Eaton 10KW Owner's manual

Owner’s Manual

8, 10, 14, 17 & 20kW Air-cooled,

Automatic Standby Generators

DANGER

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!

Not intended for use as Primary Power in place of utility

or in l ife-support applications.

 

L

I

S

T

E

D

C

U

S

DO NOT LIFT UNIT BY ROOF!

INTRODUCTION

Thank you for purchasing this co

m

pact, high per for

m

ance, air-

c ooled, engine-dr iven generator. It is designed to auto

m

atical ly

supply electr ical power to operate critical loads dur ing a uti lity

power failure.

This unit is factory installed in an all-weather,

m

et al enclosure that

is intended exclusively for outdoor installation. This generator

will operate using either vapor withdrawn liquid propane

(

L

P

)

or

natural gas

(

N

G

)

.

NOTE:

This generator is suitable for supplying typic al

residential loads such as Induction Motors (sump

pumps, ref rigerators, air conditioners, furnaces, etc.),

Electronic Components (computer, monitor, TV, etc.),

Lighting Loads and Microwaves.

READ THIS MANUAL THOROUGHLY 

If any por tion of this

m

anual is not understood, contact the n earest

D

ealer for star ting, operating and servicing procedures.

Throughout this publication, and on tags and decals affi xed to the

g enerator,

D

A

N

G

E

R

,

W

A

R

N

I

N

G

, CA

U

TI

O

N

and

N

O

TE blocks are

used to aler t personnel to special instructions about a par ticular

operation that

m

a y be hazardous if perfor

m

ed incorrectly or care-

lessly.

O

bser ve the

m

carefully. Their definitions are as follows:

DANGER

After this heading, read i nstructions that, if not

strictly complied with, will result in serious per-

sonal injury, incl uding death, in addition to prop-

erty damage.

After this heading, read instructions that, if not

strictly complied with, may result in serious per-

sonal injury or property damage.

After this heading, read instructions that, if not

strictly complied with, could result in damage to

equipment and/or property.

NOTE:

After this heading, read explanatory statements that

require special emphasis.

These safety warnings cannot eliminate the hazards that they

indicate. Common sense and strict compliance with the special

instructions while performing the service are essential to pre-

venting accidents.

Four co

mm

only used safety sy

m

bols acco

m

pany the

D

A

N

G

E

R

,

W

A

R

N

I

N

G

and CA

U

TI

O

N

blocks. The type of infor

m

ation each

indicates follows:



This symbol points out important safety informa-

tion that, if not followed, could endanger per-

sonal safety and/or property of others.



This symbol points out potential explosion haz-

ard.



This symbol points out potential fire hazard.



This symbol points out potential electrical shock

hazard.

The operator is responsible for proper and safe use of the equip-

m

ent. The

m

anufacturer strongly reco

mm

end s that the operator

read this

O

wner

'

s Manual

and thoroughly und erstand all instruc-

tions before using this equip

m

ent. The

m

anufacturer also strongly

reco

mm

end s instructing other users t o properly star t and operate

the unit. Thi s prepares the

m

if they n eed to operate the equip

m

ent

in an e

m

ergency.

CONTENTS 

This

m

anual c ontains per tinent owner’s infor

m

ation for these

m

odels:

7 k

W

N

G

, 8 k

W

L

P, single-cylinder

G

H

-410 Engine•

9 k

W

N

G

, 10 k

W

L

P, V-twin

G

T-530 Engine•

13 k

W

N

G

, 14 k

W

L

P, V-twin

G

T-990 Engine•

16 k

W

N

G

, 17 k

W

L

P, V-twin

G

T-990 Engine•

18 k

W

N

G

, 20 k

W

L

P, V-twin

G

T-999 Engine•

OPERATION AND MAINTENANCE 

It is the operator

'

s responsibility to per f or

m

all safety ch ecks, to

m

ake sure that all

m

aintenance for safe oper ation is perfor

m

ed

pro

m

ptly, and to have the equip

m

ent check ed periodically by a

D

ealer.

N

or

m

al

m

aintenance service and replace

m

ent of par ts

are the responsibility of the owner/operator and, as such, are not

c onsidered defects in

m

aterials or work

m

an ship within the ter

m

s

of the warranty. Individual operating habi ts and usa ge contribute to

the need for

m

aintenance service.

Proper

m

aintenance and care of the generator ensures a

m

ini

m

u

m

nu

m

ber of proble

m

s and keep operating expenses at a

m

ini

m

u

m

.

S

ee a

D

ealer for se rvice aids and accessories.

HOW TO OBTAIN SERVICE 

W

hen the generator requires servicing or repairs, contact a

D

ealer

for assistan ce.

S

ervice technicians are factory-traine d and are

capable of handling all service needs.

W

hen contacting a

D

ealer about par ts and service, always supply

the co

m

plete

m

odel nu

m

ber and serial nu

m

ber of the unit as given

on its data decal, which is located on the generator.

S

ee sec tion

"

The

G

enerator

"

for decal location.

Model No. _________________ Serial No. ______________

Table of Contents

Air-cooled Generators

1

Introduction . .. .. .. .. .. .. .. .. .. . Inside Front Cover

R

ead This Manual Thoroughly ........ .................................. ...IFC

Contents ............................................................................IFC

O

peration and Maintenance............................. ....................IFC

H

ow to

O

btain

S

ervice ....................................................... .IFC

Table of Contents . .. .. .. .. .. .. .. .. .. . . .. .. . . .. .. . . .. . . .. . 1

Safety Rules .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 2

S

tandards Index ................ .....................................................3

Section 1 – General Information . .. .. .. .. .. .. .. .. 4

1.1

U

npacking/Inspection .................. ...................................4

1.2 Protec tion

S

yste

m

s ........................................................4

1.3

N

EC

R

eq uire

m

ent for Arc Fault Circuit

Inte rruption Breaker for Bedroo

m

s ..................................4

1.4 E

m

ission Infor

m

ation........................... ...........................5

1.5 The

G

enerator .................. ..............................................6

1.6

S

pecifications . ......................................................... ......7

1.7

S

yste

m

S

et

L

E

D

........ .....................................................8

1.8 Fuel

R

eq uire

m

ents and

R

ec o

mm

endations ................... ...8

1.9 Fuel Consu

m

ption ........ ........... .......................................8

1.10

R

ec onf iguring the Fuel

S

yste

m

................................ ........9

1.11

L

ocation .......... .............................................................10

1.12 Battery

R

eq uire

m

ents ...................................................13

1.13 Battery Installation .......................................... ..............13

1.14 The Battery ..................................................................13

1.15 Battery Charger ............................................................14

Section 2 – Post Installation Start-up

and Adjustments .. .. .. .. .. .. .. .. . . .. 14

2.1 Before Initial

S

tar tup ................................................. ....14

2.2 Electrical Checks .............................. ............................14

2.3

G

enerator Tests

U

nder

L

oad ..........................................15

2.4 Checki ng Auto

m

atic

O

peration ......... .............................15

2.5 Engine

G

overnor Adjust

m

ent .. ........... ...........................16

2.6 Voltage

R

egulator Adjust

m

ent ................... ....................16

Section 3 – Operation .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 17

3.1 Control Panel Inter face ... .................................. ............17

3.2 Auto

m

atic Transfer

O

peration ........... .............................18

3.3

S

eq uence of Auto

m

atic

O

peration .................................18

3.4 Manual Transfer

O

peration ............................................19

3.5

S

ide Co

m

par t

m

ent

(

V-twin

O

nly

)

..................................20

3.6 Protec tion

S

yste

m

s ......................................................21

Section 4 – Maintenance . .. .. .. .. .. .. .. .. .. .. .. .. .. 22

4.1 Fuse .... ......................................................... ................22

4.2 Checki ng the Engine

O

il

L

evel .......................................22

4.3 Changing the Engine

O

il .................. ........... ...................23

4.4 Changing the Engine Air Cleaner ........... ........................24

4.5

S

par k Plug

(

s

)

.......................................... .....................25

4.6 Battery Maintenance ...................... ...............................25

4.7 Adjusting

G

H

-410/

G

T-530/990/999 Va lve Clearance ......25

4.8 Cooling

S

yste

m

............................................................26

4.9 Att ention After

S

ub

m

ersion ...........................................27

4.10 Corrosion Protection.....................................................27

4.11

O

ut of

S

ervice Procedure ..............................................27

4.12

S

ervice

S

c hedule ...... ...................................................28

Section 5 – Troubleshooting . .. .. .. .. .. .. .. .. .. .. 29

5.1 Troubleshooting

G

uide ..................................................29

Section 6 – Appendix . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 30

6.1 Menu

S

yste

m

N

avigation ........ ........... ...........................30

Section 7 – Installation Diagrams .. .. .. .. .. .. . 32

Section 8 – Warranty . .. .. .. .. .. .. .. .. .. .. . . .. . . .. .. . . 36

2

S

tudy these

S

AFETY

R

U

L

E

S

carefully before insta lling, ope rating

or servicing this equip

m

ent. B eco

m

e fa

m

iliar with this

O

wner ’s

Manual

and with the unit. The generator can operat e safely, effi-

ciently and reliably only if it is properly installed, ope rated and

m

aintained. Many accidents are caused by failing to foll ow si

m

ple

and funda

m

ent al rules or precautions.

The

m

anufacturer cannot anticipate every possible circu

m

stance

that

m

ight involve a hazard. The wa rning s in this

m

anual, and on

tags and decals affixed to the unit are, therefore, not all-inclusive. If

using a procedure, work

m

ethod or operating technique the

m

anu-

facturer do es not specifically reco

mm

end, ensure that it is safe for

ot hers. Also

m

ake sure the procedure, work

m

ethod or operating

technique utilized does not render the generator unsafe.

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 install, operate and main-

tain 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.



Installation must always comply with applicable

codes, standards, laws and regulations.



A running generator gives off carbon monoxide,

and odorless, colorless poison gas. Breathing in

carbon monox ide can cause headaches, fatigue,

di ziness, nausea, vomitting, confusion, fainting,

siezures or death.



GENERAL HAZARDS



For safety reasons, the

m

anufact urer reco

mm

ends that this equip-•

m

ent be installed, serviced and repaired by a

S

ervice

D

ealer or

othe r co

m

petent, qualified electrician or installation technician who

is fa

m

iliar with applicable codes, standards and regulations. The

operator also

m

ust co

m

ply with all such codes, standards and

regulations.

The engine exhaust fu

m

es contain carbon

m

onoxide, which •

can b e

D

EA

D

L

Y. This dange rous gas, if breathed in sufficient

c oncentra tions, can cause unconsciousness or even death.

D

o

N

O

T alter or add to the exhaust syste

m

or do anything that

m

ight render the syste

m

unsafe or in nonco

m

pliance with appli-

cable c odes and standards.

Install a batte ry operated carbon

m

onoxide alar

m

indoors, •

according to

m

anufacturer

'

s instructions/reco

mm

endations.

Adequate, unobstr ucted flow o f cooling and ventilating air is •

c ritical to correct generator operation.

D

o not alter the instal-

lation or per

m

it even par tial blockage of ventilation provisions,

a s this can seriously affec t safe operation of the generator. The

generator MUST be installed and operated outdoors only.

Keep hands, feet , clothing, etc., away fro

m

drive belts, fans, •

and other

m

oving or hot parts.

N

ever re

m

ove any dr ive belt or

fan guard while the unit is operating.

W

hen working on this equip

m

ent, r e

m

ain ale r t at all ti

m

es. •

N

ever work on the equip

m

ent wh en physically or

m

ent ally

fatigued.

Inspect the generator regularly, and contact the nearest

D

ealer •

for par ts needing repair or replace

m

ent.

Before perfor

m

ing any

m

aintenance on the generator, di scon-•

nect its battery cables to prevent accidental start up.

D

isconnect

the cable fro

m

the battery post indi cated by a

N

E

G

ATIVE,

N

E

G

or

(

–

)

first, then re

m

ove th e P

O

S

ITIVE, P

O

S

or

(

+

)

cable.

W

hen

reconnecting the cables, connect the P

O

S

ITIVE cable first, the

N

E

G

ATIVE cable last.

N

ever use the generator or any of its par ts as a step.

S

tepping •

on the unit can stress and break par ts, and

m

a y result in dan-

g erous operating conditions fro

m

leaking exhaust gases, fuel

leakage, oil leakage, etc.



ENGINE EXHAUST HAZARDS



G

enerator engine exhaust contains

D

EA

D

L

Y carbon

m

onox-•

ide, an odorless, colorless poisonous gas. Brea thing carbon

m

onoxide can cause: dizziness, throbbing te

m

ples, nausea,

m

uscular twitching, headache, vo

m

iting, weakness and sleepi-

ness, inability to think clearly, fainting, unconsciousness or

even death. If you experience any carbon

m

onoxide poisoning

sy

m

pto

m

s,

m

ove i nto fresh air and i

mm

edi ately seek

m

edical

attention.

N

ever operate the generator set with the vehicle inside any •

garage or other enclosed area.

IMPORTANT SAFETY INSTRUCTIONS

Air-cooled 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 operators and potential operators of this equipment.



The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

WARNING:



This product contains or emits chemicals

known to the state of California t o cause

cancer, birth defects or other reproductive harm.

WARNING:



3



ELECTRICAL HAZARDS



All genera tors covered by this

m

anual produce dangerous •

elect rical voltages and can cause fatal electrical shock.

U

tility

power delivers extre

m

ely high and da ngerous volt ages to the

transfer switch as does the standby generator when it is i n

operation. Avoid contact with bare wire s, ter

m

inals, connec-

tions, etc., while the un it is runni ng. Ensure all appropriate

c overs, guards and barriers are in place, secured and/or locked

bef ore operating the generator. If work

m

ust be done around

an operating unit, stand on a n insulated, dry surface to reduce

shock hazard.

D

o not handle any kind of ele ctrical device while stand-•

ing in water, while barefoot, or while hands or feet are wet.

D

A

N

G

E

R

O

U

S

E

L

ECT

R

ICA

L

S

HO

CK MAY

R

E

S

U

L

T.

The

N

ational Electrical Code

(

N

EC

)

requires the fra

m

e and external •

electrically conductive par ts of the generator to be connected to

an approved ear th ground.

L

ocal electrical codes also

m

ay require

proper grounding of the generator electrical syste

m

.

After installi ng this ho

m

e standby electrical syste

m

, the gener a-•

tor

m

a y crank a nd star t at any ti

m

e without warning.

W

hen this

occurs, load circuits are transferred to the

S

TA

N

D

BY

(

g enera-

tor

)

power source. To prevent possible injury if such a star t and

transfer occur, always set the generator’s A

U

T

O

/

O

FF/MA

N

U

A

L

switch to its

O

FF position before working on equip

m

ent and

re

m

ove the 15A fuse fro

m

the generator control panel.

In case of acciden t caused by electric shock, i

mm

ediately shut •

down the source of electrical power. If this is not possible,

atte

m

pt to free the victi

m

fro

m

the live conductor. AV

O

I

D

I

R

ECT

C

O

N

TACT

W

IT

H

T

H

E VICTIM.

U

se a nonconducting i

m

ple

m

ent,

such as a dry rope or board, to free the victi

m

fro

m

the live

conductor. If th e victi

m

is unconscious, apply first aid and get

i

mm

ediate

m

edical help.

N

ever wear jewelry when working on this equi p

m

ent. Jewelry •

can conduct electricity resulting in electric shock, or

m

a y get

caught in

m

oving co

m

ponents causing injury.



FIRE HAZARDS



For fire safety, the generator

m

ust be installed and

m

aintained •

properly. Installation must always comply with applicable

codes, standards, l aws a nd regul ations. Adhere strictly

to local, state and national electrical and building codes.

Co

m

ply with reg ulations the

O

ccupational

S

afety and

H

ealt h

Ad

m

inistration

(

O

S

H

A

)

has establish ed. Also, ensure that the

g enerator is installed in accordance with th e

m

anufacturer’s

instructions and reco

mm

endations. Fo llowi ng prop er installa-

tion, do nothing that

m

ight alter a safe insta llation and render

the un it in nonco

m

pliance with the afore

m

entioned codes,

standards, laws a nd regulations.

Kee p a fire extinguisher near the gene rator at all ti

m

es. •

Extinguishers rated “ABC” by the

N

ational Fire Protection

Association are appropriate for use on the standby electric

syste

m

. Keep the extinguisher properly charged and be fa

m

iliar

with its use. Consult the local fire d epar t

m

ent with any ques-

tions per taining to fire extinguishers.



EXPLOSION HAZARDS



D

o not s

m

oke a round the generator.

W

ipe up any fuel or oil •

spills i

mm

edi ately. Ensur e that no co

m

bustible

m

aterials are left

in the generator co

m

par t

m

ent, or on or near the generator, as

FI

R

E or EXP

L

O

S

I

O

N

m

a y result. Keep the area surrounding the

g enerator clean and free fro

m

debris.

G

a seous fluids such as nat ural ga s and liquid propane

(

L

P

)

•

gas are extre

m

ely EXP

L

O

S

IVE . Install the fuel supply syste

m

according to applicable fuel-gas codes. Before placing the

ho

m

e standby electric syste

m

into service, fuel syste

m

lines

m

ust be properly purged and leak tested according to applica-

ble code . After installation, inspect the fuel syste

m

period ically

for leaks.

N

o leakage is per

m

itted.

STANDARDS INDEX 

In the absence of per tinent st andards, codes, regula tions and

laws, the published infor

m

ation listed below

m

a y be used for

instal lation g uidance for this equip

m

ent.

1.

N

FPA

N

o. 37,

S

TATI

O

N

A

R

Y C

O

MB

U

S

TI

O

N

E

N

G

I

N

E

S

A

N

D

G

A

S

T

U

R

BI

N

E

S

, available fro

m

the

N

ational Fire Protection

Association, 470 Atlantic Avenue, Boston, MA 02210.

2.

N

FPA

N

o. 76A, E

SS

E

N

TIA

L

E

L

ECT

R

ICA

L

S

Y

S

TEM

S

F

O

R

H

EA

L

T

H

CA

R

E FACI

L

ITIE

S

, available sa

m

e as Ite

m

1.

3.

N

FPA

N

o. 54,

N

ATI

O

N

A

L

F

U

E

L

G

A

S

C

O

D

E , available sa

m

e as

Ite

m

1.

4.

N

FPA

N

o. 58, AME

R

ICA

N

ATI

O

N

A

L

S

TA

N

D

A

R

D

F

O

R

S

T

O

R

A

G

E A

N

D

H

A

N

D

L

I

N

G

O

F

L

I

Q

U

EFIE

D

PET

R

O

L

E

U

M

G

A

S

,

available sa

m

e as Ite

m

1.

5.

N

FPA

N

o. 70,

N

FPA

H

A

N

D

B

OO

K

O

F

N

ATI

O

N

A

L

E

L

ECT

R

IC

C

O

D

E , available sa

m

e as Ite

m

1.

6. Ar ticle X,

N

ATI

O

N

A

L

B

U

I

L

D

I

N

G

C

O

D

E , av ailable fro

m

the

A

m

erican Insurance Assoc iation, 85 John

S

treet,

N

ew York,

N

.Y. 10038.

7. A

G

R

IC

U

L

T

U

R

A

L

W

I

R

I

N

G

H

A

N

D

B

OO

K, available fro

m

the Food

and Energy Council, 909

U

niversity Avenue, Colu

m

bia, M

O

65201.

8. A

S

AE EP-3634, I

N

S

TA

LL

ATI

O

N

A

N

D

MAI

N

TE

N

A

N

CE

O

F

FA

R

M

S

TA

N

D

BY E

L

ECT

R

ICA

L

S

Y

S

TEM

S

, available fro

m

the

A

m

erican

S

ociety of Agricultural Engineers, 2950

N

ile s

R

oad,

S

t. Joseph, MI 49085.

9.

N

FPA

N

o. 30, F

L

AMMAB

L

E A

N

D

C

O

MB

U

S

TIB

L

E

L

I

Q

U

I

D

S

C

O

D

E , available sa

m

e as Ite

m

1.

IMPORTANT SAFETY INSTRUCTIONS

Air-cooled Generators

DANGER



Only qualified electricians or contractors should

attempt such installations, which must comply

strictly with applicable codes, standards and regu-

l ations.

1.1 UNPACKING/INSPECTION

After unpacking, carefully inspect the contents for d a

m

age.

This standby generator set is ready for installation with a factory •

supplied and pre-

m

ounted base pad and h as a weather protec-

tive enclosure that is intended for outdoor installation only.



If this generat or is used to power electrical load

circuits normally powered by a utility power

source, it i s required by code to install a transfer

switch. The transfer switch must effectively isolate

the electrical system from the utility distribution

system when the generator is operating (NEC 700,

701 & 702). Failure to isolate an electrical system

by such means will result i n damage to the gen-

erator and also may result in injury or death to

utility power workers due to backfeed of electrical

energy.

If any loss or da

m

age is noted at ti

m

e of delivery, have the

person

(

s

)

m

aking the delivery note all da

m

age on the freight bill

or affix their signature under the consignor

'

s

m

e

m

o of loss or

da

m

age.

If a loss or d a

m

age is noted after delivery, separate the da

m

aged

m

aterials and contact the carrier for clai

m

procedures.

“ Concealed da

m

age” is understood to

m

ean da

m

age to the con-

tents of a package that is not in evidence at the ti

m

e of delivery,

but is discovered later.

To properly open the roof, press down on the center top lip and

release the latch. If pressure is not applied fro

m

the top, the roof

m

a y appear stuck. Always verify that the side lock is unlocke d

bef ore atte

m

pting to lift the roof.

1.2 PROTECTION SYSTEMS

U

nlike a n auto

m

obile engine, the generator

m

a y have to run for

long periods of ti

m

e with no oper ator present to

m

onitor engine

c onditions. For that reason, the engine is equipped with the fol-

lowi ng syste

m

s that prot ect it against potentially da

m

aging condi -

tions:

1.

L

ow

O

il Pressure

S

ensor

2.

H

igh Te

m

perature

S

ensor

3.

O

vercran k

4.

O

versp eed

5.

R

PM

S

ensor

6.

L

ow Batter y

There are readouts on the control panel to notify personnel that one

of these failures has occurred . There is also a

S

yste

m

S

et

L

E

D

(

single cylinder

)

or a

S

tatus

m

essage on the display

(

V-twins

)

that

displays when all of the conditions described in the

"

S

yste

m

S

et

L

E

D

"

section are true.

1.3 NEC REQUIREMENT FOR ARC FAULT

CIRCUIT INTERRUPTION BREAKER FOR

BEDROOMS

In 2001, the

N

ational Electric Code

(

N

EC

)

introduced a require

m

ent

for new construct ion. This new require

m

ent indicates the nee d for

Arc Fault Circuit Interrupters to be used to protect the co

m

plete

branch circuit that feeds a dwelling bedroo

m

. The actual

N

EC

require

m

ent is ind icate d b elow.

1.3.1 SECTION 210.12 ARC FAULT CIRCUIT INTER- 

RUPTER PROTECTION

1.

D

efinition: An arc fault circ uit i nterrupt er is a device intended

to provide protection fro

m

the effects of arc fault s by recog-

nizing characteristics unique to arcing and by functioning to

de-energize the circuit when an arc fault is detected.

2.

D

welling

U

nit Bedroo

m

s: All branch circuits that supply 125

volt , single-phase, 15 and 20 a

m

pere outlets installed in

dwelling unit bedroo

m

s shall be protected by an arc fault cir-

c uit interrupter listed to provi de protection of the entire branch

cir cuit.

S

ection 210.12 requires that AFCI protect ion be provided on branch

cir cuits that supply outlets

(

receptacle, lighting, etc.

)

in dwell-

ing bedroo

m

s. The require

m

ent is li

m

ited to 15 and 20 a

m

pere,

125 volt circuit s. There is no prohibition against providing AFCI

protection on other circuits or in locations oth er than b edroo

m

s.

Because circuits are often shared between a bedroo

m

and other

areas such as closets and hallways, providing AFCI protection on

the co

m

plete circuit would co

m

ply with 210.12.

If during the installation of the ho

m

e standby syste

m

the decision

is

m

ade to provi de back up power to a bedroo

m

branch circuit,

then the circuit breaker in the transfer switch should be replaced

with an Arc Fault Circui t Int errupter.

It is

m

ost i

m

por tant that breakers only be switched like for like.

For instance, if replacing a 15A breaker, it M

U

S

T be replaced wi th

a 15A AFCI breaker.

L

ikewise, a 20A breaker M

U

S

T be replaced

with a 20A AF CI.

These AFCI breakers are available at the nearest hardware store.

Eaton Cat #

D

esc ription

B

R

115AF 1

"

15A

S

ing le Pole AFCI

C

H

115AF 3/4

"

15A

S

ing le Pole AFCI

B

R

120AF 1

"

20A

S

ing le Pole AFCI

C

H

120AF 3/4

"

20A

S

ing le Pole AFCI

Section 1 — General Information

Air-cooled Generators

4

Section 1 — General Information

Air-cooled Generators

5

1.4 EMISSION INFORMATION

The Environ

m

ent al Protection Agency requires that this generator

c o

m

plies with exhaust e

m

ission standards. This generator is cer ti-

fied to

m

eet the applicable EPA e

m

ission levels. Additional infor-

m

ation regarding the require

m

ents set by the EPA is as fo llows:

The generator is cer tified for use as a stationary engine for standby

power generation. Any other use

m

a y be a violation of federal

and/or local laws. It is i

m

por tant that to follow the

m

aintenance

spe cifications in the

"

Maintenance

"

section to ensure that the

engine co

m

plies with the applicable e

m

ission stand ards for the

dur ation of the engine’s life. This engine is certified to operate on

L

iquid Propane fuel and pipeline

N

atural

G

a s. The e

m

ission control

syste

m

on the generator consists of the following:

Fuel Metering

S

yste

m

•

Carburetor/

m

ixer asse

m

bly•

Fuel regulator•

Air Induction

S

yste

m

•

Intake pipe/

m

anifold•

Air cleaner•

Ignition

S

yste

m

•

S

par k plug•

Ignition

m

odule•

The E

m

issions Co

m

pliance Period referred to on the E

m

issions

Co

m

pliance

L

abel indica tes the nu

m

ber of operating hours for

which the engine has been shown to

m

eet Federal e

m

ission

require

m

ents.

S

ee the table below to deter

m

ine t he co

m

pliance

period f or the generator. The displace

m

ent of the gene rator is listed

on the E

m

issions Co

m

pliance

L

abel.

D

isplace

m

ent Category Co

m

pliance Period

< 66 cc

A 300

H

ours

B 125

H

ours

C 50

H

ours

 66 cc -

< 225 cc

A 500

H

ours

B 250

H

ours

C 125

H

ours

 225 cc

A 1000

H

ours

B 500

H

ours

C 250

H

ours

6

Section 1 — General Information

Air-cooled Generators

1.5 THE GENERATOR

Data Label

(see sample)

Oil

Dipstick

Exhaust

Enclosure

Composite Base Oil Filter Battery Compartment

Fuel

Regulator

Fuel Inlet

(back)

Air Filter

Circuit

Breaker

Control

Panel

Data Label

(see sample)

Oil

Dipstick

Exhaust

Enclosure

Composite Base Oil Filter Battery Compartment

Fuel

Regulator

Fuel Inlet

(back)

Air Filter

Circuit Breakers

GFCI Outlet

(All 17 & 20kW)

Control

Panel

Figure 1.3 – 14, 17 and 20k W, V-twin,

GT-990/GT-999 Engine (door removed)

Figure 1.1 – 8kW, Single Cylinder, GH-410 Engine

(door removed)

Data Label

(see sample)

Oil

Dipstick

Exhaust

Enclosure

Composite Base Oil Filter Battery Compartment

Fuel

Regulator

Fuel Inlet

(back)

Air

Filter

Circuit

Breaker

Control

Panel

Figure 1.2 – 10kW, V-t win, GT-530 Engine

(door removed)

Data Label Sample

7

Section 1 — General Information

Air-cooled Generators

1.6 SPECIFICATIONS

1.6.1 GENERATOR 

Model 8kW 10kW 14kW 17kW 20kW

R

ated Maxi

m

u

m

Power Capacity

(

W

atts*

)

7,000

N

G

8,000

L

P

9,000

N

G

10,000

L

P

13,000

N

G

14,000

L

P

16,000

N

G

17,000

L

P

18,000

N

G

20,000

L

P

R

ated Voltage 120/240

R

ated Maxi

m

u

m

L

oad Current

(

A

m

ps

)

120 Volts**

(

N

G

/

L

P

)

58.3/66.6 75.0/83.3 108.3/116.6 133.3/141.6 150.0/166.6

240 Volts

(

N

G

/

L

P

)

29.2/33.3 37.5/41.6 54.2/58.3 66.6/70.8 75.0/83.3

Main Circuit Breaker 35 A

m

p 45 A

m

p 60 A

m

p 65 A

m

p 100 A

m

p

Phase 1

N

u

m

ber of

R

otor Poles 2

R

ated AC Frequen cy 60

H

z

Battery

R

equ ire

m

ent

G

roup 26

R

, 12 Vol ts and

350 CCA Mini

m

u

m

G

roup 26

R

, 12 Vol ts and 525 CCA Mini

m

u

m

W

eight

(

unit only in lbs.

)

340 387 439 455/421 450

Enclosure

S

teel

S

teel

S

teel

S

teel/Alu

m

inu

m

Alu

m

inu

m

N

or

m

al

O

perating

R

ange -20

°

F

(

-28.8

°

C

)

to 77

°

F

(

25

°

C

)

* Maxi

m

u

m

wattage and current are subject to a nd li

m

ited by such factors as fuel Btu content, a

m

bient te

m

perature, altitude, engine power and condition, etc. Maxi

m

u

m

power de creases 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

)

a

m

bient te

m

perature.

**

L

oad curr ent values shown for 120 volts are

m

axi

m

u

m

T

O

TA

L

values for two separate circuits. The

m

axi

m

u

m

current in each circuit

m

ust not exceed the value stated for t he 240 volts.

*** Circ uits to be

m

oved

m

ust be prot ected by sa

m

e size breaker. F or exa

m

ple, a 15 a

m

p circu it in the

m

a in panel

m

ust be a 15 a

m

p circu it in the transfer switch.

1.6.2 ENGINE 

Model 8 kW 10 kW 14/17 kW 20 kW

Type of Engine

G

H

-410

G

T-530

G

T-990

G

T-999

N

u

m

ber of Cylinders 1 2 2 2

R

ated

H

orse power @ 3,600 rp

m

14.8 18 32 36

D

isplace

m

ent 410cc 530cc 992cc 999cc

Cylinder Block Alu

m

inu

m

w/Cast Iron

S

leeve

Valve Arrange

m

ent

O

verhead Valves

Ignition

S

yste

m

S

olid-state w/Magneto

R

eco

mm

ended

S

park Plug

R

C14YC BP

R

6

H

S

R

C14YC

R

C12YC

S

park Plug

G

ap 0.76

mm

(

0.030 inch

)

0.76

mm

(

0.030 inch

)

1.02

mm

(

0.040 inch

)

0.76

mm

(

0.030 inch

)

Co

m

pression

R

atio 8.6:1 9.5:1 9.5:1 9.5:1

S

tar ter 12 V

D

C

O

il Capacity Including Filter Approx. 1.5

Q

ts Approx. 1.7

Q

ts Approx. 1.7

Q

ts Approx. 1.7

Q

ts

R

eco

mm

ended

O

il Filter Par t # 070185F

R

eco

mm

ended Air Filter Par t # 0

G

3332 Par t # 0E9581 Par t # 0C8127 Par t # 0

G

5894

O

perating

R

PM 3,600

1.7 SYSTEM SET LED

The “

S

yste

m

S

et ”

L

E

D

(

single cylinder

)

or

"

R

eady to

R

un

"

on the

display

(

v-twin

)

is ready when all of the fol lowing conditions are

true:

1. The A

U

T

O

/

O

FF/MA

N

U

A

L

switch is set to the A

U

T

O

position.

2. The utility voltage being supplied to the unit is being sensed

by the PCB. If the utility sense voltage is not connected to the

unit or if it is below approxi

m

ately 150-160 volts AC, then the

syste

m

set light will flash rapidly

(

8k

W

)

. This indicat es that if

the A

U

T

O

/

O

FF/MA

N

U

A

L

switch is placed in the Auto position,

the generator will star t.

3.

N

o alar

m

s are present, for exa

m

ple, low oil pressure, hi gh

te

m

perature, etc.

1.8 FUEL REQUIREMENTS

AND RECOMMENDATIONS

With LP gas, use only the vapor withdrawal system. This type of

syste

m

uses the vapors for

m

ed above the liquid fuel in t he storage

tank.

The engine has been fitted with a fuel carburetion syste

m

th at

m

eets the specifications of the 1997 California Air

R

esources

Board for ta

m

per-proof du al fuel syste

m

s. Th e unit will run on

natural ga s or

L

P gas, but it has been factory set to run on natural

gas.

S

hould the pri

m

ary fuel need to be changed to

L

P gas, the

fuel syste

m

needs to be reconfigured.

S

ee the reconfig uring the

Fuel

S

yste

m

section for instructions on reconfiguration of the fuel

syste

m

.

R

ec o

mm

ended 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

c ubic foot for

L

P ga s. Ask the fuel supplier for the Btu content of

the fuel.

R

eq uired fuel pressure for natural gas is five (5) inches to seven

(7) inches water column (0.18 to 0.25 psi); and for liquid pro-

pane, 10 inches to 12 inches of water column (0.36 to 0.43 psi).

The primary regulator for the propane supply is NOT INCLUDED

with the generator.

NOTE:

All pipe sizing, construction and layout must comply

with NFPA 54 for natural gas applications and NFPA

58 for liquid propane applications. Once the genera-

t or is installed, verify that the fuel pressure NEVER

drops below four (4) inches w ater column for natural

gas or 10 inches water column for liquid propane.

Prior to install ation of the generator, the installer should consult

loca l fuel suppliers or the fire

m

arshal to check codes and regula-

tions for proper installation.

L

ocal codes will

m

andate correct rout-

ing of gaseous fuel line piping around gardens, shrubs and other

landscaping to prevent any d a

m

age.

S

pecial considerations should be given when installing the unit

where local conditions include flooding, torn ados, hurricanes,

ear thquakes a nd unstable ground for the flexibility and strength of

piping and their connecti ons.

U

se an approved pipe sealant or joint co

m

pound on all threaded

fitting.

All installed gaseous fuel piping

m

ust be purged and leak tested

pri or to initial star t-up in accord ance with local codes, standards

and regulations.

1.9 FUEL CONSUMPTION

Unit

Nat. Gas LP Vapor

1/2 Load Full Load 1/2 Load Full Load

7/8 k

W

77 140 0.94/34 1.68/62

9/10 k

W

102 156 1.25/46 1.93/70

13/14 k

W

156 220 1.56/58 2.30/84

16/17 k

W

183 261 1.61/59 2.57/94

18/20 k

W

206 294 1.89/69 2.90/106

*

N

atural gas is in cubic feet per hour.

**

L

P is in gallons per hour/cubic feet per hour.

*** Values given are approxi

m

ate.

Verify t hat g as

m

eter is capable of provid ing enough fuel flow to

include household appliances.

1.9.1 BTU FLOW REQUIREMENTS - 

NATURAL GAS

BT

U

flow req uired for each unit based on 1000 BT

U

per c ubic

foot.

7k

W

— 140,000 BT

U

/

H

our•

9k

W

— 156,000 BT

U

/

H

our•

13k

W

— 220,000 BT

U

/

H

our•

18k

W

— 294,000 BT

U

/

H

our•

DANGER



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 settl e in low areas.

NOTE:

A minimum of one approved manual shut-off valve

must be installed in the gaseous fuel supply line. The

valve must be easily accessible. Local codes deter-

mine the proper location.

Section 1 — General Information

Air-cooled Generators

8

9

1.10 RECONFIGURING THE FUEL SYSTEM

1.10.1 8 KW, 410CC ENGINE 

To reconfigure the fuel syste

m

fro

m

N

G

to

L

P, follow these steps

(

Figur e 1.4

)

:

NOTE:

The primary regulator for the propane supply is NOT

INCLUDED with the generator. A fuel pressure of 10

t o 12 inches of water column (0.36 to 0.43 psi) to the

fuel inlet of the generator MUST BE SUPPLIED.

1. Turn off the

m

ain gas supply

(

i f connected

)

.

2.

O

pen the roof and re

m

ove the door.

3.

R

e

m

ove the battery

(

i f installed

)

.

4. Take the plast ic T-handle fuel selector in th e poly bag supplied

with the generator.

5.

L

ocat e the selector knob on the air box cover, behind the

yel low air filter door and power bulge. The unit co

m

es fro

m

the factory in the

N

G

(

N

atural

G

a s

)

position.

G

rasping the

T-handle, inser t the pin end into the hole in the selector knob

and pull out to overco

m

e spring pressure and then twist

clockwise 90 degrees and allow th e selector to retur n in once

alig ned with the

L

P

(

L

iquid Propane

)

position.

6.

S

ave this tool with the

O

wner

'

s Manual.

7. Install the battery, door and close the roof.

8.

R

everse the procedure to conv er t back to natural gas.

Figure 1.4 – Fuel Selector

NOTE:

Use an approved pipe sealant or joint compound on

all threaded fittings to reduce the possibility of leak-

age.

1.10.2 10, 14, 17 AND 20KW, V-TWIN ENGINES 

To reconfigure the fuel syste

m

fro

m

N

G

to

L

P, follow these steps:

NOTE:

The primary regulator for the propane supply is NOT

INCLUDED with the generator. A fuel pressure of 10

t o 12 inches of water column (0.36 to 0.43 psi) to the

fuel inlet of the generator MUST BE SUPPLIED.

1.

O

pen the roof.

2. For 10kW units:

L

oosen cla

m

p and slide back the air inlet

hose.

S

lide fuel selector on carburetor out towards the back of the •

enclosure

(

Figur es 1.5 and 1. 6

)

.

R

eturn the inlet hose and tighten cla

m

p securely.•

For 14, 17 and 20kW units: re

m

ove the air cleaner cover.

S

lide the selector lever out towards the back of the enclosure •

(

Figur es 1.7 and 1. 8

)

.

R

eturn the ai r cleaner cover and tighten the two thu

m

b •

screws.

Figure 1.5 - 10kW, GT-530 (Inlet Hose Slid Back)

Fuel Selection

Lever - "In"

Position for

Natural Gas

Fuel

Figure 1.6 - 10kW, GT-530 (Inlet Hose Slid Back)

Fuel Selection

Lever - "Out"

Position for

Liquid Propane

(Vapor) Fuel

Section 1 — General Information

Air-cooled Generators

10

3. Close the roof.

4.

R

everse the procedure to conv er t back to natural gas.

Figure 1.7 - 14, 17, & 20kW,

GT-990/GT-999 (Airbox Cover Removed)

Fuel Selection Lever - "In" Position for Natural Gas Fuel

Figure 1.8 - 14, 17, & 20kW,

GT-990/GT-999 (Airbox Cover Removed)

Fuel Selection Lever - "Out" Position for Liquid Propane

(Vapor) Fuel

1.11 LOCATION

1.11.1 GENERATOR 

Install the generator set, in its protective enclosure, outdoors,

where adequate cooling and ventilating ai r is always available

(

Figur e 1.9

)

. Consider these factors:

The installation of the generator • must comply strictly with

NFPA 37, NFPA 54, NFPA 58, and NFPA 70 standards.

Install the unit where air inlet and outlet openings will not •

beco

m

e obstructed by l eaves, grass, snow, etc.. If prevailing

winds will cause blowing or drifting, consider using a wind-

break to protect the unit.

Install the generat or on high ground where water levels will not •

rise and endanger it.

Allow suf ficient roo

m

on all sides of the g enerator for

m

ainte-•

nance and servicing. This unit

m

ust be installed in accordance

with curr ent applicable

N

FPA 37 and

N

FPA 70 standards; as

well as any other federal, state and local codes for

m

ini

m

u

m

distances fro

m

other structures.

D

O

N

O

T install under wooden

decks or structures unless there is at least four

(

4

)

feet of clear-

ance above the generator, three

(

3

)

feet of clearance on sides

and front, and 18 inches of clearance at back of unit.

Install the unit where ra in gutter down spouts, roof run-off, •

landscape irrigation, water sprinklers or su

m

p pu

m

p discharge

does not f lood the un it or spray th e enclosure, including any air

inlet or outlet openings.

Install the unit where services will not be a ffected or obstructed, •

including concealed, underground or covered services such as

elect rical, fuel, phone , air conditioning or irrigation.

W

here strong prevailing winds blow fro

m

on e d irection, face the •

g enerator air inlet openings to the prevailing winds.

Figure 1.9 – Generator Clearances

Install the g enerator as close as p ossible t o the fuel supply, to •

reduce the length of piping.

Install the generator as close as possible to the transfer switch. •

R

EMEMBE

R

T

H

AT

L

A

W

S

O

R

C

O

D

E

S

MAY

R

E

G

U

L

ATE T

H

E

D

I

S

TA

N

CE A

N

D

L

O

CATI

O

N

.

The genset

m

ust be installed on a le vel surface. The base fra

m

e •

m

ust be level within two

(

2

)

in ches all around.

The generator is typically placed on pea gravel or crushed •

stone. Check local codes if a concrete slab is required. If a

c oncrete base slab is required, all fede ral, state and local codes

should be followed.

S

pecial attention should be given to the

c oncrete base slab which should exceed the length and width

of the generator by a

m

ini

m

u

m

of six

(

6

)

inches

(

0.152

m

eters

)

on all sides.

Section 1 — General Information

Air-cooled Generators

11

DANGER



The engine exhaust fumes contain carbon mon-

ox ide, whi ch can be DEADLY. This dangerous

gas, if breathed in sufficient concentrations,

can cause unconsciousness or even death. This

generator must be instal led properly, in strict

compliance with applicable codes and stan-

dards. Following installation, do nothing that

might render the system unsafe or in noncom-

pliance with such codes and standards.

• Operate the generator outdoors ONLY.

• Keep exhaust gases from ent ering a confined

area through windows, doors, ventilation, crawl

spaces or other openings (Figure 1.9).

• Generac Power Systems as a responsible manu-

facturer highly recommends that carbon monox-

ide detector(s) be installed indoors according to

the manufacturer

'

s instructions/recommendations.

• The generator must me mounted safely per appli-

cable codes and the manufacturer

'

s specifica-

tions. Do NOT alter or add to the exhaust syst em,

or do anything that might render the exhaust sys-

tem unsafe or in noncompliance with applicable

codes and standards.

1.11.2 INSTALLATION GUIDELINES FOR EATON 

STATIONARY AIR-COOLED 8, 10, 14, 17 AND

20 KW GENERATORS.

The

N

ational Fire Protection Association has a standard for the

inst allation and use of st ationary co

m

bustion engines. That

standard is

N

FPA 37 and its require

m

ents li

m

it the spacing of an

enclosed gene rator set fro

m

a structure or wall

(

Figur e 1.10

)

.

N

FPA 37,

S

ection 4.1.4, E ngines

L

ocat ed

O

utdoors. Engines, and

their weatherproof housings if provid ed, t hat are inst alled outdoors

shall be locate d at least 5 ft. fro

m

openings in walls and at least 5

ft. fro

m

structures having co

m

bustible walls. A

m

ini

m

u

m

separa-

tion shall not be requ ired where the following conditions exist:

1. The adjacent wall o f t he structure has a fire resistance rating

of at least 1 hour.

2. The weatherproof enclosure is constructed of nonco

m

bus-

tible

m

aterials and it has been de

m

onstrated that a fire within

the en cl osure will not ignite co

m

bustible

m

aterials outside t he

enclosure.

Annex A — Explanatory Material

A4.1. 4

(

2

)

Means of de

m

onst rating co

m

pliance are by

m

eans

of full scale fire test or by calculation procedures.

Because of the li

m

ited spaces that are freque ntly available for

instal lation, it has beco

m

e apparent that exception

(

2

)

would be

beneficial for

m

an y residential and co

mm

ercial installations.

W

ith

that in

m

ind, the

m

anufacturer contracted with an inde pendent

testing laboratory to run full sca le fire tests to assure that the

Eaton enclosure woul d not ignite co

m

bustible

m

aterials outside

the enclosure.

The criteria was to d eter

m

ine the worst ca se fire scenario within

the generator and to deter

m

ine the ignitability of ite

m

s outside

the engine enclosure at various distances. The Eaton enclosure

is constructed of non-co

m

bustible

m

aterials and the results and

c onclusi ons fro

m

the independent testing lab indicated that any

fire within the generator enclosure would not pose any ignition risk

to nearby co

m

bustibles or structures, with or without fire service

personnel response.

Based on this testing and the require

m

ents of

N

FPA 37,

S

ec 4.1.4,

the gu idelines for installation of the generators listed above are

c hanged to 18 inches

(

457

mm

)

fro

m

the back side of the genera-

tor t o a stationary wall or building. For adequate

m

aintenance a nd

air flow clearance, the area above the generator should be at least

4 feet with a

m

ini

m

u

m

of 3 feet at the front and ends of the enclo-

sure. This would include trees, shrubs and vegetation that could

obstruct air flow.

S

ee the diagra

m

on the reverse of this page and

the installation drawing within the owner’s

m

anual for detail s.

G

enerator exhaust contains

D

EA

D

L

Y carbon

m

onoxide gas. This

dangerous gas can cause unconsciousness or death.

D

o not place

the un it near windows, doors, fresh air in takes

(

furnaces, etc.

)

or

an y openings in the building or str ucture, including windows and

doors of an attached garage.

Section 1 — General Information

Air-cooled Generators

12

Section 1 — General Information

Air-cooled Generators

Figure 1.10 – Install ation Guidelines

18 inches

Minimum Distance

36 inches

60 inches 60 inches

Existing Wall

No windows or openings in the wall permitted

within 5 feet from any point of the generator.

Top o f Ge n er a to r

48” Minimum

60” Recommended

Minimum From Ends

18 inches

Minimum

Generator

Clearance from windows,

doors, any openings in the

wall, shrubs or vegetation

over 12” in height

Clearance from the ends and front of the

generator should be 36 inches. This

would include shrubs, trees and any

kind of vegetation. Clearance at the top

should be a minimum of 48 inches from

any structure, overhang or projections

from the wall. The generator should not

be placed under a deck or other

structure that is closed in and would limit

or contain air flow.

These guidelines are based upon fire

testing of the generator enclosure and

the manufacturer’s requirement for air

flow for proper operation. Local codes

may be different and more restrictive

than what is described here.

This drawing supersedes installation instructions in all Carrier air-cooled installation and owner’s manuals dated

previous to May 26, 2007.

13

1.12 BATTERY REQUIREMENTS

S

ee the

S

pecifications section for correct battery size and rating



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 pow er supply is not turned off, spark-

ing can occur at the battery posts and cause an

explosion.

1.13 BATTERY INSTALLATION

Fill the battery with the prope r electrolyte fluid if necessary and

have the battery fully charged before installing it.

Before instal ling and connecting the battery, co

m

plete the follow-

ing steps:

1.

S

et the generator

'

s A

U

T

O

/

O

FF/MA

N

U

A

L

switch to

O

FF.

2. Turn off utility power supply to the transfer switch.

3.

R

e

m

ove the 7.5A fuse fro

m

the generator control panel.

Battery cables were factory connected at the generator

(

Figur e

1.11

)

. Connect cables to battery posts as follows:

4. Connect the red battery cab le

(

fro

m

star ter contactor

)

to the

battery post indicated by a p ositive, P

O

S

or

(

+

)

.

5. Connect the black battery cable

(

fro

m

fra

m

e ground

)

to the

battery post indicated by a negative,

N

E

G

or

(

—

)

.

Figure 1.11 – Battery Cable Connections

NOTE:

Dielectric grease should be used on battery posts to

aid in the prevention of corrosi on.

NOTE:

Damage will result if battery connec ti ons are made

in reverse.

NOTE:

In areas where temperatures regularly fall below 10

°

F (-12

°

C) it is recommended that a pad type battery

heater be installed to aid in cold climate starting.

1.14 THE BATTERY

DANGER



Do not dispose of the battery in a fire. The

battery is capable of exploding.



A battery presents a risk of electrical shock

and hi gh short circuit current. The following pre-

cautions are to be observed when working on

batteries:

• Remove the 7.5A fuse from the generator 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

• Disconnect charging source prior to connecting or

disconnecting battery terminals.



Do not open or mutilate the battery. Released

electrolyte has been known to be harmful to the

skin and eyes, and to be toxic.



The electrolyte is a dilute sul furic 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 prot ective clothing;

• Where electrolyte contacts the skin, wash it off

immediately with water;

• Where electrolyte contacts the eyes, flush thor-

oughly and immediately with water and seek medi-

cal attention; and

• Spilled electrolyte is to be washed down wi th 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.



Lead-acid batteries present a risk of fire

because they generate hydrogen gas. The fol-

lowing

procedures are to be followed:

• DO NOT SMOKE when near the battery;

• DO NOT cause flame or spark i n battery area; and

• Discharge static electricity from body before

t ouching the battery by first touching a grounded

metal surface.

Section 1 — General Information

Air-cooled Generators

14



Be sure the AUTO/OFF/MANUAL switch is set to

the OFF position before connecting the battery

cables. If the switch is set to AUTO or MANUAL,

the generator can crank and start as soon as

the battery cables are connected.



Be sure the utility power supply is turned off

and the 7.5A fuse is removed from the generator

control panel, or sparking may occur at the bat-

tery posts as the cables are attached and cause

an explosion.

S

ervicing of the battery is to be per for

m

ed or supervised by per-

sonnel knowledgeable o f batteries and the required precautions.

Keep unauthorized personnel away fro

m

batteries.

S

ee the

S

pecifications section for the correct size and rating when

replacing the battery.

H

ave these procedures per for

m

ed at the

intervals spe cified in the “

S

ervice

S

c hedule.” A nega tive ground

syste

m

is used. Battery connections are shown on the wiring dia-

gra

m

s. Make sure t he battery is correctly connected and ter

m

inals

are tight.

O

bser ve batt ery polarity when connecting the battery to

the generator set.

1.15 BATTERY CHARGER

NOTE:

These generators DO NOT contain an internal battery

charger.

NOTE:

The manufacturer provides a battery trickle charger

that is active when the unit is set up for automatic

operation. With the battery installed and ut ility power

source voltage available to the transfer switch, the

battery recei ves a trickle charge to prevent self-

discharge. The trickle charger is designed to help

extend the life of the battery by maint aining the bat-

tery. The trickle charge feature cannot be used to

recharge a discharged battery.

A separate bat tery charger

m

odule is included with the generator.

(

For battery charger installation, see th e

G

enerator Install

G

uidelines

included with the unit.

)

2.1 BEFORE INITIAL START-UP

NOTE:

These units have been run and tested at the factory

prior to being shipped and do not require any type

of break-in.

Before star ting, co

m

plete the following:

1.

S

et the generator’s

m

ain circuit bre aker to its

O

FF

(

or

O

PE

N

)

position.

2.

S

et the genera tor

'

s A

U

T

O

/

O

FF/MA

N

U

A

L

switch to the

O

FF

position.

3. Turn

O

FF all loads connected to the transf er switch ter

m

inals

T1 and T2.

4. Check the engine cra nkcase oil level and, if necessary, fi ll to

the d ipstick F

U

LL

m

ark with the r eco

mm

ended oil.

D

o not fill

above the F

U

LL

m

ark.

5. Check the fuel sup ply.

G

a seous fuel lines

m

ust ha ve been

properly purged and leak tested in accordance with applicable

fuel-gas codes. All fuel shutoff valves in the fuel supply lines

m

ust be open.

D

uring initial star t up only, the generat or

m

a y exceed the nor

m

al

nu

m

ber of star t atte

m

pts and experience an “ove r crank” fault

(

S

ee

the

"

O

vercran k

"

section

)

. This is due to accu

m

ulated air in the fuel

syste

m

during installation.

R

eset the control board and restar t up

to two

m

ore ti

m

es, if necessary. If unit fails to star t, contact the

loca l dealer for assistance.



Never operate the engine with t he oil level

below the “Add” mark on the dipstick. Doing this

could damage the engine.

2.2 ELECTRICAL CHECKS

Co

m

plete electrical checks as follows:

1.

S

et the g enerator

'

s

m

ain circuit breaker to its

O

FF

(

or

O

PE

N

)

position.

2.

S

et the genera tor

'

s A

U

T

O

/

O

FF/MA

N

U

A

L

switch to the

O

FF

position.

3. Turn

O

FF all loads connected to the transf er switch ter

m

inals

T1 and T2.

4. Turn on the utilit y power supply to the transfer switch using

the

m

eans provided

(

such as a utility

m

ain line circuit break-

er

)

.

DANGER



The transfer switch is now electrically “ hot.”

Contact with “hot” parts will result in extremely

hazardous and possibl y fatal electrical shock.

Proceed with caution.

5.

U

se an accurate AC volt

m

eter to check uti lity power source

volt age across transfer switch ter

m

inals

N

1 and

N

2.

N

o

m

inal

line -to-line voltage shoul d be 240 volts AC.

6. Check utility power source voltage across ter

m

inals

N

1 and

the transfer switch neutral lug; then across ter

m

inal

N

2 and

neutral.

N

o

m

inal li ne-to-neutral voltage should be 120 volts

AC.

7.

W

hen cer tain that utility supply voltage is co

m

patible with

transfer switch and load circuit ratings, turn

O

FF the utility

power supply to the transfer swit ch.

8.

O

n the generator panel, set the Auto/

O

ff/ Ma nual switc h to

MA

N

U

A

L

. The engine should crank and star t.

9.

L

et the e ngine war

m

up for about five

m

inutes to allow inte r-

nal te

m

peratures to stabilize. Then, set the generator’s

m

ain

cir cuit breaker to its

O

N

(

or closed

)

position.

DANGER



Proceed with caution! Generator power voltage

is now supplied to the transfer switch. Contac t

with live transfer switch parts wi ll result in dan-

gerous and possibly fatal electrical shock.

Section 2 — Post Installation Start-up and Adjust ments

Air-cooled Generators

15

10. Connect an accurat e AC volt

m

eter and a frequency

m

eter

across transfer switch ter

m

inal lugs E1 and E2. 8k

W

voltage

should be 230-240 volts at a frequency of 61-63

H

er tz. 14,

17 and 20k

W

voltage should be 247-249 at a frequency of

59.5-60.5

H

er tz. 10k

W

voltage should be 220-230 volts at a

frequency of 59.5-60.5

H

er tz.

11. Connect the AC volt

m

eter test leads across ter

m

inal l ugs E1

and neutral; then across E2 and neutral. In both cases, volt-

age reading should be 121-126 volts AC

(

8k

W

)

, and 125-126

volts AC

(

10, 14, 17 and 20k

W

)

.

12.

S

et the generator’s

m

ain circuit bre aker to its

O

FF

(

or

O

PE

N

)

position.

L

et the engine run at no-load for a few

m

inutes to

stabilize internal engine generat or te

m

peratures.

13.

S

et the generat or

'

s A

U

T

O

/

O

FF/MA

N

U

A

L

switch to

O

FF. The

engine should shut down.

NOTE:

It is important not to proceed unt il certain that gener-

ator AC voltage and frequency are correct and within

the stated limits. Generally, if both AC frequency and

voltage are high or low, the engine governor requires

adjustment* (*GH410 only). If frequency is correct,

but voltage is high or low, the generator’s voltage

regulator requires adjustment.

2.3 GENERATOR TESTS UNDER LOAD

To test the generator set with electrical loads app lied, proceed as

follows:

1.

S

et generator’s

m

ain circuit breaker to its

O

FF

(

or

O

PE

N

)

posi -

tion.

2. Turn

O

FF all loads connected to the transf er switch ter

m

inals

T1 and T2.

3.

S

et the generator

'

s A

U

T

O

/

O

FF/MA

N

U

A

L

switch to

O

FF.

4. Turn

O

FF the utility power supply to the transfer switch,

using the

m

eans provided

(

such as a utility

m

ain lin e circuit

breaker

)

.



Do not attempt manual transfer switch operation

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 electri-

cal shock.

5. Manually set the transfer switch to the

S

TA

N

D

BY posi tion, i.e.,

load ter

m

inals connected to the generator

'

s E1/E2 ter

m

inals.

The transfer switc h operating lever should be down.

6.

S

et the generator

'

s A

U

T

O

/

O

FF/MA

N

U

A

L

switch t o MA

N

U

A

L

.

The engine should crank and star t i

mm

edi ately.

7.

L

et the engine stabilize and war

m

up for a few

m

inutes.

8.

S

et th e generator’s

m

ain cir cuit breaker to its

O

N

(

or C

L

O

S

E

D

)

position.

L

oads are now powered by the sta ndby generator.

9. Turn

O

N

the load center fed by the transfer switch

(

T1 and

T2

)

.

10. Connect an accurat e AC volt

m

eter and a frequency

m

eter

across ter

m

inal lugs E1 and E2.

8k

W

volt age should be g reater than 230 volts and frequency •

should be greater than 58

H

z.

10, • 14, 17 and 20k

W

voltage should be greater than 240 volts

and frequency should be 60

H

z.

11.

L

et the generator run at full rated load for 20-30

m

inutes.

L

isten for unusual noises, vibration or other indications of

abnor

m

al operation. Check for oil leaks, evidence of overheat-

ing, etc.

12.

W

hen testing under l oa d is co

m

plete, turn

O

FF el ectrical

loads.

13.

S

et the g enerator

'

s

m

ain circuit breaker to its

O

FF

(

or

O

PE

N

)

position.

14.

L

et the engine run at no-load for a few

m

inutes.

15.

S

et the A

U

T

O

/

O

FF/MA

N

U

A

L

switch to

O

FF. The engine should

shut down.

2.4 CHECKING AUTOMATIC OPERATION

To check the syste

m

for proper auto

m

atic operation, proceed as

follows:

1.

S

et generator’s

m

ain circuit breaker to its

O

FF

(

or

O

PE

N

)

posi -

tion.

2. Check that the A

U

T

O

/

O

FF/MA

N

U

A

L

switch is set to

O

FF.

3. Turn

O

FF the utility power supply to the transfer switch, using

m

eans provided

(

such as a utility

m

ain line circuit breaker

)

.

4. Manually set the transfer switch to t he

U

TI

L

ITY position, i.e.,

load ter

m

inals connected to the utility power source side.

5. Turn

O

N

the utility power supply to the transfer switch,

using the

m

eans provided

(

such as a utility

m

ain line circuit

breaker

)

.

6.

S

et the generator

'

s

m

ain circuit breaker to its

O

N

(

or C

L

O

S

E

D

)

position.

7.

S

et the A

U

T

O

/

O

FF/MA

N

U

A

L

switch to A

U

T

O

. The syste

m

is

now read y for auto

m

atic operati on.

8. Turn

O

FF the utili ty p ower supply to the transfer switch.

W

ith the A

U

T

O

/

O

FF/MA

N

U

A

L

switch at A

U

T

O

, the engine should

c rank and star t when the utility source power is turned

O

FF after a

10 second delay. After sta r ting, the transfer switch should connect

load circuits to the standby side after a 20 to 50 second selectable

dela y.

L

et t he syste

m

go through its entire auto

m

atic sequence of

operation.

W

ith the generator running and load s powe red by generator AC

output, turn

O

N

the utility power supply to the transfer switch. The

following should occur:

After about 10 seconds, the switch should transfer loads back •

to the utility power source.

About one

m

inute after re-transfer, the engine should shut •

down.

•

Section 2 — Post Installation Start-up and Adjust ments

Air-cooled Generators

16

2.5 ENGINE GOVERNOR ADJUSTMENT

If both AC frequency and voltage are correspondingly high or low,

adjust th e engine governor as follows:

2.5.1 8 KW UNITS 



The engine must be OFF to perform steps 1 and

2.

1.

L

oosen the governor cla

m

p bolt

(

Figur e 2.1

)

.

2.

H

old the governor lever at its wide open throttle position

(

clockwise

)

, and rotate the governor sha ft clockwise as far

a s it will go. Then, tighten the governor lever cla

m

p bolt to 70

inch-pounds

(

8

N

-

m

)

.

3.

S

tar t t he gen erator; let it stabilize and wa r

m

up at no-load.

4. Connect a f req uency

m

eter across t he generators AC output

leads.

Figure 2. 1 — Engine Governor Adjustment

Single Cylinder Engines

GOVERNOR

SHAFT

PRIMARY

ADJUST

SCREW

GOVERNOR

CLAMP

BOLT

SECONDARY

ADJUST SCREW

5. Turn the p ri

m

ary adjust screw to obtain a frequency reading

of 61.5

H

er tz. Turn the sec ondar y adjust screw to obtain a

frequency of 62.5

H

z.

2.5.2 10, 14, 17 & 20KW UNITS 

NOTE:

All V-twin units DO NOT require an engine governor

adjustment due to t heir design.

2.5.3 ADDITIONAL CORROSION 

PROTECTION

Periodically spray all engine linkage par ts and brackets with corro-

sion inhibiting spray such as

W

D

-40 or a co

m

parable product.

2.6 VOLTAGE REGULATOR

ADJUSTMENT

2.6.1 8 & 10KW UNITS 

D

ue to the brushless de sign of these two alternators, no voltage

regulator is use d and therefore no voltage adjust

m

ent is re quired.

2.6.2  14, 17 & 20KW UNITS

W

ith the f req uency between 59.5 -60.5

H

er tz at no-load, slowly

turn the slot ted p otentio

m

eter

(

Figur e 2.2

)

until line voltage reads

247-249 volts.

Figure 2. 2 – Voltage Adjust ment Potentiometer

Turn to

adjust voltage.

NOTE:

The access panel on top of t he control panel must be

removed to adjust the voltage regulator.

NOTE:

The voltage regulator is housed behind the genera-

t or

'

s control panel. The regulator maintains a voltage

in direct proportion to frequency at a 2-to-1 ratio. For

example, at 60 Hertz, line-to-neutral vol tage will be

124 volts.

Section 2 — Post Installation Start-up and Adjust ments

Air-cooled Generators

17

Section 3 — Operation

Air-cooled Generators

3.1 CONTROL PANEL INTERFACE

3.1.1 USING THE AUTO/ OFF/MANUAL SWITCH 

(FIGURES 3.1 & 3.2)

1. “A

U

T

O

” Position –

S

electing this switch activates fully auto-

m

atic syste

m

operation. It also allows the unit to auto

m

ati-

cally star t and exercise the engine every seven days with the

setting of the exercise ti

m

er

(

see the

S

etting the Exercise

Ti

m

er section

)

.

2. “

O

FF” Position – This switch position shuts down the engine.

This position also preven ts auto

m

atic operati on.

3. “MA

N

U

A

L

” Position –

S

et the switch to MA

N

U

A

L

to cra nk

and star t the engine. Transfer to standby power will not occur

unless there is a utility failure.

Figure 3. 1 – 8kW Generator Control Panel

SET

EXERCISE

SYSTEM READY

LOW BATTERY

LOW OIL PRESSURE

HIGH OIL TEMPERATURE

OVERSPEED

RPM SENSOR LOSS

OVERCRANK



With the switch set to AUTO, the engine may

crank and start at any time without warning.

Such automati c starting occurs when utility

power source voltage droops below a preset

level or during the normal exercise cycle. To

prevent possible injury that might be c aused

by such sudden starts, always set t he switch to

OFF and remove the fuses before working on or

around the generator or transfer switch. Then,

place a “DO NOT OPERATE” tag on the genera-

t or panel and on the transfer switch.

Figure 3. 2 – 10/14/17 & 20kW Generator Control

Panel

ENTER

ECS

3.1.2 SETTING THE EXERCISE TIMER 

This generator is equipped with an exercise ti

m

er.

O

nce it is set,

the generator will star t and exerci se every seven d ays, on the day

of the week and at the ti

m

e of day specified.

D

uring this exe rcise

period, the unit runs for approxi

m

ately 12

m

inutes and then shuts

down. Transfe r of loads to the generator outpu t doe s not occur

duri ng the exercise cycle unless utility powe r is lost.

8kW



A switch on the control panel

(

see Fig ure 3.1

)

per

m

its selection of

the day and ti

m

e for the syste

m

to exercise. At the chosen ti

m

e,

per for

m

the f ollowing sequence to select the desired day and ti

m

e

of day the syste

m

will exercise.

R

e

m

e

m

ber season al ti

m

e changes

affect the exercise settings.

1. Verify that the A

U

T

O

/

O

FF/MA

N

U

A

L

switch is set to A

U

T

O

.

2. Press and hold the “

S

et Exercise” switch for several seconds.

All the red

L

E

D

’s will stop flashing i

mm

edi ately and the ge n-

erator will star t.

3. The gen erator will star t and run for approxi

m

ately 12

m

inutes

and then shut down. The exerciser is now set to run at this

ti

m

e of day each week.

Example: If the “

S

et Exercise” pressed on

S

aturday afternoon at

2:00 p.

m

., the generator will star t and exercise for approxi

m

ately

12

m

inutes every

S

aturday at 2:00 p.

m

.

NOTE:

The exerciser will only work in the AUTO mode and

will not work unless this procedure is performed.

The exerciser will need to be reset every time the 12

volt battery is disconnected and then reconnected,

and when the fuse is removed and/or replaced.

18

10 to 20 KW - INSTALLATION ASSISTANT



U

pon f irst power up of the generator, the display inter face will

begin an installation assistant. The assistant will pro

m

pt the user

to set the

m

ini

m

u

m

settings to operate. These settings are si

m

-

ply: Cur rent

D

ate/Ti

m

e and Exercise

D

a y/Ti

m

e. The

m

aintenance

intervals will be initialized when the exercise ti

m

e is entered

(

Figur e

3.2

)

.

The exe rcise settings can be changed at any ti

m

e via t he

"

E

D

IT

"

m

enu

(

see Appendix,

"

Menu

S

yste

m

"

)

.

If the 12 vo lt battery is disconnected or t he fuse re

m

oved, the

Installation Assistant will operate upon powe r restoration. The

only difference is the di splay will only pro

m

pt the custo

m

er for the

c urrent Ti

m

e and

D

ate.

IF THE INSTALLER TESTS THE GENERATOR PRIOR

TO INSTALLATION, PRESS THE “ENTER” KEY TO

AVOID SETTING UP THE EXERCISE TIME. THIS WILL

ENSURE THAT WHEN THE CUSTOMER POWERS UP

THE UNIT, HE WILL STILL BE PROMPTED TO ENTER

AN EX ERCI SE TIME.

NOTE:

The exerciser will only work in the AUTO mode and

will not work unless this procedure is performed.

The current date/time will need to be reset every ti me

the 12 volt battery is disconnected and then recon-

nected, and/or when the fuse is removed.

3.1.3 DISPLAY INTERFACE 

8 kW LED Display



S

even

(

7

)

L

E

D

’s are p rovided f or user status indications. The

L

E

D

functions are:

1.

S

yste

m

R

eady

(

green

)

2.

L

ow Batter y

(

red

)

3.

L

ow

O

il Pressure

(

red

)

4.

H

igh

O

il Te

m

perature

(

red

)

5.

O

ver

S

peed

(

red

)

6.

R

PM

S

ensor

L

oss

(

red

)

7.

O

ver Crank

(

red

)

S

ee the Protection

S

yste

m

s section for details.

10 to 20KW DISPLAY INTERFACE MENUS



The

L

C

D

display is organized as detailed below:

The “

H

o

m

e” page, t his page is the default page which will be •

displayed if no keys are pressed for 30 seconds. This page

nor

m

ally shows the current

S

tatus

m

essage and the current

date and ti

m

e. The highest priority activ e Alar

m

and/or

W

arning

will be auto

m

atical ly post ed on this page as well as flashing

the backlight when suc h a n event is detected. In the case of

m

ultipl e Alar

m

s or

W

arning s, only the first

m

essage will be

displayed. To clear an Alar

m

or

W

arning, see the Protection

S

yste

m

s section - Clear Alar

m

.

The display backlight is nor

m

ally o ff. If the user presses any •

key, the backlight will co

m

e on auto

m

atical ly and r e

m

ain on for

30 seconds after the last ke y was pressed.

The “Main Menu” page will allow the user to navigate to all other •

pages or sub-

m

enus by using the

L

eft/

R

ight and Ente r keys.

This page ca n be accessed at any ti

m

e with several presses of

the dedicated Escape key. Each press of the Escape key takes

you back to the previous

m

enu until the

m

ain

m

enu is reached.

This page displays the following options:

H

I

S

T

O

R

Y;

S

TAT

U

S

;

E

D

IT; A

N

D

EB

U

G

.

(

S

ee the Appendix -

"

Menu

S

yste

m

"

.

)

3.2 AUTOMATIC TRANSFER OPERATION

To select auto

m

atic operati on, do the following:

1. Make sure the transfer swit ch

m

ain contacts are set to their

U

TI

L

ITY position, i.e., loads connected to the utility power

source

(

Figur e 3.2

)

.

2. Be sure that nor

m

al

U

TI

L

ITY power sour ce voltage is avail -

able to transfer switch ter

m

inal lugs

N

1 and

N

2

(

R

efer to the

Electrical

D

ata section

)

.

3.

S

et the generator’s A

U

T

O

/

O

FF/MA

N

U

A

L

switch to A

U

T

O

.

4.

S

et th e generator’s

m

ain cir cuit breaker to its

O

N

(

or C

L

O

S

E

D

)

position.

W

ith the preceding steps co

m

plete, the generator will star t auto-

m

atical ly when utility source voltage drops be low a preset level.

After the unit star ts, loads are transferred to the standby power

source.

R

efer to the

S

eq uence of Au to

m

atic

O

peration section.

3.3 SEQUENCE OF AUTOMATIC OPERATION

3.3.1 UTILITY FAILURE 

Initial Conditions:

G

enerator in Auto, ready to run, load being sup-

plied by utility source.

W

hen utility fails

(

below 70% of no

m

inal

)

,

a 10 second line interrupt delay ti

m

e is star ted. If the utility is stil l

gone when the ti

m

er expires, the engine will crank and star t.

O

nce

star ted, a 20 to 50 second selectable engine wa r

m

-up ti

m

er will be

initiated.

W

hen the war

m

-up ti

m

er expir es, the control will transfer

the load to the ge nerator. If the utility power is restored

(

above 80%

of no

m

inal

)

at any ti

m

e f ro

m

the initiation of the engine star t until

the generator is r eady to accept load

(

and the war

m

-up ti

m

e has

not elapsed

)

, the controller will co

m

plete the star t cycle and run

the generator through its nor

m

al cool down cycle ; however, the

load will re

m

ain on the utility source.

3.3.2 CRANKING 

The syste

m

will control the c yclic cranking as follows: 16 se cond

c rank, seven

(

7

)

sec ond rest, 16 second crank, seven

(

7

)

sec ond

rest followed by three

(

3

)

addi tional cycles of seven

(

7

)

second

c ranks followed by seven

(

7

)

second rests.

Choke Operation



1. The 990/999cc engines have an electric choke in the air

box that is auto

m

atical ly controlled by the electronic control

board.

2. The 530cc engines have an el ectric choke on the divid er panel

air inlet hose that is auto

m

atical ly controlled by the electronic

c ontrol board.

3. The 410cc engines have a choke behind the air box that is

auto

m

atical ly control led by the electronic control board.

Section 3 — Operation

Air-cooled Generators

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