W __--- FEN ON e_ AZALEA A�/SyPHALT CMF _ ROAD 0.O'N FEN ON R �9 0.0'E 0 O m o z 1 CO w - C 13 m ai Kw r o�Z U o L_m SURVEYORS GERT I f=I GP�T I ON a1 ¢o FEN +' omgra( m O 3 1\ m 0 6Z 2.2'E tnw V WE HERESY C"iEIZTII-Y TO DAVID P. AMES, �iARJA L. „I \O ? ¢ 5NE - j AMES, 1 ST EQUITY NATIONAL TITLE & CLOSING SERVICES, FIRST AMERICAN TITLE INSURANCE -� J LAWN UP COMPANY & W E W O GROUP, L L C THAT THI5 SURVEY WAS 43 V To 18'E PREPARED IN ACCORDANCE WITH THE CODE OF P E._OR /� A 1 LAND SURVEYS ADOPTED BY THE NEW YORK r ON MAIN ROAD (N.Y.5. RTIE. 2� ' �O OF PROFESSIONAL LAND SURVEYORS. `� 1 \ ml UJ vY 1N VV ` o W VV W W W W W— 1 I' LANDWARD LIMIT OF O ' C O WATER MAIN �o FRESHWATER WETLANDS a p rn \_ 0 X _ b ,,, _ + ,•t 3 rAS LOCATED BY YOUNG & — Z N FEN YOUNG ON MAR. 26, 2019 CMF 4'E 0 1 = Z 0.3'N z NIL DI c c�[ c m 0.0'E zw 0 m IsN d`nM1, �58c3 Q- r 0--m CMF ¢z -� 6 V lz�' a Ny NU Ul 0.1'N UwiLLI y / WAIEN METER 0 �+',0.. 0� 0.0'E PLASTIC SHED !j .4 HOWARD W. YOUNG, N. ,5. L.5. NO. 455CI5 0 I J X 0 V p FEN ON UP TO 3.4'E w w 00 I ELECTRIC t� Ij FEN rnw w METER 6.0'E a w - now or formerly I o� _v LU To_wn of Southold J91.2' p ROOF OVER FEN -WOOD PORCH 2,T W —' SURVEY FOR POST & 1.3'WWIRE �E - ' ( IDAYID AME5 4 FENCE t, 0 •Dw �� \, \�u p. 0MARJA L. AMES GENERATOR — �� (/) (� Pg \\ *,�� BRICK SAC UNITS F 4? - PORTABLE \ gK'�(J0 �t at MQttItUGk, Town of Southold n WALK A RO +' O METAL & \ �qk• 0 A I I � - 6z c2 CANVAS �. �. , 5uffolk County, New York 26.5' _ ELEC. PANEL ++ 0 CARPORT LP1 A o STONE ST CE w\'� U w/.LU UP TO 8.2'E �� I NFL SURVEY 0 \ \ 2 STORYa WALL 0 HFRAMEOUSE 8.5 V / O \ �gw�(�0:Dc�� a,� . m o \ o FRAME LP2 _� \d .� aw�� \ �` County Tax Map District 1000 Section 115 Block 06 Lot -7 oGARAGE ~ \� J a ° \A FIELD SURVEY COMPLETED MAR. 26, 20141 BSTONE ORDER DIN �O �Q \ �i°'�OUpD�� o \ MAP PREPARED DULY 02, 2019 \o. Q 0 Record of Revisions FRAME DW o 0w \0\* REVISION DATE SHED 00a VtJ\J\,p\wJG\(�U �0 \ FINAL SURVEY JUNE oa 2020 UPDATE SURVEY JUNE 29, 2021 STONE oo O �g�OGOGj�h mop WALL �Fk 0 s 0 J O C ° INSET 100 0 50 100 200 300 Scale: 1" = 100' D %I JOB NO. 201Q-0033 50ALE: I' = 40' DWG. 2019_0033_fs I OF I GENERAC° ELECTRICAL INSPECTION REQUIRED APR D AS NOT D DAT1g, g.p,# FEE: BY; NOTIFY BUILDING DEPARTMENT AT . 765-1802 8 AM TO 4 PM FOR-THE - Installation an FOLLOWING INSPECTIONS: 1. FOUNDATION - TWO REQUIRED FOR POURED CONCRETE wner O 's Manual2• ROUGH - FRAMING & PLUMBING 3. INSULATION 4. FINAL - CONSTRUC-r!ON MUST B OMP TE I. 7910513 and 16kW Air-cooled, Automata. ffit � sHE REQUIREMENTS OF THE CODES OF NEW YORK STATE. NOT RESPONSIBLE FOR DESIGN OR CONSTRUCTION ERRORS. C @us OCCUPANCY OR LISTED USE IS UNLAWFUL 0 WITHOUTCERTIF / COMPLY WITH,ALL CODES OF OF OCCUPANCY NEW YORK STATE & TOWN CODE" AS REQUIRED AND CONDITIO S Or NI BOARD GUARDIAN' S UST S -- N.Y�.DE�� D 0 ®Not intended for use in critical life support Models: 005240, 005280 (6 kW NG, 7 kW LP) applications. 005241, 005281 (9 kW NG, 10 kW LP) ®Only qualified electricians or contrac- 005242, 005282 (13 kW NG, 13 kW LP) tors should attempt installation! Deadly 15 kW NG, 16 kW LP 005244, exhaust fumes. Outdoor installation only. 005243, ( ) 005283, 005284 www.generac'.com I 888 ■A Tableof • Introduction.............................................................1 Operation..............................................................15 Read This Manual Thoroughly...............................................1 3.1 Using the AUTO/OFF/MANUAL Switch..........................15 Contents...............................................................................1 3.2 Automatic Transfer Operation 15 Operation and Maintenance...................................................1 p How to Obtain Service...........................................................1 3.3 Sequence of Automatic Operation.................................16 Authorized Dealer Locator Number.............................................1 3.4 Manual Transfer Operation............................................16 Safety Rules 2 3.5 Setting the Exercise Timer............................................17 Standards Index....................................................................3 3.6 Protection Systems......................................................17 Maintenance.........................................................18 General Information................................................4 4.1 Fuses...........................................................................18 1.1 Unpacking/Inspection.....................................................4 4.2 Checking the Engine Oil Level.......................................19 1.2 Protection Systems........................................................4 4.3 Changing the Engine Oil 19 1.3 NEC Requirement for Arc Fault Circuit 4.4 Changing the Engine Air Cleaner...................................20 Interruption Breaker for Bedrooms..................................4 4.5 Spark Plug(s) 1.4 The Generator................................................................5 4.6 Battery Maintenance.....................................................21 1.5 Specifications................................................................6 4.7 Adjusting GH-41 O/GT 530/990 Valve Clearance.............22 1.6 System Set LED.............................................................7 4.8 Cooling System............................................................23 1.7 Fuel Requirements and Recommendations.....................7 4.9 Attention After Submersion...........................................23 1.8 Fuel Consumption..........................................................7 4.10 Corrosion Protection 1.9 Reconfiguring the Fuel System.......................................8 4.11 Out of Service Procedure..............................................23 1.10 Location.........................................................................9 4.12 Service Schedule 25 ......................................................... 1.11 Battery Requirements...................................................10 1.12 Battery Installation........................................................10 11 Troubleshooting ....................................................26 1.13 The Battery .................................................................. 5.1 Troubleshooting Guide..................................................26 Post Installation Start-up and Adjustments..........11 Notes ....................................................................27 2.1 Before Initial Startup.....................................................11 Mounting Dimensions...........................................30 2.2 Check Transfer Switch Operation..................................12 Warranty...............................................................32 2.3 Electrical Checks..........................................................12 2.4 Generator Tests Under Load.........................................12 2.5 Checking Automatic Operation......................................13 2.6 Adjusting the Fuel Regulator- 7kW(Natural Gas Only).................................................13 2.7 Engine Governor Adjustment........................................14 2.8 Voltage Regulator Adjustment.......................................14 AUTHORIZED DEALER LOCATION To locate the nearest AUTHORIZED DEALER,please call this number: 1-800-333-1322 DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER or visit www.guardiangenerators.com. INTRODUCTION The operator is responsible for proper and safe use of the equip- Thank you for purchasing this model of the Guardian product line ment. The manufacturer strongly recommends that the operator by Generac Power Systems Inc. This model is a compact, high read this Owner's Manual and thoroughly understand all instruc- performance, air-cooled, engine-driven generator designed to tions before using this equipment.The manufacturer also strongly automatically supply electrical power to operate critical loads dur- recommends instructing other users to properly start and operate ing a utility power failure. the unit.This prepares them if they need to operate the equipment This unit is factory installed in an all-weather, metal enclosure that in an emergency. is intended exclusively for outdoor installation. This generator CONTENTS will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG). This manual contains pertinent owner's information, including warranty, electrical diagrams, exploded views and lists of repair READ THIS MANUAL THOROUGHLY parts,for these different models: If any portion of this manual is not understood,contact the nearest • 05240 & 05280—6 kW NG, 7 kW LP single-cylinder GH-410 Dealer for starting, operating and servicing procedures. Engine Throughout this publication, and on tags and decals affixed to the • 05241 & 05281 — 9.0 kW NG, 10 kW LP, V-twin GT-530 generator, DANGER, WARNING, CAUTION and NOTE blocks are Engine used to alert personnel to special instructions about a particular • 05242&05282—13 kW NG, 13 kW LP, V-twin GT-990 Engine operation that may be hazardous if performed incorrectly or care- • 05243, 05244, 05283 &05284—15 kW NG, 16 kW LP,V-twin lessly. Observe them carefully.Their definitions are as follows: GT-990 Engine ' 1 ' 0 M=1 Z4111 OPERATION AND MAINTENANCE INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF It is the operator's responsibility to perform all safety checks, to NOT AVOIDED,WILL RESULT IN DEATH OR SERIOUS INJURY. make sure that all maintenance for safe operation is performed AWARNING! promptly, and to have the equipment checked periodically by a Dealer. Normal maintenance service and replacement of parts Indicates a hazardous situation or action which, if not are the responsibility of the owner/operator and, as such, are not avoided, could result in death or serious injury. considered defects in materials or workmanship within the terms of the warranty.Individual operating habits and usage contribute to A CAUTION! the need for maintenance service. Indicates a hazardous situation or action which, if not Proper maintenance and care of the generator ensures a minimum avoided, could result in minor or moderate injury. number of problems and keep operating expenses at a minimum. NOTE: See a Dealer for service aids and accessories. Notes contain additional information important to a procedure HOW TO OBTAIN SERVICE and will be found within the regular text body of this manual. When the generator requires servicing or repairs, contact a Dealer These safety warnings cannot eliminate the hazards that they for assistance. Service technicians are factory-trained and are indicate. Common sense and strict compliance with the special capable of handling all service needs. instructions while performing the action or service are essential to When contacting a Dealer about parts and service, always supply preventing accidents. the complete model number and serial number of the unit as given Four commonly used safety symbols accompany the DANGER, on its data decal,which is located on the generator.See section"The WARNING and CAUTION blocks. The type of information each Generator"for decal location. indicates is as follows: Model No. Serial No. This symbol points out important safety information that, if not followed, could endanger personal safety and/or property of others. CALIFORNIA PROPOSITION 65 WARNING ®This symbol points out potential explosion hazard. Engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects ®This symbol points out potential fire hazard. and other reproductive harm. AThis symbol points out potential electrical shock hazard. CALIFORNIA PROPOSITION 65 WARNING This product contains or emits chemicals known to the State of California to cause cancer, birth defects and other reproductive harm. i 'Safety Rules SAFETY RULES GENERAL HAZARDS A'WARNING!I For safety reasons, the manufacturer recommends that this ASave These Instructions—The manufacturer equipment be installed, serviced and repaired by a Service suggests that these rules for safe operation Dealer or other competent, qualified electrician or installation be copied and posted near the unit's instal- technician who is familiar with applicable codes, standards lation site. Safety should be stressed to all and regulations. The operator also must comply with all such operators and potential operators of this equipment. codes,standards and regulations. Study these SAFETY RULES carefully before installing, operating The engine exhaust fumes contain carbon monoxide, which or servicing this equipment. Become familiar with this Owner's can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. Manual and with the unit. The generator can operate safely, effi- ciently and reliably only if it is properly installed, operated and Do NOT alter or atltl to the exhaust system or do anything that might render the system unsafe or in noncompliance with appli- maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions. cable codes and standards. • Install a battery operated carbon monoxide alarm indoors, The manufacturer cannot anticipate every possible circumstance according to manufacturer's instructions/recommendations. that might involve a hazard. The warnings in this manual, and on Adequate, unobstructed flow of cooling and ventilating air is tags and decals affixed to the unit are,therefore,not all-inclusive.If critical to correct generator operation. Do not alter the instal- using a procedure,work method or operating technique the manu- lation or permit even partial blockage of ventilation provisions, facturer does not specifically recommend,ensure that it is safe for as this can seriously affect safe operation of the generator.The others. Also make sure the procedure, work method or operating generator MUST be installed and operated outdoors only. technique utilized does not render the generator unsafe. • 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. ADespite the safe design of this generator, • When working on this equipment, remain alert at all times. operating this equipment imprudently, Never work on the equipment when physically or mentally neglecting its maintenance or being careless fatigued. can cause possible injury or death. Permit • Inspect the generator regularly, and contact the nearest Dealer only responsible and capable persons to for parts needing repair or replacement. install, operate and maintain this equipment. • Before performing any maintenance on the generator, discon- OPotentially lethal voltages are generated by nect its battery cables to prevent accidental start up.Disconnect these machines. Ensure all steps are taken to the cable from the battery post indicated by a NEGATIVE, NEG render the machine safe before attempting to or(—)first,then remove the POSITIVE,POS or(+)cable.When work on the generator. reconnecting the cables, connect the POSITIVE cable first,the Parts of the generator are rotating and/or hot NEGATIVE cable last. during operation. Exercise care near running • Never use the generator or any of its parts as a step. Stepping generators. on the unit can stress and break parts, and may result in dan- gerous operating conditions from leaking exhaust gases, fuel Installation must always comply with appli- leakage, oil leakage, etc. cable codes, standards, laws and regula- tions. ELECTRICAL HAZARDS ®A running generator gives off carbon mon- . All generators covered b this manual produce dangerous oxide, an odorless, colorless poison gas. g y p g Breathing in carbon monoxide can cause electrical voltages and can cause fatal electrical shock. Utility headaches, fatigue, diziness, nausea,vomit- power delivers extremely high and dangerous voltages to the ting, confusion, fainting, siezures or death. transfer switch as does the standby generator when it is in operation. Avoid contact with bare wires, terminals, connec- tions, etc., while the unit is running. Ensure all appropriate covers, guards and barriers are in place,secured and/or locked before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce shock hazard. • Do not handle any kind of electrical device while stand- ing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT. 2 Safety Rulej • The National Electrical Code(NEC)requires the frame and external STANDARDS INDEX electrically conductive parts of the generator to be connected to In the absence of pertinent standards,codes,regulations and laws, an approved earth ground.Local electrical codes also may require the published information listed below may be used as installation proper grounding of the generator electrical system. guide for this equipment. • After installing this home standby electrical system,the genera- tor may crank and start at any time without warning.When this 1. NFPA No. 37, STATIONARY COMBUSTION ENGINES AND GAS occurs, load circuits are transferred to the STANDBY (genera- TURBINES,available from the National Fire Protection Association, tor)power source.To prevent possible injury if such a start and 470 Atlantic Avenue,Boston,MA 02210. transfer occur, always set the generator's AUTO/OFF/MANUAL 2. NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH switch to its OFF position before working on equipment and CARE FACILITIES,available same as Item 1. remove the 15A fuse from the generator control panel. 3. NFPA No.54, NATIONAL FUEL GAS CODE, available same as Item • In case of accident caused by electric shock, immediately shut 1. down the source of electrical power. If this is not possible, 4. NFPA No. 58, AMERICAN NATIONAL STANDARD FOR STORAGE attempt to free the victim from the live conductor.AVOID DIRECT AND HANDLING OF LIQUEFIED PETROLEUM GAS, available same CONTACT WITH THE VICTIM. Use a nonconducting implement, as Item 1. such as a dry rope or board, to free the victim from the live 5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL ELECTRIC CODE, conductor. If the victim is unconscious, apply first aid and get available same as Item 1. immediate medical help. 6. Article X,NATIONAL BUILDING CODE,available from the American • Never wear jewelry when working on this equipment. Jewelry Insurance Association, 85 John Street,New York, N.Y.10038. can conduct electricity resulting in electric shock, or may get 7. AGRICULTURAL WIRING HANDBOOK,available from the Food and caught in moving components causing injury. Energy Council,909 University Avenue,Columbia, MO 65201. FIRE HAZARDS 8. ASAE EP-3634, INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRICAL SYSTEMS, available from the American • For fire safety, the generator must be installed and maintained Society of Agricultural Engineers,2950 Niles Road,St.Joseph,MI properly. Installation must always comply with applicable 49085. codes, standards, laws and regulations. Adhere strictly 9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE, to local, state and national electrical and building codes. available same as Item 1. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure that the 11111,11171 generator is installed in accordance with the manufacturer's Only qualified electricians or contractors instructions and recommendations. Following proper installa- should attempt such installations,which must tion, do nothing that might alter a safe installation and render comply strictly with applicable codes, stan- the unit in noncompliance with the aforementioned codes, dards and regulations. standards, laws and regulations. • Keep a fire extinguisher near the generator at all times. Extinguishers rated 'ABC" by the National Fire Protection Association are appropriate for use on the standby electric system. Keep the extinguisher properly charged and be familiar with its use. Consult the local fire department with any ques- tions pertaining to fire extinguishers. EXPLOSION HAZARDS • Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result. Keep the area surrounding the generator clean and free from debris. • Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE. Install the fuel supply system according to applicable fuel-gas codes. Before placing the home standby'electric system into service, fuel system lines must be properly purged and leak tested according to applica- ble code.After installation, inspect the fuel system periodically for leaks. No leakage is permitted. 3 General Information There are LED readouts on the control panel to notify personnel that one of these faults has occurred. There is also a System Only qualified electricians or contractors Set LED that is lit when all of the conditions described in section should attempt such installations,which must "System Set LED"are true. (See the "Protection Systems"section comply strictly with applicable codes, stan- for details.) dards and regulations. 1.1 UNPACKING/INSPECTION 1.3 NEC REQUIREMENT FOR ARC After unpacking, carefully inspect the contents for damage. FAULT CIRCUIT INTERRUPTION • This standby generator set is ready for installation with afactory BREAKER FOR BEDROOMS supplied and pre-mounted base pad and has a weather protec- In 2001,the National Electric Code(NEC)introduced a requirement tive enclosure that is intended for outdoor installation only. for new construction.This new requirement indicates the need for • This UL listed standby generator set is packaged with an auto- Arc Fault Circuit Interrupters to be used to protect the complete matic transfer switch with built in load center.The combination branch circuit that feeds a dwelling bedroom. The actual NEC transfer switch and load center is pre-wired with a two foot and requirement is indicated below. 30 foot conduit. Circuit breakers for emergency circuit connec- tions are included (if equipped). 1.3.1 SECTION 210.12 ARC FAULT CIRCUIT • This UL listed,2-pole switch is rated at 100 AC amperes at 250 INTERRUPTER PROTECTION volts maximum.This transfer switch is for indoor use only(if equipped). 1. Definition: An are fault circuit interrupter is a device intended (AWARNINGi to provide protection from the effects of arc faults by recog- nizing characteristics unique to arcing and by functioning to QIf this generator is used to power electrical load de-energize the circuit when an arc fault is detected. circuits normally powered by a utility power 2. Dwelling Unit Bedrooms: All branch circuits that supply 125 source, it is required by code to install a trans- volt, single-phase, 15 and 20 ampere outlets installed in fer switch. The transfer switch must effectively dwelling unit bedrooms shall be protected by an arc fault cir- isolate the electrical system from the utility distribution system when the generator is oper- cuit interrupter listed to provide protection of the entire branch ating (NEC 700, 701 &702). Failure to isolate an circuit. electrical system by such means will result in Section 210.12 requires that AFCI protection be provided on branch damage to the generator and also may result in circuits that supply outlets (receptacle, lighting, etc.) in dwell- injury or death to utility power workers due to ing bedrooms. The requirement is limited to 15 and 20 ampere, backfeed of electrical energy. 125 volt circuits. There is no prohibition against providing AFCI If any loss or damage is noted at time of delivery, have the protection on other circuits or in locations other than bedrooms. person(s) making the delivery note all damage on the freight bill Because circuits are often shared between a bedroom and other or affix their signature under the consignor's memo of loss or areas such as closets and hallways, providing AFCI protection on damage. the complete circuit would comply with 210.12. If a loss or damage is noted after delivery, separate the damaged If during the installation of the home standby system the decision materials and contact the carrier for claim procedures. is made to provide back up power to a bedroom branch circuit, then the circuit breaker in the transfer switch should be replaced "Concealed damage" is understood to mean damage to the con- with an Arc Fault Circuit Interrupter. tents 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 1.2 PROTECTION SYSTEMS with a 20A AFCI. Unlike an automobile engine, the generator may have to run for These AFCI breakers are available at the nearest hardware store. long periods of time with no operator present to monitor engine conditions. For that reason, the engine is equipped with the fol- Siemens Item # Description lowing systems that protect it against potentially damaging condi- O115AF 15A Single Pole AFCI tions: 1. Low Oil Pressure Sensor 4. Overspeed 0120AF 20A Single Pole AFCI 2. High Temperature Sensor 5. RPM Sensor 3. Overcrank 6. Low Battery 4 General Informatiorp 1.4 THE GENERATOR Figure 1.1- 7kW, Single Cylinder GH-410 Engine Figure 1.2- 10kW, V-twin GT-530 Engine Control Control Panel Data Panel Oil Data Air Filter Oil Decal Dipstick Decal Cover Dipstick Exhaust Exhaust ° Enclosure Enclosure Air Filter am Fuel Fuel Inlet Inlet °Do (Back) °O° (Back) Fuel ° Fuel Regulator Regulator O O O O Composite Base Oil Filter Battery Compartment Composite Base Oil Filter Battery Compartment Figure 1.3- 13kW and 16kW, V-twin GT-990 Engine Air Filter Cover Control Oil Data Panel Dipstick Decal Exhaust Enclosure Fuel Inlet (Back) Fuel Regulator O O Composite Base Oil Filter Battery Compartment 5 General Information 1.5 SPECIFICATIONS 1.5.1 GENERATOR Model 05240&05280 05241 &05281 05242&05282 05243&05244 05283&05284 Rated Max.Continuous 6,000 NG/7,000 LP 9,000 NG/10,000 LP 13,000 NG/13,000 LP 15,000 NG/16,000 LP Power Capacity Watts* Rated Volta a 1 120/240 120/240 1 120/240 1 120/240 Rated Max.Continuous Load Current(Amps) 120 Volts** 50.0 NG/58.3 LP 75.0 NG/83.3 LP 108.3 NG/108.3 LP 125 NG/133.3 LP 240 Volts 25.0 NG/29.2 LP 37.5 NG/41.7 LP 54.1 NG/54.1 LP 62.5 NG/66.6 LP Main Line Circuit Breaker 30 Amp 45 Amp 55 Amp 65 Am Circuits*** 50A 240V - - - 1 40A,240V - - 1 1 30A 240V 1 1 1 - 20A 240V ' - 1 - 1 20A 120V 1 3 3 5 15A 120V 5 3 5 5 Phase 1 1 1 1 Number of Rotor Poles 2 2 2 2 Rated AC Frequency 60 Hz 60 Hz 60 Hz 60 Hz Power Factor 1 1 1 1 Recommended Air Filter Part#OC8127 Part#OE9581 Part#OC8127 Part#OC8127 Battery Requirement Group 26 Group 26 Group 26 Group 26 12 Volts and 12 Volts and 12 Volts and 12 Volts and 350 Cold-cranking 525 Cold-cranking 525 Cold-cranking 525 Cold-cranking Amperes Minimum Amperes Minimum Amperes Minimum Amperes Minimum Battery Warming Blanket OF6148DSRV Weight(Unit Only) 336 Pounds 375 Pounds 425.5 Pounds 445&414 Pounds Enclosure I Steel/Aluminum Normal Operating Range -20oF(-28.8°C)to 104°F(40oC) * Maximum wattage and current are subject to and limited by such factors as fuel Btu content,ambient temperature,alklude,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°D ambient temperature. **Load current values shown for 120 volts are maximum TOTAL values for two separate circuits.The maximum current in each circuit must not exceed the value stated for 240 volts. ***Circuits to be moved must be protected by same size breaker.For example,a 15 amp circuit in main panel must be a 15 amp circuit in transfer switch. 1.5.2 ENGINE Model 05240&05280 05241 &05281 05242&05282 05243&05244 05283&05284 Type of Engine GH-410 GT-530 GT 990 GT-990 Number of Cylinders 1 2 2 2 Rated Horsepower 14.5 @ 3,600 rpm 18 @ 3,600 rpm 30 @ 3,600 rpm 30 @ 3,600 rpm Displacement 410cc 530cc 992cc 992cc Cylinder Block Aluminum w/Cast Aluminum w/Cast Aluminum w/Cast Aluminum w/Cast Iron Sleeve Iron Sleeve Iron Sleeve Iron Sleeve Valve Arrangement Overhead Valves Overhead Valves Overhead Valves Overhead Valves Ignition System Solid-state w/Ma neto Solid-state w/Ma neto Solid-state w/Ma neto Solid-state w/Ma neto Recommended Spark Plug RC14YC BPR6HS RC14YC RC14YC Spark Plug Gap 0.76 mm 0.030 inch 0.76 mm 0.030 inch 1.02 mm 0.040 inch 1.02 mm 0.040 inch Compression Ratio 8.6:1 9.5:1 9.5:1 9.5:1 Starter 12 Vdc 12 Vdc 12 Vdc 12 Vdc Oil Capacity Including Filter Approx.1.5 Qts Approx.1.7 Qts Approx.1.7 Qts Approx.1.7 Qts Recommended Oil Filter Part#070185F Part#070185F Part#070185E I Part#070185F Recommended Air Filter Part#OC8127 Part#OE9581 Part#OC8127 Part#OC8127 Operating RPM 3,600 3,600 3,600 3,600 6 neral • • 1.6 SYSTEM SET LED Use an approved pipe sealant or joint compound on all threaded The "System Set' LED is lit when all of the following conditions fitting. are true: All installed gaseous fuel piping must be purged and leak tested 1. The AUTO/OFF/MANUAL switch is set to the AUTO position. prior to initial start-up in accordance with local codes, standards 2. The utility voltage being supplied to the unit is being sensed and regulations. by the PCB.If the utility sense voltage is not connected to the unit or if it is below approximately 150-160 volts AC, then 1.8 FUEL CONSUMPTION the system set light will flash rapidly.This indicates that if the AUTO/OFF/MANUAL switch is placed in the Auto position,the Unit Nat.Gas(*) LP Vapor(**) generator will start. 1/2 Load Full Load 1/2 Load Full Load 3. ' No alarms are present, for example, low oil pressure, high 6/7 kW 66 119 0.82/30 1.47/54 temperature, etc. 9/10 kW 102 156 1.25/46 1.93/70 1.7 FUEL REQUIREMENTS 13/13 kW 156 220 1.55/57 1 2.18/80 AND RECOMMENDATIONS 15/16 kW 173 1 245 1.59/59 1 2.51/92 With LP as,use only the vapor withdrawals stem.This a of *Natural gas is n cubic feet per hour. 9 Y P Y �p **LP is in gallons per hour/cubic feet per hour. system uses the vapors formed above the liquid fuel in the storage ***Values given are approximate. tank. The engine has been fitted with a fuel carburetion system that 1.8.1 BTU FLOW REQUIREMENTS-NATURAL GAS meets the specifications of the 1997 California Air Resources BTU flow required for each unit based on 1000 BTU per cubic Board for tamper-proof dual fuel systems. The unit will run on foot. 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 • 6kW—119,000 BTU/Hour fuel system needs to be reconfigured. See the Reconfiguring the • 9kW—156,000 BTU/Hour Fuel System section for instructions on reconfiguration of the fuel • 13kW—220,000 BTU/Hour system. • 15kW—245,000 BTU/Hour Recommended fuels should have a Btu content of at least 1,000 r 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 Gaseous fuels such as natural gas and liquid ® the fuel. propane (LP) gas are highly explosive. Even Required fuel pressure for natural gas is 5 inches to 7 inches the slightest spark can ignite such fuels and water column (0.18 to 0.25 psi); and for liquid propane, 10 cause an explosion. No leakage of fuel is inches to 12 inches of water column (0.36 to 0.43 psi). permitted. Natural gas, which is lighter than NOTE: air, tends to collect in high areas. LP gas is heavier than air and tends to settle in low All pipe sizing, construction and layout must comply with NFPA areas. 54 for natural gas applications and NFPA 58 for liquid propane NOTE: applications.Once the generator is installed,verify that the fuel pressure NEVER drops below four (4) inches water column for A minimum of one approved manual shut-off valve must be natural gas or 10 inches water column for liquid propane. installed in the gaseous fuel supply line.The valve must be eas- Prior to installation of the generator, the installer should consult ily accessible. Local codes determine the proper location. local fuel suppliers or the fire marshall to check codes and regula- tions for proper installation.Local codes will mandate correct rout- ing of gaseous fuel line piping around gardens, shrubs and other landscaping to prevent any damage. Special considerations should be given when installing the unit where local conditions include flooding, tornados, hurricanes, earthquakes and unstable ground for the flexibility and strength of piping and their connections. 7 General Information 1.9 RECONFIGURING THE 9. Reverse procedure steps 1-6 to reinstall demand regulator. FUEL SYSTEM 10. Take the plastic plug supplied in the poly-bag with the genera- tor and press it into the 3/4" hole on the bottom of the air 1.9.1 7 KW. 41OCC ENGINE cleaner base (Figure 4.6). 11. Reverse the procedure to convert back to natural gas. To reconfigure the fuel system from NG to LP follow these steps 12. Check for gas leakage at the pipe plug, hose connection and (Figure 1.4): fittings. NOTE: 1.9.2 10. 13 AND 16KW. V-TWIN ENGINES The primary regulator for the propane supply is NOT INCLUDED To reconfigure the fuel system from NG to LP,follow these steps: with the generator. A fuel pressure of 10 to 12 inches of water NOTE: column(0.36 to 0.43 psi)to the fuel inlet of the generator MUST BE SUPPLIED. The primary regulator for the propane supply is NOT INCLUDED 1. Turn off the main gas supply (if connected). with the generator.A fuel pressure of 10 to 12 inches of water 2. Open the roof and remove the door. column(0.36 to 0.43 psi)to the fuel inlet of the generator MUST 3. Remove the battery (if installed). BE SUPPLIED. 4. Disconnect wire#0 and wire#14 from the gas solenoid on- 1. Open the roof. top of the demand regulator. 2. For 10kW units: Loosen clamp and slide back the air inlet 5. Remove the carburetor fuel hose from the outlet port of the hose. demand regulator. - Slide fuel selector on carburetor out towards the back of the 6. Remove the demand regulator by removing the fastener that enclosure (Figures 1.5 and 1.6). retains the regulator mounting bracket. • Return the inlet hose and tighten clamp securely. 7. Remove the square headed steel pipe plug from outlet port For 13 and 16kW units: remove the air cleaner cover. #1 and the brass hose barb fitting from outlet port#2. - Slide the selector lever out towards the back of the enclosure 8. Refit the brass hose barb fitting to outlet port #1 and the (Figures 1.7 and 1.8). square headed steel pipe plug to outlet port#2. • Return the air cleaner cover and tighten the two thumb screws. Figure 1.4—Demand Regulator 3. Close the roof. HOSE aPLUG 4. Reverse the procedure to convert back to natural gas. SMTLHED SIDES FUEL HOSE` Figure 1.5- 10kW, GT-530(Inlet Hose Slid Back) PIPE FUELHOSE .n BPASSHOSE PLUG BRASSHOSE R"'. FITTING OUTLET ADJUSTMENT P0i1T » • UI SCREW O �.y FUELJET Fuel Selection ;. •, . 0 0 0 o L .t o 0 0 0 0 rvsmon Veld Pt�ttLJlHel as m " 0 0 D Fuel d ^ 0 0 0 O NG FUEL SYSTEM LP FUEL SYSTEM q.' STATIC ■ PRESSURE r•m",°,T TAP 0 0 PUNNING PRESSURE TAP NOTE: Use an approved pipe sealant or joint compound on all threaded fittings to reduce the possibility of leakage. 8 General Informatio Figure 1.6- 10M,, GT-530(inlet Hose Slid Back) 1.10 LOCATION 1.10.1 GENERATOR A WARNING! ' uel Selection en me exhaust fumes contain carbon F g �The 9- Lever-"Out" monoxide, which can be DEADLY. This dan- Position for gerous gas, if breathed in sufficient concen- Liquid Propane trations can cause unconsciousness or even " " x death. This exhaust system must be installed (Vapor) Fuel properly, in strict compliance with applicable codes and standards. Following installation .;, g do nothing that might render the system unsafe or in noncompliance with such codes is and standards. ' • Operate the generator outdoors ONLY. ? �, .':r� ,,{;.,; '. •:sue=',,�,��. r.vw>' • Keep exhaust gases from entering a confined area through windows, doors, ventilation or Figure 1.7- 13/16kW, GT-990 (Airbox Cover Removed) other openings (Figure 1.9). Install the generator set, in its protective enclosure, outdoors, Fuel Selection Lever-"In"Position for Natural as Fuel where adequate cooling and ventilating air is always available - -- (Figure 1.9). Consider these factors: m The installation of the generator must comply strictly with NFPA 37,NFPA 54,NFPA 58,and NFPA 70 standards(http:// www.nfpa.org/). r " Install the unit where air inlet and outlet openings will not r& `fit become obstructed by leaves, grass, snow, etc.. If prevailing 4_ ' W ° _ winds will cause blowing or drifting, consider using a wind-Ti) break to protect the unit. q Install the generator on high ground where water levels will not rise and endanger it. Allow sufficient room on all sides of the generator for mainte- nance and servicing. This unit must be installed in accordance ` with current applicable NFPA 37 and NFPA 70 standards; as well as any other federal, state and local codes for minimum distances from other structures. DO NOT install under wooden Figure 1.8- 13/16kW, GT-990 (Airbox Cover Removed) decks or structures. • Install the unit where rain gutter down spouts, roof run-off, landscape irrigation, water sprinklers or sump pump discharge Fuel Selection Lever-"Out"Position for Liquid Propane does not flood the unit or spray the enclosure, including any air (Vapor) Fuel inlet or outlet openings. Figure 1.9—Generator Clearances ■i■li i - 9 General Information • Install the unit where services will not be affected or obstructed, 1.12 BATTERY INSTALLATION including concealed, underground or covered services such as Fill the battery with the proper electrolyte fluid if necessary and electrical,fuel, phone, air conditioning or irrigation. have the battery fully charged before installing it. • Where strong prevailing winds blow from one direction,face the generator air inlet openings to the prevailing winds. Before installing and connecting the battery, complete the follow- Install the generator as close as possible to the fuel supply,to ing steps: reduce the length of piping. 1. Set the generator's AUTO/OFF/MANUAL switch to OFF. • Install the generator as close as possible to the transfer switch. 2. Turn off utility power supply to the transfer switch. REMEMBER THAT LAWS OR CODES MAY REGULATE THE 3. Remove the 15A fuse from the generator control panel. DISTANCE AND LOCATION. Battery cables were factory connected at the generator (Figure • The genset must be installed on a level surface.The base frame 1.10). Connect cables to battery posts as follows: must be level within two (2) inches all around. 4. Connect the red battery cable (from starter contactor)to the 1.10.2 TRANSFER SWITCH battery post indicated by a positive, POS or(+). 5. Connect the black battery cable (from frame ground) to the 1.10.2.1 7, 10, 13, and 16 kW Units (if equipped) battery post indicated by a negative, NEG or(—). NOTE: The transfer switch shipped with this generator is enclosed in a Dielectric grease should be used on battery posts to aid in the NEMA 1 enclosure.This type of enclosure is intended for indoor use only. Follow these rules: prevention of corrosion. • Install the transfer switch indoors on a firm, sturdy supporting NOTE: structure. Damage will result if battery connections are made in reverse. • To prevent switch distortion, level the switch if necessary.This can be done by placing washers between the switch enclosure Figure 1.10—Battery Cable Connections and mounting surface. • Never install the switch where water or any corrosive substance BLACK LEAD might drip onto the enclosure. /(FROM FRAME) • Protect the switch at all times against excessive moisture, dust, dirt, lint, construction grit and corrosive vapors. RED LEAD A WARNING! (FROM STARTER ®k If the AUTO/OFF/MANUAL switch is not set CONTACTOR) to its OFF position, the generator can crank and start as soon as the battery cables are RED connected. If the utility power supply is not _ { + turned off, sparking can occur at the battery BATTERY posts and cause an explosion. 1.11 BATTERY REQUIREMENTS BLACK See the Specifications section for correct battery size and rating. NOTE: In areas where temperatures regularly fall below 100 F(-120 C) it is recommended that a pad type battery heater be installed to aid in cold climate starting (see Specifications). NOTE: The generator is equipped with a battery trickle charger that is active when the unit is set up for automatic operation. With the battery installed and utility power source voltage available to the transfer switch, the battery receives a trickle charge while the engine is not running, to prevent self-discharge. The trickle charger is designed to help extend the life of the battery by maintaining the battery when the unit is not running. The trickle charge feature cannot be used to recharge a discharged battery. 10 Post • Adjustments 1.13 THE BATTERY ABe sure the utility power supply is turned off and the 15A fuse is removed from the gener- ator control panel, or sparking may occur at the battery posts as the cables are attached ADo not dispose of the battery in a fire. The and cause an explosion. battery is capable of exploding. Servicing of the battery is to be performed or supervised by per- QA battery presents a risk of electrical shock sonnel knowledgeable of batteries and the required precautions. and high short circuit current. The following Keep unauthorized personnel away from batteries. precautions are to be observed when work- See the Specifications section for the correct size and rating when ing on batteries: replacing the battery. When using a maintenance-free battery, it • Remove the 15A fuse from the generator con- is not necessary to check the specific gravity or electrolyte level. trol panel. Have these procedures performed at the intervals specified in the • Remove watches, rings or other metal objects; "Service Schedule." A negative ground system is used. Battery • Use tools with insulated handles; connections are shown on the wiring diagrams.Make sure the bat- • Wear rubber gloves and boots; tery is correctly connected and terminals are tight.Observe battery • Do not lay tools or metal parts on top of the polarity when connecting the battery to the generator set. battery; and • Disconnect charging source prior to connecting or disconnecting battery terminals. 2.1 BEFORE INITIAL STARTUP AWARNING!; NOTE: ADo not open or mutilate the battery. These units have been run and tested at the factory prior to Released electrolyte has been known to being shipped and do not require any type of break-in. be harmful to the skin and eyes, and to be Before starting, complete the following: toxic. 1. Set the generator's main circuit breaker to its OFF (or OPEN) The electrolyte is a dilute sulfuric acid that is position. harmful to the skin and eyes. It is electrically 2. Set the generator's AUTO/OFF/MANUAL switch to the OFF conductive and corrosive. position. The following procedures are to be observed: 3. Turn OFF all breakers on the load center of the transfer box(T1 • Wear full eye protection and protective clothing; and T2). • Where electrolyte contacts the skin, wash it off 4. Turn OFF all loads connected to the transfer switch terminals immediately with water; T1 and T2. • Where electrolyte contacts the eyes, flush thor- 5. Check the engine crankcase oil level and, if necessary, fill to oughly and immediately with water and seek the dipstick FULL mark with the recommended oil. Do not fill medical attention; and above the FULL mark. • Spilled electrolyte is to be washed down with 6. Check the fuel supply. Gaseous fuel lines must have been an acid neutralizing agent. A common practice properly purged and leak tested in accordance with applicable is to use a solution of 1 pound (500 grams) fuel-gas codes. All fuel shutoff valves in the fuel supply lines bicarbonate of soda to 1 gallon (4 liters) of must be open. water. The bicarbonate of soda solution is to be added until the evidence of reaction (foam- During initial start up, after installation, it is normal for the genera- ing) has ceased. The resulting liquid is to be for to exceed the normal number of start attempts and experience flushed with water and the area dried. an "over crank" fault. This is due to accumulated air in the fuel QLead-acid batteries present a risk of fire system during shipment. '�' because they generate hydrogen gas. The NOTE: following procedures are to be followed: This procedure applies to 13kW and 16kW units only and should • DO NOT SMOKE when near the battery; be performed by trained personnel. • DO NOT cause flame or spark in battery area; and A CAUTION! • Discharge static electricity from body before touching the battery by first touching a ground- Never operate the engine with the oil level ed metal surface. below the "Add" mark on the dipstick. Doing ABe sure the AUTO/OFF/MANUAL switch is set this could damage the engine. to the OFF position before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are con- nected. n Post Installation • and Adjustments 2.2 CHECK TRANSFER SWITCH 10. Connect an accurate AC voltmeter and a frequency meter across transfer switch terminal lugs E1 and E2. 7kW voltage OPERATION should be 242-252 volts at a frequency of 61-63 Hertz. 10, Refer to the "Manual Transfer Operation" section, of the owner's 13,and 16kW voltage should be 247-249 volts at a frequency manual for procedures. of 57.5-59.5 Hertz. 11. Connect the AC voltmeter test leads across terminal lugs E1 and neutral;then across E2 and neutral. In both cases, volt- Do not attempt manual transfer switch opera. age reading should be 121-126 volts AC (7kW),and 125-126 volts AC (10, 13 and 16kW). tion until all power voltage supplies to the transfer switch have been positively turned 12. Set the generator's main circuit breaker to its OFF (or OPEN) off. Failure to turn off all power voltage sup- position. Let the engine run at no-load for a few minutes to plies will result in extremely hazardous and stabilize internal engine generator temperatures. possibly fatal electrical shock. 13. Set the generator's AUTO/OFF/MANUAL switch to OFF. The engine should shut down. 2.3 ELECTRICAL CHECKS NOTE: Complete electrical checks as follows: It is important not to proceed until certain that generator AC voltage and frequency are correct and within the stated limits. 1. Set the generator's main circuit breaker to its OFF (or OPEN) Generally, if both AC frequency and voltage are high or low, position. the engine governor requires adjustment* (*GH410 only). If 2. Set the generator's AUTO/OFF/MANUAL switch to the OFF frequency is correct,but voltage is high or low,the generator's position. voltage regulator requires adjustment. 3. Turn OFF all breakers on the load center of the transfer box(T1 and T2). 2.4 GENERATOR TESTS UNDER 4. Turn on the utility power supply to the transfer switch using the means provided (such as a utility main line circuit break- LOAD er). To test the generator set with electrical loads applied, proceed as rill 3 follows: The transfer switch is now electrically 1. Set generator's main circuit breaker to its OFF(or OPEN)posi- "hot." Contact with "hot" parts will result in tion. extremely hazardous and possibly fatal elec- 2. Turn OFF all breakers on the load center of the transfer box(T1 trical shock. Proceed with caution. and T2). 5. Use an accurate AC voltmeter to check utility power source 3. Set the generator's AUTO/OFF/MANUAL switch to OFF. voltage across transfer switch terminals N1 and N2. Nominal 4. Turn OFF the utility power supply to the transfer switch, line-to-line voltage should be 240 volts AC. using the means provided (such as a utility main line circuit 6. Check utility power source voltage across terminals N1 and breaker). the transfer switch neutral lug; then across terminal N2 and A ARNINGI neutral. Nominal line-to-neutral voltage should be 120 volts AC. Do not attempt manual transfer switch opera- 7. When certain that utility supply voltage is compatible with Ation until all power voltage supplies to the transfer switch and load circuit ratings, turn OFF the utility transfer switch have been positively turned power supply to the transfer switch. off. Failure to turn off all power voltage sup- 8. On the generator panel,set the AUTO/OFF/MANUAL switch to plies will result in extremely hazardous and MANUAL.The engine should crank and start. possibly fatal electrical shock. 9. Let the engine warm up for about five minutes to allow inter- 5. Manually set the transfer switch to the STANDBY position,i.e., nal temperatures to stabilize. Then, set the generator's main load terminals connected to the generator's E1/E2 terminals. circuit breaker to its ON (or CLOSED) position. 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. QProceed with caution! Generator power volt- 7. Let the engine stabilize and warm up for a few minutes. A age is now supplied to the transfer switch. 8. Set the generator's main circuit breaker to its ON (or closed) Contact with live transfer switch parts will position. Loads are now powered by the standby generator. result in dangerous and possibly fatal electri- 9. Turn ON the load center of the transfer switch (T1 and T2). cal shock. 12 Post InstallationStart-up • Adjustments 10. Connect an accurate AC voltmeter and a frequency meter 2.6 ADJUSTING THE FUEL across terminal lugs E1 and E2. • 7kW voltage should be greater than 230 volts and frequency REGULATOR - 7KW (NATURAL should be greater than 58 Hz. GAS ONLY) • 10, 13 &16kW voltage should be greater than 240 volts and 1 NOTE: frequency should be greater than 60 Hz. 11. Let the generator run at full rated load for 20-30 minutes. All V-twin engine units DO NOT require a fuel regulator adjust- Listen for unusual noises, vibration or other indications of ment due to the fuel system design. abnormal operation.Check for oil leaks,evidence of overheat- Although the generator has been factory set to provide maximum ing, etc. power, it may be necessary in some areas to adjust this setting. If 12. When testing under load is complete, turn OFF electrical experiencing engine problems at high or full load conditions, fol- loads. low these steps. It will require a frequency meter to perform this 13. Set the generators main circuit breaker to its OFF (or OPEN) procedure. position. 1. Turn off utility power to the main distribution panel in the 14. Let the engine run at no-load for a few minutes. house. This can be done by switching the service main 15. Set the AUTO/OFF/MANUAL switch to OFF.The engine should breaker to the off or open position. shut down. 2. Allow the generator to start. Before loading the generator, confirm that the No Load Frequency, with the roof open and 2.5 CHECKING AUTOMATIC door off, is set to 63-63.5 Hz. Transfer load to emergency circuits. OPERATION 3. Turn on appliances, lights, pumps, etc.,that are on the emer- To check the system for proper automatic operation, proceed as gency circuits in an attempt to fully load the generator. Be follows: cautious not to overload the generator.Use the following chart 1. Set generator's main circuit breaker to its OFF(or OPEN)posi- as a guide: tion. 4. When 3/4 load has been achieved.Connect a frequency meter 2. Check that the AUTO/OFF/MANUAL switch is set to OFF. to the output lugs of the generator's main line circuit breaker. 3. Turn OFF the utility power supply to the transfer switch, using 5. The fuel regulator is fitted with one adjustment screw. While means provided (such as a utility main line circuit breaker). watching the frequency meter, slowly turn the adjustment 4. Manually set the transfer switch to the UTILITY position, i.e., screw clockwise or counterclockwise until the highest fre- load terminals connected to the utility power source side. quency is read on the meter. Only limited adjustment is avail- 5. Turn ON the utility power supply to the transfer switch, able because of the set pin. Under no circumstances should using the means provided (such as a utility main line circuit any of the pins be removed (Figure 2.3). breaker). Figure 2.3— AW Fuel Regulator 6. Set the generator's main circuit breaker to its ON (or CLOSED)) position. 7. Set the AUTO/OFF/MANUAL switch to AUTO. The system is 410cc Engine now ready for automatic operation. 8. Turn OFF the utility power supply to the transfer switch. With the AUTO/OFF/MANUAL switch at AUTO, the engine should crank and start when the utility source power is turned OFF after a O 10 second delay.After starting,the transfer switch should connect Adjustment load circuits to the standby side after a 15 second delay. Let the Screw Set system go through its entire automatic sequence of operation. (One side Pin With the generator running and loads powered by generator AC Only) output,turn ON the utility power supply to the transfer switch.The following should occur: • After about 15 seconds,the switch should transfer loads back to the utility power source. • About one minute after retransfer, the engine should shut down. 6. When the highest frequency is reached maximum power has been set. From this point turn the adjustment screw 1/4 turn counterclockwise. The regulator is now set. 7. Turn utility power to the main distribution panel back on.This can be done by switching the service main breaker to the on or closed position. Allow the generator to shut down. 13 Post Installation Start-up and Adjustments JAWARNING!l 3. Start the generator; let it stabilize and warm up at no-load. ADo not make any unnecessary adjustments. 4. Connect a frequency meter across the generators AC output Factory settings are correct for most appli- leads. cations. However, when making adjustments, 5. Turn the primary adjust screw to obtain a frequency reading be careful to avoid overspeeding the engine. of 61.5 Hertz. Turn the secondary adjust screw to obtain a If this procedure or the test equipment is not available, locate the frequency of 62.5 Hz. nearest Dealer and they can perform the adjustments. 6. When frequency is correct at no load, check the AC voltage reading. If voltage is incorrect, the voltage regulator may NOTE: require adjustment (See the Voltage Regulator Adjustment A service fee may be charged for this adjustment. section). 2.7.2 13 KW AND 16 KW UNITS 2.7 ENGINE GOVERNOR NOTE: ADJUSTMENT All V-twin units DO NOT require an engine governor adjustment If both AC frequency and voltage are correspondingly high or low, due to their design. adjust the engine governor as follows: 2.7.1 7 KW UNITS 2.7.3 ADDITIONAL CORROSION PROTECTION A;WARNING! Periodically spray all engine linkage parts and brackets with corro- AThe engine must be OFF to perform steps 1 sion inhibiting spray such as WD-40 or a comparable product. and 2. 1. Loosen the governor clamp bolt(Figure 2.4). 2.8 VOLTAGE REGULATOR 2. Hold the governor lever at its wide open throttle position ADJUSTMENT (clockwise), and rotate the governor shaft clockwise as far as it will go.Then,tighten the governor lever clamp bolt to 70 inch-pounds (8 N-m). Unit 1 120 Volts 1 240 Volts 7 kW 50.0 amps 25.0 amps Figure 2.4—Engine Governor Adjustment Single Cylinder Engines 2.8.1 7KW UNITS SECONDARY With the frequency between 62-63 Hertz at no-load, slowly turn ADJUST SCREW the slotted potentiometer(Figure 2.5) until line voltage reads 248- 252 volts. 2.8.2 10, 13,AND 16KW UNITS With the frequency between 58-59 Hertz at no-load, slowly turn the slotted potentiometer(Figure 2.3) until line voltage reads 247- GOVERNOR 249 volts. SHAFT s NOTE: GOVERNOR ® I PRIMARY The access panel on top of the control panel must be removed CLAM to adjust the voltage regulator. BOLT ADJUST SCREW NOTE: ® The voltage regulator is housed above the generator's control panel.The regulator maintains a voltage in direct proportion to frequency at a 2-to-1 ratio. For example, at 62 Hertz, line-to- neutral voltage will be 124 volts. � 4 14 Operatio Figure 2.5— Voltage Adjustment Potentiometer 3.1.3 "MANUAL"POSITION Set the switch to MANUAL to crank and start the engine.Transfer to standby power will not occur unless there is a utility failure. ® Q 0 -0 0 ® AWARNI r ® 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 O Turn to O below a preset level or during the normal adjust voltage. exercise cycle. To prevent possible injury that might be caused by such sudden starts, always set the switch to OFF and remove the O fuses before working on or around the gen- erator or transfer switch. Then, place a "DO NOT OPERATE"tag on the generator panel ® ® and on the transfer switch. 3.1.4 CHOKE OPERATION 1. 990 engines have an electric choke in the air box that is auto- 3.1 USING THE AUTO/OFF/ matically controlled by the electronic control board. 2. 530 engines have an electric choke on the divider panel air MANUAL SWITCH (FIGURE 3.1) inlet hose that is automatically controlled by the electronic control board. 3.1.1 `AUTO"POSITION 3. 410 engines do not have a choke. Selecting this switch position activates fully automatic system operation.It also allows the unit to automatically start and exercise 3.2 AUTOMATIC TRANSFER the engine every seven days with the setting of the exercise timer OPERATION (see the Setting the Exercise Timer section). To select automatic operation, do the following: 3.1.2 "OFF"POSITION 1. Make sure the transfer switch main contacts are set to their UTILITY position, i.e., loads connected to the utility power This switch position shuts down the engine. This position also source (Figure 3.2). prevents automatic operation. 2. Be sure that normal UTILITY power source voltage is avail- able to transfer switch terminal lugs N1 and N2 (Refer to the Figure 3.1—Generator Control Panel Electrical Data section). 3. Set the generator's AUTO/OFF/MANUAL switch to AUTO. CONTROL AND INFORMATION CENTER 4. Set the generator's main circuit breaker to its ON(or CLOSED) SYSTEM SET position. LOW BATTERY With the preceding steps complete, the generator will start auto- AUTO. OFF MAN. LOWOIL matically when utility source voltage drops below a preset level. HIGHTEMP SYSTEM FUSE After the unit starts, loads are transferred to the standby power OV ER SPEED O NO RPM SENSE IF FLASHING C—OVERCRANK source. Refer to the Sequence of Automatic Operation section. 15A SET 00 IJIIJ EXERCISE sr....... TIME 15 Operation 3.3 SEQUENCE OF AUTOMATIC 3.4 MANUAL TRANSFER OPERATION OPERATION The generator's control panel houses a control logic circuit board. 3.4.1 TRANSFER TO GENERATOR This board constantly monitors utility power source voltage. Should that voltage drop below a preset level, circuit board action POWER SOURCE will signal the engine to crank and start. After the engine starts, To start the generator and activate the transfer switch manually, the circuit board signals the transfer switch to activate and con- proceed as follows: nect load circuits to the standby power supply (load terminal lugs T1/T2 connect to terminal lugs El/E2). Refer to the Electrical Data 1. Set the generator's AUTO/OFF/MANUAL switch to OFF. section. 2. Set the generator's main circuit breaker to its OFF (or OPEN) The generator must run at 50 Hz or greater for the transfer output position. to be activated. Once activated, it will remain active even if the 3. Turn OFF the utility power supply to the transfer switch frequency dips below 50 Hz. using the means provided (such as a utility main line circuit Upon restoration of utility source voltage above a preset level, breaker). generator circuit board action signals the transfer switch to trans- fer loads back to that power supply.After retransfer,the engine is Do not attempt to activate the transfer switch signalled to shut down. A&manually until all power voltage supplies to The actual sequence of operation is controlled by sensors and the switch have been positively turned off. timers on a control logic circuit board, as follows: Failure to turn off all power voltage supplies may result in extremely hazardous and pos- A. Utility Voltage Dropout Sensor sibly fatal electrical shock. • This sensor monitors utility source voltage. 4. Use the manual transfer handle inside the transfer switch to • If utility source voltage drops below about 65 percent of the move the main contacts to their STANDBY position, i.e., loads nominal supply voltage, the sensor energizes a 10 second connected to the standby power source (Figure 3.2). timer. 5. To crank and start the engine, set the AUTO/OFF/MANUAL • Once the timer has expired,the engine will crank and start if switch to MANUAL. utility is still low. 6. Let the engine stabilize and warm up for a few minutes. B. Engine Warm-up Time Delay 7. Set the generator's main circuit breaker to its ON(or CLOSED) • This mechanism lets the engine warm up for about five position.The standby power source now powers the loads. (5) seconds before the load is transferred to the standby source. Figure 3.2—Manual Transfer Switch Operation C. Standby Voltage Sensor • This sensor monitors generator AC output voltage. When the voltage has reached 50 percent of the nominal rated voltage, transfer to standby can occur. LOAD CONNECTED TO UTILITY POWER SOURCE D. Utility Voltage Pickup Sensor LOAD CONNECTED TO STANDBY POWER SOURCE • This sensor monitors utility power supply voltage.When that voltage is restored above 75 percent of the nominal source voltage, a retransfer time delay starts timing. 0 0 E. Retransfer Time Delay 000000 • This timer runs for about 15 seconds. • At end of a 15-second delay,circuit board action de-energizes MANUAL TRANSFER transfer relay in the transfer switch if utility is still present. HANDLE • Retransfer to utility power source then occurs. F. Engine Cool-down Timer TRANSFER SWITCH • When the load is transferred back to utility power source,the 0 0 OPERATING LEVER engine cool-down timer starts timing. • The timer will run for about one minute,and the generator will then shut down. 16 Operation 3.4.2 TRANSFER BACK TO UTILITY POWER SOURCE NOTE: When utility power has been restored,transfer back to that source The exerciser will only work in the AUTO mode and will not work and shut down the generator. This can be accomplished as fol- unless this procedure is performed.The exerciser will need to lows: be reset every time the 12-volt battery is disconnected and then 1. Set the generator's main circuit breaker to its OFF (or OPEN) reconnected, and when the 15A fuse is removed. position. The 16kW unit has a low speed exercise option. Dip switch 1 on 2. Let the engine run for a minute or two at no-load to stabilize the control board is factory set to OFF. This allows the engine to the internal temperatures. run at a slower speed during weekly exercise periods for quieter 3. Set the generator's AUTO/OFF/MANUAL switch to operation.If this Dip switch is set to ON,the generator will exercise its OFF (or OPEN) position.The engine should shut down. at it's normal speed. 4. Check that utility power supply to the transfer switch is turned This DIP switch position is only read at board power up. If the DIP OFF. switch position is changed, power to the board must be cycled for the micro controller to recognize the new DIP switch position. QDo not attempt to activate the transfer switch Low speed exercise will be handled as follows: manually until all power voltage supplies 1. The standard start sequence will be initiated. to the switch have been positively turned off. 2. The unit will run at 2,400 RPM. Failure to turn off all power voltage supplies 3. If utility is lost during exercise,the controller will do the follow- may result in extremely hazardous and pos- ing: sibly fatal electrical shock. • Wait 10 seconds for utility to return. 5. Use the manual transfer handle inside the transfer switch to • If utility returns within 10 seconds, continue to exercise at move the main contacts back to their UTILITY position, i.e., 2,400 RPM. loads connected to the utility power source (Figure 3.2). • If utility is still lost after 10 seconds, run the engine up to 6. Turn ON the utility power supply to the transfer switch using 3600 RPM and transfer the load. At this time the controller the means provided. will exit the exercise routine and assume full automatic opera- 7. Set the system to automatic operation as outlined in Automatic tion. Transfer Operation section. 3.5 SETTING THE EXERCISE TIMER 3.6 PROTECTION SYSTEMS This generator is equipped with an exercise timer. Once it is set, 3.6.1 LOW OIL PRESSURE SWITCH the generator will start and exercise once every seven days,on the This switch (Figure 3.3)has normally closed contacts that are held day of the week and at the time of day the following sequence is open by engine oil pressure during cranking and operating.Should completed. During this exercise period, the unit runs for approxi- oil pressure drop below the 8 psi range,switch contacts close,and mately 12 minutes and then shuts down. Transfer of loads to the the engine shuts down.The unit should not be restarted until oil is generator output does not occur during the exercise cycle unless added.The AUTO/OFF/MANUAL switch must then be turned to OFF utility power is lost. and then back to AUTO. A switch on the control panel (see Figure 3.1) permits selection of the day and time for the system to exercise. At the chosen time, 3.6.2 HIGH TEMPERATURE SWITCH perform the following sequence to select the desired day and time of day the system will exercise. Remember seasonal time changes This switch's contacts (Figure 3.3)close if the temperature should affect the exercise time settings. exceed approximately 1440 C (2930 F), initiating an engine shut- 1. Verify that the AUTO/OFF/MANUAL switch is set to AUTO. down. The generator will automatically restart and the LED on the generator control panel will reset once the temperature has 2. Press and hold the "Set Exercise Time" switch for several returned to a safe operating level. seconds,then release.All the red LED's will flash for approxi- mately 10 seconds and.then stop. 3. Once the red LED's stop flashing,the generator will start and run for approximately 12 minutes and then shut down. The exerciser is now set to run at this time of day each week. Example: If the "Set Exercise Time" switch is pressed on Saturday afternoon at 2:00 p.m., the generator will start and exercise for approximately 12 minutes every Saturday at 2:00 p.m.. 17 Maintenance Figure 3.3—Low Oil Pressure and If the unit fails to start, the overcrank alarm LED will be illumi- High Temperature Switches nated. Low Oil Switch High Temp Switch 3.6.4 OVERSPEED This feature protects the generator from damage by shutting it fi down if it happens to run faster than the preset limit. This protec- tion also prevents the generator from supplying an output that could potentially damage appliances connected to the generator circuit. Contact the nearest Authorized Dealer if this failure P, occurs. Oil Filter 3.6.5 RPM SENSOR FAILURE Oil During cranking, if the board does not see a valid RPM signal Drain within three (3) seconds, it will shut down and latch out on RPM Hose sensor loss. During running, if the RPM signal is lost for one full second the board will shut down the engine, wait 15 seconds, then re-crank 3.6.3 OVERCRANK the engine. This feature prevents the generator from damaging itself when it • If an RPM signal is not detected within the first three (3) sec- continually attempts to start and another problem,such as no fuel onds of cranking, the control board will shut the engine down supply, prevents it from starting. The unit will crank and rest for and latch out on RPM sensor loss. a preset time limit.Then, it will stop cranking, and the LED on the • If the RPM signal is detected the engine will start and run nor- generator control panel will light indicating an overcrank failure. mally. If the RPM signal is subsequently lost again,the control The AUTO/OFF/MANUAL switch will need to be set to OFF and then board will try one more re-crank attempt before latching out and back to AUTO to reset the generator control board. flashing the overspeed LED. NOTE: If the fault is not repaired, the overcrank feature will continue 3.6.6 LOW BATTERY to activate. The microprocessor will continually monitor the battery voltage and turn on the Low Battery LED if the battery voltage falls below 3.7.3.1 Approximate Crank Cycle Times 11.0 volts for one(1)minute.No other action is taken on a low bat- 7kW Units: tery condition. Low battery voltage is a non-latching alarm which • 15 seconds ON will automatically clear if the battery voltage rises above 11.0 volts. • 7 seconds OFF Battery voltage is NOT monitored during the crank cycle. • 7 seconds ON • 7 seconds OFF 4.1 FUSES • 7 seconds ON The 15-amp fuse on the generator panel protects the DC control • 7 seconds OFF circuit against overload (Figure 4.1). This fuse is wired in series • 7 seconds ON with the battery output lead to the panel. If this fuse element has • 7 seconds OFF melted open,the engine will not be able to crank or start. Replace • 7 seconds ON this fuse using only an identical 15-amp replacement fuse. To • 7 seconds OFF replace the fuse, push the fuse holder cap down and rotate it • 7 seconds ON counterclockwise.Whenever the fuse is removed or replaced,the If the unit fails to start, the overcrank alarm LED will be illumi- exercise timer needs to be reset. nated. 10kW, 13kW and 16kW Units: Figure 4.1—Generator Control Panel • 16 seconds ON • 7 seconds OFF CONTROL AND INFORMATION CENTER • 16 seconds ON � SYSTEM SET • 7 seconds OFF LOW BATTERY • 7 seconds ON AUTO. OFF MAN. LOWOIL HIGH TEMP • 7 seconds OFF SYSTEM FUSE OVERSPEED O � NO RPM SENSEIFFLASHING • 7 seconds ON WVERCRANK • 7 seconds OFF 15A SET 000 • 7 seconds ON „ EXTIMEERCISE • 7 seconds OFF 18 4.2 CHECKING THE ENGINE Figure 4.4—Oil Dipstick and Fill, OIL LEVEL MIN and 16kW For oil capacities, see the Specifications section. For engine oil recommendations, see the Engine Oil Recommendations section. oil Dipstick To check the engine oil level, proceed as follows (Figures 4.2,4.3 and 4.4): - 1. Move the AUTO/OFF/MANUAL switch to the OFF position. o 2. Remove the dipstick and wipe it dry with a clean cloth. 3. Completely insert the dipstick; then, remove it again. The oil oil Fill level should be at the dipstick "Full" mark. If necessary, add oil to the "Full" mark only. DO NOT FILL ABOVE THE "FULL' MARK. o j A CAUTION! / ANever operate the engine with the oil level o (� below the "Add" mark on the dipstick. Doing I I this could damage the engine. 4. Install the dipstick. 5. Reset the AUTO/OFF/MANUAL switch to its original position. 4.3 CHANGING THE ENGINE OIL Figure 4.2—Oil Dipstick and Fill, 7kW 4.3.1 OIL CHANGE INTERVALS See the"Service Schedule"section. Oil Dipstick and Fill 4.3.2 ENGINE OIL RECOMMENDATIONS All oil should meet minimum American Petroleum Institute (API) 0 Service Class SJ, SL or better. Use no special additives. Select the oil's viscosity grade according to the expected operating tem- perature. A CAUTION! p AAny attempt to crank or start the engine before it has been properly serviced with the ® recommended oil may result in an engine failure. SAE 30 Figure 4.3—Oil Dipstick and Fill, 10kW Oil Dipstick P °F -20 -10 0 10 20 32 40 60 80 100 e _ °C-30 .20 -10 0 10 20 30 40 Temperature Range of Expected Use LU Ion o - Oil Fill o. 19 Maintenance 4.3.3 OIL & OIL FILTER CHANGE PROCEDURE 4.4 CHANGING THE ENGINE To change the oil, proceed as follows: AIR CLEANER 1. Start the engine by moving the AUTO/OFF/MANUAL switch to MANUAL and run until it is thoroughly warmed up.Then shut 4.4.1 7. 13,AND 16KW GENERATORS OFF the engine by moving the switch to the OFF position. See Figures 1.1 and 1.2,for the location of the air cleaner.Use the 2. Immediately after the engine shuts OFF, pull the oil drain hose following procedures (Figure 4.6, 7kW; Figure 4.8, 13/16kW): (Figure 4.5)free of its retaining clip. Remove the cap from the hose and drain the oil into a suitable container. 1. Lift the roof and remove the door. 3. After the oil has drained, replace the cap onto the end of the oil 2. Turn the two screws counterclockwise to loosen. drain hose.Retain the hose in the clip. 3. Remove the cover and air filter. Change the engine oil filter as follows: 4. Wipe away dust or debris from inside of the air box and 1. With the oil drained, remove the old oil filter by turning it around edges. counterclockwise. 5. Install the new air cleaner into the air box. 2. Apply a light coating of clean engine oil to the gasket of the 6. Install the cover. Turn the two cover screws clockwise to new filter. See the Specifications section for recommended tighten. filter. See the Service Schedule section for air cleaner maintenance.See 3. Screw the new filter on by hand until its gasket lightly contacts the Specifications section for air filter replacement part number. the oil filter adapter.Then,tighten the filter an additional 3/4 to one turn (Figure 4.4). Figure 4.6— 7 kW, Engine Air Cleaner Location Figure 4.5—Oil Drain Hose and Filter Low Oil Switch High Temp Switch ' Air Cleaner �--looy.P 0 Oil Filter Oil 3/4" Drain Hose Hole n 4. Refill with the proper recommended oil (see the Engine Oil Recommendations section). See the Specifications section for oil capacities. 5. Start the engine, run for one (1) minute, and check for leaks. 4.4.2 1OKW GENERATORS 6. Shutdown and recheck oil level, add as needed. DO NOT OVER FILL. See Figure 1.2 for the location of the air cleaner. Use the following 7. Reset the AUTO/OFF/MANUAL switch to the AUTO position. procedure (Figure 4.7): 1. Lift the roof and remove the door. 2. Turn the worm gear clamp screw counterclockwise to loos- en. 3. Pull the old filter off the divider panel hub. 4. Wipe away dust or debris from the panel hub. 5. Install the new air cleaner onto the hub. 6. Turn the worm gear clamp screw clockwise to tighten. 7. Replace door and roof. 20 a`, iln,A Figure 4.7— MIN Engine Air Cleaner 3. Check the spark plug gap using a wire feeler gauge.Adjust the gap to 0.76 mm (0.030 inch) for 7 and 10kW; and 1.02 mm (0.040 inch) for 13/16 kW by carefully bending the ground electrode (Figure 4.9). Control Figure 4.9—Setting the Spark Plug Gap 0, 10 Panel Air Filter oC)o 4.6 BATTERY MAINTENANCE Figure 4.8— 13 kW and 16 kW Engine The battery should be inspected per the "Service Schedule" sec- Air Cleaner tion.The following procedure should be followed for inspection: 1. Inspect the battery posts and cables for tightness and corro- Screw sion.Tighten and clean as necessary. 2. Check the battery fluid level of unsealed batteries and, if nec- essary, fill with Distilled Water Only. Do not use tap water in batteries. 3. Have the state of charge and condition checked.This should be done with an automotive-type battery hydrometer. Cover ®Do not dispose of the battery in a fire. The battery is capable of exploding. A battery presents a risk of electrical shock Filter Aand high short circuit current. The following precautions are to be observed when work- ing on batteries: • Remove the 15A fuse from the generator con- trol panel. • Remove watches, rings or other metal objects; • Use tools with insulated handles; • Wear rubber gloves and boots; • Do not lay tools or metal parts on top of the battery; and • Disconnect charging source prior to connecting 4.5 SPARK PLUG(S) or disconnecting battery terminals. Reset the spark plugs) gap or replace the spark plug(s) as neces- AWARNING! sary. See the Service Schedule section for maintenance require- ments. �Do not open or mutilate the battery. Released electrolyte has been known to be harmful to 1. Clean the area around the base of the spark plug(s) to keep the skin and eyes, and to be toxic. dirt and debris out of the engine. The electrolyte is a dilute sulfuric acid that is 2. Remove the spark plug(s) and check the condition. Replace harmful to the skin and eyes. It is electrically the spark plug(s) if worn or if reuse is questionable. See the conductive and corrosive. The following Service Schedule section for recommended inspection. Clean procedures are to be observed: by scraping or washing using a wire brush and commercial solvent. Do not blast the spark plug(s)to clean. 21 • Wear full eye protection and protective clothing; Make sure the piston is at Top Dead Center (TDC) of its com- • Where electrolyte contacts the skin, wash it off pression stroke (both valves closed).To get the piston at TDC, immediately with water; remove the intake screen at the front of the engine to gain • Where electrolyte contacts the eyes, flush access to the flywheel nut. Use a large socket and socket thoroughly and immediately with water and wrench to rotate the nut and hence the engine in a clockwise seek medical attention; and direction. While watching the piston through the spark plug • Spilled electrolyte is to be washed down with hole. The piston should move up and down. The piston is at an acid neutralizing agent. A common practice TDC when it is at its highest point of travel. is to use a solution of 1 pound (500 grams) To adjust valve clearance (if necessary): bicarbonate of soda to 1 gallon (4 liters) of water. The bicarbonate of soda solution is to • Make sure the engine is at 60°to 80°F. be added until the evidence of reaction (foam- • Make sure that the spark plug wire is removed from the spark ing) has ceased. The resulting liquid is to be plug and out of the way. flushed with water and the area dried. • Remove the four screws attaching the valve cover with a#2 or ®Lead-acid batteries present a risk of fire #3 Phillips screwdriver. because they generate hydrogen gas. The • Loosen the rocker jam nut. Use an 10mm alien wrench to turn following procedures are to be followed: the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge. Correct clearance • DO NOT SMOKE when near the battery; is 0.002-0.004 inch (0.05-0.1 mm). • DO NOT cause flame or spark in battery area; and Figure 4.10- Valve Clearance Adjustment • Discharge static electricity from body before touching the battery by first touching a ground- Rocker ed metal surface. Pivot Ball Arm ®Be sure the AUTO/OFF/MANUAL switch is set Stud to the OFF position before connecting the Jam Nut battery cables. If the switch is set to AUTO Valve or MANUAL, the generator can crank and Stem start as soon as the battery cables are con- nected. ABe sure the utility power supply is turned off and the 15A fuse is removed from the gener- ator control panel, or sparking may occur at the battery posts as the cables are attached and cause an explosion. 4.7 ADJUSTING GH-410/GT 530/990 VALVE CLEARANCE After the first six(6)months of operation,check the valve clear- NOTE: ance in the engine, adjust if necessary. Hold the rocker arm jam nut in place as the pivot ball stud is Important: If feeling uncomfortable about doing this procedure or turned. the proper tools are not available, please contact the Authorized When valve clearance is correct, hold the pivot ball stud in place Dealer for service assistance. This is a very important step to with the allen wrench and tighten the rocker arm jam nut.Tighten insure longest life for the engine. the jam nut to 174 in/lbs. torque. After tightening the jam nut, To check valve clearance: recheck valve clearance to make sure it did not change. • The engine should be cool before checking.If valve clearance is • Install new valve cover gasket. 0.002"- 0.004" (0.05-0.1 mm), adjustment is not needed. • Re-attach the valve cover. • Remove spark plug wires and position wires away from plugs. NOTE: • Remove spark plugs. Start all four screws before tightening or it will not be possible to get all the screws in place.Make sure the valve cover gasket is in place. • Install spark plugs. • Re-attach the spark plug wire to the spark plug. • On the GT-530 and GT-990, repeat the process for the other cylinder. 22 Maintenance 4.8 COOLING SYSTEM 4.10 CORROSION PROTECTION Air inlet and outlet openings in the generator compartment must Periodically wash and wax the enclosure using automotive type be open and 'unobstructed for continued proper operation. This products. Frequent washing is recommended in salt water/coastal includes such obstructions as high grass, weeds, brush, leaves areas. Spray engine linkages with a light oil such as WD-40. and snow. Without sufficient cooling and ventilating air flow, the engine/gen- 4.11 OUT OF SERVICE PROCEDURE erator quickly overheats, which causes it to quickly shut down. (See Figure 4.11 for vent locations.) 4.11.1 REMOVAL FROM SERVICE Make sure the doors and roof are in place during operation as If the generator cannot be exercised every seven days, and will running the generator with them removed can effect cooling air be out of service longer than 90 days, prepare the generator for movement. storage as follows: Figure 4.11—Cooling Vent Locations 1. Start the engine and let it warm up. 2. Close the fuel shutoff valve in the fuel supply line and allow AIR the unit to shut down. OUTLET AIR INTAKE 3. Once the unit has shut down, it will signal a low oil fault. 4. Set the generator's main circuit breaker to its OFF (or OPEN) ❑ position. 411 ❑0 5. Set the AUTO/OFF/MANUAL switch to OFF and turn off the utility power to the transfer switch.Remove the 15A fuse from ❑ Elthe generator control panel. Disconnect the battery cables as ❑ outlined in "General Hazards". a -CDw 6. While the engine is still warm from running, drain the oil completely. Refill the crankcase with oil. See "Engine Oil Recommendations". 7. Attach a tag to the engine indicating the viscosity and clas- AWARNING!1 sification of the oil in the crankcase. A' ' The exhaust from this product gets extremely 8• Remove the spark plug(s) and spray fogging agent into the hot and remains hot after shutdown. High spark plug(s) threaded openings. Reinstall and tighten the grass, weeds, brush, leaves, etc. must spark plug(s). remain clear of the exhaust. Such materi- 9. Remove the battery and store it in a cool, dry room on a als may ignite and burn from the heat of the wooden board. Never store the battery on any concrete or exhaust system. earthen floor. 10. Clean and wipe the entire generator. A CAUTION! AThe maximum ambient temperature for the generator is 400 C (1040 F). 4.9 ATTENTION AFTER SUBMERSION If the generator has been submerged in water, it must not be started and operated. Following any submersion in water, have an Authorized Dealer thoroughly clean, dry and inspect the generator. If the structure(ex.home)has been flooded,it should be inspected by a certified electrician to ensure there won't be any electrical problems during generator operation or when utility is returned. 23 Maintenance 4.11.2 RETURN TO SERVICE To return the unit to service after storage, proceed as follows: 1. Verify that utility power is turned off and that the AUTO/OFF/ MANUAL switch is set to OFF. 2. Check the tag on the engine for oil viscosity and classification. Verify that the correct recommended oil is used in the engine (see the Engine Oil Recommendations section). If necessary, drain and refill with the proper oil. 3. Check the state of the battery. Fill all cells of unsealed bat- teries to the proper level with distilled water. DO NOT USE TAP WATER IN THE BATTERY. Recharge the battery to 100 percent state of charge, or, if defective, replace the battery. See "Specifications,"for type and size. 4. Clean and wipe the entire generator. 5. Make sure the 15A fuse is removed from the generator con- trol panel. Reconnect the battery. Observe battery polarity. Damage may occur if the battery is connected incorrectly. 6. Open the fuel shutoff valve. 7. Insert the 15A fuse into the generator control panel. Start the unit by moving the AUTO/OFF/MANUAL switch to MANUAL. Allow the unit to warm up thoroughly. 8. Stop the unit by setting the AUTO/OFF/MANUAL switch to OFF. 9. Turn on the utility power to the transfer switch. 10. Set the AUTO/OFF/MANUAL switch to AUTO. 11. The generator is now ready for service. NOTE: If the battery was dead or disconnected, the exercise timer must be reset. 24 Maintenance 4.12 SERVICE SCHEDULE ATTENTION: It is recommended that all service work be performed by the nearest Dealer. SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action Inspect Change Clean W = Weekly R = Replace as Necessary M = Monthly * = Notify Dealer Y =Yearly if Repair is Needed. FUEL Fuel lines and connections* X M LUBRICATION Oil level X M Oil X Every 200 hours**, or 24 hours of continuous use, or 2Y Oil filter X Every 200 hours**, or 24 hours of continuous use, or 2Y COOLING Enclosure louvers X X W BATTERY Remove corrosion, X X M ensure dryness Clean and tighten X X M battery terminals Check charge state X R EVERY 6 M Electrolyte level X R EVERY 6 M unsealed batteries only)* ENGINE AND MOUNTING Air cleaner X R 2Y or 200 hours Sparkplug(s) X R 2Y or 200 hours GENERAL CONDITION Vibration, Noise,Leakage, X M Temperature* COMPLETE TUNE-UP* TO BE COMPLETED BY A DEALER 2Y or 200 hours * Contact the nearest dealer for assistance if necessary. **Change oil and filter after first eight(8)hours of operation and then every 200 hours thereafter,or two(2)years,whichever occurs first.Change sooner when operating under a heavy load or in a dusty or dirty environment or in high ambient temperatures. 25 7roubleshootin, g 5.1 TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank. 1. Fuse blown. 1. Correct short circuit condition, replace 15A fuse in generator control panel. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables. as necessary. 3. Defective starter contactor. (7 kM 3. * 4. Defective starter motor. 4. * 5. Dead Battery. 5. Charge or replace battery. The engine cranks but 1. Out of fuel. 1. Replenish fuel/Turn on fuel valve. will not start. 2. Defective fuel solenoid (FS). 2. * 3. Open#14 wire from 3. * engine control board. 4. Defective spark plug(s). 4. Clean, re-gap or replace plug(s). 5. Valve lash out of adjustment. 5. Reset valve lash. 6. Choke not operating. 6. Verify choke plate moves freely. The engine starts hard 1. Air cleaner plugged 1. Check, replace air cleaner. and runs rough. or damaged. 2. Defective spark plug(s). 2. Clean, re-gap or replace plug(s). 3. Fuel regulator not set. 3. Set Fuel Regulator. 4. Fuel pressure incorrect. 4. Confirm fuel pressure to regulator is 10-12"water column (0.36-0.43 psi)for LP and 5-7"water column (0.18-0.25 psi) for natural gas. 5. Fuel selector in wrong position. 5. Move selector to correct position. 6. Choke remains closed. 6. Verify choke plate moves freely. The AUTO/OFF/MANUAL switch 1. Defective switch. 1. * is set to OFF, but the engine 2. AUTO/OFF/MANUAL switch 2. * continues to run. wired incorrectly. 3. Defective control board. 3. * There is no AC output from 1. Main line circuit breaker is in 1. Reset circuit breaker the generator. the OFF (or OPEN) position. to ON (or CLOSED). 2. Generator internal failure. 2. There is no transfer to 1. Defective transfer switch coil. 1. standby after utility 2. Defective transfer relay. 2. source failure. 3. Transfer relay circuit open. 3. 4. Defective control logic board. 4. Unit consumes large 1. Engine over filled with oil. 1. Adjust oil to proper level. amounts of oil. 2. Engine breather defective. 2. * 3. Improper type or viscosity of oil. 3. See"Engine Oil Recommendations". 4. Damaged gasket, seal or hose. 4. Check for oil leaks. *Contact the nearest Authorized Dealer for assistance. 26 27 28 29 Mounting Dimensions Drawing No. 1 • 299 Inel 747 698 129.41 127.51 O �302 207 11191 1821 TRANSFER SWITCH (IF SUPPLIED) uFnnlc r1oLEs 4 CORn!£Rs "DO NOT LIFT BY ROOF" r 604.5 993 1123.81 f46.971 0 7ns 128261 O O 624.6 1234.2 124.591 762m 13.001 148591 PEA GRAVEL LEFT SIDE VIEW N°M MUM FRONT VIEW 30 Drawing No. iF9424-D ' Mounting Dimiensions —Z AIR INTAKE 0 4 72 m MINIMUM DISTANCE AIR OUTLETS llaol 914m 136.01 ° MINIMUM OPEN AREA Q ON SIDES AND FRONT ° 0 390.8 MM 5� U5.381 'W®p AIR INTAKE o ❑ O o� 08.4 146.391 INLET- TOP HOLE 990cc ENGINE (1/2- NPTI BOTTOM HOLE 530cc AND 410cc ENGINES (VT NPT) NSE SUPPLIED ADAPTER) REOURED FUEL PRESSURE- NATURAL GAS = 5.7- WATER COLUMN LIQUID PROPANE (VAPORI = 10-W WATER COLUMN CABLE ACCESS HOLE ❑ 2741 1 ® ® O 360.8 79.5 0 114211 260.1 13.131 ROUNDING LUG 110241 � O RIGHT SIDE VIEW REAR VIEW ^ALL DIMENSIONS ]It MILLIMETERS [INCHES] 31 Warranty NOTE:This Emission Control Warranty Statement pertains to this product only IF the generator size is 15 kW or below. CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board(CARB)and Generac Power Systems,Inc. (Generac)are pleased to explain the Emission Control System Warranty on your new engine.* In California, new utility, and lawn and garden equipment engines must be designed, built and equipped to meet the state's stringent anti-smog standards. Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse,neglect,unapproved modification or improper maintenance of your engine. Your emission control system may include parts such as the carburetor,ignition system and exhaust system.Generac will repair your engine at no cost to you for diagnosis,replacement parts and labor,should a warrantable condition occur. MANUFACTURER'S EMISSION CONTROL SYSTEM WARRANTY COVERAGE: Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted.If, during such warranty period, any emission-related component or system on your engine is found to be defective in materials or workmanship,repairs or replacement will be performed by a Generac Authorized Warranty Service Facility. PURCHASER'S/OWNER'S WARRANTY RESPONSIBILITIES: As the engine purchaser/owner,you are responsible for the completion of all required maintenance as listed in your factory supplied Owner's Manual. For warranty purposes,Generac recommends that you retain all receipts covering maintenance on your engine.However,Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance. As the engine purchaser/owner,you should,however,be aware that Generac may deny any and/or all warranty coverage or responsibility if your engine, or a part/component thereof,has failed due to abuse,neglect,improper maintenance or unapproved modifications,or the use of counterfeit and/or"grey market"parts not made,supplied or approved by Generac. You are responsible for contacting a Generac Authorized Warranty Service Facility as soon as a problem occurs.The warranty repairs should be completed in a reasonable amount of time,not to exceed 30 days. Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility. To locate the Generac Authorized Warranty Service Facility nearest you,call our toll-free number: 1-800-333-1322 IMPORTANT NOTE:This warranty statement explains your rights and obligations under the Emission Control System Warranty(ECS Warranty),which is provided to you by Generac pursuant to California law. See also the "Generac Limited Warranties for Generac Power Systems, Inc.,"which is enclosed herewith on a separate sheet,also provided to you by Generac.The ECS Warranty applies only to the emission control system of your new engine.If there is any conflict in terms between the ECS Warranty and the Generac Warranty,the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine. Warranty service can be performed only by a Generac Authorized Warranty Service Facility.When requesting warranty service,evidence must be presented showing the date of the sale to the original purchaser/owner. If you have any questions regarding your warranty rights and responsibilities,you should contact Generac at one of the following addresses: For Air-cooled Product... For Liquid-cooled Product... ATTENTION WARRANTY DEPARTMENT ATTENTION WARRANTY DEPARTMENT GENERAL POWER SYSTEMS, INC. GENERAC POWER SYSTEMS, INC. P.O. BOX 297 211 MURPHY DRIVE WHITEWATER,WI 53190 EAGLE,WI 53119 Part 1 32 Warranty- EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty(ECS Warranty)for 1995 and later model year engines: (a)Applicability:This warranty shall apply to 1995 and later model year engines.The ECS Warranty Period shall begin on the date the new engine or equip- ment 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 subse- quent 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: a)Spark plug 1.2)LPG/Natural Gas carburetion assembly and its internal components. b)Ignition module a)Fuel controller(if so equipped) 4)Catalytic Muffler Assembly(if so equipped)including: b)Mixer and its gaskets(if so equipped) a)Muffler gasket c)Carburetor and its gaskets(if so equipped) b)Exhaust manifold d)Primary gas regulator(if so equipped) 5)Crankcase Breather Assembly including: e)LP liquid vaporizer(if so equipped) a)Breather connection tube 2)Air Induction System including: a)Intake pipe/manifold b)Air cleaner 3)Ignition System including: '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 33 GENERAC POWER SYSTEMS "THREE YEAR" LIMITED WARRANTY FOR "AIR-COOLED EMERGENCY AUTOMATIC STANDBY GENERATORS" For a period of three years from successful activation of the unit(one(1)year or one thousand hours,whichever occurs first,for units in international markets),Generac Power Systems, Inc.(Generac)warrants that its standby 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(s)which,upon examination,inspection and testing by Generac or an Authorized/Certified Generac Service Dealer,is found to be defective.Any equipment that the pur- chaser/owner claims to be defective must be examined by the nearest Authorized/Certified Generac Service Dealer.This warranty applies only to Generac emergency automatic standby generators used in"Standby"applications as Generac has defined Standby.Scheduled Maintenance,as outlined by the generator owner's manual,is highly recommended.This Scheduled Maintenance should be performed by an Authorized/Certified Generac Service Dealer.This will verify service has been performed on the unit throughout the warranty period. WARRANTY SCHEDULE UNITED STATES AND CANADA YEARS ONE and TWO-Limited comprehensive coverage on mileage,labor and parts listed. • All COMPONENTS YEAR THREE-Limited comprehensive coverage on parts listed • ALL COMPONENTS INTERNATIONAL YEAR ONE(or 1000 hours,whichever occurs first)-Limited comprehensive coverage on labor and parts listed. • All COMPONENTS Extended Warranties are not available on units sold into International Markets. GUIDELINES: 1. Warranty begins upon the successful activation of the unit 2. Unit should be Registered and Proof of Purchase and Maintenance must be available. 3. Warranty is transferable between ownership of original installation site. 4. Warranty only applies to permanently wired and mounted units. 5. Any and all warranty repairs and/or concerns,must be performed and/or addressed by an Authorized/Certified Generac Service Dealer,or branch thereof.Repairs or diagnostics per- formed by individuals other than Authorized/Certified Generac Service Dealers not authorized in writing by Generac will not be covered. 6. A Generac Transfer Switch is highly recommended to be used in conjunction with the generator set.If a Non-Generac Transfer Switch is substituted for use and directly causes dam- age to the generator set,no warranty coverage shall apply. 7. 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. 8. All warranty expense allowances are subject to the conditions defined in Generac's General Service Policy Manual. THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING: 1. Any unit built/manufacturer prior to April 2010. 2. Generac generators that utilize non-Generac replacement parts. 3. Costs of normal maintenance(i.e.tune-ups,associated part(s),adjustments,loose/leaking clamps,installation and start-up). 4. Units sold,rated or used for"Prime Power","Trailer Mounted"or"Rental Unit"applications as Generac has defined Prime Power,Trailer Mounted or Rental Unit.Contact a Generac Distributor for Prime Power,Trailer Mounted or Rental Unit definition. 5. Damage to generator system(including transfer switch)caused by improper installation or costs necessary to correct installation. 6. 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. 7. Fuel connections other than conventional utility company supplied natural gas systems or conventional LP vapor withdrawal systems. 8. Any failure caused by contaminated fuels,oils,coolants/antifreeze or lack of proper fuels,oils or coolants/antifreeze. 9. 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. 10. 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 fluid replacement to perform as designed.This warranty will not cover repair when normal use has exhausted the life of a part(s)or engine. 11. 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. 12. Damage related to rodent and/or insect infestation. 13. Products that are modified or altered in a manner not authorized by Generac in writing. 14. Covered warranty labor rates are based on normal working hours.Overtime,holiday,or emergency labor costs for repairs outside of normal business hours will be the responsibility of the customer. 15. 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). 16. Failure due to misapplication. 17. Telephone,cellular phone,facsimile,internet access or other communication expenses. 18. Living or travel expenses of person(s)performing service,except as specifically included within the terms of a specific unit warranty period. 19. Expenses related to"customer instruction"or troubleshooting where no manufacturing defect is found. 20. Rental equipment used while warranty repairs are being performed and/or overnight freight costs for replacement part(s). 21. Costs incurred for equipment used for removal and/or reinstallation of generator,(i.e.:cranes,hoists,lifts,etc.) 22. Planes,ferries,railroad,buses,helicopters,snowmobiles,snow-cats,off-road vehicles or any other mode of transport deemed abnormal. 23. 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.Any implied warranties which are allowed by law,shall be limited in duration to the terms of the express warranty provided herein.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 8 - Waukesha,WI 53187 Ph: (888) GENERAC (436-3722) • Fax: (262) 544-4851 To locate the nearest Authorized Dealer and to download schematics,exploded parts views and parts lists visit our website: www.generac.com Part No.OH8524 Revision B(05/10) Part No.OF9421 Revision M(11/10/10) Printed in U.S.A.