Owner’s Manual 8, 10, 12, 14, 16, 17 & 20kW Air-cooled, Automatic Standby Generators US C LISTED DO NOT LIFT UNIT BY ROOF! Not intended for use as Primary Power in place of utility or in life-support applications. DANGER DEADLY EXHAUST FUMES.
INTRODUCTION Thank you for purchasing this compact, high performance, air-cooled, engine-driven generator. It is designed to automatically supply electrical power to operate critical loads during a utility power failure. This unit is factory installed in an all-weather, metal enclosure that is intended exclusively for outdoor installation. This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG).
Table of Contents Air-cooled Generators Introduction ........................ Inside Front Cover Read This Manual Thoroughly ........................ IFC Contents .......................................................... IFC Operation and Maintenance ............................ IFC How to Obtain Service ..................................... IFC Section 3 – Operation .....................................16 Table of Contents ...............................................1 3.1 3.2 3.3 3.4 3.5 3.
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. • WARNING: • The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.
IMPORTANT SAFETY INSTRUCTIONS Air-cooled Generators 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 operation. Avoid contact with bare wires, terminals, connections, etc., while the unit is running.
Section 1 — General Information Air-cooled Generators DANGER qualified electricians or contractors should Only attempt such installations, which must comply strictly with applicable codes, standards and regulations. 1.1 UNPACKING/INSPECTION After unpacking, carefully inspect the contents for damage. • This standby generator set is ready for installation with a factory supplied and pre-mounted base pad and has a weather protective enclosure that is intended for outdoor installation only.
Section 1 — General Information Air-cooled Generators 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. 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.
Section 1 — General Information Air-cooled Generators 1.5 THE GENERATOR Figure 1.1 – 8kW, Single Cylinder, GH-410 Engine (door removed) Figure 1.
Section 1 — General Information Air-cooled Generators 1.6 SPECIFICATIONS 1.6.1 GENERATOR Model Rated Maximum Power Capacity (Watts*) 8kW 10kW 12kW 14kW 16kW 17kW 20kW 7,000 NG 8,000 LP 9,000 NG 10,000 LP 12,000 NG 12,000 LP 13,000 NG 14,000 LP 16,000 NG 16,000 LP 16,000 NG 17,000 LP 18,000 NG 20,000 LP Rated Voltage 120/240 Rated Maximum Load Current (Amps) 120 Volts** (NG/LP) 58.3/66.6 75.0/83.3 100.0/100.0 108.3/116.6 133.3/133.3 133.3/141.6 150.0/166.6 240 Volts (NG/LP) 29.
Section 1 — General Information Air-cooled Generators 1.7 SYSTEM SET LED The “System Set” LED (single cylinder) or "Ready to Run" on the display (v-twin) is ready when all of the following conditions are true: 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 voltage is not connected to the unit or if it is below approximately 150-160 volts AC, then the system set light will flash rapidly (8kW).
Section 1 — General Information Air-cooled Generators NOTE: 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 determine the proper location. Use an approved pipe sealant or joint compound on all threaded fittings to reduce the possibility of leakage. 1.10 RECONFIGURING THE FUEL SYSTEM 1.10.1 8 KW, 410CC ENGINE To reconfigure the fuel system from NG to LP, follow these steps (Figure 1.
Section 1 — General Information Air-cooled Generators Figure 1.6 - 10kW, GT-530 (Inlet Hose Slid Back) 1.11 LOCATION 1.11.1 GENERATOR Fuel Selection Lever - "Out" Position for Liquid Propane (Vapor) Fuel Figure 1.7 - 12, 14, 16, 17, & 20kW, GT-990/GT-999 (Airbox Cover Removed) Fuel Selection Lever - "In" Position for Natural Gas Fuel Figure 1.
Section 1 — General Information Air-cooled Generators • Install the generator as close as possible to the fuel supply, to reduce the length of piping. • Install the generator as close as possible to the transfer switch. REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE AND LOCATION. • The genset must be installed on a level surface. The base frame must be level within two (2) inches all around. • The generator is typically placed on pea gravel or crushed stone.
Section 1 — General Information Air-cooled Generators NOTE: Dielectric grease should be used on battery posts to aid in the prevention of corrosion. NOTE: Damage will result if battery connections 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 not dispose of the battery in a fire. The Do battery is capable of exploding.
Section 2 — Post Installation Start-up and Adjustments Air-cooled Generators 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 starting, complete the following: 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 breakers on the load center of the transfer box (T1 and T2). 4.
Section 2 — Post Installation Start-up and Adjustments Air-cooled Generators 12. Set the generator’s main circuit breaker to its OFF (or OPEN) position. Let the engine run at noload for a few minutes to stabilize internal engine generator temperatures. 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.
Section 2 — Post Installation Start-up and Adjustments Air-cooled Generators 2.6 ENGINE GOVERNOR ADJUSTMENT If both AC frequency and voltage are correspondingly high or low, adjust the engine governor as follows: 2.6.1 8 KW UNITS The engine must be OFF to perform steps 1 and 2. 1. Loosen the governor clamp bolt (Figure 2.1). 2. Hold the governor lever at its wide open throttle position (clockwise), and rotate the governor shaft clockwise as far as it will go.
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) Figure 3.2 – 10/12/14/16/17 & 20kW Generator Control Panel 1. “AUTO” Position – Selecting this switch activates fully automatic system operation. It also allows the unit to automatically start and exercise the engine every seven days with the setting of the exercise timer (see the Setting the Exercise Timer section). 2.
Section 3 — Operation Air-cooled Generators NOTE: 10 to 20KW DISPLAY INTERFACE MENUS 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.
Section 3 — Operation Air-cooled Generators 3.3 SEQUENCE OF AUTOMATIC OPERATION 3.3.1 UTILITY FAILURE Initial Conditions: Generator in Auto, ready to run, load being supplied by utility source. When utility fails (below 65% of nominal), a 10 second (optionally programmable on the 17 and 20kW only) line interrupt delay time is started. If the utility is still gone when the timer expires, the engine will crank and start. Once started, a five (5) second engine warmup timer will be initiated.
Section 3 — Operation Air-cooled Generators 2. Auto • Will start and run if Utility fails for 10 consecutive seconds. • Will start a five (5) second engine warm-up timer. • Will not transfer if utility subsequently returns. • Will transfer to generator if utility is still not present. • Will transfer back to utility once utility returns (above 75% of nominal) for 15 seconds.
Section 3 — Operation Air-cooled Generators Figure 3.4 – Side Compartment DANGER not attempt to activate the transfer switch Do manually until all power voltage supplies to the switch have been positively turned off. Failure to turn off all power voltage supplies may result in extremely hazardous and possibly fatal electrical shock. 5. Use the manual transfer handle inside the transfer switch to move the main contacts back to their UTILITY position, i.e.
Section 3 — Operation Air-cooled Generators High Engine Temperature (Shutdown Alarm – Auto Reset) A 10 second delay on start-up and one (1) second delay before shutdown. Auto reset when the condition clears and restart the engine if a valid start signal is still present. This switch’s contacts (Figure 3.6) close if the temperature should exceed approximately 144° C (293° F), initiating an engine shutdown. Once the oil temperature drops to a safe level the switch’s contacts open again.
Section 4 — Maintenance Air-cooled Generators 3.6.3 MAINTENANCE ALERTS (10 - 20KW ONLY) Third priority Maintenance Message When a maintenance period expires, a warning message will be displayed. (16 through 20kW models include an external yellow LED which will illuminate.) The alert can be reset by pressing the Enter key, which will cause the user to be prompted to confirm the action. Resetting will clear the alert and reset the maintenance counters for all conditions annunciated.
Section 4 — Maintenance Air-cooled Generators 4.3 CHANGING THE ENGINE OIL 4.3.1 OIL CHANGE INTERVALS See the "Service Schedule" section. 4.3.2 ENGINE OIL RECOMMENDATIONS All oil should meet minimum American Petroleum Institute (API) Service Class SJ, SL or better. Use no special additives. Select the oil's viscosity grade according to the expected operating temperature. 4. Refill with the proper recommended oil (see the Engine Oil Recommendations section).
Section 4 — Maintenance Air-cooled Generators Figure 4.5 — 12, 14, 16, 17 & 20kW Engine Air Cleaner Screw Cover Filter 4.4.3 8KW GENERATOR See "The Generator" section to locate the air box. Use the following procedures to replace the dirty air filter within the air box (Figure 4.7). 1. Lift the roof and remove the door. 2. Push back on the latch of the yellow air filter access door to swing open. 3. Pull out the old air filter and discard appropriately. 4.
Section 4 — Maintenance Air-cooled Generators Figure 4.8 – Setting the Spark Plug Gap SET PLUG GAP AT 0.76 mm (.030 inch) - 8, 10 & 20kW; 1.02 mm (.040 inch) - 12, 14, 16 & 17kW 4.6 BATTERY MAINTENANCE The battery should be inspected per the "Service Schedule" section. The following procedure should be followed for inspection: 1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary. 2.
Section 4 — Maintenance Air-cooled Generators • Make sure the piston is at Top Dead Center (TDC) of its compression stroke (both valves closed). To get the piston at TDC, remove the intake screen at the front of the engine to gain access to the flywheel nut. Use a large socket and socket wrench to rotate the nut and hence the engine in a clockwise direction. While watching the piston through the spark plug hole. The piston should move up and down.
Section 4 — Maintenance Air-cooled Generators 4.10 CORROSION PROTECTION Periodically wash and wax the enclosure using automotive type products. Frequent washing is recommended in salt water/coastal areas. Spray engine linkages with a light oil such as WD-40. 4.11 OUT OF SERVICE PROCEDURE 4.11.1 REMOVAL FROM SERVICE If the generator cannot be exercised every seven days, and will be out of service longer than 90 days, prepare the generator for storage as follows: 1. Start the engine and let it warm up. 2.
Section 4 — Maintenance Air-cooled Generators 4.12 SERVICE SCHEDULE ATTENTION: It is recommended that all service work be performed by the nearest Dealer. SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action R = Replace as Necessary W = Weekly Inspect Change Clean * = Notify Dealer if Repair is Needed. M = Monthly Y = Yearly FUEL Fuel lines and connections* X M X M or 24 hours of continuous operation. LUBRICATION Oil level Oil X 2Y or 200 hours of operation.
Section 5 — Troubleshooting Air-cooled Generators 5.1 TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank. 1. Fuse blown. 1. Correct short circuit condition, replace 7.5A fuse in generator control panel. 2. Tighten, clean or replace as necessary. 3. * 4. * 5. Charge or replace battery. 2. Loose, corroded or defective battery cables. 3. Defective starter contactor. (8 kW) 4. Defective starter motor. 5. Dead Battery. The engine cranks but will not start.
Section 6 — Appendix Air-cooled Generators 6.1 MENU SYSTEM NAVIGATION To get to the MENU, use the "Esc" key from any page. It may need to be pressed many times before getting to the menu page. The currently selected menu is displayed as a flashing word. Navigate to the menu required by using the +/- keys. When the menu required is flashing, press the ENTER key. Depending on the menu selected, there may be a list of choices presented.
ENTER +/- ESC Use the “ENTER” key to select items or enter data. Use the “+/-” key to navigate through the menu. Press the “ESCAPE” key to jump back up through the menu levels.
Section 7 — Notes Air-cooled Generators 32
Section 8 — Installation Diagrams Air-cooled Generators Circuit Breakers - Drawing No.
Section 8 — Installation Diagrams Air-cooled Generators Generator - Drawing No.
Section 8 — Installation Diagrams Air-cooled Generators Generator - Drawing No.
Section 9 – Warranty Air-cooled Generators NOTE: This Emission Control Warranty Statement pertains to this product only IF the generator size is 15 kW or below. CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new engine.
Section 9 – Warranty Air-cooled Generators EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.
Part No. 0G8334 Revision B (04/24/08) Catalog No. OMASPCA-S-01 Printed in U.S.A.