Generac Power Systems Portable Generator 04389 3 04456 3 04390 3 User Manual

Installation and  
Owner’s Manual  
Air-cooled, Prepackaged  
Automatic Standby Generators  
Models:  
C
US  
04389-3 (6 kW NG, 7 kW LP)  
04456-3 (12 kW NG, 12 kW LP)  
04390-3 (13 kW NG, 15 kW LP)  
L
ISTED  
Not intended for use as Primary Power in place of utility or in  
life-support applications.  
DANGER  
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!  
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Table of Contents  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
Introduction ........................Inside Front Cover  
Section 3 – Operation ....................................14  
3.1 Break-in Procedure .....................................14  
3.2 Using the Auto/Off/Manual Switch...............14  
3.3 Automatic Transfer Operation.....................15  
3.4 Sequence of Automatic Operation ...............15  
3.5 Manual Transfer Operation.........................16  
3.6 Setting the Exercise Timer ..........................17  
3.7 Protection Systems......................................17  
Read This Manual Thoroughly........................ IFC  
Contents.......................................................... IFC  
Operation and Maintenance ............................ IFC  
How to Obtain Service..................................... IFC  
Authorized Dealer Locator Number................... IFC  
Safety Rules ........................................................2  
Standards Index..................................................3  
Section 1 – General Information...................4  
1.1 Unpacking/Inspection....................................4  
1.2 Protection Systems........................................4  
Section 4 – Maintenance...............................18  
4.1 Fuses...........................................................18  
4.2 Checking the Engine Oil Level.....................18  
4.3 Changing the Engine Oil..............................19  
4.4 Changing the Oil Filter ................................19  
4.5 Changing the Engine Air Cleaner.................19  
4.6 Spark Plug(s) ..............................................20  
4.7 Battery Maintenance....................................20  
1.3 NEC Requirement for Arc Fault Circuit  
Interruption Breaker for Bedrooms ..............4  
1.4 The Generator...............................................5  
1.5 Specifications................................................6  
1.6 System Set LED ............................................7  
1.7 Fuel Requirements and Recommendations ...7  
1.8 Fuel Consumption.........................................7  
1.9 Reconfiguring the Fuel System ......................7  
1.10 Location ........................................................8  
1.11 Battery Installation........................................9  
1.12 The Battery ...................................................9  
4.8 Adjusting GH-410/GT-990/760  
Valve Clearance............................................21  
4.9 Cooling System ...........................................21  
4.10 Attention After Submersion.........................22  
4.11 Corrosion Protection...................................22  
4.12 Out of Service Procedure.............................22  
4.13 Service Schedule.........................................23  
Section 2 – Post Installation Start-up  
and Adjustments .......................10  
2.1 Before Initial Startup...................................10  
Section 5 – Troubleshooting........................ 24  
5.1 Troubleshooting Guide................................24  
2.2 Check Transfer Switch Operation ...............10  
2.3 Electrical Checks ........................................10  
2.4 Generator Tests Under Load.......................11  
2.5 Checking Automatic Operation....................11  
Section 6 – Notes ........................................... 25  
Section 7 – Electrical Data........................... 28  
Section 8 – Exploded Views and  
Parts Lists................................... 42  
Section 9 – Mounting Dimensions............. 63  
Section 10 – Warranty................................... 64  
2.6 Adjusting the Regulator  
(Natural Gas Only).......................................12  
2.7 Engine Governor Adjustment......................13  
2.8 Voltage Regulator Adjustment......................14  
1
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IMPORTANT SAFETY INSTRUCTIONS  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation  
be copied and posted near the unit’s installation site. Safety should be stressed to all opera-  
tors and potential operators of this equipment.  
WARNING:  
contains chemicals known to the state  
of California to cause cancer, birth  
defects or other reproductive harm.  
GENERAL HAZARDS  
The engine exhaust from this product  
For safety reasons, the manufacturer recommends  
that the installation, initial start-up and main-  
tenance of this equipment is carried out by an  
Authorized Dealer.  
• The engine exhaust fumes contain carbon monox-  
ide, which can be DEADLY. This dangerous gas, if  
breathed in sufficient concentrations, can cause  
unconsciousness or even death. This exhaust  
system must be installed properly, in strict com-  
pliance with applicable codes and standards.  
Following installation, do nothing that might ren-  
der the system unsafe or in noncompliance with  
such codes and standards.  
• Keep hands, feet, clothing, etc., away from drive  
belts, fans, and other moving or hot parts. Never  
remove any drive belt or fan guard while the unit  
is operating.  
WARNING:  
This product contains or emits chemicals  
known to the state of California to cause  
cancer, birth defects or other reproductive harm.  
Study these SAFETY RULES carefully before install-  
ing, operating or servicing this equipment. Become  
familiar with this Owner’s Manual and with the  
unit. The generator can operate safely, efficiently and  
reliably only if it is properly installed, operated and  
maintained. Many accidents are caused by failing to  
follow simple and fundamental rules or precautions.  
The manufacturer cannot anticipate every possible  
circumstance that might involve a hazard. The warn-  
ings in this manual, and on tags and decals affixed  
to the unit are, therefore, not all-inclusive. If using  
a procedure, work method or operating technique  
the manufacturer does not specifically recommend,  
ensure that it is safe for others. Also make sure the  
procedure, work method or operating technique uti-  
lized does not render the generator unsafe.  
• Adequate, unobstructed flow of cooling and venti-  
lating air is critical to correct generator operation.  
Do not alter the installation or permit even partial  
blockage of ventilation provisions, as this can seri-  
ously affect safe operation of the generator. The  
generator MUST be installed outdoors.  
• When working on this equipment, remain alert  
at all times. Never work on the equipment when  
physically or mentally fatigued.  
• Inspect the generator regularly, and contact the  
nearest Authorized Dealer for parts needing repair  
or replacement.  
• Before performing any maintenance on the gen-  
erator, disconnect its battery cables to prevent  
accidental start up. Disconnect the cable from the  
battery post indicated by a NEGATIVE, NEG or (–)  
first. Reconnect that cable last.  
• Never use the generator or any of its parts as a  
step. Stepping on the unit can stress and break  
parts, and may result in dangerous operating con-  
ditions from leaking exhaust gases, fuel leakage,  
oil leakage, etc.  
DANGER  
Despite the safe design of this generator,  
operating this equipment imprudently, neglecting  
its maintenance or being careless can cause  
possible injury or death. Permit only responsible  
and capable persons to operate or maintain this  
equipment.  
Potentially lethal voltages are generated by  
these machines. Ensure all steps are taken to  
render the machine safe before attempting to  
work on the generator.  
Parts of the generator are rotating and/or hot  
during operation. Exercise care near running  
generators.  
2
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IMPORTANT SAFETY INSTRUCTIONS  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
• Keep a fire extinguisher near the generator at all  
times. Extinguishers rated ABC” by the National  
Fire Protection Association are appropriate for  
use on the standby electric system. Keep the extin-  
guisher properly charged and be familiar with its  
use. Consult the local fire department with any  
questions pertaining to fire extinguishers.  
ELECTRICAL HAZARDS  
• All generators covered by this manual produce  
dangerous electrical voltages and can cause fatal  
electrical shock. Utility power delivers extremely  
high and dangerous voltages to the transfer switch  
as does the standby generator when it is in opera-  
tion. Avoid contact with bare wires, terminals,  
connections, etc., while the unit is running. Ensure  
all appropriate covers, guards and barriers are in  
place before operating the generator. If work must  
be done around an operating unit, stand on an  
insulated, dry surface to reduce shock hazard.  
• Do not handle any kind of electrical device while  
standing in water, while barefoot, or while hands or  
feet are wet. DANGEROUS ELECTRICAL SHOCK  
MAY RESULT.  
EXPLOSION HAZARDS  
• Do not smoke around the generator. Wipe up any  
fuel or oil spills immediately. Ensure that no com-  
bustible materials are left in the generator com-  
partment, or on or near the generator, as FIRE or  
EXPLOSION may result. Keep the area surround-  
ing the generator clean and free from debris.  
• Gaseous fluids such as natural gas and liquid pro-  
pane (LP) gas are extremely EXPLOSIVE. Install  
the fuel supply system according to applicable  
fuel-gas codes. Before placing the home standby  
electric system into service, fuel system lines must  
be properly purged and leak tested according to  
applicable code. After installation, inspect the fuel  
system periodically for leaks. No leakage is permit-  
ted.  
• The National Electrical Code (NEC) requires the  
frame and external electrically conductive parts of  
the generator to be connected to an approved earth  
ground. Local electrical codes also may require  
proper grounding of the generator electrical system.  
• After installing this home standby electrical sys-  
tem, the generator may crank and start at any  
time without warning. When this occurs, load cir-  
cuits are transferred to the STANDBY (generator)  
power source. To prevent possible injury if such a  
start and transfer occur, always set the generator’s  
Auto/Off/Manual switch to its OFF position before  
working on equipment and remove the 7.5A and  
15A fuses from the generator control panel.  
• In case of accident caused by electric shock, imme-  
diately shut down the source of electrical power. If  
this is not possible, attempt to free the victim from  
the live conductor. AVOID DIRECT CONTACT WITH  
THE VICTIM. Use a nonconducting implement,  
such as a dry rope or board, to free the victim from  
the live conductor. If the victim is unconscious,  
apply first aid and get immediate medical help.  
• Never wear jewelry when working on this equip-  
ment. Jewelry can conduct electricity resulting in  
electric shock, or may get caught in moving com-  
ponents causing injury.  
STANDARDS INDEX  
In the absence of pertinent standards, codes, regu-  
lations and laws, the published information listed  
below may be used as installation guide for this  
equipment.  
1. NFPA No. 37, STATIONARY COMBUSTION  
ENGINES AND GAS TURBINES, available from  
the National Fire Protection Association, 470  
Atlantic Avenue, Boston, MA 02210.  
2. NFPA No. 76A, ESSENTIAL ELECTRICAL  
SYSTEMS FOR HEALTH CARE FACILITIES,  
available same as Item 1.  
3. NFPA No. 54, NATIONAL FUEL GAS CODE,  
available same as Item 1.  
4. NFPA No. 58, AMERICAN NATIONAL STANDARD  
FOR STORAGE AND HANDLING OF LIQUEFIED  
PETROLEUM GAS, available same as Item 1.  
5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL  
ELECTRIC CODE, available same as Item 1.  
6. Article X, NATIONAL BUILDING CODE, available  
from the American Insurance Association, 85  
John Street, New York, N.Y. 10038.  
FIRE HAZARDS  
For fire safety, the generator must be installed  
and maintained properly. Installation always must  
comply with applicable codes, standards, laws  
and regulations. Adhere strictly to local, state and  
national electrical and building codes. Comply  
with regulations the Occupational Safety and  
Health Administration (OSHA) has established.  
Also, ensure that the generator is installed in  
accordance with the manufacturer’s instructions  
and recommendations. Following proper installa-  
tion, do nothing that might alter a safe installation  
and render the unit in noncompliance with the  
aforementioned codes, standards, laws and regula-  
tions.  
7. AGRICULTURAL WIRING HANDBOOK, avail-  
able from the Food and Energy Council, 909  
University Avenue, Columbia, MO 65201.  
8. ASAE  
EP-3634,  
INSTALLATION  
AND  
MAINTENANCEOFFARMSTANDBYELECTRICAL  
SYSTEMS, available from the American Society  
of Agricultural Engineers, 2950 Niles Road, St.  
Joseph, MI 49085.  
9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE  
LIQUIDS CODE, available same as Item 1.  
3
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Section 1 — General Information  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
There are LED readouts on the control panel to notify  
DANGER  
personnel that one of these faults has occurred.  
There is also a “System Set” LED that is lit when all  
of the conditions describe in Section 1.3 are true.  
Only qualified electricians or contractors should  
attempt such installations, which must comply  
strictly with applicable codes, standards and  
regulations.  
1.3 NEC REQUIREMENT FOR ARC  
FAULT CIRCUIT INTERRUPTION  
1.1 UNPACKING/INSPECTION  
After unpacking, carefully inspect the contents for  
damage.  
BREAKER FOR BEDROOMS  
In 2001, the National Electric Code (NEC) intro-  
duced a requirement for new construction. This new  
requirement indicates the need for Arc Fault Circuit  
Interrupters to be used to protect the complete  
branch circuit that feeds a dwelling bedroom. The  
actual NEC requirement is indicated below.  
• This standby generator set has been factory sup-  
plied with a weather protective enclosure that is  
intended for outdoor installation only.  
• This UL listed standby generator set is packaged  
with an automatic transfer switch with built in  
load center. The combination transfer switch and  
load center is pre-wired with a two foot and 30 foot  
conduit. Circuit breakers for emergency circuit  
connections are included.  
1.3.1 SECTION 210.12 ARC FAULT CIRCUIT  
INTERRUPTER PROTECTION  
1. Definition: An arc fault circuit interrupter is a  
device intended to provide protection from the  
effects of arc faults by recognizing characteristics  
unique to arcing and by functioning to de-ener-  
gize the circuit when an arc fault is detected.  
2. Dwelling Unit Bedrooms: All branch circuits that  
supply 125 volt, single-phase, 15 and 20 ampere  
outlets installed in dwelling unit bedrooms shall  
be protected by an arc fault circuit interrupter  
listed to provide protection of the entire branch  
circuit.  
Section 210.12 requires that AFCI protection be  
provided on branch circuits that supply outlets  
(receptacle, lighting, etc.) in dwelling bedrooms. The  
requirement is limited to 15 and 20 ampere, 125  
volt circuits. There is no prohibition against provid-  
ing AFCI protection on other circuits or in locations  
other than bedrooms. Because circuits are often  
shared between a bedroom and other areas such as  
closets and hallways, providing AFCI protection on  
the complete circuit would comply with 210.12.  
• This UL listed, 2-pole switch is rated at 100 AC  
amperes at 250 volts maximum. This transfer  
switch is for indoor use only.  
If this generator is used to power electrical load  
circuits normally powered by a utility power  
source, it is required by code to install a trans-  
fer switch. The transfer switch must effectively  
isolate the electrical system from the utility dis-  
tribution system when the generator is operat-  
ing (NEC 700, 701 & 702). Failure to isolate an  
electrical system by such means will result in  
damage to the generator and also may result in  
injury or death to utility power workers due to  
backfeed of electrical energy.  
If any loss or damage is noted at time of delivery, have  
the person(s) making the delivery note all damage  
on the freight bill or affix their signature under the  
consignor's memo of loss or damage.  
If during the installation of the home standby system  
the decision is made to provide back up power to a  
bedroom branch circuit, then the circuit breaker in  
the transfer switch should be replaced with an Arc  
Fault Circuit Interrupter.  
If a loss or damage is noted after delivery, separate  
the damaged materials and contact the carrier for  
claim procedures.  
“Concealed damage” is understood to mean damage  
to the contents of a package that is not in evidence at  
the time of delivery, but is discovered later.  
It is most important that breakers only be switched  
like for like. For instance, if replacing a 15A breaker,  
it MUST be replaced with a 15A AFCI breaker.  
Likewise, a 20A breaker MUST be replaced with a  
20A AFCI.  
1.2 PROTECTION SYSTEMS  
Unlike an automobile engine, the generator may have  
to run for long periods of time with no operator pres-  
ent to monitor engine conditions. For that reason, the  
engine is equipped with the following systems that  
protect it against potentially damaging conditions:  
These AFCI breakers are available at the nearest  
Home Depot or hardware store.  
Siemens Item #  
Q115AF  
Description  
15A Single Pole AFCI  
20A Single Pole AFCI  
1. Low Oil Pressure Sensor  
2. High Temperature Sensor  
3. Overcrank  
4. Overspeed  
Q120AF  
4
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Section 1 — General Information  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
1.4 THE GENERATOR  
Figure 1.1 – 7 kW, Single Cylinder GH-410 Engine  
Control  
Panel  
Oil  
Dipstick  
Data  
Decal  
GFCI  
Outlet  
Exhaust  
Enclosure  
Fuel  
Regulator  
Fuel  
Inlet  
Battery  
Compartment  
Oil Filter  
Figure 1.2 – 12 kW and 15 kW, V-twin GT-990/760 Engine  
Control  
Panel  
Oil  
Dipstick  
Data  
Decal  
GFCI  
Outlet  
Exhaust  
Enclosure  
Fuel  
Regulator  
Fuel  
Inlet  
Composite Base  
Battery  
Compartment  
Oil Filter  
5
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Section 1 — General Information  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
1.5 SPECIFICATIONS  
1.5.1 GENERATOR  
Model 04389  
Model 04456  
Model 04390  
Rated Max. Continuous Power  
6,000 NG/7,000 LP  
12,000 NG/12,000 LP  
13,000 NG/15,000 LP  
Capacity (Watts*)  
Rated Voltage  
120/240  
120/240  
120/240  
Rated Max. Continuous Load  
Current (Amps)  
120 Volts**  
50.0 NG/58.3 LP  
100.0 NG/100.0 LP  
108.3 NG/125.0 LP  
240 Volts  
25.0 NG/29.2 LP  
50.0 NG/50.0 LP  
54.2 NG/62.5 LP  
Main Line Circuit Breaker  
Phase  
30 Amp  
50 Amp  
65 Amp  
1
1
1
Number of Rotor Poles  
Rated AC Frequency  
Power Factor  
2
2
2
60 Hz  
1
60 Hz  
1
60 Hz  
1
Recommended Air Filter  
Battery Requirement  
Part # 0C8127  
Group 26/26R  
12 Volts and  
Part # 0C8127  
Group 26/26R  
12 Volts and  
Part # 0C8127  
Group 26/26R  
12 Volts and  
350 Cold-cranking  
Amperes Minimum  
525 Cold-cranking  
Amperes Minimum  
525 Cold-cranking  
Amperes Minimum  
Weight  
375 Pounds  
470 Pounds  
487 Pounds  
Output Sound Level @  
23 ft (7m) at full load  
68 db (A)  
70.5 db (A)  
71.5 db (A)  
Normal Operating Range  
-20°F (-28.8°C) to 104°F (40°C)  
* Maximum wattage and current are subject to and limited by such factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc. Maximum power  
decreases about 3.5 percent for each 1,000 feet above sea level; and also will decrease about 1 percent for each 6° C (10° F) above 16° C (60° F) ambient temperature.  
** Load current values shown for 120 volts are maximum TOTAL values for two separate circuits. The maximum current in each circuit must not exceed the value stated for 240  
volts.  
1.5.2 ENGINE  
Model 04389  
GH-410  
Model 04456  
GT-760  
Model 04390  
GT-990  
Type of Engine  
Number of Cylinders  
Rated Horsepower  
Displacement  
1
2
2
14.5 @ 3,600 rpm  
410cc  
26 @ 3,600 rpm  
763cc  
30 @ 3,600 rpm  
992cc  
Cylinder Block  
Aluminum w/Cast  
Iron Sleeve  
Aluminum w/Cast  
Iron Sleeve  
Aluminum w/Cast  
Iron Sleeve  
Valve Arrangement  
Ignition System  
Recommended Spark Plug  
Spark Plug Gap  
Compression Ratio  
Starter  
Overhead Valves  
Solid-state w/Magneto  
RC14YC  
0.76 mm (0.030 inch)  
8.6:1  
Overhead Valves  
Solid-state w/Magneto  
RC12YC  
0.508 mm (0.020 inch)  
9.5:1  
Overhead Valves  
Solid-state w/Magneto  
RC12YC  
0.508 mm (0.020 inch)  
9.5:1  
12 Vdc  
12 Vdc  
12Vdc  
Oil Capacity Including Filter  
Recommended Oil Filter  
Recommended Air Filter  
Operating RPM  
Approx. 1.5 Qts  
Part # 070185B  
Part # 0C8127  
3,600  
Approx. 1.7 Qts  
Part # 070185B  
Part # 0C8127  
3,600  
Approx. 1.7 Qts  
Part # 070185B  
Part # 0C8127  
3,600  
6
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Section 1 — General Information  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
1.6 SYSTEM SET LED  
DANGER  
The “System Set” LED is lit when all of the following  
conditions are true:  
Gaseous fuels such as natural gas and liquid  
propane (LP) gas are highly explosive. Even the  
slightest spark can ignite such fuels and cause  
an explosion. No leakage of fuel is permitted.  
Natural gas, which is lighter than air, tends to  
collect in high areas. LP gas is heavier than air  
and tends to settle in low areas.  
1. The AUTO/OFF/MANUAL switch is set to the  
AUTO position.  
2. The utility voltage being supplied to the unit is  
being sensed by the PCB. If the utility sense volt-  
age is not connected to the unit or if it is below  
168 volts AC, then the system set light will flash  
rapidly. This indicates that if the AUTO/OFF/  
MANUAL switch is placed in the Auto position,  
the generator will start.  
1.9 RECONFIGURING THE  
FUEL SYSTEM  
3. The “Not In Auto” dip switch is set to the OFF  
position on the control board.  
1.9.1 7 KW, 410CC ENGINE  
To reconfigure the fuel system from NG to LP,  
follow these steps (Figure 1.3):  
4. No alarms are present, for example, low oil pres-  
sure, high temperature, etc.  
1.7 FUEL REQUIREMENTS  
NOTE:  
AND RECOMMENDATIONS  
The primary regulator for the propane supply is  
NOT INCLUDED with the generator. A fuel pres-  
sure of 10 to 12 inches of water column (0.36 to  
0.43 psi) to the fuel inlet of the generator MUST  
BE SUPPLIED.  
With LP gas, use only the vapor withdrawal  
system. This type of system uses the vapors formed  
above the liquid fuel in the storage tank.  
The engine has been fitted with a fuel carburetion  
system that meets the specifications of the 1997  
California Air Resources Board for tamper-proof  
dual fuel systems. The unit will run on natural gas or  
LP gas, but it has been factory set to run on natural  
gas. Should the primary fuel need to be changed to  
LP gas, the fuel system needs to be reconfigured. See  
Section 1.9 for instructions on reconfiguration of the  
fuel system.  
1. Turn off the main gas supply (if connected).  
2. Open the roof and remove the door.  
3. Remove the battery (if installed).  
4. Disconnect wire #0 and wire #14 from the gas  
solenoid on top of the demand regulator.  
5. Remove the carburetor fuel hose from the outlet  
port of the demand regulator.  
6. Remove the demand regulator by removing the  
fastener that retains the regulator mounting  
bracket.  
7. Remove the square headed steel pipe plug from  
outlet port #1 and the brass hose barb fitting  
from outlet port #2.  
Recommended fuels should have a Btu content of at  
least 1,000 Btus per cubic foot for natural gas; or at  
least 2,520 Btus per cubic foot for LP gas. Ask the  
fuel supplier for the Btu content of the fuel.  
Required fuel pressure for natural gas is 5 inches to  
7 inches water colum (0.18 to 0.25 psi); and for  
liquid propane, 10 inches to 12 inches of water  
column (0.36 to 0.43 psi).  
Figure 1.3 – Demand Regulator  
HOSE & PLUG  
SWITCHED SIDES  
NOTE:  
Any piping used to connect the generator to the  
fuel supply should be of adequate size to ensure  
the fuel pressure NEVER drops below 4 inches  
water colum for natural gas or 10 inches water  
column for liquid propane for all load ranges.  
FUEL HOSE  
PIPE  
PLUG  
FUEL HOSE  
BRASS HOSE  
FITTING  
BRASS HOSE  
FITTING  
OUTLET  
PORT  
ADJUSTMENT  
SCREW  
FUEL JET  
1.8 FUEL CONSUMPTION  
Model #  
Nat. Gas (*)  
LP Vapor (**)  
1/2 Load Full Load  
1/2 Load  
Full Load  
1.47/54  
2.08/76  
2.40/88  
04389  
04456  
04390  
66  
119  
215  
220  
0.82/30  
1.53/56  
1.58/58  
152  
156  
*Natural gas is in cubic feet per hour.  
**LP is in gallons per hour/cubic feet per hour.  
*** Values given are approximate.  
NG FUEL SYSTEM  
LP FUEL SYSTEM  
7
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Section 1 — General Information  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
8. Refit the brass hose barb fitting to outlet port #1  
13. To adjust the system to run on LP fuel, turn  
BOTH adjuster screws 1/2 TURN CLOCKWISE.  
The system should now be set for maximum  
power and best perfomance. DO NOT, UNDER  
ANY CIRCUMSTANCES, REMOVE THE SET  
PINS FROM THE REGULATOR HOUSING.  
THIS WILL VOID THE WARRANTY.  
14. It may be necessary to make minor adjustments  
to the preset adjustment screw settings to achieve  
maximum power, particularly at higher altitudes.  
If experiencing problems with the unit producing  
maximum power, follow the procedure in Section  
2.6 (Adjusting the Fuel Regulator).  
and the square headed steel pipe plug to outlet  
port #2.  
9. Reverse procedure steps 1-5 to reinstall demand  
regulator.  
10. Take the plastic plug supplied in the poly-bag  
with the generator and press it into the 3/4” hole  
on the bottom of the air cleaner base (Figure  
4.6).  
11. Reverse the procedure to convert back to natural  
gas.  
1.9.2 12KW AND 15KW, V-TWIN ENGINES  
To reconfigure the fuel system from NG to LP, follow  
Figure 1.4 - Demand Regulator  
these steps:  
NOTE:  
OUTLET PORTS  
FUEL HOSE  
The primary regulator for the propane supply is  
NOT INCLUDED with the generator. A fuel pres-  
sure of 10 to 12 inches of water column (0.36 to  
0.43 psi) to the fuel inlet of the generator MUST  
BE SUPPLIED.  
BRASS HOSE  
FITTING  
IDLE CIRCUIT  
BRASS HOSE  
SMALL  
FUEL JET  
PORT  
FITTING  
1
NP  
REGULATOR  
HOUSING PORT  
ADJUSTER  
SCREWS  
1. Turn off the gas supply. (if connected)  
2. Open the roof and remove the door.  
3. Remove the battery. (if installed)  
4. Remove the engine air in baffle located on the left-  
hand side of the battery compartment. Two M6  
screws are located on top of the baffle and two  
M6 screws are located on the inside of the baffle  
towards the back.  
1.10 LOCATION  
5. Remove the small hose clamp and hose from the  
fuel regulator. It may be necessary to pry the hose  
off of the brass fitting using a screwdriver to gen-  
tly lift up the hose edge.  
1.10.1 GENERATOR  
Install the generator set, in its protective enclosure,  
outdoors, where adequate cooling and ventilating air  
is always available. Consider these factors:  
6. Remove the small brass hose fitting from the  
regulator casting.  
• Install the unit where air inlet and outlet open-  
ings will not become obstructed by leaves, grass,  
snow, etc. If prevailing winds will cause blowing or  
drifting, consider using a windbreak to protect the  
unit.  
7. Place the small fuel jet, thread side first, into the  
threaded hole originally occupied by the brass  
hose fitting (Figure 1.4).  
8. Using a short No. 2 Phillips screw driver, thread  
the small fuel jet into the regulator casting. Do  
not over tighten.  
• Install the generator on high ground where water  
levels will not rise and endanger it.  
• Allow sufficient room on all sides of the generator  
for maintenance and servicing. A good rule is to  
allow three feet of space on all sides.  
• Where strong prevailing winds blow from one  
direction, face the generator air inlet openings to  
the prevailing winds.  
9. Apply thread sealant to the threads of the hose  
fitting and replace it into the regulator body.  
10. Re-attach the small hose and hose clamp and  
tighten as necessary.  
11. Replace the engine air in baffle using the four M6  
screws.  
• Install the generator as close as possible to the fuel  
12. Identify both brass adjustment screws on the  
regulator.  
supply, to reduce the length of piping.  
• Install the generator as close as possible to  
the transfer switch. HOWEVER, REMEMBER  
THAT LAWS OR CODES MAY REGULATE THE  
DISTANCE.  
The genset must be installed on a level surface. The  
base frame must be level within two (2) inches all  
around.  
NOTE:  
One adjustment screw can be accessed from the  
front of the unit and the second can be accessed  
from the back of the unit enclosure by removing  
the plastic hole plug. The screw can be turned  
with a long flat blade screwdriver.  
8
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Section 1 — General Information  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
4. Connect the red battery cable (from starter con-  
1.10.2 TRANSFER SWITCH  
tactor) to the battery post indicated by a positive,  
POS or (+).  
1.10.2.1 7 kW, 12 kW and 15 kW Units  
5. Connect the black battery cable (from frame  
ground) to the battery post indicated by a nega-  
tive, NEG or (—).  
The transfer switch shipped with this generator is  
enclosed in a NEMA 1 enclosure. This type of enclo-  
sure is intended for indoor use only. Follow these  
rules:  
NOTE:  
Damage will result if battery connections are made  
• Install the transfer switch indoors on a firm, sturdy  
supporting structure.  
To prevent switch distortion, level the switch if  
necessary. This can be done by placing washers  
between the switch enclosure and mounting sur-  
face.  
• Never install the switch where water or any corro-  
sive substance might drip onto the enclosure.  
• Protect the switch at all times against excessive  
moisture, dust, dirt, lint, construction grit and cor-  
rosive vapors.  
in reverse.  
NOTE:  
The generator is equipped with a battery trickle  
charger that is active when the unit is set up for  
automatic operation. With the battery installed  
and utility power source voltage available to the  
transfer switch, the battery receives a trickle  
charge while the engine is not running, to prevent  
self-discharge. The trickle charger is designed to  
help extend the life of the battery by maintain-  
ing the battery when the unit is not running. The  
trickle charge feature cannot be used to recharge  
a discharged battery.  
If the AUTO/OFF/MANUAL switch is not set to its  
OFF position, the generator can crank and start  
as soon as the battery cables are connected. If  
the utility power supply is not turned off, spark-  
ing can occur at the battery posts and cause an  
explosion.  
1.12 THE BATTERY  
DANGER  
Do not dispose of the battery in a fire. The  
battery is capable of exploding.  
1.11 BATTERY INSTALLATION  
Fill the battery with the proper electrolyte fluid if  
necessary and have the battery fully charged before  
installing it.  
A battery presents a risk of electrical shock  
and high short circuit current. The following pre-  
cautions are to be observed when working on  
batteries:  
Before installing and connecting the battery, complete  
the following steps:  
• Remove the 7.5A and 15A fuses from the genera-  
tor control panel.  
• Remove watches, rings or other metal objects;  
• Use tools with insulated handles;  
• Wear rubber gloves and boots;  
• Do not lay tools or metal parts on top of the  
battery; and  
1. Set the generator's AUTO/OFF/MANUAL switch to  
OFF.  
2. Turn off utility power supply to the transfer  
switch.  
3. Remove the 7.5A and 15A fuses from the genera-  
tor control panel.  
Battery cables were factory connected at the genera-  
tor (Figure 1.5). Connect cables to battery posts as  
follows:  
• Disconnect charging source prior to connecting or  
disconnecting battery terminals.  
Do not open or mutilate the battery. Released  
Figure 1.5 – Battery Cable Connections  
electrolyte has been known to be harmful to the  
skin and eyes, and to be toxic.  
The electrolyte is a dilute sulfuric acid that is  
harmful to the skin and eyes. It is electrically  
conductive and corrosive.  
The following procedures are to be observed:  
• Wear full eye protection and protective clothing;  
• Where electrolyte contacts the skin, wash it off  
immediately with water;  
• Where electrolyte contacts the eyes, flush  
thoroughly and immediately with water and seek  
medical attention; and  
9
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Section 2 — Post Installation Start-up and Adjustments  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
5. Check the engine crankcase oil level and, if neces-  
• Spilled electrolyte is to be washed down with an  
acid neutralizing agent. A common practice is to  
use a solution of 1 pound (500 grams) bicarbonate  
of soda to 1 gallon (4 liters) of water. The bicar-  
bonate of soda solution is to be added until the  
evidence of reaction (foaming) has ceased. The  
resulting liquid is to be flushed with water and the  
area dried.  
sary, fill to the dipstick FULL mark with the rec-  
ommended oil. Do not fill above the FULL mark.  
6. Check the fuel supply. Gaseous fuel lines must  
have been properly purged and leak tested in  
accordance with applicable fuel-gas codes. All  
fuel shutoff valves in the fuel supply lines must  
be open.  
Lead-acid batteries present a risk of fire because  
they generate hydrogen gas. The  
following procedures are to be followed:  
Never operate the engine with the oil level  
• DO NOT SMOKE when near the battery;  
• DO NOT cause flame or spark in battery area; and  
• Discharge static electricity from body before touch-  
ing the battery by first touching a grounded metal  
surface.  
below the “Add” mark on the dipstick. Doing  
this could damage the engine.  
2.2 CHECK TRANSFER SWITCH  
OPERATION  
Be sure the AUTO/OFF/MANUAL switch is set to  
Refer to Section 3.5, of the owner’s manual for man-  
ual operation procedures.  
the OFF position before connecting the battery  
cables. If the switch is set to AUTO or MANUAL,  
the generator can crank and start as soon as the  
battery cables are connected.  
DANGER  
Be sure the utility power supply is turned off  
Do not attempt manual transfer switch opera-  
tion until all power voltage supplies to the  
transfer switch have been positively turned off.  
Failure to turn off all power voltage supplies  
will result in extremely hazardous and possibly  
fatal electrical shock.  
and the 7.5A and 15A fuses are removed from  
the generator control panel, or sparking may  
occur at the battery posts as the cables are  
attached and cause an explosion.  
Servicing of the battery is to be performed or super-  
vised by personnel knowledgeable of batteries and  
the required precautions. Keep unauthorized person-  
nel away from batteries.  
2.3 ELECTRICAL CHECKS  
Complete electrical checks as follows:  
When replacing the battery, use the following type of  
battery: Group 26/26R 12-volt DC, negative ground  
battery with a rating of 350 cold-cranking amps mini-  
mum for 7 kW; 525 cold-cranking amps minimum  
for 12 and 15 kW at -17.8º C (0º F) minimum. When  
using a maintenance-free battery, it is not necessary  
to check the specific gravity or electrolyte level. Have  
these procedures performed at the intervals specified  
in the “Service Schedule.” A negative ground system  
is used. Battery connections are shown on the wiring  
diagrams. Make sure the battery is correctly connect-  
ed and terminals are tight. Observe battery polarity  
when connecting the battery to the generator set.  
1. Set the generator's main circuit breaker to its  
OFF (or open) position.  
2. Set the generator's Auto/Off/Manual switch to the  
OFF position.  
3. Turn OFF all loads connected to the transfer  
switch terminals T1 and T2.  
4. Turn on the utility power supply to the transfer  
switch using the means provided (such as a utility  
main line circuit breaker).  
DANGER  
The transfer switch is now electrically “hot.”  
Contact with “hot” parts will result in extremely  
2.1 BEFORE INITIAL START-UP  
hazardous and possibly fatal electrical shock.  
Proceed with caution.  
Before starting, complete the following:  
5. Use an accurate AC voltmeter to check utility  
power source voltage across transfer switch ter-  
minals N1 and N2. Nominal line-to-line voltage  
should be 240 volts AC.  
6. Check utility power source voltage across termi-  
nals N1 and the transfer switch neutral lug; then  
across terminal N2 and neutral. Nominal line-to-  
neutral voltage should be 120 volts AC.  
1. Set the generator’s main circuit breaker to its  
OFF (or open) position.  
2. Set the generator's AUTO/OFF/MANUAL switch to  
the OFF position.  
3. Turn OFF the utility power supply to the transfer  
switch using the means provided (such as the  
utility main line circuit breaker).  
4. Turn OFF all loads connected to the transfer  
switch terminals T1 and T2.  
10  
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Section 2 — Post Installation Start-up and Adjustments  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
7. When certain that utility supply voltage is compat-  
ible with transfer switch and load circuit ratings,  
turn OFF the utility power supply to the transfer  
switch.  
Do not attempt manual transfer switch opera-  
tion until all power voltage supplies to the  
transfer switch have been positively turned off.  
Failure to turn off all power voltage supplies  
will result in extremely hazardous and possibly  
fatal electrical shock.  
8. On the generator panel, set the AUTO/OFF/  
MANUAL switch to MANUAL. The engine should  
crank and start.  
9. Let the engine warm up for about five minutes to  
allow internal temperatures to stabilize. Then, set  
the generator’s main circuit breaker to its ON (or  
CLOSED) position.  
5. Manually set the transfer switch to the STANDBY  
position, i.e., load terminals connected to the  
generator's E1/E2 terminals. The transfer switch  
operating lever should be down.  
6. Set the generator's AUTO/OFF/MANUAL switch  
to MANUAL. The engine should crank and start  
immediately.  
DANGER  
Proceed with caution! Generator power voltage  
is now supplied to the transfer switch. Contact  
with live transfer switch parts will result in dan-  
gerous and possibly fatal electrical shock.  
7. Let the engine stabilize and warm up for a few  
minutes.  
10. Connect an accurate AC voltmeter and a fre-  
quency meter across transfer switch terminal  
lugs E1 and E2. Voltage should be 242-252 volts;  
frequency should read about 61-63 Hertz.  
11. Connect the AC voltmeter test leads across ter-  
minal lug E1 and neutral; then across E2 and  
neutral. In both cases, voltage reading should be  
121-126 volts AC.  
12. Set the generator’s main circuit breaker to its  
OFF (or open) position. Let the engine run at no-  
load for a few minutes to stabilize internal engine  
generator temperatures.  
8. Set the generator’s main circuit breaker to its ON  
(or closed) position. Loads are now powered by  
the standby generator.  
9. Turn ON electrical loads connected to transfer  
switch T1 and T2. Apply an electrical load equal  
to the full rated wattage/amperage capacity of the  
installed generator.  
10. Connect an accurate AC voltmeter and a frequen-  
cy meter across terminal lugs E1 and E2. Voltage  
should be greater than 230 volts; frequency  
should be greater than 58 Hertz.  
11. Let the generator run at full rated load for 20-30  
minutes. Listen for unusual noises, vibration or  
other indications of abnormal operation. Check  
for oil leaks, evidence of overheating, etc.  
12. When testing under load is complete, turn OFF  
electrical loads.  
13. Set the generator's AUTO/OFF/MANUAL switch to  
OFF. The engine should shut down.  
NOTE:  
It is important not to proceed until certain that  
generator AC voltage and frequency are correct  
and within the stated limits. Generally, if both AC  
frequency and voltage are high or low, the engine  
governor requires adjustment. If frequency is cor-  
rect, but voltage is high or low, the generator’s  
voltage regulator requires adjustment.  
13. Set the generator's main circuit breaker to its  
OFF (or OPEN) position.  
14. Let the engine run at no-load for a few minutes.  
15. Set the AUTO/OFF/MANUAL switch to OFF. The  
engine should shut down.  
2.5 CHECKING AUTOMATIC  
2.4 GENERATOR TESTS UNDER LOAD  
To test the generator set with electrical loads applied,  
proceed as follows:  
OPERATION  
To check the system for proper automatic operation,  
proceed as follows:  
1. Set generator’s main circuit breaker to its OFF  
(or OPEN) position.  
1. Set generator’s main circuit breaker to its OFF  
(or OPEN) position.  
2. Turn OFF all loads connected to the transfer  
switch terminals T1 and T2.  
2. Check that the AUTO/OFF/MANUAL switch is set  
3. Set the generator's AUTO/OFF/MANUAL switch to  
OFF.  
4. Turn OFF the utility power supply to the transfer  
switch, using the means provided (such as a util-  
ity main line circuit breaker).  
to OFF.  
3. Turn OFF the utility power supply to the transfer  
switch, using means provided (such as a utility  
main line circuit breaker).  
4. Manually set the transfer switch to the UTILITY  
position, i.e., load terminals connected to the util-  
ity power source side.  
11  
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Section 2 — Post Installation Start-up and Adjustments  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
5. Turn ON the utility power supply to the transfer  
5. The fuel regulator is fitted with one (7 kW), or two  
(12 & 15 kW) adjustment screws. While watch-  
ing the frequency meter, slowly turn the adjust-  
ment screws clockwise or counterclockwise one  
at a time until the highest frequency is read on  
the meter. Only limited adjustment is available  
because of the set pin. Under no circumstances  
should any of the pins be removed (Figures 2.1  
and 2.2).  
switch, using the means provided (such as a util-  
ity main line circuit breaker).  
6. Set the AUTO/OFF/MANUAL switch to AUTO. The  
system is now ready for automatic operation.  
7. Turn OFF the utility power supply to the transfer  
switch.  
With the AUTO/OFF/MANUAL switch at AUTO, the  
engine should crank and start when the utility source  
power is turned OFF. After starting, the transfer  
switch should connect load circuits to the standby  
side. Let the system go through its entire automatic  
sequence of operation.  
Figure 2.1 — Dual Fuel Regulators  
V-twin  
410  
With the generator running and loads powered by  
generator AC output, turn ON the utility power supply  
to the transfer switch. The following should occur:  
Adjustment  
Adjustment  
Screw  
(Both Sides)  
Set  
Pin  
• After about 13 seconds, the switch should transfer  
loads back to the utility power source.  
• About one minute after retransfer, the engine  
should shut down.  
Screw  
(One Side  
Only)  
Set Pin  
(Both Sides)  
2.6 ADJUSTING THE REGULATOR  
(NATURAL GAS ONLY)  
6. When the highest frequency is reached maximum  
power has been set. From this point turn both  
adjustment screws 1/4 turn counterclockwise.  
The regulator is now set.  
Although the generator has been factory set to pro-  
vide maximum power, it may be necessary in some  
areas to adjust this setting. Because natural gas has  
different BTU or power content across the country  
the engine may not perform as designed.  
Figure 2.2 — Placement of Regulator  
If experiencing engine problems at high or full load  
conditions follow these steps. It will require a fre-  
quency meter to perform this procedure.  
1. Turn off utility power to the main distribution  
panel in the house. This can be done by switching  
the service main breaker to the off or open posi-  
tion.  
2. Allow the generator to start. Before loading the  
generator, confirm that the No Load Frequency,  
with the roof open and door off, is set to 63-63.5  
Hz. Transfer load to emergency circuits.  
3. Turn on appliances, lights, pumps, etc., that are  
on the emergency circuits in an attempt to fully  
load the generator. Be cautious not to overload  
the generator. Use the following chart as a guide:  
Adjustment Screw  
Unit  
7 kW  
12 kW  
13 kW  
120 Volts  
50.0 amps  
100.0 amps  
108.3 amps  
240 Volts  
25.0 amps  
50.0 amps  
54.1 amps  
7. Turn utility power to the main distribution panel  
back on. This can be done by switching the ser-  
vice main breaker to the on or closed position.  
Allow the generator to shut down.  
4. When 3/4 load has been achieved. Connect a fre-  
quency meter to the output lugs of the generator’s  
main line circuit breaker.  
Do not make any unnecessary adjustments.  
Factory settings are correct for most applica-  
tions. However, when making adjustments, be  
careful to avoid overspeeding the engine.  
12  
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Section 2 — Post Installation Start-up and Adjustments  
Air-cooled 7 kW, 12 kW and 15 kW Generators  
If this procedure or the equipment are not available,  
locate the nearest Dealer and they can perform the  
adjustments.  
2.7.2 12 KW AND 15 KW UNITS  
1. Loosen governor clamp bolt (See Figure 2.4).  
2. Completely remove the idle spring.  
3. With governor arm at wide open throttle position,  
rotate governor shaft fully clockwise. Tighten  
clamp bolt to 84 inch-pounds.  
NOTE:  
A service fee may be charged for this adjustment.  
4. Start