Generac 7 kW 005837R0 Manuel utilisateur

7kW Air-cooled,

Automatic Standby Generators

Owner's Manual

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Introduction .............................................. 1

Read This Manual Thoroughly ................................................1

Safety Rules ............................................. 1

Contents ...............................................................................1

Operation and Maintenance....................................................1

How to Obtain Service ...........................................................1

Standards Index .....................................................................3

General Information ................................. 4

1.1 Unpacking/Inspection .....................................................4

1.2 Protection Systems ........................................................4

1.3 NEC Requirements .........................................................4

1.4 Emission Information......................................................4

1.5 The Generator ................................................................5

1.6 Specifications ................................................................5

1.7 System Ready LED .........................................................6

1.8 Fuel Requirements and Recommendations ......................6

1.9 Fuel Consumption ..........................................................6

1.10 Reconfiguring the Fuel System ........................................6

1.11 High Altitude Operation ...................................................7

1.12 Location .........................................................................8

1.13 Battery Requirements ...................................................10

1.14 Battery Installation ........................................................10

1.15 The Battery ..................................................................10

1.16 Battery Charger ............................................................11

Post Installation Start-up and

Adjustments ........................................... 11

2.1 Before Initial Startup .....................................................11

2.2 Check Transfer Switch Operation ..................................11

2.3 Electrical Checks ..........................................................11

2.4 Generator Tests Under Load ..........................................12

2.5 Checking Automatic Operation ......................................12

2.6 Engine Governor Adjustment ........................................13

Operation ................................................ 13

3.1 Control Panel Interface .................................................13

3.2 Automatic Transfer Operation ........................................14

3.3 Sequence of Automatic Operation .................................14

3.4 Manual Operation .........................................................15

3.5 Side Compartment .......................................................15

3.6 Protection Systems ......................................................16

3.7 Shutting the Generator Down While Under Load ............17

Maintenance ........................................... 17

4.1 Performing Scheduled Maintenance ..............................17

4.2 Fuse .............................................................................18

4.3 Checking the Engine Oil Level .......................................18

4.4 Changing the Engine Oil ................................................18

4.5 Changing the Engine Air Cleaner ...................................19

4.6 Spark Plug ...................................................................19

4.7 Battery Maintenance .....................................................19

4.8 Adjusting OHV-432 Valve Clearance ..............................20

4.9 Cooling System ............................................................20

4.10 Attention After Submersion ...........................................21

4.11 Corrosion Protection.....................................................21

4.12 Out of Service Procedure ..............................................21

4.13 Service Schedule .........................................................22

Troubleshooting ..................................... 23

5.1 Troubleshooting Guide ..................................................23

Installation Diagrams ............................ 24

Warranty ................................................. 28

MANUAL DEL PROPIETARIO .........31

MANUEL D'ENTRETIEN...................59

Table of Contents

WARNING!

California Proposition 65

Engine exhaust and some of its constituents are known to the state of California to cause cancer,

birth defects, and other reproductive harm.

WARNING!

California Proposition 65

This product contains or emits chemicals known to the state of California to cause cancer,

birth defects, and other reproductive harm.

1

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, composite enclosure and is

intended exclusively for outdoor installation. This generator will operate

using either vapor withdrawn liquid propane (LP) or natural gas (NG).

NOTE:

This generator is suitable for supplying typical residential loads such

as Induction Motors (sump pumps, refrigerators, air conditioners,

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

Lighting Loads and Microwave ovens.

READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, contact the nearest Dealer

for starting, operating and servicing procedures.

The information contained herein was based on machines in production

at the time of publication. The manufacturer reserves the right to modify

this manual at any time.

SAFETY RULES

Throughout this publication, and on tags and decals affixed to the genera-

tor, DANGER, WARNING, CAUTION and NOTE blocks are used to alert

personnel to special instructions about a particular operation that may be

hazardous if performed incorrectly or carelessly. Observe them carefully.

Their definitions are as follows:

INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF

NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.

Indicates a hazardous situation or action which, if not

avoided, could result in death or serious injury.

Indicates a hazardous situation or action which, if not

avoided, could result in minor or moderate injury.

NOTE:

Notes contain additional information important to a procedure

and will be found within the regular text body of this manual.

These safety warnings cannot eliminate the hazards that they

indicate. Common sense and strict compliance with the special

instructions while performing the action or service are essential to

preventing accidents.

Four commonly used safety symbols accompany the DANGER,

WARNING and CAUTION blocks. The type of information each

indicates is as follows:



This symbol points out important safety information that,

if not followed, could endanger personal safety and/or

property of others.





This symbol points out potential explosion hazard.



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 equipment. The

manufacturer strongly recommends that the operator read this Owner's

Manual and thoroughly understand all instructions before using this

equipment. The manufacturer also strongly recommends instructing other

users to properly start and operate the unit. This prepares them if they

need to operate the equipment in an emergency.

CONTENTS

This manual contains important instructions that should be followed

during installation and maintenance of the generator and batteries for the

model: 6 kW NG, 7 kW LP, single-cylinder OHV 432 Engine.

OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety checks, to make sure

that all maintenance for safe operation is performed promptly, and to have

the equipment checked periodically by a Dealer. Normal maintenance ser-

vice and replacement of parts are the responsibility of the owner/operator

and, as such, are not considered defects in materials or workmanship

within the terms of the warranty. Individual operating habits and usage

contribute to the need for maintenance service.

Proper maintenance and care of the generator ensures a minimum number

of problems and keep operating expenses at a minimum. See a Dealer for

service aids and accessories.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs, contact a Dealer for

assistance. Service technicians are factory-trained and are capable of

handling all service needs.

When contacting a Dealer about parts and service, always supply the

complete model number and serial number of the unit as given on its data

decal, which is located on the generator. See section "The Generator" for

decal sample and location.

Model No. _________________ Serial No. ______________

Introduction

AUTHORIZED SERVICE DEALER LOCATION

To locate the nearest AUTHORIZED

SERVICE DEALER, please call this number:

1-800-333-1322

or locate us on the web at:

www.generac.com

2

Study these SAFETY RULES carefully before installing, operating

or servicing this equipment. Become familiar with this Owner’s

Manual and with the unit. The generator can operate safely, effi-

ciently 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 warnings 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 manu-

facturer does not specifically recommend, ensure that it is safe for

others. Also make sure the procedure, work method or operating

technique utilized does not render the generator unsafe.



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 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 and immediately after operation.

Exercise care near running generators.



Installation must always comply with appli-

cable codes, standards, laws and regula-

tions.



A running generator gives off carbon mon-

oxide, and odorless, colorless poison gas.

Breathing in carbon monoxide can cause

headaches, fatigue, diziness, nausea, vomit-

ting, confusion, fainting, siezures or death.

GENERAL HAZARDS

• For safety reasons, the manufacturer recommends that this equip-

ment be installed, serviced and repaired by a Service Dealer or other

competent, qualified electrician or installation technician who is

familiar with applicable codes, standards and regulations. The opera-

tor also must comply with all such codes, standards and regulations.

• The engine exhaust fumes contain carbon monoxide, which

can be DEADLY. This dangerous gas, if breathed in sufficient

concentrations, can cause unconsciousness or even death.

Do NOT alter or add to the exhaust system or do anything that

might render the system unsafe or in noncompliance with appli-

cable codes and standards.

• Install a battery operated carbon monoxide alarm indoors,

according to manufacturer's instructions/recommendations.

• Adequate, unobstructed flow of cooling and ventilating air is

critical to correct generator operation. Do not alter the instal-

lation or permit even partial blockage of ventilation provisions,

as this can seriously affect safe operation of the generator. The

generator MUST be installed and operated outdoors only.

• 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.

• 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 Dealer

for parts needing repair or replacement.

• Before performing any maintenance on the generator, discon-

nect its battery cables to prevent accidental start up. Disconnect

the cable from the battery post indicated by a NEGATIVE, NEG

or (–) first, then remove the POSITIVE, POS or (+) cable. When

reconnecting the cables, connect the POSITIVE cable first, the

NEGATIVE 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 dan-

gerous operating conditions from leaking exhaust gases, fuel

leakage, oil leakage, etc.

EXHAUST HAZARDS

• Generator engine exhaust contains DEADLY carbon monox-

ide, an odorless, colorless poisonous gas. Breathing carbon

monoxide can cause: dizziness, throbbing temples, nausea,

muscular twitching, headache, vomiting, weakness and sleepi-

ness, inability to think clearly, fainting, unconsciousness or

even death. If you experience any carbon monoxide poisoning

symptoms, move into fresh air and immediately seek medical

attention.

• Never operate the generator set inside any garage or other

enclosed area.

ELECTRICAL HAZARDS

• All generators covered by this manual produce dangerous elec-

trical 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. Ensure all appropriate covers, guards

and barriers are in place, secured and/or locked before operat-

ing the generator. If work must be done around an operating

unit, stand on an insulated, dry surface to reduce shock hazard.

• Do not handle any kind of electrical device while stand-

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

DANGEROUS ELECTRICAL SHOCK MAY RESULT.



 IMPORTANT SAFETY INSTRUCTIONS: 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.

Safety Rules

3

• 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 system, the genera-

tor may crank and start at any time without warning. When this

occurs, load circuits are transferred to the STANDBY (genera-

tor) 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 fuse from the generator control panel.

• In case of accident caused by electric shock, immediately 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 equipment. Jewelry

can conduct electricity resulting in electric shock, or may get

caught in moving components causing injury.

FIRE HAZARDS

• For fire safety, the generator must be installed and maintained

properly. Installation must always 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 regulations.

• Keep a fire extinguisher near the generator at all times.

Extinguishers rated “ABC” by the National Fire Protection

Association are appropriate for use on the standby electric

system. Keep the extinguisher properly charged and be familiar

with its use. Consult the local fire department with any ques-

tions pertaining to fire extinguishers.

EXPLOSION HAZARDS

• Do not smoke around the generator. Wipe up any fuel or oil

spills immediately. Ensure that no combustible materials are left

in the generator compartment, or on or near the generator, as

FIRE or EXPLOSION may result. Keep the area surrounding the

generator clean and free from debris.

• Gaseous fluids such as natural gas and liquid propane (LP)

gas are extremely EXPLOSIVE. Install the fuel supply system

according to applicable fuel-gas codes. Before placing the

home standby electric system into service, fuel system lines

must be properly purged and leak tested according to applica-

ble code. After installation, inspect the fuel system periodically

for leaks. No leakage is permitted.

STANDARDS INDEX

In the absence of pertinent standards, codes, regulations and

laws, the published information listed below may be used for

installation guidance 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.

7. AGRICULTURAL WIRING HANDBOOK, available from the Food

and Energy Council, 909 University Avenue, Columbia, MO

65201.

8. ASAE EP-3634, INSTALLATION AND MAINTENANCE OF

FARM STANDBY ELECTRICAL 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.

Safety Rules



Only qualified electricians or contractors

should attempt such installations, which must

comply strictly with applicable codes, stan-

dards 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 protec-

tive enclosure that is intended for outdoor installation only.

• This UL listed standby generator set may be packaged with

an automatic transfer switch with built in load center. Circuit

breakers for emergency circuit connections are included (if

equipped).

• This UL listed, 2-pole switch is rated at 50 AC amperes at 250

volts maximum. The 50 Amp 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

distribution system when the generator is oper-

ating (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 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 con-

tents of a package that is not in evidence at the time 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 from the top, the roof

may appear stuck. Always verify that the side lock is unlocked

before attempting to lift the roof.

1.2 PROTECTION SYSTEMS

Unlike an automobile engine, the generator may have to run for

long periods of time with no operator present to monitor engine

conditions. For that reason, the engine is equipped with the follow-

ing systems that protect it against potentially damaging conditions:

1. Low Oil Pressure Sensor 4. Overspeed

2. High Temperature Sensor 5. RPM Sensor

3. Overcrank 6. Low Battery

There are LED's on the control panel to notify personnel that one of

these failures has occurred. There is a Status LED that illuminates

when all of the conditions described in the "Ready to Run" section

are true.

1.3 NEC REQUIREMENTS

Local code enforcement may require that AFCI’s be incorporated

into the transfer switch distribution panel. The Transfer Switch pro-

vided with this generator has a distribution panel that will accept

AFCI’s.

Siemens Part No. Q115AF - 15A or Q120AF - 20A can be obtained

from a local electrical wholesaler and will simply replace any of

the single pole circuit breakers supplied in the Transfer Switch

distribution panel.

1.4 EMISSION INFORMATION

The Environmental Protection Agency requires that this generator

complies with exhaust emission standards. This generator is certi-

fied to meet the applicable EPA emission levels. Additional infor-

mation regarding the requirements set by the EPA is as follows:

The generator is certified for use as a stationary engine for standby

power generation. Any other use may be a violation of federal and/

or local laws. It is important to follow the maintenance specifica-

tions in the "Maintenance" section to ensure that the engine com-

plies with the applicable emission standards for the duration of the

engine’s life. This engine is certified to operate on Liquid Propane

fuel and pipeline Natural Gas. The emission control system on the

generator consists of the following:

• Fuel Metering System

• Carburetor/mixer assembly

• Fuel regulator

• Air Induction System

• Intake pipe/manifold

• Air cleaner

• Ignition System

• Spark plug

• Ignition module

4

General Information

5

1.5 THE GENERATOR

Figure 1.1 – 7kW, Single Cylinder, LV-432 Engine (door

removed)

Exhaust

Enclosure

Base

Fuel Regulator

Battery

Fuel Inlet

Ground Lug

Oil Filter

Data Label

(see sample)

Air Filter

Circuit Breaker

Control Panel

Data label Sample

1.6 SPECIFICATIONS

1.6.1 GENERATOR

Rated Voltage ........................................................................240

Rated Maximum Load Current (Amps) at 240 Volts (LP)* .....29.2

Main Circuit Breaker ........................................................30 Amp

Transfer Switch Load Center Circuits

30A, 240V ................................................................................1

20A, 120V ..................................................................................1

15A, 120V ................................................................................5

Phase .......................................................................................1

Number of Rotor Poles ..............................................................2

Rated AC Frequency ...........................................................60 Hz

Battery Requirement ...............................Group 26R, 12 Volts and

525 CCA Minimum

Weight (unit only in lbs.) .......................................................225

Enclosure ................................................................... Composite

Normal Operating Range: This unit is tested in accordance to UL

2200 standards with an operating temperature of -20 °F (-29 °C)

to 122 °F. (50 °C). For areas where temperatures fall below 32

°F (0 °C), a cold weather kit and synthetic oil is required. When

operated above 77º F (25º C) there may be a decrease in engine

power. (Please reference the engine specifications section).

These generators are rated in accordance with UL2200, Safety

Standard for Stationary Engine Generator Assemblies; and CSA-

C22.2 No. 100-04 Standard for Motors and Generators.

* Natural Gas ratings will depend on specific fuel Btu content. Typical derates are

between 10-20% off the LP gas rating.

** Circuits to be moved must be protected by same size breaker. For example,

a 15 amp circuit in the main panel must be a 15 amp circuit in the transfer

switch.

1.6.2 ENGINE

Type of Engine ..............................................................OHV-432

Number of Cylinders .................................................................1

Rated Horsepower @ 3,600 rpm* .......................................14.8

Displacement ....................................................................432cc

Cylinder Block ................................Aluminum w/Cast Iron Sleeve

Valve Arrangement .............................................Overhead Valves

Ignition System .........................................Solid-state w/Magneto

Recommended Spark Plug .............................................RC12YC

Spark Plug Gap .........................................0.76 mm (0.030 inch)

Compression Ratio ..............................................................8.2:1

Starter ............................................................................12 VDC

Oil Capacity Including Filter........................Approx. 1.1 Qts (1.0L)

Recommended Oil Filter ......................................Part # 0H9039

Recommended Air Filter ......................................Part # 0H6104

Operating RPM ...................................................................3,600

* Engine power is subject to and limited by such factors as fuel Btu content,

ambient temperature and altitude. Engine 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.

General Information

1.7 SYSTEM READY LED

The "System Ready LED" is illuminated when all of the following

conditions are true:

1. The AUTO/OFF/MANUAL switch is set to the AUTO position.

2. The utility voltage supplied to the unit is sensed by the control-

ler.

3. No alarms are present, for example, low oil pressure, high

temperature, etc.

1.8 FUEL REQUIREMENTS AND

RECOMMENDATIONS

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 field convertible fuel system. 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 the recon-

figuring the Fuel System section for instructions on reconfiguration

of the fuel system.

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 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 generator is installed, verify that the fuel

pressure NEVER drops below five (5) inches water column for

natural gas or 10 inches water column for liquid propane.

Prior to installation of the generator, the installer should consult

local fuel suppliers or the fire marshal to check codes and regula-

tions for proper installation. Local codes will mandate correct rout-

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

landscaping to prevent any damage.

Special considerations should be given when installing the unit

where local conditions include flooding, tornados, hurricanes,

earthquakes and unstable ground for the flexibility and strength of

piping and their connections.

Use an approved pipe sealant or joint compound on all threaded

fittings.

All installed gaseous fuel piping must be purged and leak tested

prior to initial start-up in accordance 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

6/7 kW 85/2.41 148/4.19 0.99/3.75 1.26/4.79

Values given are approximate.

* Natural gas is in cubic feet per hour / cubic meters per hour.

** LP is in gallons per hour / liters per hour.

Verify that gas meter is capable of providing enough fuel flow to

include household appliances.

1.9.1 BTU FLOW REQUIREMENTS - NATURAL GAS

BTU flow required for each unit based on 1000 BTU per cubic foot.

• 6kW — 148,000 BTU/Hour





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.

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.

1.10 RECONFIGURING THE FUEL

SYSTEM

1.10.1 7 KW, 432CC ENGINE

1. Remove the generator enclosure roof by turning the four

quarter turn latches on the roof top. Push down slightly on the

latch then turn 90 degrees to release. The latch should pop up

as shown in Figure 1.2.

6

General Information

7

Figure 1.2 — Turn Latch

2. Remove the two side panels of the enclosure by lifting the

panels straight up until they are clear (Figure 1.3).

Figure 1.3 — Remove Side Panels

3. Carefully place the roof and side panels to one side.

4. Locate the fuel throttle assembly mounted to the engine

intake.

5. To change the fuel selection, remove the hose clamp and hose

from the throttle assembly (Figure 1.4).

Figure 1.4 — Remove Hose Clamp & Hose

6. Remove the Natural Gas (Larger ID) fuel jet from the fuel inlet

(Figure 1.5).

7. Obtain the fuel jet for Propane (Smaller ID that has been sup-

plied loose with the owners manual).

8. Verify that the O-ring, supplied loose with the owners manual

is installed, into the groove of the fuel jet.

9. Insert the Propane fuel jet into the end of the fuel inlet.

10. Reinstall the hose and clamp onto the fuel inlet and secure.

11. Verify the hose has not been kinked in any way.

12. The generator is now ready to run on LP Vapor fuel.

Figure 1.5 — Remove Fuel Jet

Throttle

Assembly

Fuel Jet

Fuel Inlet

O-Ring (installed)

Hose Clamp

Regulator

Hose

1.11 HIGH ALTITUDE OPERATION

The fuel system on this generator may be influenced by operation

at higher altitudes. Proper operation can be ensured by installing

an altitude kit when required. See the table below to determine

when an altitude kit is required. Operating this generator without

the proper altitude kit installed may increase the engine’s emis-

sions and decrease fuel economy and performance. Kits may be

obtained from any Dealer, and should be installed by a qualified

individual.

Unit Fuel Altitude Range* Kit Part Number

6/7 kW

LP Vapor 0- 6500 ft** Not Required

Nat. Gas

0- 2000 ft Not Required

2000 - 6500 ft** OJ7057

" Elevation above sea level

** At elevations above 6500 ft. the engine may experience

decreased performance.

General Information

Remove Clamp

and Hose

8

1.12 LOCATION



The engine exhaust fumes contain carbon

monoxide, which can be DEADLY. This dan-

gerous gas, if breathed in sufficient con-

centrations, can cause unconsciousness or

even death. This generator must be installed

properly, in strict compliance with applicable

codes and standards. Following installation,

do nothing that might render the system

unsafe or in noncompliance with such codes

and standards.

Operate the generator outdoors ONLY.

• Keep exhaust gases from entering a confined

area through windows, doors, ventilation, crawl

spaces or other openings (Figure 1.9).

• It is highly recommended that carbon monox-

ide detector(s) be installed indoors according

to the manufacturer's instructions/recommen-

dations.

• The generator must be mounted safely per

applicable codes and the manufacturer's speci-

fications. Do NOT alter or add to the exhaust

system, or do anything that might render the

exhaust system unsafe or in noncompliance

with applicable codes and standards.

1.12.1 GENERATOR

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

where adequate cooling and ventilating air is always available

(Figure 1.6). 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

become obstructed by leaves, grass, snow, etc. If prevailing

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

break to protect the unit.

• Install the generator on high ground where water levels will not

rise and endanger it.

• Allow sufficient room on all sides of the generator for mainte-

nance and servicing. This unit must be installed in accordance

with current applicable NFPA 37 and NFPA 70 standards; as

well as any other federal, state and local codes for minimum

distances from other structures. DO NOT install under wooden

decks or structures.

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

landscape irrigation, water sprinklers or sump pump discharge

does not flood the unit or spray the enclosure, including any air

inlet or outlet openings.

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

including concealed, underground or covered services such as

electrical, fuel, phone, air conditioning or irrigation.

• Where strong prevailing winds blow from one direction, face the

generator air inlet openings to the prevailing winds.

• 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.

Figure 1.6 – Generator Clearances

• The generator is typically placed on pea gravel or crushed

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

concrete base slab is required, all federal, state and local codes

should be followed. Special attention should be given to the

concrete base slab which should exceed the length and width

of the generator by a minimum of six (6) inches (0.152 meters)

on all sides.

1.12.2 NEW INSTALLATION GUIDELINES FOR

STATIONARY AIR-COOLED 7KW GENERATORS.

The National Fire Protection Association has a standard for the

installation and use of stationary combustion engines. That

standard is NFPA 37 and its requirements limit the spacing of an

enclosed generator set from a structure or wall (Figure 1.7).

NFPA 37, Section 4.1.4, Engines Located Outdoors. Engines, and

their weatherproof housings if provided, that are installed outdoors

shall be located at least 5 ft. from openings in walls and at least 5

ft. from structures having combustible walls.

Generator exhaust contains DEADLY carbon monoxide gas. This

dangerous gas can cause unconsciousness or death. Do not place

the unit near windows, doors, fresh air intakes (furnaces, etc.) or

any openings in the building or structure, including windows and

doors of an attached garage.

General Information

9

General Information

Figure 1.7 – Installation Guidelines

60 inches Minimum Distance All Around

36” if the surface has a fire resistant rating of at least one hour per NFPA 37

Existing Wall

No operable windows or openings in the wall permitted

within 5 feet from any point of the generator.

60” Minimum

60” Recommended

Minimum From Ends

Clearance from the ends and front of the generator

must be 36” minimum per NFPA 37. This would

include shrubs, trees and any kind of vegetation.

Clearance at the top should be a minimum of 60

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 constrain air flow.

These guidelines are based upon the

requirements of NFPA 37 and the

manufacturer’s requirement for air flow

for proper operation. Local codes may

be different and more restrictive than

what is described here.

Top of Generator

Generator

NOTE:

Failure to follow these minimum clearance guidelines may result in the generator failing inspection by the local building, electrical or fire

inspector requiring the generator be reinstalled in the correct location.

10

General Information

1.12.3 TRANSFER SWITCH

The transfer switch that shipped inside the carton with the genera-

tor is enclosed in a NEMA 1 (indoor rated only) enclosure.

• 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 surface.

• Never install the switch where water or any corrosive substance

might drip onto the enclosure.

• Protect the switch at all times against excessive moisture, dust,

dirt, lint, construction grit and corrosive vapors.





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. Sparking can occur at the battery

posts and cause an explosion.

1.13 BATTERY REQUIREMENTS

See the Specifications section for correct battery size and rating.

1.14 BATTERY INSTALLATION

Fill the battery with the proper electrolyte fluid if necessary and

have the battery fully charged before installing it.

Before installing and connecting the battery, complete the follow-

ing steps:

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 fuse from the generator control panel.

Battery cables were factory connected at the generator (Figure

1.8). Connect cables to battery posts as follows:

4. Connect the red battery cable (from starter contactor) to the

battery post indicated by a positive, POS or (+).

5. Connect the black battery cable (from frame ground) to the

battery post indicated by a negative, NEG or (—).

6. Install the battery post covers (included).

7. Install fuse.

Figure 1.8 – Battery Cable Connections

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 fall below 32° F (0° C) it is

required that a pad type battery heater be installed to aid in

cold weather starting.

1.15 THE BATTERY





Do not dispose of the battery in a fire. The

battery is capable of exploding.



A battery presents a risk of electrical shock

and high short circuit current. The following

precautions are to be observed when work-

ing on batteries:

• Remove the 7.5A fuse from the generator con-

trol panel.

• Remove watches, rings or other metal objects.

• Use tools with insulated handles.

• Wear rubber gloves and boots.

• Do not lay tools or metal parts on top of the

battery.

• 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 sulfuric acid that

is harmful to the skin and eyes. It is electri-

cally conductive and corrosive.

The following procedures are to be observed:

• Wear full eye protection and protective clothing.

• If electrolyte contacts the skin, wash it off

immediately with water.

• If electrolyte contacts the eyes, flush thorough-

ly and immediately with water and seek medical

attention.

• 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 bicarbonate of soda (baking 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:

11

• DO NOT SMOKE when near the battery.

• DO NOT cause flame or spark in battery area.

• Discharge static electricity from body before

touching the battery by first touching a ground-

ed metal surface.



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 gener-

ator 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 supervised by per-

sonnel knowledgeable of batteries and the required precautions.

Keep unauthorized personnel away from batteries.

See the Specifications section for the correct size and rating when

replacing the battery. 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 dia-

grams. Make sure the battery is correctly connected and terminals

are tight. Observe battery polarity when connecting the battery to

the generator set.

1.16 BATTERY CHARGER

It operates as a trickle charger which ensures output is continually

optimized to promote maximum battery life and charging levels are

at safe conditions.

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.

NOTE:

This unit comes filled with oil from the factory. Check the oil

level and add the appropriate amount if necessary.

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. Turn OFF all loads connected to the transfer switch terminals

T1 and T2.

5. Check the engine crankcase oil level and, if necessary, fill to

the dipstick FULL mark with the recommended 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.

During initial start up only, the generator may exceed the normal

number of start attempts and experience an “over crank” fault (See

the "Overcrank" section). This is due to accumulated air in the fuel

system during installation. Reset the control board and retry up to

two more times, if necessary. If unit fails to start, contact the local

dealer for assistance.



Never operate the engine with the oil level

below the “Add” mark on the dipstick. Doing

so could damage the engine.

2.2 CHECK TRANSFER SWITCH

OPERATION

Refer to the "Manual Transfer Operation" section, of the owner’s

manual for procedures.



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 sup-

plies will result in extremely hazardous and

possibly fatal electrical shock.

2.3 ELECTRICAL CHECKS

Complete electrical checks as follows:

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. Turn ON the utility power supply to the transfer switch using

the means provided (such as a utility main line circuit break-

er).



The transfer switch is now electrically ener-

gized or “live.” Contact with electrically “hot”

parts will result in extremely hazardous and

possibly fatal electrical shock. Proceed with

caution.

5. Use an accurate AC voltmeter to check utility power source

voltage across transfer switch terminals N1 and N2. Nominal

line-to-line voltage should be 240 volts AC.

6. Check utility power source voltage across terminals N1 and

the transfer switch neutral lug; then across terminal N2 and

neutral. Nominal line-to-neutral voltage should be 120 volts

AC.

7. When certain that utility supply voltage is compatible with

transfer switch and load circuit ratings, turn OFF the utility

power supply to the transfer switch.

8. On the generator panel, set the Auto/Off/ Manual switch to

MANUAL. The engine should crank and start.

Post Installation Start-up and Adjustments

12

9. Let the engine warm up for about five minutes to allow inter-

nal temperatures to stabilize. Then, set the generator’s main

circuit breaker to its ON (or closed) position.



Proceed with caution! Generator power volt-

age is now supplied to the transfer switch.

Contact with live transfer switch parts will

result in dangerous and possibly fatal electri-

cal shock.

10. Connect an accurate AC voltmeter and a frequency meter

across transfer switch terminal lugs E1 and E2. Voltage

should be 240-245 at a frequency of 62-63 Hertz.

11. Connect the AC voltmeter test leads across terminal lugs E1

and neutral; then across E2 and neutral. In both cases, voltage

reading should be 120-125 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.

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.

2.4 GENERATOR TESTS UNDER

LOAD

To test the generator set with electrical loads applied, proceed as

follows:

1. Set generator’s main circuit breaker to its OFF (or OPEN) posi-

tion.

2. Turn OFF all breakers on the load center of the transfer box (T1

and T2).

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 utility main line circuit

breaker).



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 sup-

plies will result in extremely hazardous and

possibly fatal electrical shock.

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.

7. Let the engine stabilize and warm up for a few minutes.

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 the load center of the transfer switch (T1 and T2).

10. Connect an accurate AC voltmeter and a frequency meter

across terminal lugs E1 and E2. Voltage should be greater

than 230 volts, and frequency should be greater than 58 Hz.

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 overheat-

ing, etc.

12. When testing under load is complete, turn OFF electrical

loads.

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

OPERATION

To check the system for proper automatic operation, proceed as

follows:

1. Set generator’s main circuit breaker to its OFF (or OPEN) posi-

tion.

2. Check that the AUTO/OFF/MANUAL switch is set 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 utility power source side.

5. Turn ON the utility power supply to the transfer switch,

using the means provided (such as a utility main line circuit

breaker).

6. Set the generator's main circuit breaker to its ON (or CLOSED)

position.

7. Set the AUTO/OFF/MANUAL switch to AUTO. The system is

now ready for automatic operation.

8. Turn OFF the utility power supply to the transfer switch.

With the AUTO/OFF/MANUAL switch at AUTO, the engine should

crank and start when the utility source power is turned OFF after a

10 second delay. After starting, the transfer switch should connect

load circuits to the standby side after a five (5) second delay. Let

the system go through its entire automatic sequence of operation.

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:

• After about 15 seconds, the switch should transfer loads back

to the utility power source.

• About one minute after re-transfer, the engine should shut

down.

Post Installation Start-up and Adjustments

13

Operation

2.6 ENGINE GOVERNOR

ADJUSTMENT

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

adjust the engine governor as follows:



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. Then, tighten the governor lever clamp bolt to 70

inch-pounds (8 N-m).

3. Start the generator; let it stabilize and warm up at no-load.

4. Connect a frequency meter across the generators AC output

leads.

5. Turn the adjust screw to obtain a frequency reading of 62.5

Hz.

Figure 2.1 — Engine Governor Adjustment Single

Cylinder Engines

3.1 CONTROL PANEL INTERFACE

3.1.1 USING THE AUTO/OFF/MANUAL SWITCH

(FIGURE 3.1)



With the switch set to AUTO, the engine may

crank and start at any time without warning.

Such automatic 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 caused

by such sudden starts, always set the switch

to OFF and remove the fuses before work-

ing on or around the generator or transfer

switch. Then, place a “DO NOT OPERATE”

tag on the generator panel and on the trans-

fer switch.

1. “AUTO” Position – Selecting this switch activates fully auto-

matic 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 sec-

tion).

2. “OFF” Position – This switch position shuts down the engine.

This position also prevents automatic operation.

3. “MANUAL” Position – Set the switch to MANUAL to crank

and start the engine. Transfer to standby power will not occur

unless there is a utility failure.

3.1.2 SETTING THE EXERCISE TIMER

This generator is equipped with an exercise timer. Once it is set,

the generator will start and exercise every seven days, on the day

of the week and at the time of day specified. During this exercise

period, the unit runs for approximately 12 minutes and then shuts

down. Transfer of loads to the generator output does not occur

during the exercise cycle unless utility power is lost.

A switch on the control panel (see Figure 3.1) permits selection of

the day and time for the system to exercise. At the chosen time,

perform the following sequence to select the desired day and time

of day the system will exercise. Remember seasonal time changes

affect the exercise settings.

1. Verify that the AUTO/OFF/MANUAL switch is set to AUTO.

2. Press and hold the “Set Exercise” switch for several seconds.

All the red LED’s will stop flashing immediately and the gen-

erator will start.

3. The generator will start and run for approximately 12 minutes

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

time of day each week.

Example: If the “Set Exercise” pressed on Saturday afternoon at

2:00 p.m., the generator will start and exercise for approximately

12 minutes every Saturday at 2:00 p.m.

Figure 3.1 – Generator Control Panel

SET

EXERCISE

SYSTEM READY

LOW BATTERY

LOW OIL PRESSURE

HIGH OIL TEMPERATURE

OVERSPEED

RPM SENSOR LOSS

OVERCRANK

14

Set-up Procedure

1. Ensure Utility power is supplied to the Transfer Switch.

2. Remove the 7.5A Fuse from the Control Panel.

3. Wait ten (10) seconds.

4. Install the 7.5A Fuse.

5. Set the AUTO/OFF/MANUAL switch to AUTO.

6. All the LEDs on the Control Panel will begin to flash.

7. Press and hold the SET EXERCISE button for five (5) seconds.

8. Only the System Ready LED will remain on, the rest will stop

flashing.

9. The Generator will crank, start and run for twelve (12) min-

utes. It will NOT transfer during this time unless Utility is lost.

10. At the end of the Exercise period the Generator will shut down.

NOTE:

The exerciser will only work in the AUTO mode and will not work

unless this procedure is performed. The excercise time will

need to be reset every time the 12 volt battery is disconnected

and then reconnected, and/or when the fuse is removed.

3.2 AUTOMATIC TRANSFER

OPERATION

To select automatic operation, do the following:

1. Make sure the transfer switch main contacts are set to their

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

source (Figure 3.1).

2. Be sure that normal UTILITY power source voltage is avail-

able to transfer switch terminal lugs N1 and N2 (Refer to the

Electrical Data section).

3. Set the generator’s AUTO/OFF/MANUAL switch to AUTO.

4. Set the generator’s main circuit breaker to its ON (or CLOSED)

position.

With the preceding steps complete, the generator will start auto-

matically when utility source voltage drops below a preset level.

After the unit starts, loads are transferred to the standby power

source. Refer to the Sequence of Automatic Operation section.

3.3 SEQUENCE OF AUTOMATIC

OPERATION

3.3.1 UTILITY FAILURE

Initial Conditions: Generator in Auto, ready to run, load being sup-

plied by utility source. When utility fails (below 65% of nominal),

a 10 second line interrupt delay time is started. If the utility is still

not present when the timer expires, the engine will crank and start.

Once started, a five (5) second engine warm-up timer will be initi-

ated. When the warm-up timer expires, the control will transfer the

load to the generator. If the utility power is restored (above 75% of

nominal) at any time from the initiation of the engine start until the

generator is ready to accept load (5 second warm-up time has not

elapsed), the controller will complete the start cycle and run the

generator through its normal cool down cycle; however, the load

will remain on the utility source.

3.3.2 CRANKING

The system will control the cyclic cranking as follows: 16 second

crank, seven (7) second rest, 16 second crank, seven (7) second

rest followed by three (3) additional cycles of seven (7) second

cranks followed by three (3) second rests.

Choke Operation

The 432cc engines have a choke behind the air box that is auto-

matically controlled by the electronic control board.

Failure to Start

This is defined as any of the following occurrences during crank-

ing:

1. Not reaching starter dropout within the specified crank cycle.

Starter dropout is defined as four (4) cycles at 1,000 RPM.

2. Reaching starter dropout, but then not reaching 2200 RPM

within 15 seconds. In this case the control board will go into

a rest cycle for seven (7) seconds, then continue the rest of

the crank cycle.

During a rest cycle the start and fuel outputs are de-energized and

the magneto output is shorted to ground.

Cranking Conditions

The following notes apply during cranking cycle.

1. Starter motor will not engage within five (5) seconds of the

engine shutting down.

2. The fuel output will not be energized with the starter.

3. The starter and magneto outputs will be energized together.

4. Once the starter is energized the control board will begin look-

ing for engine rotation. If it does not see an RPM signal within

three (3) seconds it will shut down and latch out on RPM

sensor loss.

5. Once the control board sees an RPM signal, it will energize the

fuel solenoid and continue the crank sequence.

6. Starter motor will disengage when speed reaches starter

dropout.

7. If the generator does not reach 2200 RPM within 15 seconds,

re-crank cycle will occur.

8. If engine stops turning between starter dropout and 2200

RPM, the board will go into a rest cycle for seven (7) seconds

then re-crank (if additional crank cycles exist).

9. Once started, the generator will wait for a hold-off period

before starting to monitor oil pressure and oil temperature

(refer to the Alarm Messages section for hold-off times).

10. During Manual start cranking, if the Mode switch is moved

from the Manual position, the cranking stops immediately.

11. During Auto mode cranking, if the Utility returns, the cranking

cycle does NOT abort but continues until complete. Once the

engine starts, it will run for one (1) minute, then shut down.

Operation

15

3.3.3 LOAD TRANSFER

The transfer of load when the generator is running is dependent

upon the operating mode as follows:

1. Manual

• Will not transfer to generator if utility is present.

• Will transfer to generator if utility fails (below 65% of nominal for

10 consecutive seconds.

• Will transfer back when utility returns for 15 consecutive sec-

onds. The engine will continue to run until removed from the

Manual mode.

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.

• Will transfer back to utility if the generator is shut down for any

reason (such as the switch is in the OFF position or a shutdown

alarm.

• After transfer, will shut down engine after one (1) minute cool-

down time.

3. Exercise

• Will not exercise if generator is already running in either Auto or

Manual mode.

• During exercise, the controller will only transfer if utility fails

during exercise for 10 seconds, and will switch to Auto mode.

3.3.4 UTILITY RESTORED

Initial Condition: Generator supplying power to customer load.

When the utility returns (above 75% of nominal), a 15 second

return to utility timer will start. At the completion of this timer, if

the utility supply is still present and acceptable, the control will

transfer the load back to the utility and run the engine through a

one (1) minute cool down period and then shut down. If utility fails

for three (3) seconds during this cool down period, the control

will transfer load back to the generator and continue to run while

monitoring for utility to return.

3.4 MANUAL OPERATION

This transfer switch is suitable for manual transfer under load

providing the dead front cover is in place.

Manual operation must be checked BEFORE the transfer switch

is operated electrically. To check manual operation, proceed as

follows:

1. Turn the generator’s AUTO/OFF/MANUAL switch to OFF.

2. Turn OFF both UTILITY (service disconnect breaker) and the

main line circuit breaker on the generator.

3. Note position of the 2 switches below the transfer switch

operator.

• Utility supply switch (left side) ON and Generator supply

switch (right side) OFF – LOAD terminals are connected to

the Utility.

• Utility supply switch (left side) OFF and Generator supply

switch (right side) ON – LOAD terminals are connected to the

Generator.

3.4.1 CLOSE TO UTILITY SOURCE SIDE

Before proceeding, verify the position of the transfer mechanism

by observing the position of 50A, 2-pole switches.

If the Utility Supply switch (left side) is ON, no further action is

required.

If not, move the Utility Supply switch handle to the ON position.

Note: the Generator Supply switch handle should move to the OFF

position.

The customer load is now connected to the Utility supply.

3.4.2 CLOSE TO GENERATOR SOURCE SIDE

Before proceeding, verify the position of the transfer mechanism

by observing the position of 50A, 2-pole switches.

If the Generator Supply switch (right side) is ON, no further action

is required.

If not, move the Generator Supply switch handle to the ON posi-

tion. Note: the Utility Supply switch handle should move to the OFF

position.

The customer load is now connected to the Generator supply.

3.4.3 RETURN TO UTILITY SOURCE SIDE

Move the Utility Supply switch handle to the ON position. Note: the

Generator Supply switch handle should move to the OFF position.

The customer load is now connected to the Utility supply.

3.5 SIDE COMPARTMENT

(FIGURES 3.2 & 3.3)

Local codes may require this compartment to be locked. A hasp is

provided so the owner can secure the compartment with their own

padlock. Check local codes in the area.

3.5.1 MAIN CIRCUIT BREAKER

This is a 2-pole breaker rated according to the Specifications sec-

tion.

Figure 3.2 – Side Compartment

Operation

16

Figure 3.3 – Open Side Compartment

3.6 PROTECTION SYSTEMS

3.6.1 ALARMS

Low Oil Pressure (Shutdown Alarm)

A five (5) second delay on start-up and eight (8) second delay

once the engine is running.

This switch (Figure 3.4) has normally closed contacts that are

held open by engine oil pressure during operation. Should the oil

pressure drop below the five (5) PSI range, switch contacts close

and the engine shuts down. The unit should not be restarted until

oil level is verified.

High Oil 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 3.4) close if the temperature should

exceed approximately 124° C (255° F), initiating an engine shut-

down. Once the oil temperature drops to a safe level the switch’s

contacts open again.

Over Crank (Shutdown Alarm)

This occurs if the engine has not started within the specified crank

cycle. (See "Cranking" section.)

Over Speed (Shutdown Alarm)

4320 RPM for three (3) seconds or 4500 RPM immediately. This

feature protects the generator from damage by shutting it down

if it happens to run faster than the preset limit. This protection

also prevents the generator from supplying an output that could

potentially damage appliances connected to the generator circuit.

Contact the nearest Dealer if this failure occurs.

Figure 3.4 – Low Oil Pressure and

High Temperature Switches

RPM Sensor Loss (Shutdown Alarm)

During cranking, if the Control Board does not see a valid RPM

signal within three (3) seconds, it will shut down and lock out on

RPM sensor loss. While engine is running, if RPM signal is lost for

two (2) seconds the Control Board will shut the engine down, wait

15 seconds, then re-crank the engine. If no RPM signal is detected

within the first three (3) seconds of cranking, the Control Board

will shut the engine down and latch out on RPM sensor loss. If the

RPM signal is detected, the engine will start and run normally. If

the RPM signal is subsequently lost again, the Control Board will

try one more re-crank attempt before latching out and displaying

the RPM sensor failure message.

Clear Alarms

Clear alarms by setting the AUTO/OFF/MANUAL switch to the OFF

position.

3.6.2 WARNINGS

Second Priority (Non-latching) Displayed on the control panel.

Warnings automatically clear when the monitored condition goes

away. Warnings cannot cause shutdowns.

Low Battery

The Control Board monitors battery voltage and illuminates an

LED warning if the battery voltage falls below 11.9 volts for one

(1) minute. Warning is automatically cleared if the battery voltage

rises above 12.4 volts. Battery voltage is not monitored during the

crank cycle.

3.6.3 PANEL ORIENTATION

When replacing the panels after installation or maintenance, the

orientation of each panel is critical to proper cooling and operation

of the generator. Slide each panel into the corner post as identified

in Figure 3.5. Note the decals on each panel for the correct place-

ment, including the roof.

Operation

17

Figure 3.5 — Panel Location

BACKTOP

TOP

BACK

BA

C

K

TO

P

TO

P

B

A

CK

3.7 SHUTTING THE GENERATOR

DOWN WHILE UNDER LOAD

To safely stop and start a loaded generator follow these steps.

ISOLATE THE MAIN SERVICE DISTRIBUTION PANEL

1. At the main service distribution panel, open (turn off) the main

service entrance breaker.

STOPPING THE GENERATOR

1. Turn the Main Circuit Breaker off (Figure 3.6).

2. Allow the generator to run for 1 minute without load to cool

down.

Figure 3.6 – Open Side Compartment

3. Turn the Auto/Off/Manual switch to the Off position (Figure

3.7).

4. If the generator will be left off for longer than 1 hour without

utility present remove the 7.5 Amp Main Fuse from the control

panel (Figure 3.7). This will prevent the control panel from

running down the battery.

STARTING THE GENERATOR

1. If the Main Fuse was removed, replace the fuse.

2. Turn the Auto/Off/Manual switch to the Auto position. After a

short delay the generator will start.

3. Allow the generator to run for 15 seconds to allow the engine

to warm up.

4. Turn on the Main Circuit Breaker.

Figure 3.7 – Generator Control Panel

SET

EXERCISE

SYSTEM READY

LOW BATTERY

LOW OIL PRESSURE

HIGH OIL TEMPERATURE

OVERSPEED

RPM SENSOR LOSS

OVERCRANK

REPOWER THE MAIN SERVICE DISTRIBUTION PANEL

1. At the main service distribution panel, close (turn on) the main

service entrance breaker.

This method will ensure proper transfer between generator and

utility in the event that utility returns while the generator is shut

off.

4.1 PERFORMING SCHEDULED

MAINTENANCE

It is important to perform service as specified in the Maintenance

Schedule for proper generator operation, and to ensure that the

generator complies with the applicable emission standards for the

duration of its useful life. Service and repairs may be performed

by any capable person or repair shop. Additionally, emissions criti-

cal maintenance must be performed as scheduled in order for the

Emissions Warranty to be valid. Emissions critical maintenance

consists of servicing the air filter and spark plugs in accordance

with the Maintenance Schedule.

Maintenance

18

4.2 FUSE

The 7.5 amp fuse on the control panel protects the DC control

circuit against overload (Figures 3.1 and 3.2). This fuse is wired

in series with the battery output lead to the panel. If this fuse ele-

ment has melted open, the engine will not be able to crank or start.

Replace this fuse using only an identical 7.5 amp replacement

fuse. Whenever the fuse is removed or replaced, the exercise timer

needs to be reset.

4.3 CHECKING THE ENGINE OIL

LEVEL

For oil capacities, see the Specifications section. For engine oil

recommendations, see the Engine Oil Recommendations section.

When power outages necessitate running the generator for extend-

ed periods of time, the oil level should be checked daily.

To check the engine oil level, proceed as follows (Figures 4.1):

1. If the generator is running during a utility outage, first turn OFF

all associated loads running in the residence. Second, turn the

generator's main circuit breaker to the OFF position.

2. Move the AUTO/OFF/MANUAL switch to the OFF position.

3. Remove the dipstick and wipe it dry with a clean cloth.

4. Completely insert the dipstick; then, remove it again. The oil

level should be at the dipstick “Full” mark. If necessary, add

oil to the “Full” mark only. DO NOT FILL ABOVE THE “FULL”

MARK.

5. Install the dipstick.

6. Reset the AUTO/OFF/MANUAL switch to its original position.

7. If the generator was running during a utility outage, first turn

the generator's main circuit breaker back to the ON position.

Second, turn ON needed loads in the residence.



Never operate the engine with the oil level

below the “Add” mark on the dipstick. Doing

this could damage the engine.

Figure 4.1 — Oil Dipstick and Fill

4.4 CHANGING THE ENGINE OIL



Hot oil may cause burns. Allow engine to

cool before draining oil. Avoid prolonged

or repeated skin exposure with used oil.

Thoroughly wash exposed areas with soap.

4.4.1 OIL CHANGE INTERVALS

See the "Service Schedule" section.

4.4.2 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 tem-

perature.

• SAE 30  Above 32° F

• 10W-30  Between 40° F and -10° F

• Synthetic 5W-30  10° F and below

SAE 30

SA E 3 0

Synthetic 5W-30

Sy nth et ic 5W- 30

10W-30

10 W-3 0



Any attempt to crank or start the engine

before it has been properly serviced with the

recommended oil may result in an engine

failure.

4.4.3 OIL & OIL FILTER CHANGE PROCEDURE

To change the oil, proceed as follows:

1. Start the engine by moving the AUTO/OFF/MANUAL switch to

MANUAL and run until it is thoroughly warmed up. Then shut

OFF the engine by moving the switch to the OFF position.

2. Immediately after the engine shuts OFF, pull the oil drain hose

(Figure 4.1) free of its zip-tie. Remove the cap from the hose

and drain the oil into a suitable container.

3. After the oil has drained, replace the cap onto the end of the

oil drain hose. Retain the hose in the zip-tie when finished.

Change the engine oil filter as follows:

1. With the oil drained, remove the old oil filter by turning it

counterclockwise.

2. Apply a light coating of clean engine oil to the gasket of the

new filter. See the Specifications section for recommended

filter.

Maintenance

Oil Dipstick

and Fill

Oil Drain

Hose

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Generac 7 kW 005837R0 Manuel utilisateur

Generac 7 kW 005837R0 Manuel utilisateur

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