Power Protect 12kW - Generator BRIGGS & STRATTON - Free user manual and instructions

USER MANUAL Power Protect 12kW BRIGGS & STRATTON

Standby Generator 12kW

en Installation and Operation Manual

Important Safety Instructions. 3

Safety Symbols and Meanings. 3

Safety Alert Symbol and Signal Words. 3

Safety Messages. 3

FCC Statement Part 15 to User. 6

Thank You. 6

Where to Find Us. 6

For Future Reference 6

General Information. 7

Equipment Description. 7

7

Owner Responsibilities. 7

Delivery Inspection. 7

Shipment Contents. 7

Generator Placement. 8

Cold Weather Kit. 8

Generator Location Considerations. 9

Installation Factors to Consider. 9

Product Use. 9

Reduce the Risk of Carbon Monoxide Poisoning. 9

Reducing the Risk of Fire. 12

Other General Location Guidelines. 12

Installation 13

Lift the Generator. 13

Anchor the Generator and Wind Ratings. 13

Electrical and Fuel Inlet Locations. 14

Access Panels - Installation and Removal. 15

Fuel Installation Plan 16

Electrical Field Connections. 19

Engine Oil 22

Battery. 22

System Control Board. 23

Initial Start-Up (No Load) 24

Operation 26

Features and Controls. 26

Important Owner's Considerations 27

Automatic Operation Sequence 27

Set the Exercise Timer. 27

Maintenance. 29

Servicing the System 29

Maintenance Schedule 29

Generator Maintenance 29

Clean the Generator. 30

Engine Maintenance. 30

Change the Oil and the Oil Filter. 31

Adjust Valve Lash. 31

Electronic Governor System 32

Electronic Governor Check Feature. 32

Servicing the Spark Plugs 32

Engine Air Cleaner 33

Exhaust System Maintenance. 34

Fuel System Maintenance. 34

Mixer/Throttle Control Device. 34

Alarms (Service Code Detection System) 34

Acknowledge and the Reset Alarms. 34

Electrical System Maintenance. 35

Troubleshooting 37

Troubleshooting Table 37

Wiring Diagram and Schematic. 39

Specifications. 40

Generator Specifications 12kW. 40

Engine Specifications 12kW. 40

Important Safety Instructions

SAVE THESE INSTRUCTIONS - This manual contains important instructions that must be read, understood, and obeyed during installation of generator kits and/or accessories.

Safety Symbols and Meanings

Symbol Meaning

Safety alert symbol shows a possible personal injury hazard.

Read Manual. Failure to obey warnings, instructions, installation manual, and Operator's Manual could result in death or serious injury.

Explosion

Electric Shock

Auto-start

Fire

Chemical Burn

Toxic Fume

Eye Protection

Hot Surface

Rotating Parts

Safety Alert Symbol and Signal Words

The safety alert symbol identifies safety information about hazards that could result in personal injury. A signal word (DANGER, WARNING, or CAUTION) is used to indicate the likelihood and the potential severity of injury. In addition, a hazard symbol is used to represent the type of hazard.

DANGER indicates a hazard which, if not avoided, will result in death or serious injury.

WARNING indicates a hazard which, if not avoided, could result in death or serious injury.

CAUTION indicates a hazard which, if not avoided, could result in minor or moderate injury.

NOTICE indicates information considered important but not hazard-related.

Safety Messages

WARNING

Failure to read and obey the operator's manual, all warnings, and operating instructions could result in death or serious injury.

WARNING

This product can expose you to chemicals including used engine oil, which is known to the State of California to cause cancer, and carbon monoxide, which is known to the State of California to cause birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.

WARNING

This product contains lead and lead compounds, known to the state of California to cause birth defects or other reproductive harm. Wash your hands after handling this product. Cancer and Reproductive Harm - www.P65Warnings.ca.gov.

WARNING

Engine exhaust contains carbon monoxide, a poisonous gas that could kill you in minutes. You cannot smell it, see it, or taste it. Even if you do not smell exhaust fumes, you could still be exposed to carbon monoxide gas.

• Operate this product ONLY outdoors in an area that will not accumulate deadly exhaust gas.
• Direct exhaust gas away from any windows, doors, ventilation intakes, soffit vents, crawl spaces, open garage doors or other openings that can allow exhaust gas to enter inside or be drawn into a potentially occupied building or structure.
• Carbon monoxide detector(s) MUST be installed and maintained indoors according to the manufacturer's instructions/recommendations. Smoke alarms cannot detect carbon monoxide gas.
• If you start to feel sick, dizzy, weak, or your carbon monoxide alarm sounds while using this product, get to fresh air right away. Call emergency services. You may have carbon monoxide poisoning.

WARNING

Storage batteries give off explosive hydrogen gas during recharging. Slightest spark could ignite hydrogen and cause explosion, resulting in death or serious injury.

• DO NOT dispose of battery in a fire. Recycle battery.
• DO NOT allow any open flame, spark, heat, or lit cigarette during and for several minutes after charging a battery.

WARNING

Battery electrolyte fluid contains acid and is extremely caustic. Contact with battery contents could cause severe chemical burns.

DO NOT open or mutilate the battery
- Wear protective goggles, rubber apron, rubber boots and rubber gloves.
- Immediately wash electrolyte from skin with water.
- If electrolyte contacts eyes, immediately flush with water and seek medical attention.
- Spilled electrolyte is to be washed down with an acid neutralizing agent.

WARNING

A battery's high short circuit current could result in serious injury.

• Remove watches, rings, or other metal objects.
• Use tools having insulated handles.
• Disconnect charging source prior to connecting or disconnecting battery terminals.
• Do not lay tools or metal parts on top of batteries.
• Disconnect the negative (-) cable at the battery during installation and maintenance.

WARNING

With the battery connected, the generator may crank and start without warning resulting in death or serious injury.

• Do not connect the negative (-) cable at the battery until the installation is complete.

WARNING

With the battery connected, the generator may crank and start without warning resulting in death or serious injury.

• Before servicing, stop the generator and disconnect the negative (-) cable at the battery.

WARNING

Failure to isolate generator from utility power could result in death or serious injury to electric utility workers due to backfeed of electrical energy.

• Use a UL listed transfer switch to connect to a building electrical system.

WARNING

Generator and utility voltage could cause electrical shock or burn resulting in death or serious injury.

• Installation must be performed by a licensed professional.
• Disconnect all sources of electricity before installing or servicing equipment.
• Ground system before applying power.

WARNING

Hazardous Voltage - Installing low and high voltage wire in same conduit could cause electric shock or burns, resulting in death or serious injury.

• Do not run low and high voltage wire in the same conduit unless the insulation rating on ALL wiring is rated for 600V. See NFPA 70 for more information.

WARNING

Exhaust heat/gases could ignite combustibles or structures resulting in death or serious injury.

• Exhaust outlet of enclosure must have at least 5 ft. (1.5m) minimum clearance from any structure, shrubs, trees, or any kind of vegetation.
• Enclosure must be at least 5 ft (1.5m) from windows, doors, any wall opening, shrubs, or vegetation over 12 inches (30.5 cm) in height.
• Enclosure must have a minimum of 5 ft. (1.5 m) overhead clearance from any structure, overhang, or trees.
• DO NOT place enclosure under a deck or other type of structure that may confine airflow.
• Smoke detector(s) MUST be installed and maintained indoors according to the manufacturer's instructions. Carbon monoxide alarms cannot detect smoke.
• Do not place enclosure in a manner other than shown in illustrations.

WARNING

Exhaust heat/gases could ignite combustibles causing a fire, resulting in death or serious injury.
- Remove all combustible materials from in and around the generator compartment.

WARNING

Hazardous Voltage - Contact with power lines could cause electric shock or burns, resulting in death or serious injury.

• If lifting or hoisting equipment is used, DO NOT contact any power lines.
• DO NOT lift or move generator without assistance.

WARNING

Propane and Natural Gas are extremely flammable and explosive, which could cause burns, fire or explosion resulting in death or serious injury.

• Installation must be performed by a licensed professional.
• Install the fuel supply system according to NFPA 37 and other applicable fuel-gas codes.
• Before placing the generator into service, the fuel system lines must be properly purged and leak tested.
• NO leakage is permitted.
• DO NOT operate engine if smell of fuel is present.

WARNING

Propane and Natural Gas are extremely flammable and explosive, which could cause burns, fire or explosion resulting in death or serious injury.

• The generator is equipped with an automatic safety gas fuel shut-off valve.
• DO NOT operate the equipment if the fuel shut-off valve is missing or inoperative.

WARNING

Propane and Natural Gas are extremely flammable and explosive, which could cause burns, fire or explosion resulting in death or serious injury.

• LP gas is heavier than air and will settle in low areas.
• Natural gas is lighter than air and will collect in high areas.
• The slightest spark could ignite these fuels and cause an explosion.
  DO NOT light a cigarette or smoke.

WARNING

Generator and utility voltage could cause electrical shock or burn resulting in death or serious injury.

DO NOT allow unqualified persons to operate or service this equipment.

WARNING

Accidental engine spark can cause an electric shock or fire and could result in entanglement, traumatic amputation or laceration.

Before you make adjustments or repairs:

• Disconnect the spark plug wire and keep it away from the spark plug.
• Disconnect the battery wire from the negative battery terminal (only engines with electric start.)
• Use only the correct tools.

When you check for spark:

• Use an approved spark plug tester.
• Do not check for spark with the spark plug removed.

NOTICE: Improper treatment of generator could damage it and shorten its life.

• Use generator only for intended uses.
• If you have questions about intended use, contact your authorized dealer.
• Operate generator only on level surfaces.
• Adequate, unobstructed flow of cooling and ventilating air is critical to correct generator operation.
• The access panels/doors must be installed whenever the unit is running.
• DO NOT expose generator to excessive moisture, dust, dirt, or corrosive vapor.
• Remain alert at all times while working on this equipment. Never work on the equipment when you are physically or mentally fatigued.
• DO NOT insert any objects through cooling slots.
  DO NOT use the generator or any of its parts as a step. Stepping on the unit could cause stress and break parts. This may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

• Shut off generator if:

• electrical output is lost.

• equipment sparks, smokes, or emits flames.
• unit vibrates excessively or makes unusual noises.

FCC Statement Part 15 to User

Pursuant to part 15.21 of the FCC Rules, you are cautioned that changes or modifications to the product not expressly approved by Briggs & Stratton could void your authority to operate the product.

This device complies with part 15 of the FCC Rules.

Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.

• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

• Consult the dealer or an experienced radio/TV technician for help.

Thank You

Thank you for purchasing this quality-built Briggs & Stratton® generator. We are pleased that you have placed your confidence in the Briggs & Stratton brand. When operated and maintained according to the instructions in this manual, your generator will provide many years of dependable service.

This manual contains safety information to make you aware of the hazards and risks associated with standby generators and how to avoid them. This product is only for use as an optional generator system which provides an alternate source of electric power and to serve loads such as heating, refrigeration systems, and communication systems that, when stopped during any power outage, could cause discomfort or inconvenience.

SAVE THESE INSTRUCTIONS - This manual contains important instructions that must be obeyed during installation, operation, and maintenance of the generator and batteries.

This generator system requires professional installation before use. The installer must obey the instructions completely.

Where to Find Us

You never have to look far to find support and service for your equipment. There are many authorized service dealers worldwide that provide quality service. You can also contact Customer Service by phone at 800-732-2989 between 8:00 AM and 5:00 PM central time or click on Dealer Locator at www.briggsandstraton.com, which provides a list of authorized dealers

For Future Reference

Please fill out the information below and keep with your receipt. Have this information at hand if it becomes necessary to contact your installer or authorized dealer regarding service or repair of the unit.

Date of Purchase:

Dealer / Retailer:

Dealer's / Retailer's Phone Number:

GENERATOR:

Model Number:

Model Revision:

Serial Number:

ENGINE:

Model Number:

General Information

For most applications, this manual contains the information necessary for the correct installation, operation, and maintenance of the equipment. All efforts have been made to make sure that the information in this manual is accurate and current. We reserve the right to change the product and this document without notification.

Equipment Description

• Emergency generator systems are intended to automatically supply illumination, power, or both, to designated areas and equipment in the event of failure of the normal supply. Emergency systems can also provide power for such functions as ventilation where essential to maintain life, where current interruption of the normal supply would produce serious life safety or health hazards.
• Legally Required standby generator systems are intended to automatically supply power to selected loads in the event of failure of the normal source which can create hazards or prevent rescue or fire-fighting operations.

Installer Responsibilities

• Read and obey the safety instructions.
  Install only a NRTL-approved transfer switch that is compatible with the generator.
• Read and obey the instructions in this Installation and Operation Manual.
• Installation must strictly comply with all applicable codes, industry standards, laws, and regulations.
• Allow sufficient room on all sides of the generator for maintenance and service.
• Discuss the generator placement with owner.
• Make sure that ALL manuals are given to the owner after the installation has been completed.

Owner Responsibilities

• Read and obey the instructions in this Installation and Operation Manual.
• Follow a regular schedule for maintaining and using the generator, as specified in this manual.
• Carbon monoxide detector(s) MUST be installed and maintained indoors according to the manufacturer's instructions and recommendations. Smoke alarms cannot detect carbon monoxide gas.
• Smoke detector(s) MUST be installed and maintained indoors according to the manufacturer's instructions and recommendations. Carbon monoxide alarms cannot detect smoke.

Delivery Inspection

Avoid damage from dropping, bumping, or collision with the shipping carton.

After removing the carton, carefully inspect the generator for any damage that may have occurred during shipment.

If loss or damage is found at the time of delivery, have the person(s) making the delivery notate the loss or damage on the freight bill and affix his signature under the consignor's memo of loss or damage. If the loss or damage is notated after delivery, separate the damaged materials and then contact the carrier for claim procedures. Missing or damaged parts are not warranted.

Shipment Contents

The generator system is supplied with:

Oil (5W30 Full Synthetic)
- Flexible fuel line
- Quick Operation Manual
Product and emissions warranty booklet
- Two access keys
- Two 15 Amp ATO-type fuses
- Four lifting hole caps
- Touch up paint
- Oil Warmer (pre-installed)
- Two 1/4-20 screws (for enclosure anchoring for wind rated areas)

Not included (You will need):

• Carbon monoxide detector(s)
• Smoke detector(s)
  Starting battery
• Connecting wire and conduit
• Fuel supply valves/plumbing
• Crane, lifting straps, chains or cables
• Two 60" (152cm) lengths of 3/4 " (1.9cm) nominal minimum Schedule 40 steel pipe (NOT conduit)
• Torque screwdriver, 5 to 50 inch-pound range
  Multi-meter

Generator Placement

Before installing the generator, consult with the owner and convey the following requirements, which must be satisfied before the installation is complete. There are two equally important safety concerns in regards to carbon monoxide poisoning and fire. There are also several general location guidelines that must be met before the installation is considered complete.

WARNING

Engine exhaust contains carbon monoxide, a poisonous gas that could kill you in minutes. You cannot smell it, see it, or taste it. Even if you do not smell exhaust fumes, you could still be exposed to carbon monoxide gas.

• Operate this product ONLY outdoors in an area that will not accumulate deadly exhaust gas.
• Direct exhaust gas away from any windows, doors, ventilation intakes, soffit vents, crawl spaces, open garage doors or other openings that can allow exhaust gas to enter inside or be drawn into a potentially occupied building or structure.
• Carbon monoxide detector(s) MUST be installed and maintained indoors according to the manufacturer's instructions/recommendations. Smoke alarms cannot detect carbon monoxide gas.
  If you start to feel sick, dizzy, weak, or your carbon monoxide alarm sounds while using this product, get to fresh air right away. Call emergency services. You may have carbon monoxide poisoning.
  DO NOT run this product inside homes, garages, basements, crawlspaces, sheds, or other partially-enclosed spaces even if using fans or opening doors and windows for ventilation. Carbon monoxide can quickly build up in these spaces and can linger for hours, even after this product has shut off.

(A) Exhaust outlet side of enclosure.
(B) Air inlet side of enclosure.

Cold Weather Kit

If the generator operates in temperatures below 30^ (-1^) it is recommended that a Cold Weather Kit be installed.

Cold Weather Kit, Part No. 6578, includes:

• Battery Warmer
• Battery Stand

Fuel Regulator Warmer Kit, Part Number 6845, includes:

Regulator warmer
- Deflector bracket
Harness

These items are available at your local service dealer.

If you need more information, please call 800-732-2989 between 8:00 AM and 5:00 PM CT.

Generator Location Considerations

The installation location of the generator has a direct effect on:

1. The amount and size of the plumbing required to fuel the generator.
2. The amount and size of the wiring required to control and connect the generator.
3. The safety of the installation regarding exhaust gas and carbon monoxide hazards, fire risks, proximity to other utilities, and exposure to weather elements.

Specific location guidelines are discussed in the next section. The owner and installer must consult one another to determine how the site can affect installation costs and compliance with local codes and standards.

There are two critical safety concerns to be addressed - carbon monoxide poisoning and the risk of fire, as follows:

Installation Factors to Consider

The illustrations shown in this manual are for typical circumstances. They are meant to familiarize you with the installation options available for the generator.

Federal and local codes, appearance, noise levels, fuel types, and distances are installation factors that must be considered. Remember that, as the distance increases from the existing electrical service and gaseous fuel supply, and the number of bends in the fuel supply increases, compensations must be made for piping and wiring materials. This is necessary to comply with local codes and overcome electrical voltage drops and gaseous fuel pressure drops.

Product Use

This product is only for use as an optional generator system which provides an alternate source of electric power and to serve loads such as heating, refrigeration, and communication systems that, when stopped during any power outage, can cause discomfort or inconvenience.

Every effort has been made to make sure that the information in this manual is accurate and current. However, we reserve the right to change, alter, or otherwise improve the product and this document at any time without prior notice.

Only current licensed electrical and plumbing professionals can attempt generator system installations. Installations must strictly comply with all applicable codes, industry standards, laws and regulations.

Reduce the Risk of Carbon Monoxide Poisoning

In high concentrations, carbon monoxide (CO) can be fatal in minutes. However, the effects of lower concentrations can

also be lethal. This gas poses serious dangers to humans and their animals because no one can smell, see, or taste it. Symptoms of exposure to CO include:

• Watery, itchy eyes
• Throbbing temples
• Inability to think coherently
  Ringing in the ears
• Headache
• Incoherent or slurred speech
• Flushed appearance
  Inattentiveness
• Loss of physical coordination
• Tightness across the chest
• Drowsiness
• Nausea
  Dizziness
  Vomiting
  Fatigue
• Collapse
• Convulsions

If you (or someone nearby) suffers from any of the above symptoms, immediately seek fresh air and call for emergency medical help for possible carbon monoxide poisoning. If your carbon monoxide alarm sounds while using this product, immediately seek fresh air (even if you experience none of the previously mentioned symptoms).

Carbon Monoxide Detectors

NOTICE: Installing functioning CO alarms indoors is the only way to recognize CO gas. Common smoke alarms do not detect CO gas and will not alert occupants of its presence.

A CO detector is an electronic device that detects hazardous levels of CO. When a buildup of CO occurs, the detector will alert the occupants by sounding an alarm and by flashing a visual indicator light.

By law many states require a home to have a functioning carbon monoxide (CO) detector. You must install and maintain carbon monoxide detector(s) indoors according to the manufacturer's instructions and recommendations.

Contact the local building inspection division for any relevant requirements regarding the use of CO detectors. See National Fire Alarm and Signaling Code (NFPA) 72 Code and Section R315 in the International Residential Code (ICC) for additional details.

Potential Carbon Monoxide Entry Points

Operation Guidelines:

NOTICE: Operate this product only outdoors and in an area that will not allow this deadly exhaust gas to collect.

Never operate this product inside homes, garages, basements, crawl spaces, sheds, under a deck, or other partially enclosed areas and understand that using fans and opening doors in these areas may not provide adequate

ventilation. Carbon monoxide can quickly accumulate in these forbidden spaces and can remain in the air for several hours after this product has shut off.

Installation Guidelines:

Follow all illustrations in this manual when placing an enclosure.

Always point the generator's engine exhaust away from occupied areas. Never expose your neighbors' homes to the

engine exhaust flowing from your standby generator during the installation process.

Never place the standby generator in any area where leaves or debris can accumulate.

Generator exhaust can enter through windows, doors, and other openings of a structure. Understand that exhaust and CO can seep into a structure through the smallest openings.

Protecting the Structure

Check the structure to ensure that the sealing and caulking remains adequate enough to prevent air from leaking in or out. Examine the structure for voids, cracks, or openings surrounding windows, doors, soffits, pipes, and vents, as these areas can permit exhaust gas and CO to enter the structure.

3

The table that follows includes examples of potential entry points for CO gas.

A	Windows and doors	Openings that are part of a structure's architecture can permit fresh air and CO into the structure, especially when open.
B Garage door An open or improperly unsealed garage door can allow CO to flow into a garage.
C	Attic vent	Generator exhaust can enter through attic vents and the vents for soffits, crawl spaces, and ridges or roofs.
D	Basement windows	Basement windows or hatches that permit ventilation to or from the structure's lower level also allow CO gas to enter the structure.
E Furnace intake or exhaust vent	Air intakes and furnace exhaust pipes are common entry points for CO gas.
F	Wall cracks	Any cracks in a structure's walls, including the foundation and mortar, and any gaps around windows, doors, and pipes can let CO in.
G Dryer vent Sometimes the exhaust vent for the clothes dryer lets CO gas into the structure.
H	Airflow restrictions	Areas featuring structural corners and heavy vegetation restrict the airflow and collect exhaust gas.
J	Makeup air system	Note: Keep all mechanical and gravity outdoor air intake openings for HVAC supply air systems 10 ft (3,0488 m) horizontally from the generator's enclosure. Refer to section 401 in the ICC Mechanical Code for details on requirements.
K Carbon monoxide detector(s)	Note: Installing functioning CO alarms indoors is the only way to recognize CO gas. Common smoke alarms do not detect CO gas and will not alert occupants of its presence.

Reducing the Risk of Fire

To help prevent fires, the generator must be installed a safe distance from all combustible materials. The unit's engine, alternator, and exhaust system components can become very hot during operation. Reduce the likelihood of a fire by keeping the unit properly ventilated, properly maintained, free of fuel leaks, and away from combustible materials. Also, flammable debris may collect within or outside the generator enclosure and may possibly ignite, causing a fire.

Federal and international standards describe the minimum safe clearances around and above the generator's enclosure.

Distance Requirements

An owner must maintain minimum clearances around the generator enclosure. These clearances exist primarily for fire prevention, but they also ensure adequate space for maintenance tasks, such as removing the unit's front and end panels.

The table that follows explains the correct distances required for installation.

LOCATION ITEM EXPLANATION
A	Front and end clearance	Maintain a 3 ft (.91 m) minimum clearance from the front and ends of the generator. Keep shrubs, bushes, plants, and trees this same minimum distance from the unit and never use vegetation to conceal the unit.
B Rear clearance	Since fuel and electrical connections occur here, keep 18 inches (45.70 cm) minimum clearance per independent testing laboratory, unless state codes tell you otherwise.
C	Windows, vents, and openings	Keep all operable windows, doors, vents, window wells, or openings in the wall away from the point of the generator. See Protecting the Structure section in this manual.
D Existing wall Keep the generator at least 18 inches (457 mm) away from existing walls.
E Removable fence Keep removable fences at least 3 ft (.91 m) away from the front of the generator. Removable fences include visual surrounds, fence panels, and temporary barriers without footings.
F	Overhead clearance	Maintain a 5 ft (1.52 m) minimum clearance from all structures, overhangs, and projections on a wall.
G Maintenance and servicing (not shown)		Allow adequate space to perform routine maintenance, such as servicing the engine and replacing the battery. Never use shrubs, bushes, trees, or plants to conceal the generator.

Other General Location Guidelines

• Place the standby generator in a prepared location that is flat and has provisions for water drainage.

• Install the standby generator in a location where sump pump discharge, rain gutter down spouts, roof run-off, landscape irrigation, or water sprinklers will not flood

12 BRIGGSandSTRATTON.COM

the unit or spray the enclosure and enter any air inlet or outlet openings.

• Install the standby generator where it will not affect or obstruct any services (including covered, concealed and underground), such as telephone, electric, fuel (natural gas / LPG vapor), irrigation, air conditioning, cable, septic, sewer, well and so forth.
• Install the standby generator where leaves, grass, snow, etc will not obstruct air inlet and outlet openings. If prevailing winds will cause blowing or drifting, you may need to construct a windbreak to protect the unit.

Installation

Only current licensed electrical professionals are qualified to do system installations. Installations must obey all related codes, industry standards and regulations. The equipment warranty is Void unless the system is installed by licensed electrical professionals.

Lift the Generator

WARNING

Hazardous Voltage - Contact with power lines could cause electric shock or burns, resulting in death or serious injury.

• If lifting or hoisting equipment is used, DO NOT contact any power lines.
• DO NOT lift or move generator without assistance.

Proper tools, equipment, and qualified personnel must be used in all phases of handling and moving the generator. The approximate weight of the generator is listed in the Generator Specifications section.

Use the lifting holes (A, Figure 5) in the base of the generator to lift the generator onto the concrete pad. Lift the generator in accordance with OSHA or local lifting regulations. Retouch any chipped paint with the supplied touch-up paint.

Anchor the Generator and Wind Ratings

Anchor the Unit to a Poured or Existing Concrete Slab.

To achieve the listed wind rating, the generator must be installed in strict compliance with this installation manual. The product components must be of the material specified and all screws must be installed in accordance with the

applicable provisions and the anchor manufacturer's published installation instructions.

The concrete slab/pad must meet the requirements (Figure 6) and the generator must be anchored with the anchors of Anchor Types 1 or 2.

There are three 7/16 hole locations (A, Figure 6) in the base of the generator in which to anchor the unit.

Anchor Types:

1. Qty (3) 3/8" SS ITW RED HEAD LDT, Anchor embedded 212 (64mm) in 3000 psi concrete. 3 (76mm) from the edge minimum, 6 (152mm) spacing minimum.
2. Qty (3) 3 / 8'' SS Powers/Dewalt Power Stud +SD2 Anchor embedded 212'' (64mm) in 3000 psi concrete. 3'' (76mm) from the edge minimum, 6'' (152.4mm) spacing minimum. There are four 7 / 16'' hole locations (A) in the base of the generator in which to anchor the unit.

Concrete Slab/Pad Type

WIND RATING MPH	PAD MODEL	PAD DIMENSIONS CONCRETE SPEC
		Width Length Thickness
Up to 140 Pre-cast Pad(contact dealer)	29in(737mm)	32in(813mm)	3in(76mm)	3000 PSI
140 to 175 Pre-cast Pad(contact dealer)	29in(737mm)	32in(813mm)	4in(102mm)	3000 PSI
140 to 175 Poured 30in	(762mm)	32in(813mm)	5in(127mm)	3000 PSI

These items are available at your local service dealer.

NOTICE: Unless mandated by local or state codes, or required to achieve wind rating, a concrete slab/pad is not required

Panel Attachment in Wind Rated Areas

To achieve a wind rating of 140 mph and above, (2) 1/4-20 Screws (B, Figure 7) are included and must be installed in the bottom of the front panel

Electrical and Fuel Inlet Locations

The 3/4 inch N.P.T. fuel inlet connector (A, Figure 8) and electrical inlet locations (B) are shown below.

A 12 inch knock-out is provided for the electrical inlet. This inlet may be enlarged or supplemented to accommodate a maximum conduit size of 1- 12 inches. Make sure that the installed conduit(s) enter the unit in zone (C) as shown in the drawing below so that they properly enter the electrical box and do not interfere with the fully opened roof.

Access Panels - Installation and Removal

The generator is equipped with an enclosure that has two access panels, as shown in the image that follow.

Front Panel (A, Figure 9) and roof (B) are used to access:

• Battery Compartment
  Engine Oil Drain Hose
• Engine Oil Filter
• Engine Valve Cover
• Spark Plugs

Each generator is shipped with a set of identical keys fastened to the fuel solenoid (C).

Roof Removal and Installation (Figure 10):

1. Remove or attach the roof, carefully, with the screws (A) that attach the roof to the unit.

Front Panel Removal and Installation (Figure 11):

1. Remove or attach the front panel, carefully, with the two screws (A) that attach the panel to the unit.

11

1. If installed (for wind rated regions), remove or attach the two screws (B, Figure 12) that attach the panel to the base.

12

1. Lift and flex panel outward and off of the base. Use caution to prevent damage to the battery box.

Fuel Installation Plan

Propane and Natural Gas are extremely flammable and explosive, which could cause burns, fire or explosion resulting in death or serious injury.

• Installation must be performed by a licensed professional.
• Install the fuel supply system according to NFPA 37 and other applicable fuel-gas codes.
• Before placing the generator into service, the fuel system lines must be properly purged and leak tested.
  NO leakage is permitted.
• DO NOT operate engine if smell of fuel is present.

WARNING

Propane and Natural Gas are extremely flammable and explosive, which could cause burns, fire or explosion resulting in death or serious injury.

• The generator is equipped with an automatic safety gas fuel shut-off valve.
• DO NOT operate the equipment if the fuel shut-off valve is missing or inoperative.

WARNING

Propane and Natural Gas are extremely flammable and explosive, which could cause burns, fire or explosion resulting in death or serious injury.

• LP gas is heavier than air and will settle in low areas.
• Natural gas is lighter than air and will collect in high areas.
• The slightest spark could ignite these fuels and cause an explosion.
  DO NOT light a cigarette or smoke.

TO THE INSTALLER: Consult with the generator owner(s) and convey any technical considerations that can affect their installation plans before applying these general guidelines.

The following general rules apply to gaseous fuel system piping:

• The piping material must conform to federal and local codes, be rigidly mounted, and be protected against vibration.
• Piping should be protected from physical damage, especially where it passes through flower beds, shrub beds, and other cultivated areas where damage can occur.
• Install the provided flexible fuel line (B, Figure 13) between the generator fuel inlet port (A) and the rigid

piping to prevent thermal expansion and contraction from causing excessive stress on the piping material.

• A union (C) or a flanged connection must be provided downstream to permit removal.
• A manometer test port (D) should be installed for vapor fuels. Use the port to install a manometer and check if the engine receives the correct fuel pressure for operation. A digital manometer (P/N 19495) or an analog manometer is available at your service center for vapor fuels only. When the initial test runs are completed, the manometer is removed and the port is plugged.
• For vapor fuels only: Where the formation of hydrates or ice is known to occur, piping should be protected against freezing. The termination of hard piping must include a sediment trap (E) where condensate is not likely to freeze.
• A minimum of one accessible, approved manual shutoff valve (F) shall be installed in the fuel supply line within 6 ft (180 cm) of the generator.
• You must install a manual fuel shut-off valve in the interior of the building.
• Where local conditions include earthquake, tornado, unstable ground, or flood hazards, special consideration shall be given to increase strength and flexibility of piping supports and connections.
• Piping must be of the correct size to maintain the required supply pressures and volume flow under varying generator load conditions with all gas appliances connected to the fuel system turned on and operating.
• Use a pipe sealant or joint compound approved for use with NG/LP on all threaded fittings to reduce the possibility of leakage.

NOTICE: Keep thread sealant out of the gas piping to prevent component part damage.

• Installed piping must be properly purged and leak tested, in accordance with applicable codes and standards.

13

(A) Generator Fuel Inlet
(B) Flexible Fuel Line
(C) Union Fitting

(D) Manometer Test Port
(E) Sediment Trap
(F) Manual Shut-off Valve

Fuel Consumption

Estimated fuel supply requirements at half and full load for natural gas and LP vapor fuels are shown in the table that follows:

LP Vapor (Propane)

	12kW
1/2 Load BTU/hr 155,000
	ft3/hr 62
	gal/hr 1.70
Full Load BTU/hr 209,000
	ft3/hr 84
	gal/hr 2.30

Natural Gas

	12kW
1/2 Load BTU/hr 117,000
	ft3/hr 117
Full Load BTU/hr 172,000
	ft3/hr 172

Physical Properties LP Vapor Natural Gas

Normal Atmospheric State Gas Gas
Boiling Point (°F) -44 -259
Heating Value
BTU per gallon (Net LHV*) 83,340	63,310
BTU per gallon (gross**) 91,547 n/a
BTU per cubic feet (gas) 2,500 1,000
Density***	36.39 57.75
Weight †	4.24 2.65

• LHV (Low Heat Value) is the more realistic rating.

** Gross heat value does not consider heat lost in the form of water during combustion.

*** Density is given in "Cubic Feet of Gas per Gallon of Liquid."

† Weight is given in "Pounds per Gallon of Liquid."

Fuel Type

Consider the type of fuel that your generator uses, as it affects the entire installation process. The system was factory tested and adjusted using natural gas, but it can be converted to use liquefied petroleum vapor. For correct engine function, consider factors that affect each of these fuels, such as the location and the duration of possible utility interruptions.

Follow these guidelines when choosing fuel type:

• Use clean, dry fuel that is free of moisture or any particulate material. Using fuels outside the recommended values can cause performance problems.
• In engines set up to run on propane (liquefied petroleum), only use commercial-grade HD-5 propane.

Natural gas or LP engines are certified to operate on natural or liquid propane gas. The emissions control system for this engine is EM (Engine Modifications).

Fuel Pressure

Both liquefied petroleum and natural gas fuel supply pressure at the generator's fuel inlet port must be a minimum value at full load with all gas appliances turned on and in operation.

Natural Gas must be 3.5-7 inches Water Column (WC).

Liquefied Petroleum must be 11-14 inches WC.

Make sure that all gas line shut-off valves are OPEN and that adequate fuel pressure is available whenever automatic operation is needed. Make sure that all gas line shutoff valves are OPEN and that adequate fuel pressure is available whenever automatic operation is desired.

Power Loss

Air density is less at high altitudes, resulting in less available engine power. Engine power will decrease by 3.5% for each 1,000 feet (300m) above sea level and by 1% for each 10^ (5.6^) above 77^ (25^) . Generators located in these conditions must have their transfer switch adjusted appropriately for this power decrease. See your Automatic Transfer Switch manual on how to adjust for the power decrease.

Fuel Pipe Size

NFPA 54 and 58 are common resources. The installer must consider the specific gravity of gas, compensate for a nominal amount of restriction from bends and fittings, and refer to federal and local codes for guidance.

Fuel Conversion

The engine of your home generator system is factory Calibrated and set to operate on natural gas (NG). It may also be operated on liquefied petroleum (LP) vapor.

NOTICE: Units are set to NG at the factory.

The initial factory NG settings are:

• Screw C, Figure x: 2.5 turns
  Screw D, Figure x: 0.5 turns

To convert to either fuel, do the steps that follow:

1. Push the ON/OFF Switch (A, Figure 14) on the side of the generator to the "OFF" (0) position.
2. Remove utility power to the generator to de-energize the battery charger.
3. Remove the roof.

18 BRIGGSandSTRATTON.COM

1. Remove the 15 Amp fuse (B) from the fuse holder at top of the control box.
2. Remove the front panel.
3. Disconnect the negative (-) cable at the battery.
4. Using a slotted screwdriver turn screws (C and D, Figure 15) clockwise until they are snug (over tightening can damage the mixer port).
5. Using a slotted screw driver turn screw (C) counterclockwise 1 / 4 turn.
6. Leave screw (D) seated.
7. Connect the negative (-) cable at the battery.
8. Install the front panel.
9. Install the 15 Amp fuse (B, Figure 14) into the fuse holder at top of the control box.
10. Install the roof.
11. Push the ON/OFF Switch (A) on the side of the generator to the "ON" (I) position.
12. Open Control Panel access door and verify that the panel is in Manual Mode.
13. Push and hold the CONFIG button to access the configuration menu.
14. Push SELECT to edit the items in the configuration menu.
15. To setup the generators control board for LP fuel you will need to enter the Configuration Menu by using the Dealer Password, which is available on the Power Portal.
16. Navigate to "SELECT PROFILE" and press select on the correct profile for the generator. For example "12KW_LP" for operating a 12kW unit running on LP fuel

NOTICE: Selecting a profile that is not intended for the generator can cause the generator to run erratically and could result in damage

1. To Save the new fuel setting, press and hold the STOP/CONFIG button until "Saving Settings..." is displayed.

2. For Additional information on the operation of the generator controller please refer to the online "Operation Instructions GC1030 Series GENSET Controller" manual associated with your generator.

Electrical Field Connections

WARNING

Generator and utility voltage could cause electrical shock or burn resulting in death or serious injury.

• Installation must be performed by a licensed professional.
• Disconnect all sources of electricity before installing or servicing equipment.
  Ground system before applying power.

WARNING

Hazardous Voltage - Installing low and high voltage wire in same conduit could cause electric shock or burns, resulting in death or serious injury.

• Do not run low and high voltage wire in the same conduit unless the insulation rating on ALL wiring is rated for 600V. See NFPA 70 for more information.

Low Voltage connections are made via a field connections terminal block (E, Figure 16) in main electrical area. Compare this illustration with your generator to familiarize yourself with the location of these connections.

16

Legend for System Connector Location (Figure 16):

(A) Utility Connection Connects utility 240VAC from the fuse block in ATS to the controller. Connect only one wire per terminal. Use #14 AWG (2.50 mm2) minimum 600V wire.
(B) Transfer Switch Connection — Controls the transfer switch contactor.
(C) Two-wire Start - Helps provide optional remote start contact.
(D) E-Stop - Use with the optional external E-Stop
(E) Field Connections Terminal Block — Reference the following table
(F) Power Connection (L1 and L2) - Offers power connection to the transfer switch
(G) Ground Connection Connects to the transfer switch ground wire
(H) Neutral Connection Connects to the transfer switch neutral wire
- (J) Communications Terminal Block — Reference the table that follows:

Pin Number Description Wire Type Connect To Notes

1 +12V 18AWG[1mm]		2] conductors, 600V minimum, 90°C Cu wire.	Transfer switch basic controller J7-8 12VDC.	Transfer switch Transfer Signal (only works with basic Transfer Switch Controller.
2 GND 18AWG[1mm]		2] conductors, 600V minimum, 90°C Cu wire.	Transfer switch basic controller J7-7 GND.
3 Xfer 18AWG[1mm]		2] conductors, 600V minimum, 90°C Cu wire.	Transfer switch basic controller J7-4 T/R.
4 2 WIRE START 18AWG[1mm]		2] conductors, 600V minimum, 90°C Cu wire.	Refer to Transfer switch manual to verify if this function is available.	Contact Close for Genset Start. (Only for transfer switch that provides this option). Mains monitoring must be disabled in the controller.
5 2 WIRE START 18AWG[1mm]		2] conductors, 600V minimum, 90°C Cu wire.
6 E-STOP 18AWG[1mm]		2] conductors, 600V minimum, 90°C Cu wire.	E-Stop Switch	Contact Open to Shutdown Genset
7 E-STOP 18AWG[1mm]		2] conductors, 600V minimum, 90°C Cu wire.	E-Stop Switch
8 Not Used --
Pin Number Description	Wire Type Connect To	Notes
9 VIN+	(+12V)	18AWG[1mm²] conductors, 600V minimum, 90°C Cu wire.	Refer to the Amplify Gateway Manual	Comm to WIFI module. Twisted pair #1: +12V and GND. Twisted pair #2: (A) and (B).
10 D- 18AWG[1mm]		²] conductors, 600V minimum, 90°C Cu wire.
11 D+ 18AWG[1mm]		²] conductors, 600V minimum, 90°C Cu wire.
12 GND 18AWG[1mm]		²] conductors, 600V minimum, 90°C Cu wire.
13 +12V 18AWG[1mm]		²] conductors, 600V minimum, 90°C Cu wire.	Not used Not used
14 (B) 18AWG[1mm]		²] conductors, 600V minimum, 90°C Cu wire.
15 (A) 18AWG[1mm]		²] conductors, 600V minimum, 90°C Cu wire.
16 GND 18AWG[1mm]		²] conductors, 600V minimum, 90°C Cu wire.
25 25 14AWG [2.5mm]		²] 600V minimum, 90°C Cu Wire.	Transfer switch Utility	Voltage Sensing for GENSET Start. Use either this signal or two-wire Start Signal for GENSET Start Signal (still required in two-wire start configuration for battery charger).
26 26 14AWG [2.5mm]		²] 600V minimum, 90°C Cu Wire.	Transfer switch Utility

• For power output connection (L1, L2, Neutral (N), and Ground), refer to the National Electric Code (NEC) and local codes.
• For communication wires use 600V wire and #18 AWG [1mm ^2 ] twisted-pair conductors that do not exceed a length of 500 ft (150 m).
• When connecting to the terminal block, fasten only one wire to each connector screw.
• Torque terminal block screws to 4.4 in-lb [0.5 Newton meter (N·m)].
• Torque circuit breaker connections to 45 in-lb (5 N·m).

AC System Connections

A single-phase, three-wire AC connection system is used in the generator (Figure 17). The stator assembly consists of a pair of stationary windings with two leads brought out of each winding. The junction of leads 22 and 33 forms the neutral lead, as shown schematically and as a wiring diagram.

NOTICE: Neutral is not bonded to ground at generator.

NOTICE: Generator must be used with only an UL listed transfer switch that is compatible with the generator.

17

Ground the Generator

Unless mandated by local code, additional chassis grounding to earth at the generator is not required. Any grounding at generator must use metal piercing lock washers (or equal), listed terminals installed per terminal supplier's instructions, and comply with national electrical codes and local requirements.

Power Connections from the Generator to the Transfer Switch

WARNING

Failure to isolate generator from utility power could result in death or serious injury to electric utility workers due to backfeed of electrical energy.

• Use a UL listed transfer switch to connect to a building electrical system.

Utility Circuit Connection

240V Utility leads must be routed in conduit. The 240V Utility leads deliver power to the generator's circuit board, optional battery warmer and optional oil warmer. This power also charges the battery. In AUTO Mode, when the power on these leads is lost, the generator will start. Using the installer-supplied minimum 300V, 14 [2.5 mm2] AWG wire, connect each control circuit terminal in the generator (25 and 26) to the fuse block in the automatic transfer switch

Generator Power Connections

Using the installer supplied minimum 300V wires and the table located in the Electrical Field Connections section, connect generator power output L1, L2, neutral (N), and ground to the corresponding L1, L2, neutral (N) and ground in the transfer switch.

NOTICE: Refer to the National Electric Code for correct electrical field connections and wire size calculations.

Engine Oil

NOTICE: Any attempt to crank or start the engine before it has been correctly filled with the recommended oil will result in equipment failure and service codes.

Refer to Maintenance in the Operation section of this manual for oil fill information.
- Damage to equipment resulting from failure to obey this instruction will void the engine and generator warranty.

This engine is shipped from the factory pre-run and filled with full synthetic oil (API SJ/CF 5W-30). This allows for system operation in a wide range of temperature and climate conditions. Before starting the engine, check the oil level as described in the Maintenance section of this manual.

The use of full synthetic oil does not alter the required oil change intervals described in the Operation section of this manual.

For operation in temperatures below 30^ (-1^) , the use of full synthetic oil (minimum API SJ) of viscosity 5W30 is required.

Battery

WARNING

batteries give off explosive hydrogen gas during Slightest spark could ignite hydrogen and cause a resulting in death or serious injury.

DO NOT dispose of battery in a fire. Recycle battery.
DO NOT allow any open flame, spark, heat, or lit cigarette during and for several minutes after charging a battery.

WARNING

Generator and utility voltage could cause electrical shock or burn resulting in death or serious injury.

• Installation must be performed by a licensed professional.
• Disconnect all sources of electricity before installing or servicing equipment.
  Ground system before applying power.

WARNING

Battery electrolyte fluid contains acid and is extremely caustic. Contact with battery contents could cause severe chemical burns.

DO NOT open or mutilate the battery
- Wear protective goggles, rubber apron, rubber boots and rubber gloves.
- Immediately wash electrolyte from skin with water.
If electrolyte contacts eyes, immediately flush with water and seek medical attention.
- Spilled electrolyte is to be washed down with an acid neutralizing agent.

The installer must supply and install a rechargeable 12 volt starting battery. The starting battery MUST conform to the specifications shown in the chart that follows.

Battery Specifications

Specifications Standard Cold Start (Less than 30°F / -1°C)
Volts 12 Volt DC 12 Volt DC
Amps (Minimum) 540 CCA (Cold Cranking Amps)	800 CCA (Cold Cranking Amps)
Construction Wet Lead Acid Wet Lead Acid
Terminal Type Top Post Type Battery Top Post Type Battery
Dimensions (Maximum) BCI Size 26 or BCI Size 51	BCI Size 24

WARNING

With the battery connected, the generator may crank and start without warning resulting in death or serious injury.

• Do not connect the negative (-) cable at the battery until the installation is complete.

Install the battery as described in Servicing the Battery in the Maintenance section of this manual. Always make sure

that the NEGATIVE cable is connected last and that the red POSITIVE terminal insulator is secure.

Use the supplied tie-down strap to secure the battery to the unit. Each end of the strap should be attached to the existing tabs in the base of the unit.

System Control Board

The generator control panel, located inside the generator housing, is shown in the image that follows (Figure 18). Brief descriptions of the controls used during installation are:

(A) Menu / Programming Navigation Buttons
(B) Stop / Config Button
(C) Start / Select Button
(D) Auto / Manual Button
(E) Alarm
(F) Digital Display - Displays generator mode, menu options, and alarms

NOTICE: Detailed descriptions of the controls are located in the Description of Control Keys section inside the online "Operation Instructions GC1030 Series GENSET Controller" manual associated with your generator.

Initial Start-Up (No Load)

Exhaust heat/gases could ignite combustibles causing a fire, resulting in death or serious injury.

• Remove all combustible materials from in and around the generator compartment.

The unit has been set-up for NG operation at the factory. Fuel conversion, if needed, must be completed prior to performing these steps. See Fuel Conversion.

Before operating the standby generator or placing it into service, inspect the entire installation carefully. Then, begin testing the system without electrical loads connected, as shown in the steps that follow:

NOTICE: When the generator is started for the very first time, it will require that any air in the gaseous fuel lines be purged. This can cause the engine to run roughly for a few minute.

1. Remove the two screws (A, Figure 19) that secure the circuit breaker cover to expose unit's circuit breaker.
2. Connect an accurate multi-meter to line side of the generator's main circuit breaker.
3. Set the generator's main circuit breaker to the ON (closed) position.
4. Install the 15 Amp fuse.
5. Push the ON/OFF switch, located on the side of the generator, to the ON (I) position.
6. Push the START/SELECT button on the control board. The engine will start in Low Idle Mode (LIM). Push again to bring the engine to full speed.

NOTICE: When the generator is started for the very first time, it will require that any air in the gaseous fuel lines be purged. This can cause the engine to run roughly for a few minutes

1. Listen for unusual noises, vibration or other indications of abnormal operation. Look for oil leaks while the engine runs.
2. Let the engine warm up for approximately 5 minutes to allow internal temperatures to stabilize.
3. Check the generator output at load side of circuit breaker. The voltage must be 225 - 250 Volts and the frequency must be 59 - 61 Hz.
4. Check the generator output between one generator connection lug and the neutral lug, then between the other generator connection lug and the neutral lug. In both cases, voltage reading must be between 112 and 125 Volts.
5. Push the STOP/CONFIG button on the control board. The engine will enter cool-down mode for approximately 5 minutes. Push again to stop the engine.

6. Install the circuit breaker cover.

7. When the test is completed and successful, install the front panel and the roof.

19

Operation

WARNING

Failure to read and obey the operator's manual, all warnings, and operating instructions could result in death or serious injury.

Features and Controls

12kW Generator (Figure 20)

20

Generator is shown with the roof and access covers removed for clarity.

Legend for System Connector Locations:

(A) Lifting Holes - Provided at each corner for lifting generator.
(B) Exhaust Port — High-performance muffler lowers the engine noise to comply with most residential codes.
- (C) Alternator — An electrical machine that generates an alternating current.
(D) Muffler - A device that reduces engine noise.
- (E) Air Cleaner - Uses a dry type filter element to protect the engine by filtering dust and debris out of intake air.
(F) Control Panel - Used for various test, operation and maintenance functions.
(G) Circuit Breaker - Protects the system from shorts and other over-current conditions.
- (H) Battery Compartment — For the installer supplied 12 Volt DC, battery that provides power to start the engine.
· (J) Fuel Inlet Port — Attach appropriate fuel supply to generator here.
· (K) Fuse — Located on the top of the control box.
(L) ON / OFF Switch - Used to turn the generator on (I) and off (0).

Important Owner's Considerations

WARNING

Engine exhaust contains carbon monoxide, a poisonous gas that could kill you in minutes. You cannot smell it, see it, or taste it. Even if you do not smell exhaust fumes, you could still be exposed to carbon monoxide gas.

• Operate this product ONLY outdoors in an area that will not accumulate deadly exhaust gas.
• Direct exhaust gas away from any windows, doors, ventilation intakes, soffit vents, crawl spaces, open garage doors or other openings that can allow exhaust gas to enter inside or be drawn into a potentially occupied building or structure.
• Carbon monoxide detector(s) MUST be installed and maintained indoors according to the manufacturer's instructions/recommendations. Smoke alarms cannot detect carbon monoxide gas.
• If you start to feel sick, dizzy, weak, or your carbon monoxide alarm sounds while using this product, get to fresh air right away. Call emergency services. You may have carbon monoxide poisoning.

WARNING

Propane and Natural Gas are extremely flammable and explosive, which could cause burns, fire or explosion resulting in death or serious injury.

• The generator is equipped with an automatic safety gas fuel shut-off valve.
• DO NOT operate the equipment if the fuel shut-off valve is missing or inoperative.

Engine Oil

The engine is shipped from the factory pre-run and filled with full synthetic oil (API SJ/CF 5W-30). This allows for system operation in a wide range of temperature and climate conditions. Before starting the engine, check the oil level as described in Maintenance.

NOTICE: Any attempt to crank or start the engine without being correctly filled with the recommended oil will result in equipment failure.

• Damage to equipment resulting from failure to obey this instruction will void engine and generator warranty.

Battery

The installer must supply a rechargeable 12 volt DC starting battery. See Battery in Final Installation Considerations in this manual.

15 Amp Fuse

Make sure that the fuse is correctly installed before operating your generator.

Automatic Operation Sequence

The generator's control board monitors utility voltage. If the utility voltage drops below a preset level, the control board will signal the engine to crank and start. When the utility voltage is restored above a preset voltage level, the engine is signaled to shut down. The actual system operation is not adjustable and is sequenced by sensors and timers on the control board, as follows:

Utility Voltage Dropout Sensor

• This sensor monitors the utility source voltage.
• If the utility source voltage drops below approximately 70 percent of the nominal supply voltage, the sensor initiates a timer. The timer is used to 'sense' brown-outs.
• Once the timer has expired, the engine will crank and start.

Utility Voltage Pickup Sensor

This sensor monitors the utility voltage. When the utility voltage is restored above approximately 80 percent of the nominal source voltage, a shut-down timer is initiated and the engine will go to engine cool-down.

Engine Cool-down Timer

When the utility power is sensed, the load transfers to the utility source and the engine will go into a 5 minute cool down period.

Set the Exercise Timer

1. Push and hold the Stop/Config button (B, Figure 21).
2. Push the Start/Select button (C) to enter WRITE MODE.
3. Enter the password (0000) by using the arrow keys (A) and the Start/Select button (C).
4. In the CONFIGURATION screen use the arrow keys (A) to find MODULE.
5. Push the Start/Select button (C) and using the arrow keys (A) find AUTO EXERCISE.

6. Push the Start/Select button (C) and using the arrow keys (A) select each parameter and choose the desired settings.

7. To save your settings when completed, push and hold the Stop/Config button (B) until "Saving Settings" shows on the display.

A detailed list of all the on screen parameters is located in the Configuration of GCU section inside the online "Operation Instructions GC1030 Series GENSET Controller" manual associated with your generator.

Maintenance

Servicing the System

Generator and utility voltage could cause electrical shock or burn resulting in death or serious injury.

DO NOT allow unqualified persons to operate or service this equipment.

With the battery connected, the generator may crank and start without warning resulting in death or serious injury.

• Before servicing, stop the generator and disconnect the negative (-) cable at the battery.

Before performing any generator maintenance, you must do the steps that follow.

1. Push the ON/OFF Switch on the back of the generator to the "OFF" (0) position.
2. Remove utility power to the generator to de-energize the battery charger.
3. Unlock and open the roof as described in the Access Panels section of this manual.
4. Remove the battery panel.
5. Remove the 15 Amp fuse from the fuse holder located behind the battery panel.
6. Disconnect the negative (-) cable at the battery.
7. Perform service steps as specified.
8. Connect the negative (-) cable at the battery.
9. Install the 15 Amp fuse into the fuse holder.
10. Install the battery panel.
11. Close and lock the roof.
12. Restore utility power to the generator.
13. Push the ON/OFF Switch on the back of the generator to the "ON" (I) position.
14. Set the generator mode to AUTO.

Maintenance Schedule

Obey the hourly or calendar intervals of operation, whichever occurs first.

Every 8 Hours of Operation or Daily

Clean Debris

Check the Engine Oil Level

Every 100 Hours of Operation or Annually

Change the Air Filter

Change the Engine Oil and Filter

Replace the Spark Plugs

Check the Valve Clearance

Check the Circuit Breaker Torques

Annually

Clean the Oil cooler Fins

Regular maintenance will improve the performance and extend the life of the generator. See any authorized dealer for service.

Emissions Control

Maintenance, replacement, or repair of the emissions control devices and systems can be done by any non-road engine repair establishment or an individual. However, to obtain "no charge" emissions control service, the work must be done by a factory authorized dealer. See the Emissions Warranty.

Generator Maintenance

The generator's warranty does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, the operator must maintain the generator as instructed in this manual.

Some adjustments will need to be made periodically to correctly maintain your generator.

All service and adjustments must be made at least once each season. Obey the requirements in the Maintenance Schedule chart.

Generator maintenance consists of keeping the unit clean. Operate the unit in an environment where it will not be exposed to excessive dust, dirt, moisture or any corrosive vapors. The cooling air louvers on the enclosure must not become clogged with snow, leaves, or other foreign material. To prevent generator damage caused by overheating, keep the enclosure cooling inlets and outlets clean and unobstructed at all times.

Check the cleanliness of the unit frequently and clean when dust, dirt, oil, moisture or other foreign substances are visible on its exterior/interior surface. Inspect the air inlet and outlet openings inside and outside the enclosure to make sure the air flow is not blocked.

NOTICE: Incorrect treatment of generator can damage it and shorten its life.

• DO NOT expose generator to excessive moisture, dust, dirt, or corrosive vapors.

• DO NOT insert any objects through cooling slots.

Clean the Generator

WARNING

Exhaust heat/gases could ignite combustibles causing a fire, resulting in death or serious injury.

• Keep the area near the generator clean and free of debris.

NOTICE: DO NOT use direct spray from a garden hose to clean generator. Water can enter the engine and generator and cause damage.

NOTICE: Periodically inspect the engine exterior for contamination and potential damage from dirt, leaves, rodents, spider webs, insects, etc. and remove.

1. Push the ON/OFF Switch on the back of the generator to the "OFF" (0) position.
2. Remove utility power to the generator to de-energize the battery charger.
3. Unlock and open the roof as described in the Access Panels section of this manual.
4. Remove the battery panel.
5. Remove the 15 Amp fuse from the fuse holder located behind the battery panel.
6. Disconnect the negative (-) cable at the battery.
7. Clean the generator as follows:

a. Use a damp cloth to wipe exterior surfaces clean.
b. Use a soft, bristle brush and vacuum cleaner to loosen and pick up dirt and debris.
c. Use low pressure air (not to exceed 25 psi) to blow away dirt and debris.
d. Clean the air inlets and outlets of any snow, leaves, or debris. To prevent generator damage caused by overheating, these openings must be kept unobstructed.

1. Connect the negative (-) cable at the battery.
2. Install the front panel.
3. Install the 15 Amp fuse into the fuse holder at top of the control box.
4. Install the roof.
5. Restore utility power to the generator.
6. Push the ON/OFF Switch on the side of the generator to the "ON" (I) position.
7. Set the generator mode to AUTO.

Engine Maintenance

Engine Oil

Use only Briggs & Stratton® 80028446 SAE 5W-30 full synthetic engine oil.

Check Engine Oil Level

Oil must be maintained between the "ADD" and the "FULL" marks on the dipstick. To make sure that an accurate reading is shown on the dipstick, make sure the following steps are taken before checking the oil level.

1. Push the ON/OFF Switch on the back of the generator to the "OFF" (0) position.
2. Remove utility power to the generator to de-energize the battery charger.
3. Unlock and open the roof as described in the Access Panels section of this manual.
4. Remove the battery panel.
5. Remove the 15 Amp fuse from the fuse holder located behind the battery panel.
6. Disconnect the negative (-) cable at the battery.
7. Allow approximately five minutes for the oil to drain back into the oil pan.
8. Remove the dipstick. Wipe it with a clean cloth or paper towel. Then, push the dipstick all the way into the dipstick tube.
9. Remove the dipstick and note the amount of oil on the dipstick. The oil level must be between the "ADD" and "FULL" mark.
10. If the oil level is below the "ADD" mark (Figure 22), install the dipstick and proceed to the next step.

22

1. Remove the oil filler cap from the valve cover.
2. Add the required amount of oil to bring the level up to, but not over, the "FULL" mark on the dipstick. Install the oil filler cap to the valve cover and wipe up any spilled oil
3. Connect the negative (-) cable at the battery.

4. Install the 15 Amp fuse into the fuse holder.

5. Install the battery panel.

6. Close and lock the roof.
7. Restore utility power to the generator.
8. Push the ON/OFF Switch on the back of the generator to the "ON" (I) position.
9. Set the generator mode to AUTO.

Change the Oil and the Oil Filter

Change the oil while the engine is still warm from operating.

1. Push the ON/OFF Switch on the back of the generator to the "OFF" (0) position.
2. Remove utility power to the generator to de-energize the battery charger.
3. Unlock and open the roof as described in the Access Panels section of this manual.
4. Remove the battery panel.
5. Remove the 15 Amp fuse from the fuse holder located behind the battery panel.
6. Disconnect the negative (-) cable at the batter.
7. Place the oil drain hose into an approved container.
8. Remove the brass fitting from the end of the oil drain hose.
9. When the oil has drained, replace the brass fitting on the hose.
10. Put an approved container beneath the oil filter area.
11. Remove the oil filter and dispose of it correctly.
12. Before installing a new oil filter, lightly lubricate the oil filter gasket with fresh and clean oil.
13. Install the oil filter by hand until the gasket contacts the oil filter adapter, then tighten the oil filter 12 to 34 turn.
14. Add the required amount of oil to bring the level up to, but not over, the "FULL" mark on the dipstick. Install the oil filler cap and wipe up any spilled oil.
15. Connect the negative (-) cable at the battery.
16. Install the 15 Amp fuse into the fuse holder.
17. Install the battery panel.
18. Close and lock the roof.
19. Restore utility power to the generator.
20. Push the ON/OFF Switch on the back of the generator to the "ON" (I) position.
21. Set the generator mode to AUTO.

Engine Oil

The engine is filled with full synthetic oil (API SJ/CF 5W-30). This allows for system operation in the widest range of temperature and climate conditions.

We recommend the use of Briggs & Stratton® 80028446 SAE 5W-30 full synthetic engine oil. Other high-quality detergent oils are acceptable if classified for service SJ or higher. Do not use special additives.

Synthetic oil meeting ILSAC GF-2, API certification mark and API service symbol with "SJ/CF ENERGY CONSERVING" or higher, is an acceptable oil at all temperatures. Use of synthetic oil does not alter required oil change intervals.

Adjust Valve Lash

The valve lash must be checked every 100 hours of operation. Measure the valve clearance with the engine cold. To adjust the valve lash, proceed as follows:

1. Push the ON/OFF Switch on the back of the generator to the "OFF" (0) position.
2. Remove utility power to generator to de-energize the battery charger.
3. Unlock and open the roof as described in the Access Panels section of this manual.
4. Remove the battery panel.
5. Remove the 15 Amp fuse from the fuse holder located behind the battery panel.
6. Disconnect the negative (-) cable at the battery.
7. Remove both spark plugs to ease manual rotation of engine crankshaft.
8. Access to rotate the engine by hand is available by:

a. Removing the engine intake screen in the battery compartment such that the crankshaft nut is accessible. Care must be taken when reassembling this screen using the self tapping screws as overtorqueing will strip out the partition material.

b. OR remove the front alternator outlet air scoop by removing the four screws that secure it. The crankshaft may be rotated via the aluminum alternator fan. Care should be taken not to damage the fan, and to reinstall the alternator outlet air scoop in the proper orientation.

1. Set the No. 1 cylinder at 14 (6mm) past Top Dead Center (TDC) on the compression stroke.
2. Using a feeler gage (A, Figure 23), measure the valve clearance.
3. For proper valve clearance for both the intake and exhaust see Engine Specifications Section.
4. Adjust the clearance by loosening the lock nut (B), then turn the adjusting screw (C).
5. Once the clearance is properly set, hold the adjusting screw while torqueing the lock nut to 70 in-lbs (8Nm).
6. Repeat these steps for cylinder No. 2.
7. Connect the negative (-) cable at the battery.
8. Install the 15 Amp fuse into the fuse holder.
9. Install the battery panel.
10. Close and lock the roof.

11. Restore utility power to the generator.

12. Push the ON/OFF Switch on the back of the generator to the "ON" (I) position.

13. Set the generator mode to AUTO.

23

24

Electronic Governor System

The engine electronic governor system allows for improved control and increased generator performance compared to mechanically governed systems. The result is a smooth steady-state operation without the "hunting" common to many mechanical governors. The system also reduces speed variations under engine loading and unloading and significantly reduces frequency fluctuation experienced when the engine is under higher loads.

The electronic governor system is composed of a stepper motor (B, Figure 24), stepper motor throttle control linkages (C), and throttle side linkage (A). The control board contains a digital controller that processes engine speed information and sends appropriate commands to the stepper motor to control the position of the engine throttle.

Since the electronic governing system controls the engine throttle demand based on generator load, the following service codes and/or conditions can be related to an electronic governing system issue:

• Engine Does Not Start
  Over Speed
  Under Frequency
• Unstable No Load Engine Control

While troubleshooting any of these conditions, a verification of the electronic governor system can be initiated through the control panel - Actuator Test.

Electronic Governor Check Feature

The generator has an electronic governing check feature that will turn on the stepper motor and move the throttle linkage clockwise and counterclockwise within the throttle limits. The test will rotate the stepper motor and move the throttle arm between the wide open throttle and dead idle limits for up to 10 seconds. This will allow visual verification that the stepper motor is functioning correctly and the control linkages are connected. The engine will not attempt to start during this test. If the stepper motor does not move, or if a linkage binds, then service will be required.

NOTICE: If stepper motor does not move, please make sure the stepper motor connector is attached.

Servicing the Spark Plugs

WARNING

Accidental engine spark can cause an electric shock or fire and could result in entanglement, traumatic amputation or laceration.

Before you make adjustments or repairs:

• Disconnect the spark plug wire and keep it away from the spark plug.
• Disconnect the battery wire from the negative battery terminal (only engines with electric start.)
• Use only the correct tools.

When you check for spark:

• Use an approved spark plug tester.
• Do not check for spark with the spark plug removed.

Changing the spark plugs will help your engine to start easier and operate better.

1. Push the ON/OFF Switch on the back of the generator to the "OFF" (0) position.
2. Remove utility power to the generator to de-energize the battery charger.
3. Unlock and open the roof as described in the Access Panels section of this manual.
4. Remove the battery panel.
5. Remove the 15 Amp fuse from the fuse holder located behind the battery panel.
6. Disconnect the negative (-) cable at the battery.
7. Clean the area around spark plugs.
8. Remove and inspect spark plugs.
9. Check electrode gap (A, Figure 25) with wire feeler gauge (B) and reset spark plug gap to recommended gap if necessary (see Engine Specifications at the end of this manual).

25

1. Replace the spark plugs if the electrodes are pitted, burned or the porcelain is cracked. Use the recommended replacement spark plugs (see Engine Specifications at the end of this manual).
2. Install the spark plugs and tighten them to 180 in/lbs (20 Nm).
3. Connect the negative (-) cable at the battery.
4. Install the 15 Amp fuse into the fuse holder.
5. Install the battery panel.
6. Close and lock the roof.
7. Restore utility power to the generator.

8. Push the ON/OFF Switch on the back of the generator to the "ON" (I) position.

9. Set the generator mode to AUTO.

Engine Air Cleaner

WARNING

Gaseous vapors are flammable and explosive. Fire or explosion could result in burns or death.

• Do not start and operate the engine with the air cleaner assembly (if equipped) or the air filter (if equipped) removed.

• Push the ON/OFF Switch on the back of the generator to the "OFF" (0) position.

• Remove utility power to the generator to de-energize the battery charger.
• Unlock and open the roof as described in the Access Panels section of this manual.
• Remove the battery panel.
• Remove the 15 Amp fuse from the fuse holder located behind the battery panel.
• Disconnect the negative (-) cable at the battery.
• Remove filter cartridge.
• Clean the outlet tube and check the Dust Unloader Valve (if equipped) - Use a clean cloth to wipe the filter sealing surface and the outlet tube surfaces. Make sure that all contaminant is removed before the new filter is inserted. Do not damage the sealing area on the tube. Check and squeeze the Dust Unloader Valve that is attached to the service cover to make sure it is flexible and not inverted, damaged or plugged.
• Clean the filter - Use a soft bristle brush to loosen dirt and a vacuum cleaner to remove dirt and debris. Replace the filter cartridge if you find any holes in the filter media.
• Install the clean filter correctly - Insert the filter carefully. Seat the filter by hand. Make sure it is completely seated in the air cleaner housing before you put the cover in place.
• Install the service cover. Make sure that all mounting bands, clamps, bolts, and connections in the entire air cleaner system are tight and make sure there are no holes in piping - repair if needed.
• Connect the negative (-) cable at the battery.
• Install the 15 Amp fuse into the fuse holder.
• Install the battery panel.
• Close and lock the roof.
• Restore utility power to the generator.
• Push the ON/OFF Switch on the back of the generator to the "ON" (I) position.
• Set the generator mode to AUTO.

Exhaust System Maintenance

WARNING

Contact with muffler area could cause burns resulting in serious injury.

• DO NOT touch hot parts and AVOID hot exhaust gases.
• Allow equipment to cool before touching.

When inspecting the exhaust system, check the following:

• Inspect the exhaust manifold at the cylinder head for leaks.
• Check that all retaining bolts and shields (if used) are in place.
• Inspect the fasteners between the manifold and the exhaust pipe to make sure they are tight and that there are no exhaust leaks. Repair as necessary.
• Inspect exhaust pipe connection for leaks. Repair as necessary.

It is a violation of California Public Resource Code, Section 4442, to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the exhaust system is equipped with a spark arrester, as defined in section 4442, maintained in effective working order. Other states or federal jurisdictions may have similar laws; reference Federal Regulation 36 CFR Part 261.52.

Fuel System Maintenance

WARNING

Propane and Natural Gas are extremely flammable and explosive, which could cause burns, fire or explosion resulting in death or serious injury.

• Inspect the fuel system periodically.
• NO leakage is permitted.
• DO NOT operate engine if smell of fuel is present.

Pressure Regulator

The pressure regulator components have been specifically designed and calibrated to meet the fuel system requirements of the engine.

If the regulator fails to operate or develops a leak, it must be repaired or replaced with the OEM recommended replacement parts. When inspecting the regulator, check the following:

• Check for any fuel leaks at the inlet and outlet fittings.
• Check for any fuel leaks in the regulator body.
• Check to make sure the regulator is correctly mounted and the mounting bolts are tight.
• Check the regulator for external damage.

Mixer/Throttle Control Device

The mixer and throttle body components have been specifically designed and calibrated to meet the fuel system requirements of the engine.

A dirty air filter can significantly alter the mixer performance. Make sure the air filter is clean. When inspecting the mixer and throttle body, check the following:

• Check for leaks at all the fittings.
• Make sure the mixer and throttle body are securely mounted.
• Inspect and clean the air filter element according to the recommended service intervals listed in the maintenance chart.
• Inspect air inlet hose connection and clamp. Inspect hose for cracking, splitting, or chafing. Replace as necessary.
• Check fuel lines for cracking, splitting, or chafing. Replace as necessary.
• Check for leaks at the throttle body and intake manifold.

Alarms (Service Code Detection System)

The generator will have to run for long periods of time with no operator present. For that reason, the system is equipped with sensors that automatically shut down the generator in the event of potentially damaging conditions, such as low oil pressure, high temperature, over speed, and other conditions.

The generator's control board shows service alarm descriptions on the digital display. The service alarm descriptions are listed in the "Alarms" section inside the online "Operation Instructions GC1030 Series GENSET Controller" manual associated with your generator.

Acknowledge and the Reset Alarms

Push the up and down arrows (A, Figure 26) simultaneously to reset the alarm.

26

Electrical System Maintenance

Wiring and Connections

The generator electrical system incorporates computers to control various components. The electrical system connectors and grounds require good connections. When inspecting the electrical system, check the following:

• Check the positive (+) and the negative (-) battery cables for corrosion, rubbing, chafing, burning, and make sure there are tight connections at both ends.
• Check the battery for cracks or damage to the case. Replace as necessary.
• Inspect the engine wire harness for rubbing, chafing, pinching, burning, and cracks or breaks in the wiring.
• Make sure that the engine harness connectors are correctly locked in.
• Inspect the ignition coil wire for hardening, cracking, chafing, burning, separation, and split boot covers.
• Inspect the spark plug wires for hardening, cracking, chafing, burning, separation, and split boot covers.
• Replace the spark plugs at the required intervals listed in the maintenance chart.
• Make sure that all electrical components are securely mounted to the engine or chassis.
• Make sure that any additional electrical services installed by the owner are correctly installed in the system.

Servicing the Battery

Servicing of the batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from the batteries.

WARNING

Battery electrolyte fluid contains acid and is extremely caustic. Contact with battery contents could cause severe chemical burns.

DO NOT open or mutilate the battery
- Wear protective goggles, rubber apron, rubber boots and rubber gloves.
- Immediately wash electrolyte from skin with water.
If electrolyte contacts eyes, immediately flush with water and seek medical attention.
- Spilled electrolyte is to be washed down with an acid neutralizing agent.

WARNING

Storage batteries give off explosive hydrogen gas during recharging. Slightest spark could ignite hydrogen and cause explosion, resulting in death or serious injury.

DO NOT dispose of battery in a fire. Recycle battery.
- DO NOT allow any open flame, spark, heat, or lit cigarette during and for several minutes after charging a battery.

WARNING

A battery's high short circuit current could result in serious injury.

• Remove watches, rings, or other metal objects.
• Use tools having insulated handles.
• Disconnect charging source prior to connecting or disconnecting battery terminals.
• Do not lay tools or metal parts on top of batteries.

• Disconnect the negative (-) cable at the battery during installation and maintenance.

• Push the ON/OFF Switch on the back of the generator to the "OFF" (0) position.

• Remove utility power to the generator to de-energize the battery charger.
• Unlock and open the roof as described in the Access Panels section of this manual.
• Remove the battery panel.
• Remove the 15 Amp fuse from the fuse holder located behind the battery panel.
• Disconnect the negative (-) cable at the battery.
• Disconnect the positive (+) cable at the battery.
• Service or replace the battery as required.
• Connect the positive (+) cable at the battery.
• Connect the negative (-) cable at the battery.
• Install the 15 Amp fuse into the fuse holder.
• Install the battery panel.
• Close and lock the roof.
• Restore utility power to the generator.
• Push the ON/OFF Switch on the back of the generator to the "ON" (I) position.
• Set the generator mode to AUTO.

Replacing the Battery

1. Push the ON/OFF Switch on the back of the generator to the "OFF" (0) position.
2. Remove utility power to the generator to de-energize the battery charger.
3. Unlock and open the roof as described in the Access Panels section of this manual.

4. Remove the battery panel.

5. Remove the 15 Amp fuse from the fuse holder located behind the battery panel.

6. Disconnect the negative (-) cable at the battery.
7. Disconnect the positive (+) cable at the battery.
8. Remove the battery and install replacement battery.

DON'T POLLUTE. CONSERVE RESOURCES. ORN USED BATTERY TO RECYCLING ECTION CENTER.

1. Connect the positive (+) cable at the battery.
2. Connect the negative (-) cable at the battery.
3. Install the 15 Amp fuse into the fuse holder.
4. Install the battery panel.
5. Close and lock the roof.
6. Restore utility power to the generator.
7. Push the ON/OFF Switch on the back of the generator to the "ON" (I) position.
8. Set the generator mode to AUTO.

Charging the Battery

If it is necessary to charge the battery, proceed as follows:

1. Push the ON/OFF Switch on the back of the generator to the "OFF" (0) position.

2. Remove utility power to the generator to de-energize the battery charger.

3. Unlock and open the roof as described in the Access Panels section of this manual.

4. Remove the battery panel.
5. Remove the 15 Amp fuse from the fuse holder located behind the battery panel.
6. Disconnect the negative (-) cable at the battery.

NOTICE: Failure to disconnect negative battery cable could result in equipment failure. DO NOT attempt to jump start the generator. Damage to equipment resulting from failure to follow this instruction will void engine and generator warranty.

1. Charge battery with the battery charger at 2 Amps until the battery holds 12 Volts. DO NOT exceed 13.7 volts when charging the battery.

NOTICE: DO NOT use a battery booster to quick charge a low battery.

1. Connect the negative (-) cable at the battery.
2. Install the 15 Amp fuse into the fuse holder.
3. Install the battery panel.
4. Close and lock the roof.
5. Restore utility power to the generator.
6. Push the ON/OFF Switch on the back of the generator to the "ON" (I) position.
7. Set the generator mode to AUTO.

Troubleshooting

Troubleshooting Table

The service alarm descriptions and their causes are listed in the table of the "Alarms" section inside the online "Operation Instructions GC1030 SERIES GENSET Controller" manual associated with your generator.

PROBLEM CAUSE CORRECTION
Engine is running, but no AC output is available.	1. Circuit breaker is open or defective.2. Alarm on generator control board.3. Poor wiring connections or defective transfer switch.	1. Reset or replace circuit breaker.2. Refer to Alarms section inside the online "Operation Instructions GC1030 Series GENSET Controller" manual associated with your generator. Contact local service facility.3. Check and repair or contact local service facility.
Engine runs well at no-load but "bogs down" when loads are connected.	1. Generator is overloaded.2. Short circuit in a connected load.3. Shorted generator circuit.4. Fuel pressure or mixture is incorrect.5. Kinked fuel line between regulator and engine.6. Clogged air filter.	1. Remove one or more loads.2. Disconnect shorted electrical load.3. Contact local service facility.4. See Gaseous Fuel System in this manual.5. Remove kink. Replace if necessary.6. Clean or replace air filter.
Engine will not start; or starts and runs rough.	1. 15 Amp fuse missing or blown.2. Thermal fuse(s) blown.3. Fuel supply turned off or depleted.4. Incorrect fuel selection.5. Failed battery.6. Clogged air filter.7. Throttle linkage binding.	1. Install (new) 15 Amp fuse. See System Control Board.2. Replace thermal fuse(s).3. Open fuel valve(s); check propane tank.4. Check fuel selector switch and set to proper setting. (If applicable).5. Replace battery.6. Clean or replace air filter.7. Check linkage.
Engine shuts down during operation.	1. Fuel supply turned off or depleted.2. Control board digital display shows an alarm.	1. Check fuel valves, fill propane tank.2. Refer to Alarms section inside the online "Operation Instructions GC1030 Series GENSET Controller" manual associated with your generator.
Loss of power on circuits.	1. Generator circuit breaker is open.2. Transfer switch problems.	1. Reset circuit breaker.2. See transfer switch manual.
Unit will not exercise.	1. Control board not set to AUTO.2. Exercise timer not set or set to OFF.3. Unit date and time not set.4. Failed battery.5. 15 Amp fuse missing or blown.	1. Push AUTO button on control board.2. Set exercise timer.3. Set unit date and time.4. Replace the battery.5. Install a (new) 15 Amp fuse. See System Control Board.
Excessive Vibration.	1. Loose mechanical fastener. 1. Check and repair or contact local service facility.
Odor of fuel	1. Fuel leak. 1. Turn off manual shutoff fuel valve. Contact local service facility.
Utility power returns, unit does not stop.	1. Blown fuses in transfer switch.2. 5 minute cool down not lapsed.3. Poor wire connection or defective controllers.	1. Install (new) fuses.2. Wait 5 minutes.3. Check, repair or contact local service facility.
Possible issues in MANUAL MODE. See Table 7 (Common faults and their remedial actions) inside the online "Operation Instructions GC1030 Series GENSET Controller" manual associated with your generator.
Possible issues in AUTO MODE. See Table 7 (Common faults and their remedial actions) inside the online "Operation Instructions GC1030 Series GENSET Controller" manual associated with your generator.
Possible issues with Electronic Governing. See Table 7 (Common faults and their remedial actions) inside the online "Operation Instructions GC1030 Series GENSET Controller" manual associated with your generator.

Wiring Diagram and Schematic

Specifications

Generator Specifications 12kW

Rated Maximum Load Current (at 25°C/77°F, LP) at 240 Volts	50 Amps
Rated AC Voltage 120/240 Volts
Phase Single Phase
Rated Frequency 60 Hertz
Generator Breaker 60 Amp
Normal Operating Range	-20°F (28°C) to 104°F (40°C)
Sound Rating * Low	Idle Mode	64 db(A)
	Normal Operation	70 db(A)
Shipping Weight 423 lb (192 kg)

• Per ISO 3744. Lowest mic at 23 ft (7m) at indicated load.

Engine Specifications 12kW

Displacement 38.26 ci. (627 cc)
Bore 2.972 in. (75.5 mm)
Stroke 2.756 in. (70 mm)
Spark Plug Gap 0.020 in. (0.51 mm)
Spark Plug Torque 180 Ib-in. (20 Nm)
Armature Air Gap 0.008 - 0.012 in. (0.20 - 0.30 mm)
Intake Valve Clearance 0.004 - 0.006 in. (0.10 - 0.15 mm)
Exhaust Valve Clearance 0.007 - 0.009 in. (0.15 - 0.23 mm)
Oil Type 5W30 Full Synthetic
Oil Capacity (with filter) 42 - 45 oz. (1.24 - 1.33 L)
Engine End Cover Bolt	220 Ib-in (25Nm)

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