Bryant ASPAX1BBA015 User Manual

C

U

S

Installation and

Owner’s Manual

Air-cooled Automatic

Standby Generators

Model: ASPAX1BBA015

(13 kW NG, 15 kW LP)

LISTE



D

GENERAC

POWER SYSTEMS, INC.

*This manual should remain with the unit.*

Not intended for use as Primary Power in place of utility

or in life-support applications.

R

R



DANGER

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!

INTRODUCTION

Thank you for purchasing this model of the Bryant
product line. This model is a compact, high perfor­mance, air-cooled, engine-driven generator designed
to automatically supply electrical power to operate
critical loads during a utility power failure.

This unit is factory installed in an all-weather, metal
enclosure that is intended exclusively for outdoor
installation. This generator will operate using either
vapor withdrawn liquid propane (LP) or natural gas
(NG).

This unit meets the 1998 and later California
emissions regulations. To ensure that the engine
continues to meet these regulations, refer to the
following information and instructions in this
owner’s manual.

READ THIS MANUAL THOROUGHLY



If any portion of this manual is not understood,
contact the nearest dealer for starting, operating and
servicing procedures.

Throughout this publication, and on tags and decals
affixed to the generator, 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:

DANGER

After this heading, read instructions that, if not

strictly complied with, will result in serious per­sonal injury, including death, in addition to severe
property damage.

After this heading, read instructions that, if not

strictly complied with, may result in serious per­sonal injury or property damage.

After this heading, read instructions that, if not

strictly complied with, could result in damage to
equipment and/or property.

NOTE:

After this heading, read explanatory statements

that require special emphasis.

These safety warnings cannot eliminate the haz­ards that they indicate. Common sense and strict
compliance with the special instructions while
performing the service are essential to preventing
accidents.

Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type
of information each indicates follows:

This symbol points out important safety infor-



mation that, if not followed, could endanger
personal safety and/or property of others.

This symbol points out potential explosion haz-



ard.

This symbol points out potential fire hazard.



This symbol points out potential electrical shock



hazard.

The operator is responsible for proper and safe use
of the 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 pertinent owner’s information,
including warranty, electrical diagrams, exploded
views and lists of repair parts, for model:

• Model ASPAX1BBA015 – 13 kW NG, 15 kW LP, V­twin GT-990 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 service 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,
simply 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.

The Bryant Dealer is:

Dealer Name

Address

City State Zip

Model No.______________ Serial No._______________

Table of Contents

15 kW Generator

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

Read This Manual Thoroughly ........................ IFC

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

Operation and Maintenance ............................ IFC

How to Obtain Service ..................................... IFC

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

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

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

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

1.2 Location ........................................................ 4

1.3 Protection Systems ........................................4

1.4 System Set LED ............................................4

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

1.6 Specifications ................................................ 6

1.6.1 Generator ........................................... 6

1.6.2 Engine ................................................ 6

1.7 Fuel Requirements and Recommendations ...6

1.8 Fuel Consumption ......................................... 6

1.9 Reconfiguring the Fuel System ......................7

1.9.1 15 kW, 990cc Engines ........................7

1.10 Location ........................................................ 7

1.10.1 Generator ........................................... 7

1.10.2 Transfer Switch .................................. 8

1.11 Battery Installation ........................................ 8

1.12 The Battery ................................................... 8

Section 2 – Post Installation Start-up

and Adjustments .........................9

2.1 Before Initial Start-up ....................................9

2.2 Check Transfer Switch Operation .................9

2.3 Electrical Checks ..........................................9

2.4 Generator Tests Under Load ....................... 10

2.5 Checking Automatic Operation .................... 10

2.6 Adjusting the Regulator (Natural Gas Only) .. 11

2.7 Engine Governor Adjustment ...................... 12

2.7.1 15 kW Units ..................................... 12

2.8 Voltage Regulator Adjustment ...................... 12

Section 3 – Operation ....................................12

3.1 Break-in Procedure .....................................12

3.2 Using the Auto/Off/Manual Switch ............... 13

3.2.1 “Auto” Position ..................................13

3.2.2 “Off” Position....................................13

3.2.3 “Manual” Position ............................. 13

3.3 Automatic Transfer Operation ..................... 13

3.3.1 12 VDC Accessory Outlet .................13

3.3.2 120 VAC GFCI Outlet ....................... 14

3.4 Sequence of Automatic Operation ...............14

3.5 Manual Transfer Operation .........................14

3.5.1 Transfer to Generator

Power Source .....................................14

3.5.2 Transfer Back to Utility

Power Source .....................................15

3.6 Setting the Exercise Timer .......................... 15

3.7 Protection Systems ......................................15

3.7.1 Low Oil Pressure Switch .................. 15

3.7.2 High Temperature Switch .................15

3.7.3 Overcrank ........................................16

3.7.4 Overspeed ........................................ 16

Section 4 – Maintenance ...............................16

4.1 Fuses ...........................................................16

4.2 Checking the Engine Oil Level ..................... 16

4.3 Changing the Engine Oil .............................. 16

4.3.1 Engine Oil Recommendations .......... 16

4.3.2 Oil Change Procedure .......................17

4.4 Changing the Oil Filter ................................ 17

4.5 Changing the Engine Air Cleaner ................. 17

4.5.1 15 kW Generators ............................ 17

4.6 Spark Plug(s) .............................................. 17

4.7 Battery Maintenance ....................................18

4.8 Adjusting Valve Clearance ........................... 18

4.9 Cooling System ...........................................19

4.10 Attention After Submersion .........................19

4.11 Corrosion Protection ................................... 19

4.11.1 Additional Corrosion Protection .......19

4.12 Out of Service Procedure ............................. 20

4.12.1 Removal From Service......................20

4.12.2 Return to Service ............................. 20

4.13 Service Schedule ......................................... 21

Section 5 – Troubleshooting ........................ 22

5.1 Troubleshooting Guide ................................ 22

Section 6 – Mounting Dimensions ............. 23

Section 7 – Electrical Data ........................... 24

Section 8 – Exploded Views and

Parts Lists ................................... 28

Section 9 – Warranty ..................................... 40

1

IMPORTANT SAFETY INSTRUCTIONS

15 kW Generator

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe

operation be copied and posted in potential hazard areas. Safety should be stressed to all



operators, potential operators, service and repair technicians for this equipment.





The engine exhaust from this product

contains chemicals known to the state

defects or other reproductive harm.



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

cancer, birth defects or other reproductive harm.

Study these SAFETY RULES carefully before
installing,operating or servicing this equipment.
Become familiar with this Owner’s Manual and with
the unit. The generator can operate safely, efficiently
and reliably only if it is properly installed, operated
and maintained.

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. Any personal
injury or property damage resulting from the use of a
procedure, work method or operating technique not
specifically recommended by the manufacturer, shall
be the sole responsibility of the operator. Operators
who deviate from manufacturer recommended safety
procedures and operating techniques, or fail to take
the necessary precautions, do so at their own risk.

WARNING:

of California to cause cancer, birth

WARNING:





DANGER

Despite the safe design of this generator, oper-



ating this equipment imprudently, neglecting its
maintenance or being careless can cause pos­sible injury or death. Permit only responsible
and capable persons to operate or maintain this
equipment.

Potentially lethal voltages are generated by



these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.

Parts of the generator are rotating and/or hot



during operation. Exercise care near running
generators.

2

GENERAL HAZARDS



• For safety reasons, the manufacturer recommends
that the installation, initial start-up and mainte­nance of this equipment is carried out by a deal­er.

• 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. This exhaust
system 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.

• 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.

• Adequate, unobstructed flow of cooling and venti­lating air is critical to correct generator operation.
Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seri­ously affect safe operation of the generator. The
generator MUST be installed outdoors.

• When working on this equipment, remain alert
at all times. Never work on the equipment when
physically or mentally fatigued.

• Inspect the generator regularly, and contact the
nearest dealer for parts needing repair or replace­ment.

• Before performing any maintenance on the gen­erator, disconnect its battery cables to prevent
accidental start up. Disconnect the cable from the
battery post indicated by a NEGATIVE, NEG or (–)
first. Reconnect that cable last.

• Never use the generator or any of its parts as a
step. Stepping on the unit can stress and break
parts, and may result in dangerous operating con­ditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.

ELECTRICAL HAZARDS



• All generators covered by this manual produce
dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely
high and dangerous voltages to the transfer switch
as does the standby generator when it is in opera­tion. Avoid contact with bare wires, terminals,
connections, etc., while the unit is running. Ensure
all appropriate covers, guards and barriers are in
place before operating the generator. If work must





be done around an operating unit, stand on an
insulated, dry surface to reduce shock hazard.

• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.

• 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 generator may crank and start at any time
without warning. When this occurs, load circuits
are transferred to the STANDBY (GENERATOR)
power source. To prevent possible injury if such a
start and transfer occur, always set the generator’s
AUTO/OFF/MANUAL switch to its OFF position
before working on equipment and remove the 7.5A
and 15A fuses from the generator control panel.

• In case of accident caused by electric shock, 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 always must
comply with applicable codes, standards, laws
and regulations. Adhere strictly to local, state and
national electrical and building codes. Comply
with regulations the Occupational Safety and
Health Administration (OSHA) has established.
Also, ensure that the generator is installed in
accordance with the manufacturer’s instructions
and recommendations. Following proper installa­tion, 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
questions pertaining to fire extinguishers.



IMPORTANT SAFETY INSTRUCTIONS

15 kW Generator

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
applicable 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 as installation guide for this
equipment.

1. NFPA No. 37, STATIONARY COMBUSTION

ENGINES AND GAS TURBINES, available from
the National Fire Protection Association, 470
Atlantic Avenue, Boston, MA 02210.

2. NFPA No. 76A, ESSENTIAL ELECTRICAL

SYSTEMS FOR HEALTH CARE FACILITIES,
available same as Item 1.

3. NFPA No. 54, NATIONAL FUEL GAS CODE,

available same as Item 1.

4. NFPA No. 58, AMERICAN NATIONAL STANDARD

FOR STORAGE AND HANDLING OF LIQUEFIED
PETROLEUM GAS, available same as Item 1.

5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL

ELECTRIC CODE, available same as Item 1.

6. Article X, NATIONAL BUILDING CODE, available

from the American Insurance Association, 85
John Street, New York, N.Y. 10038.

7. AGRICULTURAL WIRING HANDBOOK, avail-

able 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.

3



Section 1 — General Information

15 kW Generator

DANGER

Only qualified electricians or contractors should



attempt such installations, which must comply
strictly with applicable codes, standards and
regulations.

1.1 UNPACKING/INSPECTION

After unpacking, carefully inspect the contents for
damage.

• This standby generator set has been factory sup­plied with a weather protective enclosure that is
intended for outdoor installation 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 trans­fer switch. The transfer switch must effectively
isolate the electrical system from the utility
distribution system when the generator is oper­ating (NEC 700, 701 and 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 his or her 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 contents of a package that is not in evidence at
the time of delivery, but is discovered later.

1.2 LOCATION

To lift the generator, insert pipe having sufficient
strength and diameter through the lifting holes which
are located near the unit’s base (see Figure 1.1). The
unit may also be lifted by using a hook and hoist
method provided a spreader bar is used to ensure
the lifting lines clear the roof panel.

DANGER

When lifting or hoisting equipment is used, be



careful not to contact overhead power lines.

The generator’s weight of more than 300



pounds requires proper tools, equipment and
qualified personnel to be used in all phases of
handling and unpacking.

1.3 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 following systems that
protect it against potentially damaging conditions:

1. Low Oil Pressure Sensor 3. Overcrank

2. High Temperature Sensor 4. Overspeed
There are LED readouts on the control panel to indi-

cate that one of these faults has occurred. There is
also a “System Set” LED that is described below.

1.4 SYSTEM SET LED

The “System Set” LED is lit when all of the following
conditions are true:

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

2. The utility voltage being supplied to the unit is
being sensed by the Control PCB. If the utility
sense voltage is not connected to the unit or if it
is below 168 volts AC, then the system set light
will flash rapidly. This indicates that if the AUTO/
OFF/MANUAL switch is placed in the Auto posi­tion , the generator will start.

3. The “Not In Auto” dip switch is set to the OFF
position on the control board.

4. No alarms are present, for example, low oil pres­sure, high temperature, etc.

4

1.5 THE GENERATOR

Figure 1.1 – 15 kW, V-twin GT-990

Dipstick

Oil

Section 1 — General Information

15 kW Generator

Control

Panel

Data

Decal

Exhaust

Enclosure

Lifting Holes

Oil Filter

Battery

Compartment

GFCI
Outlet

Fuel
Regulator

Fuel
Inlet

Composite Base

5

Section 1 — General Information

15 kW Generator

1.6 SPECIFICATIONS

1.6.1 GENERATOR



Rated Max. Cont. Power Capacity (Watts*) ..... 13,000 NG/

15,000 LP†

Rated Voltage....................................................... 120/240

Rated Max. Continuous Load Current (Amps)

120 Volts + ......................................108.3 NG/125.0 LP

240 Volts .............................................. 54.2 NG/62.5 LP

Main Line Circuit Breaker ....................................65 Amp

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

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

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

Power Factor ..................................................................1

Recommended Air Filter ...........................Part # 0C8127

Battery Requirement at

-17.8° C (0° F) ....................... Group 26/26R 12 Volts and

525 Cold-cranking Amperes Minimum

Weight ........................................................... 487 Pounds

Output Sound Level @ 23 ft (7m)

at full load ................................................... 71.5 db (A)

Normal Operating Range ........................... -20°F (-28.8°C)

* Maximum wattage and current are subject to and limited by such factors

as fuel Btu content, ambient temperature, altitude, engine power and con­dition, etc. Maximum power decreases about 3.5 percent for each 1,000
feet above sea level; and also will decrease about 1 percent for each 6° C
(10° F) above 16° C (60° F).

+ Total current in two separate circuits. Current in each circuit must not

exceed the value stated for 240V.

1.6.2 ENGINE



Type of Engine ......................................................GT-990

Number of Cylinders ...................................................... 2

Rated Horsepower .................................. 30 @ 3,600 rpm

Displacement ..........................................................992cc

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

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

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

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

Spark Plug Gap ............................0.508 mm (0.020 inch)

Compression Ratio ................................................... 9.5:1

Starter .................................................................... 12Vdc

Oil Capacity Including Filter.................... Approx. 1.7 Qts

Recommended Oil Filter ........................... Part # 070185

Recommended Air Filter ...........................Part # 0C8127

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

to 104°F (40°C)

1.7 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 fuel carburetion
system that meets the specifications of the 1997
California Air Resources Board for tamper-proof
dual fuel systems. The unit will run on natural gas or
LP gas, but it has been factory set to run on natural
gas. Should the primary fuel need to be changed to
LP gas, the fuel system needs to be reconfigured. See
instructions in the “Reconfiguring the Fuel System”
section.

Recommended fuels should have a Btu content of at
least 1,000 Btus per cubic foot for natural gas; or at
least 2,520 Btus per cubic foot for LP gas. Ask the
fuel supplier for the Btu content of the fuel.

Required fuel pressure for natural gas is 5 inches

to 7 inches water column (0.18 to 0.25 psi); and
for liquid propane, 11 inches to 14 inches of water
column (0.4 to 0.5 psi).

NOTE:

Any piping used to connect the generator to the
fuel supply should be of adequate size to ensure
the fuel pressure NEVER drops below 4 inches
water column for natural gas or 10 inches water
column for liquid propane for all load ranges.

1.8 FUEL CONSUMPTION

Model # Nat. Gas (*) LP Vapor (**)
1/2 Load Full Load 1/2 Load Full Load

05207 156 220 1.58/58 2.40/88

* Natural gas is in cubic feet per hour.
** LP is in gallons per hour/cubic feet per hour.
*** Values given are approximate.

DANGER

 Gaseous fuels such as natural gas and liquid

propane (LP) gas are highly explosive. Even the
slightest spark can ignite such fuels and cause
an explosion. No leakage of fuel is permitted.
Natural gas, which is lighter than air, tends to
collect in high areas. LP gas is heavier than air
and tends to settle in low areas.

6

G

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G

OSE

S

L

T

OR

OUSING PORT

JUSTER

SC

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Section 1 — General Information

15 kW Generator

1.9 RECONFIGURING THE
FUEL SYSTEM

1.9.1 15KW, 990CC ENGINES



To reconfigure the fuel system from NG to LP, follow
these steps:

NOTE:

The primary regulator for the propane supply is
NOT INCLUDED with the generator. A fuel pres­sure of 11 to 14 inches of water column (0.4 to

0.5 psi) to the fuel inlet of the generator MUST

BE SUPPLIED.

1. Turn off the gas supply. (if connected)

2. Open the roof and remove the door.

3. Remove the battery. (if installed)

4. Remove the engine air in baffle located on the left-

hand side of the battery compartment. Two M6
screws are located on top of the baffle and two
M6 screws are located on the inside of the baffle
towards the back.

5. Remove the small hose clamp and hose from the

fuel regulator. It may be necessary to pry the hose
off of the brass fitting using a screwdriver to gen­tly lift up the hose edge.

6. Remove the small brass hose fitting from the

regulator casting.

7. Place the small fuel jet, thread side first, into the

threaded hole originally occupied by the brass
hose fitting (Figure 1.2).

8. Using a short No. 2 Phillips screw driver, thread

the small fuel jet into the regulator casting. Do
not over tighten.

9. Apply thread sealant to the threads of the hose

fitting and replace it into the regulator body.

10. Re-attach the small hose and hose clamp and

tighten as necessary.

11. Replace the engine air in baffle using the four M6

screws.

12. Identify both brass adjustment screws on the

regulator.

NOTE:

One adjustment screw can be accessed from the
front of the unit and the second can be accessed
from the back of the unit enclosure by removing
the plastic hole plug. The screw can be turned
with a long flat blade screwdriver.

13. To adjust the system to run on LP fuel, turn

BOTH adjuster screws 1/2 TURN CLOCKWISE.
The system should now be set for maximum
power and best performance. DO NOT, UNDER

ANY CIRCUMSTANCES, REMOVE THE SET
PINS FROM THE REGULATOR HOUSING.
THIS WILL VOID THE WARRANTY.

Figure 1.2 - Demand Regulator

TLET PORT

FUEL H

BRASS HOSE
FITTIN

IDLE CIRCUI

POR

1/8 NP

BRASS HOSE

FITTIN

AD

REW

REGULAT
H

MAL

FUEL JE

14. It may be necessary to make minor adjustments
to the preset adjustment screw settings to achieve
maximum power, particularly at higher altitudes.
If experiencing problems with the unit producing
maximum power, follow the procedure in Section

2.6 (Adjusting the Fuel Regulator).

1.10 LOCATION

1.10.1 GENERATOR



Install the generator set, in its protective enclosure,
outdoors, where adequate cooling and ventilating air
is always available. Consider these factors:

• Install the unit where air inlet and outlet open-

ings will not become obstructed by leaves, grass,
snow, etc. If prevailing winds will cause blowing or
drifting, consider using a windbreak to protect the
unit.

• Install the generator on high ground where water

levels will not rise and endanger it.

• Allow sufficient room on all sides of the generator

for maintenance and servicing. A good rule is to
allow three feet of space on all sides.

• Where strong prevailing winds blow from one

direction, face the generator air inlet openings to
the prevailing winds.

• 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. HOWEVER, REMEMBER
THAT LAWS OR CODES MAY REGULATE THE
DISTANCE.

• The genset must be installed on a level surface.

The base frame must be level within two (2) inches
all around.

7

Section 1 — General Information

15 kW Generator

1.10.2 TRANSFER SWITCH



1.10.2.1 15 kW Units

Transfer switches for use with this generator are sold
separately and can be purchased from dealers.

• Install any transfer switch in accordance with the
instructions supplied with the transfer switch.

• Failure to utilize a the manufacturer’s transfer
switch with this generator will void the warranty.

1.11 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 following 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 7.5 amp and 15 amp fuses from the

generator control panel.

Battery cables were factory connected at the genera­tor (Figure 1.3). Connect cables to battery posts as
follows:

4. Connect the red battery cable (from starter con-

tactor) 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. Replace the 7.5 amp and 15 amp fuses in the

generator control panel.

NOTE:

Damage will result if battery connections are made
in reverse.

Figure 1.3 – Battery Cable Connections

NOTE:

The generator is equipped with a battery trickle
charger that is active when the unit is set up for
automatic operation. With the battery installed
and utility power source voltage available to the
transfer switch, the battery receives a trickle
charge while the engine is not running, to prevent
self-discharge. The trickle charger is designed to
help extend the life of the battery by maintain­ing the battery when the unit is not running. The
trickle charge feature cannot be used to recharge
a discharged battery.

1.12 THE BATTERY

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

When replacing the battery, use the following type of
battery: Group 26/26R 12-volt battery with a rating
of 525 cold-cranking amps minimum for 15 kW at

-17.8º C (0º F) minimum. When using a maintenance­free battery, it is not necessary to check the specific
gravity or electrolyte level. Have these procedures
performed at the intervals specified in the “Service
Schedule.” A negative ground system is used. Battery
connections are shown on the wiring diagrams. Make
sure the battery is correctly connected and terminals
are tight. Observe battery polarity when connecting
the battery to the generator set.

DANGER

Do not dispose of the battery in a fire. The



battery is capable of exploding.

A battery presents a risk of electrical shock



and high short circuit current. The following pre­cautions are to be observed when working on
batteries:

• Remove the 7.5A and 15A fuses from the genera­tor control panel;

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

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

• Disconnect charging source prior to connecting or
disconnecting battery terminals.

8

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 electrically
conductive and corrosive.

Section 2 — Post Installation Start-up and Adjustments

15 kW Generator

The following procedures are to be observed:

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off
immediately with water;

• Where electrolyte contacts the eyes, immediately
flush thoroughly with water and seek medical
attention; and

• 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) or water. The bicar­bonate of soda solution is to be added until the
evidence of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water and the
area dried.

Lead-acid batteries present a risk of fire because



they generate hydrogen gas. The
following procedures are to be followed:

• DO NOT SMOKE when near the battery;

• DO NOT cause flame or spark in battery area; and

• Discharge static electricity from body before touch­ing the battery by first touching a grounded 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, or



sparking may occur at the battery posts as the
cables are attached and cause an explosion.

2.1 BEFORE INITIAL START-UP

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 the utility power supply to the transfer

switch using the means provided (such as the
utility main line circuit breaker).

4. Check the engine crankcase oil level and, if neces-

sary, fill to the dipstick FULL mark with the rec­ommended oil. Do not fill above the FULL mark.

5. 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.

Never operate the engine with the oil level



below the “Add” mark on the dipstick. Doing
this could damage the engine.

2.2 CHECK TRANSFER SWITCH
OPERATION

Refer to Section 3.5, of the owner’s manual for man­ual operation procedures.

DANGER

Do not attempt manual transfer switch opera-



tion until all power voltage supplies to the
transfer switch have been positively turned off.
Failure to turn off all power voltage supplies
will result in extremely hazardous and possibly
fatal electrical shock.

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 the utility power supply to the transfer

switch using the means provided (such as the
utility main line circuit breaker).

4. Turn on the utility power supply to the transfer

switch using the means provided (such as a utility
main line circuit breaker).

DANGER

The transfer switch is now electrically “hot.”



Contact with “hot” parts will result in extremely
hazardous and possibly fatal electrical shock.
Proceed with caution.

5. Use an accurate AC voltmeter to check utility

power source voltage across terminals N1 and
N2. Nominal line-to-line voltage should be 240
volts AC.

6. Check utility power source voltage across termi-

nals N1 and the transfer switch neutral lug; then
across terminal N2 and neutral. Nominal line-to­neutral voltage should be 120 volts AC.

7. When certain that utility supply voltage is compat-

ible with transfer switch and load circuit ratings,
turn OFF the utility power supply to the transfer
switch.

8. Set the generator's main circuit breaker to its

OFF (or open) position. Initial tests will be con­ducted at no-load condition.

9. On the generator panel, set the AUTO/OFF/

MANUAL switch to MANUAL. The engine should
crank and start.

10. Let the engine warm up for about five minutes to

allow internal temperatures to stabilize. Then, set
the generator’s main circuit breaker to its ON (or
closed) position.

9

Section 2 — Post Installation Start-up and Adjustments

15 kW Generator

DANGER

Proceed with caution! Generator power voltage



is now supplied to the transfer switch. Contact
with live transfer switch parts will result in dan­gerous and possibly fatal electrical shock.

11. Connect an accurate AC voltmeter and a fre­quency meter across transfer switch terminal
lugs E1 and E2. Voltage should be 242-252 volts;
frequency should read about 61-63 Hertz.

12. Connect the AC voltmeter test leads across ter­minal lug E1 and neutral; then across E2 and
neutral. In both cases, voltage reading should be
121-126 volts AC.

13. Set the generator’s main circuit breaker to its
OFF (or open) position. Let the engine run at no­load for a few minutes to stabilize internal engine
generator temperatures.

14. Set the generator's AUTO/OFF/MANUAL switch to
OFF. The engine should shut down.

NOTE:

It is important not to proceed until certain that
generator AC voltage and frequency are correct
and within the stated limits. Generally, if both AC
frequency and voltage are high or low, the engine
governor requires adjustment. If frequency is cor­rect, but voltage is high or low, the generator’s
voltage regulator requires adjustment.

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) position.

2. Set the generator's AUTO/OFF/MANUAL
switch to OFF.

3. 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 supplies
will result in extremely hazardous and possibly
fatal electrical shock.

4. 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.

5. Set the generator's AUTO/OFF/MANUAL switch
to MANUAL. The engine should crank and start
immediately.

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

7. Set the generator’s main circuit breaker to its ON
(or closed) position. Loads are now powered by
the standby generator.

8. Turn ON electrical loads. Apply an electrical load
equal to the full rated wattage/amperage capacity
of the installed generator.

9. Connect an accurate AC voltmeter and a frequen­cy meter across terminal lugs E1 and E2. Voltage
should be greater than 230 volts; frequency
should be greater than 58 Hertz.

10. Let the generator run at full rated load for 20-30
minutes. Listen for unusual noises, vibration or
other indications of abnormal operation. Check
for oil leaks, evidence of overheating, etc.

11. When testing under load is complete, turn OFF
electrical loads.

12. Set the generator's main circuit breakers to their
OFF (or open) positions.

13. Let the engine run at no-load for a few minutes.

14. 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 the generator’s main circuit breaker to it’s
OFF (or open) position.

2. Check that the AUTO/OFF/MANUAL switch is set
to OFF.

3. Turn OFF the utility power supply to the transfer
switch using the 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 AUTO/OFF/MANUAL switch to AUTO.
Then set the generator’s main circuit breaker to
its ON (or closed) position. The system is now
ready for automatic operation.

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

With the AUTO/OFF/MANUAL switch at AUTO, the
engine should crank and start when the utility source
power is turned OFF. After starting, the transfer
switch should connect load circuits to the standby
side. Let the system go through its entire automatic
sequence of operation.

10

Section 2 — Post Installation Start-up and Adjustments

15 kW Generator

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 six seconds, the switch should transfer
loads back to the utility power source.

• About one minute after retransfer, the engine
should shut down.

2.6 ADJUSTING THE REGULATOR

(NATURAL GAS ONLY)

Although the generator has been factory set to pro­vide maximum power, it may be necessary in some
areas to adjust this setting. Because natural gas has
different BTU or power content across the country
the engine may not perform as designed.

If experiencing engine problems at high or full load
conditions follow these steps. It will require a fre­quency meter to perform this procedure.

1. Turn off utility power to the main distribution

panel in the house. This can be done by switching
the service main breaker to the off or open posi­tion.

2. Allow the generator to start before loading the

generator. Confirm the no-load frequency with
the roof open and door off is set at 63-63.5 Hz.
Transfer load to emergency circuits.

3. Turn on appliances, lights, pumps, etc., that are

on the emergency circuits in an attempt to fully
load the generator. Be cautious not to overload
the generator. Use the following chart as a guide:

Unit 120 Volts 240 Volts

15 kW 108.3 amps 54.2 amps

Figure 2.1 — Dual Fuel Regulators

V-twin

Adjustment
Screw

(Both Sides)

Set Pin

(Both Sides)

Adjustment
Screw

(One Side
Only)

6. When the highest frequency is reached maximum
power has been set. Then turn both adjustment
screws 1/4 turn counterclockwise. Regulator is
now set.

410

Set
Pin

Figure 2.2 — Placement of Regulator

Adjustment Screw

4. When full load has been achieved. Connect a fre­quency meter to the output lugs of the generator’s
main line circuit breaker.

5. The fuel regulator is fitted with two adjustment
screws. While watching the frequency meter,
slowly turn the adjustment screw clockwise or
counterclockwise one at a time until highest fre­quency is read on the meter. Only limited adjust­ment is available between the set pins. Under no
circumstances should any of the pins be removed
(Figures 2.1 and 2.2).

7. Turn utility power to the main distribution panel
back on. This can be done by switching the ser­vice main breaker to the on or closed position.
Allow the generator to shut down.

Do not make any unnecessary adjustments.



Factory settings are correct for most applica­tions. However, when making adjustments, be
careful to avoid overspeeding the engine.

If this procedure or equipment are not available,
locate the nearest Dealer and they can perform the
adjustments.

NOTE:

A service fee may be charged for this adjustment.

11

Section 3 — Operation

15 kW Generator

2.7 ENGINE GOVERNOR ADJUSTMENT

If both AC frequency and voltage are correspondingly
high or low, adjust the engine governor as follows:

2.7.1 15 KW UNITS



1. Loosen governor clamp bolt (See Figure 2.3).

Figure 2.3 — V-twin Engine Governor

Adjustment

Idle Spring

Governor
Shaft

(Rotate

Clockwise)

Governor Clamp Bolt

2. Completely remove the idle spring.

3. With governor arm at wide open throttle position,
rotate governor shaft fully clockwise. Tighten
clamp bolt to 84 inch-pounds.

4. Start unit and apply full load. Use full load speed
adjust screw (Figure 2.4) to adjust frequency to
58 Hz.

5. Remove load, stop engine, loosen the idle adjust
screw and reconnect the idle spring.

6. Push the governor arm to the closed throttle posi­tion. Make sure the idle spring does not stretch at
all.

7. Restart the unit.

8. Slowly turn the idle adjust screw to adjust the no­load idle frequency to 63-63.5 Hz.

9. The governor is now set.

Figure 2.4 — V-twin Full Load Speed Adjust

12

No Load Idle
Adjustment Screw

Screw

Full Load Speed Adjust Screw

2.8 VOLTAGE REGULATOR
ADJUSTMENT

With the frequency between 62-63.5 Hertz, slowly
turn the slotted potentiometer (Figure 2.5) until line
voltage reads 244-252 volts.

NOTE:

Remove the access panel on top of the control
panel to adjust the voltage regulator.

Figure 2.5 – Voltage Adjustment Potentiometer

NOTE:

The voltage regulator is housed above the generator's
control panel. The regulator maintains a voltage in
direct proportion to frequency. For example, at 62
Hertz, line-to-neutral voltage will be 124 volts.

3.1 BREAK-IN PROCEDURE

Once the unit has been installed and all electrical
checks have been made, it is strongly recommended
that the following “Break-in Procedure” be completed
to ensure correct generator operation in the future.

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

AUTO.

2. Turn OFF the utility power supply to the transfer

switch using the means provided (such as a utility
main line circuit breaker).

3. The unit will start, and the transfer switch will

transfer to standby.

4. Using the transfer switch’s built-in emergency

load center, turn on circuits to load the generator
to approximately 25% rated load and run the unit
for one hour.

5. Run the unit for one hour at 50% rated load.

6. Run the unit for one hour at 75% rated load.

7. Run the unit for one hour at 100% rated load.

8. Turn ON the utility power supply to the transfer

switch, which will allow the transfer switch to
transfer back to utility power. The unit will con­tinue to run for one minute and then shut down.

9. Allow the unit to cool.

10. Set the generator’s main circuit breaker to its
OFF (or OPEN) position.

11. Set the generator's AUTO/OFF/MANUAL switch
to OFF. Remove the 7.5A and 15A fuses from the
generator control panel. Disconnect the battery
cables as outlined in “General Hazards” (page

2).

12. Drain the oil and remove the oil filter. Replace
the oil filter according to Section 3.4, “Changing
the Oil Filter”. Replace the oil with synthetic oil
as recommended in Section 3.3, “Changing the
Engine Oil”.

13. Reconnect the battery cables as outlined in
“General Hazards” (page 2) and insert the 7.5A
and 15A fuses into the generator control panel.
The generator is now ready for service.

3.2 USING THE AUTO/OFF/MANUAL

SWITCH (FIGURE 3.1)

3.2.1 “AUTO” POSITION



Selecting this switch position activates fully auto­matic system operation. It also permits starting and
exercising the engine every seven days with the set­ting of the exercise timer (see “Setting the Exercise
Timer” section). This position also is used for remote
starting, when it is set up.

3.2.2 “OFF” POSITION



This switch position shuts down the engine. This
position also prevents automatic operation.

Section 3 — Operation

15 kW Generator

With the switch set to AUTO, the engine may



crank and start at any time without warning.
Such automatic starting normally occurs when
utility power source voltage drops 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 both fuses before working on or
around the generator or transfer switch. Then,
place a “Do Not Operate” tag on the generator
panel and on the transfer switch.

3.3 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 3.2).

2. Be sure that normal utility power source voltage

is available to transfer switch terminal lugs N1
and N2.

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 automatically when utility source voltage drops
below a preset level. After the unit starts, loads are
transferred to the standby power source. Refer to
Section 3.4, “Sequence of Automatic Operation.”



3.2.3 “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.

Figure 3.1 – Generator Control Panel

MAN.

12 VDC

ACCESSORY

OUTLET 7.5A MAX

EXTERNAL

GFCI

CIRCUIT

BREAKER

SYSTEM SET

LOW OIL

HIGH TEMP.

OVER SPEED

OVER CRANK

FLA S HING GREEN LED =

N O U T IL IT Y S EN S E

4FLAS HING RED LEDS =

EX ERCIS ER NO T S ET

OUTLET FUSE

7.5A

SYSTEM FUSE

15A

AUTO

EXERCISE

OFF

SET

TIME

3.3.1 12 VDC ACCESSORY OUTLET



The generator is equipped with a 12 VDC accessory
outlet in the generator control panel (Figure 3.1).
With the generator running or in standby mode, this
outlet may be used to temporarily power low power
accessories such as a work light, cell phone, radio or
any other automotive style accessory. This outlet is
capable of delivering a MAXIMUM of 7.5 amps. If the
accessory to be used through this circuit demands
too much power, the fuse that protects this circuit
will melt open and the circuit will not be functional.

This 12 VDC outlet draws power from the gen-



erator’s starting battery and extended use of
this outlet may drain the battery and the engine
may not start. This outlet should NOT be used
for battery charging.

13

Section 3 — Operation

15 kW Generator

3.3.2 120 VAC GFCI OUTLET



The generator is equipped with an external 15 amp,
120 volt, GFCI convenience outlet that is located in
the right rear of the generator enclosure. When the
generator is running, in the absence of utility power,
this outlet may be used to power items outside a
home such as lights or power tools. This outlet may
also be used when utility power is present by run­ning the generator in manual mode. This outlet does
not provide power if the generator is not running.
This outlet is protected by a 15 amp circuit breaker
located in the generator control panel (Figure 3.1).

3.4 SEQUENCE OF AUTOMATIC
OPERATION

The generator’s control panel houses a control logic
circuit board. This board constantly monitors util­ity power source voltage. Should that voltage drop
below a preset level, circuit board action will signal
the engine to crank and start. After the engine starts,
the circuit board signals the transfer switch to acti­vate and connect load circuits to the standby power
supply (load terminal lugs T1/T2 connect to terminal
lugs E1/E2).

Upon restoration of utility source voltage above a
preset level, generator circuit board action signals the
transfer switch to transfer loads back to that power
supply. After retransfer, the engine is signalled to shut
down.

The actual sequence of operation is controlled by
sensors and timers on a control logic circuit board,
as follows:

A. Utility Voltage Dropout Sensor

• This sensor monitors utility source voltage.

• If utility source voltage drops below about 70
percent of the nominal supply voltage, the sensor
energizes a 15-second timer.

• Once the timer has expired, the engine will crank
and start.

B. Engine Warm-up Time Delay

• This mechanism lets the engine warm up for
about 10 seconds before the load is transferred
to a standby source.

C. Standby Voltage Sensor

• This sensor monitors generator AC output volt­age. When the voltage has reached 50 percent of
the nominal rated voltage, transfer to standby
can occur.

D. Utility Voltage Pickup Sensor

• This sensor monitors utility power supply volt­age. When that voltage is restored to above 70
percent of the nominal source voltage, a retrans­fer time delay starts timing.

E. Retransfer Time Delay

• This timer runs for about 15 seconds.

• At end of a 15-second delay, circuit board action
de-energizes the transfer relay in the transfer
switch.

• Retransfer to utility power source then occurs.

F. Engine Cool-down Timer

• When the load is transferred back to utility power
source, the engine cool-down timer starts tim­ing.

• The timer will run for about one minute, and the
generator will then shut down.

3.5 MANUAL TRANSFER OPERATION

3.5.1 TRANSFER TO GENERATOR POWER



SOURCE

To start the generator and activate the transfer switch
manually, proceed as follows:

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

2. Set the generator’s main circuit breaker to its
OFF (or OPEN) position.

3. Turn OFF the utility power supply to the transfer
switch using the means provided (such as a utility
main line circuit breaker).

DANGER

Do not attempt to activate the transfer switch



manually until all power voltage supplies to the
switch have been positively turned off. Failure
to turn off all power voltage supplies may result
in extremely hazardous and possibly fatal elec­trical shock.

4. Use the manual transfer handle inside the trans­fer switch to move the main contacts to their
“Standby”position, i.e., loads connected to the
standby power source (Figure 3.2).

Figure 3.2 – Manual Transfer Switch Operation

14

Section 3 — Operation

15 kW Generator

5. To crank and start the engine, set the AUTO/OFF/
MANUAL switch to MANUAL.

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

7. Set the generator’s main circuit breaker to its ON
(or CLOSED) position. The standby power source
now powers the loads.

3.5.2 TRANSFER BACK TO UTILITY POWER



SOURCE

When utility power has been restored, transfer back
to that source and shut down the generator. This can
be accomplished as follows:

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

2. Let the engine run for a minute or two at no-load
to stabilize the internal temperatures.

3. Set the generator’s AUTO/OFF/MANUAL switch
to its OFF (or OPEN) position. The engine should
shut down.

4. Check that utility power supply to the transfer
switch is turned OFF.

DANGER

Do not attempt to activate the transfer switch



manually until all power voltage supplies to the
switch have been positively turned off. Failure
to turn off all power voltage supplies may result
in extremely hazardous and possibly fatal elec­trical shock.

5. Use the manual transfer handle inside the trans­fer switch to move the main contacts back to their
UTILITY position, i.e., loads connected to the util­ity power source (Figure 3.2).

6. Turn ON the utility power supply to the transfer
switch using the means provided.

7. Set the system to automatic operation as outlined
in “Automatic Transfer Operation,” Section 2.3.

2. Hold down the set timer switch until the genera­tor starts (approximately 10 seconds) and then
release.

3. The generator will start and run for approximate­ly 12 minutes and then shut down on its own.
The exerciser will then be set to run at that time
of day every week.

NOTE:

The exerciser will only work in the AUTO mode
and will not work unless this procedure is per­formed. The exerciser will need to be reset every
time the 12-volt battery is disconnected and then
reconnected. The exerciser WILL NOT work if
dip switch 2 (Remote Not Auto) on the controller
printed circuit board is ON.

3.7 PROTECTION SYSTEMS

3.7.1 LOW OIL PRESSURE SWITCH



This switch (Figure 3.3) has normally closed contacts
that are held open by engine oil pressure during
cranking and operating. Should oil pressure drop
below the 8 psi range, switch contacts close, and the
engine shuts down. The unit should not be restarted
until oil is added, and the AUTO/OFF/MANUAL switch
must be turned to OFF and then back to AUTO.

3.7.2 HIGH TEMPERATURE SWITCH



This switch’s contacts (Figure 3.3) close if the tem­perature should exceed approximately 140º C (284º
F), initiating an engine shutdown. The generator will
automatically restart and the LED will reset once the
temperature has returned to a safe operating level.

Figure 3.3 – Low Oil Pressure and

High Temperature Switches

Low Oil Switch

High Temp Switch

3.6 SETTING THE EXERCISE TIMER

The generator is equipped with an exercise timer.
Once it is set, the generator will start and exercise
once every seven days, on the day of the week and at
the time of day the following sequence is completed.
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.

A switch on the control panel (see Figure 3.1) permits
selection of the day and time for system exercise. To
select the desired day and time of day, the following
sequence must be performed at that time.

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

Oil
Drain
Hose

L

o

o

s

e

n

Oil Filter

15

Section 4 — Maintenance

15 kW Generator

3.7.3 OVERCRANK



This feature prevents the generator from damaging
itself when it continually attempts to start and anoth­er problem, such as no fuel supply, prevents it from
starting. The unit will crank and rest for a preset time
limit. Then, it will stop cranking, and the LED will
light indicating an overcrank failure. The AUTO/OFF/
MANUAL switch will need to be set to OFF and then
back to AUTO to reset the generator control board.

NOTE:

If the fault is not repaired, the overcrank feature
will continue to activate.

3.7.3.1 Approximate Crank Cycle Times

• 15 seconds ON

• 7 seconds OFF

• 7 seconds ON

• 7 seconds OFF

• Repeat for 45 seconds

Approximately 90 seconds total

3.7.4 OVERSPEED



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.

4.2 CHECKING THE ENGINE
OIL LEVEL

For oil capacities, see the “Specifications,” Section.
For engine oil recommendations, see Section 4.3.1.
To check the engine oil level, proceed as follows
(Figure 4.2):

1. Start the generator by moving the AUTO/OFF/

MANUAL switch to the MANUAL position. Allow
it to run for a short while and then shut it down
by moving the switch to the OFF position.

2. Remove the dipstick and wipe it dry with a clean

cloth.

3. Install 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.

Never operate the engine with the oil level



below the “Add” mark on the dipstick. Doing
this could damage the engine.

4. Install the dipstick.

5. Reset the AUTO/OFF/MANUAL switch to its origi-

nal position.

Figure 4.2 — Oil Dipstick and Fill, 15 kW

Oil Dipstick

4.1 FUSES

The generator panel’s 15 amp fuse (Figure 4.1) pro­tects the DC control circuit against overload. The fuse
is wired in series with the battery output lead to the
panel. If the fuse element has melted open, the engine
cannot crank or start. Replace the fuse using only an
identical 15-amp replacement.

The generator panel’s 7.5 amp fuse protects the 12
VDC accessory socket. If the fuse element has melted
open, the 12 VDC socket will not provide power to
any accessories. Replace the fuse using only an iden­tical 7.5 amp replacement. To remove fuse, push the
fuse holder cap down and rotate counterclockwise.

Figure 4.1 – Generator Control Panel

MAN.

12 VDC

ACCESSORY

OUTLET 7.5A MAX

EXTERNAL

GFCI

CIRCUIT

BREAKER

SYSTEM SET

LOW OIL

HIGH TEMP.

OVER SPEED

OVER CRANK

FLA S HING GREEN LED =

N O U T IL IT Y S ENS E

4FLAS HIN G RED LEDS =

EX ERCIS ER NOT S ET

OUTLET FUSE

7.5A

SYSTEM FUSE

15A

AUTO

EXERCISE

TIME

OFF

SET

Oil Fill

4.3 CHANGING THE ENGINE OIL

4.3.1 ENGINE OIL RECOMMENDATIONS



Use oil of American Petroleum Institute (API) Service
Class SG, SH or SJ. Use all season SAE 5W-30
Synthetic oil. Organic break-in oil is required before
using synthetic oil.

NOTE:

The unit is supplied with “break-in” oil. See the
“Break-in Procedure” Section for the first required
oil change.

16

Section 4 — Maintenance

15 kW Generator

4.5 CHANGING THE ENGINE

 Any attempt to crank or start the engine before

it has been properly serviced with the recom­mended oil may result in an engine failure.

4.3.2 OIL CHANGE PROCEDURE



To change the oil, proceed as follows:

1. Run the engine until it is thoroughly warmed up
then shut OFF the engine.

2. Immediately after the engine shuts OFF, pull the
oil drain hose (Figure 4.3) free of its retaining
clip. 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
clip.

4. Refill with the proper recommended oil (see
“Engine Oil Recommendations”). See the
“Specifications” Section for oil capacities.

Figure 4.3 – Oil Drain Hose and Filter

AIR CLEANER

4.5.1 15 KW GENERATORS



See Figure 4.4, for the location of the air cleaner. Use
the following procedure:

1. Turn the two screws counterclockwise to loosen.

2. Remove the cover and air filter.

3. Wipe away dust or debris from inside of the air
box and around edges.

4. Install the new air cleaner into the air box.

5. Install the cover. Turn the two cover screws clock­wise to tighten.

See the “Service Schedule,” Section for air cleaner
maintenance. See the “Specifications” Section for air
filter replacement part number.

Figure 4.4 — 15 kW Engine Air Cleaner

Screw

Cover

L

o

o

s

e

n

Oil
Drain
Hose

Oil Filter

4.4 CHANGING THE OIL FILTER

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.

3. Screw the new filter on by hand until its gasket
lightly contacts the oil filter adapter. Then, tighten
the filter an additional 3/4 to one turn (Figure

4.4).

4. Refill with the proper recommended oil (see
“Engine Oil Recommendations”). See the
“Specifications” Section for oil capacities.

5. Start the engine and check for leaks.

Filter

4.6 SPARK PLUG(S)

Reset the spark plug(s) gap or replace the spark
plug(s) as necessary. See the “Service Schedule”
Section for maintenance requirements.

1. Clean the area around the base of the spark
plug(s) to keep dirt and debris out of the engine.
Clean by scraping or washing using a wire brush
and commercial solvent. Do not blast the spark
plug(s) to clean.

2. Remove the spark plug(s) and check the con­dition. Replace the spark plug(s) if worn or if
reuse is questionable. See the “Service Schedule”
Section for recommended inspection.

3. Check the spark plug gap using a wire feeler
gauge. Adjust the gap to 0.50 mm (0.020 inch) for
15 kW by carefully bending the ground electrode
(Figure 4.5).

17

Section 4 — Maintenance

15 kW Generator

Figure 4.5 – Setting the Spark Plug Gap

SET PLUG GAP AT

0.050 mm/0.020 inch

4.7 BATTERY MAINTENANCE

The battery should be inspected per the “Service
Schedule”. The following procedure should be fol­lowed for inspection:

1. Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.

2. Check the battery fluid level of unsealed batteries
and, if necessary, fill with DISTILLED WATER
ONLY. DO NOT USE TAP WATER IN BATTER­IES.

3. Have the state of charge and condition checked.
This should be done with an automotive-type bat­tery hydrometer.

DANGER

Do not dispose of the battery in a fire. The



battery is capable of exploding.

A battery presents a risk of electrical shock and



high short circuit current. The following precau­tions are to be observed when working on bat­teries:

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

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

battery; and

• Disconnect charging source prior to connecting or

disconnecting battery terminals;

• Remove the 7.5A and 15A fuses from the generator

control panel.

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 electrically
conductive and corrosive. The following
procedures are to be observed:

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off
immediately with water;

• Where electrolyte contacts the eyes, immediately
flush thoroughly with water and seek medical
attention; and

• 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) or water. The bicar­bonate of soda solution is to be added until the
evidence of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water and the
area dried.

Lead-acid batteries present a risk of fire because



they generate hydrogen gas. The
following procedures are to be followed:

• DO NOT SMOKE when near the battery;

• DO NOT cause flame or spark in battery area; and

• Discharge static electricity from body before touch­ing the battery by first touching a grounded 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 and 15A fuses are removed
from the generator control panel, or sparking
may occur at the battery posts as the cables are
attached, causing an explosion.

4.8 ADJUSTING VALVE CLEARANCE

After the first six (6) months of operation, adjust
the valve clearance in the engine.

Important: If feeling uncomfortable about doing

this procedure or the proper tools are not available,
please contact the dealer for service assistance. This
is a very important step to insure longest life for the
engine.

To adjust valve clearance:

• Make sure the engine is at room temperature.

• Make sure that the spark plug wire is removed

from the spark plug and out of the way.

• Remove the four screws attaching the valve cover

with a #2 or #3 phillips screwdriver.

18

Section 4 — Maintenance

15 kW Generator

• Make sure the piston is at Top Dead Center (TDC)
of its compression stroke (both valves closed). To
get the piston at TDC, remove the intake screen at
the front of the engine to gain access to the flywheel
nut. Use a large socket and socket wrench to rotate
the nut and hence the engine. While watching the
piston through the spark plug hole. The piston
should move up and down. The piston is at TDC
when it is up as high as it can go.

• Loosen the rocker jam nut. Use an 10mm allen
wrench to turn the pivot ball stud while checking
clearance between the rocker arm and the valve
stem with a feeler gauge. Correct clearance is

0.002-0.004 inch (0.05-0.1 mm). See Figure 4.6.

NOTE:

Hold the rocker arm jam nut in place as the pivot
ball stud is turned.

When valve clearance is correct, hold the pivot ball
stud in place with the allen wrench and tighten the
rocker arm jam nut. Tighten the jam nut to 174
in/lbs. torque. After tightening the jam nut, recheck
valve clearance to make sure it did not change.

Figure 4.6 - Valve Clearance Adjustment

4.9 COOLING SYSTEM

Air inlet and outlet openings in the generator com­partment must be open and unobstructed for con­tinued proper operation. This includes such obstruc­tions as high grass, weeds, brush, leaves and snow.

Without sufficient cooling and ventilating air flow, the
engine/generator quickly overheats, which causes it
to quickly shut down. (See Figure 4.7 for vent loca­tions.)

The exhaust from this product gets extremely



hot and remains hot after shutdown. High grass,
weeds, brush, leaves, etc. must remain clear of
the exhaust. Such materials may ignite and burn
from the heat of the exhaust system.

Figure 4.7 – Cooling Vent Locations

Pivot Ball

Jam Nut

• Install new valve cover gasket.

• Re-attach the valve cover.

Start all four screws before tightening or it will not
be possible to get them in place. Make sure the
valve cover gasket is in place.

• Re-attach the spark plug wire to the spark plug.

• Repeat the process for the other cylinder.

Stud

NOTE:

Rocker

Arm

Valve
Stem

The maximum ambient temperature for the



generator is 48.9° C (104° F).

4.10 ATTENTION AFTER SUBMERSION

If the generator has been submerged in water, it MUST
NOT be started and operated. Following any submer-

sion in water, have a dealer thoroughly clean and dry
the generator.

4.11 CORROSION PROTECTION

Periodically wash and wax the enclosure using auto­motive type products. Frequent washing is recom­mended in salt water/coastal areas. Spray engine
linkages with a light oil such as WD-40.

4.11.1 ADDITIONAL CORROSION



PROTECTION

Periodically spray all engine linkage parts and brack­ets with corrosion inhibiting spray such as WD-40 or
a comparable product.

19

Section 4 — Maintenance

15 kW Generator

4.12 OUT OF SERVICE PROCEDURE

4.12.1 REMOVAL FROM SERVICE



If the generator cannot be exercised every seven days,
and will be out of service longer than 90 days, pre­pare the generator for storage as follows:

1. Start the engine and let it warm up.

2. Close the fuel shutoff valve in the fuel supply line

and allow the unit to shut down.

3. Once the unit has shut down, it will signal a low

oil fault.

4. Set the generator’s main circuit breaker to its

OFF (or open) position.

5. Set the Auto/Off/Manual switch to OFF and

turn off the utility power to the transfer switch.
Remove the 7.5A and 15A fuses from the genera­tor control panel. Disconnect the battery cables
as outlined in “General Hazards” (page 2). Turn
on the utility power supply to the transfer switch
in order to power the emergency load centers cir­cuits while utility power is available.

6. While the engine is still warm from running,

drain the oil completely. Refill the crankcase with
oil. See ”Engine Oil Recommendations,” Section.

7. Attach a tag to the engine indicating the viscosity

and classification of the oil in the crankcase.

8. Remove the spark plug(s) and spray fogging

agent into the spark plug(s) threaded openings.
Reinstall and tighten the spark plug(s).

9. Remove the battery and store it in a cool, dry

room on a wooden board. Never store the battery
on any concrete or earthen floor.

10. Clean and wipe the entire generator.

4.12.2 RETURN TO SERVICE



To return the unit to service after storage, proceed
as follows:

1. Verify that utility power is turned off and that the
Auto/Off/Manual switch is set to OFF.

2. Check the tag on the engine for oil viscosity and
classification. Verify that the correct recom­mended oil is used in the engine (see “Engine Oil
Recommendations”). If necessary, drain and refill
with the proper oil.

3. Check the state of the battery. Fill all cells of
unsealed batteries to the proper level with dis­tilled water. DO NOT USE TAP WATER IN THE
BATTERY. Recharge the battery to 100 percent
state of charge, or, if defective, replace the bat­tery. See the “Specifications” Section, for type and
size.

4. Clean and wipe the entire generator.

5. Remove the 7.5A and 15A fuses from the genera­tor control panel. Reconnect the battery. Observe
battery polarity. Damage may occur if the battery
is connected incorrectly.

6. Open the fuel shutoff valve.

7. Insert the 7.5A and 15A fuses into the generator
control panel. Start the unit by moving the Auto/
Off/Manual switch to MANUAL. Allow the unit to
warm up thoroughly.

8. Stop the unit by setting the Auto/Off/Manual
switch to OFF.

9. Turn on the utility power to the transfer switch.

10. Set the Auto/Off/Manual switch to AUTO.

11. The generator is now ready for service.

NOTE:

If the battery was dead or disconnected, the exer­cise timer must be reset.

20

Section 4 — Maintenance

15 kW Generator

4.13 SERVICE SCHEDULE

ATTENTION: It is recommended that all service work

be performed by the nearest dealer.

SYSTEM/COMPONENT PROCEDURE FREQUENCY

X = Action Inspect Change Clean W = Weekly
R = Replace as Necessary M = Monthly
* = Notify Dealer Y = Yearly

if Repair is Needed.

FUEL

Fuel lines and connections* X M

LUBRICATION

Oil level X M

Oil X AFTER BREAK-IN,

AND Y

Oil filter X AFTER BREAK-IN,

AND Y

COOLING

Enclosure louvers X X W

BATTERY

Remove corrosion, X X M

ensure dryness

Clean and tighten

battery terminals

Check charge state

Electrolyte level X R EVERY 6 M
(unsealed batteries only)*

ENGINE AND MOUNTING

Air cleaner X R Y

Spark plug(s) X R Y

GENERAL CONDITION

Vibration, Noise, Leakage, X M
Temperature*

COMPLETE TUNE-UP* TO BE COMPLETED BY A DEALER

X X M

X R EVERY 6 M

21

Section 5 — Troubleshooting

15 kW Generator

5.1 TROUBLESHOOTING GUIDE

Problem Cause Correction

The engine will not crank. 1. Fuse blown 1. Replace 15A fuse on generator con-

trol panel.

2. Loose, corroded or defective 2. Tighten, clean or replace
battery cables as necessary.

3. Defective starter contactor (7 kW) 3. *

4. Defective starter motor 4. *

5. Dead Battery 5. Charge or replace battery.

The engine cranks but 1. Out of fuel 1. Replenish fuel.
will not start. 2. Defective fuel solenoid (FS) 2. *

3. Open #14 wire from 3. *
engine control board

4. Defective spark plug(s) 4. Clean, re-gap or replace plug(s).

5. Valve lash out of adjustment. 5. Reset valve lash.

The engine starts hard 1. Air cleaner 1. Check, replace air cleaner.
and runs rough. plugged or damaged

2. Defective spark plug(s) 2. Clean, re-gap or replace plug(s).

3. Fuel regulator not set. 3. Set fuel regulator.

4. Fuel pressure incorrect. 4. Confirm fuel pressure is at (0.4-0.5
psi) for LP, and 5-7” water column
(0.18-0.25 psi) for natural gas.

The AUTO/OFF/MANUAL switch 1. Defective switch 1. *
is set to OFF, but the engine 2. AUTO/OFF/MANUAL switch 2. *

continues to run. wired incorrectly

3. Defective control board 3. *

There is no AC output from 1. Main line circuit breaker open 1. Reset circuit breaker
the generator. to ON (or closed).

2. Generator internal failure 2. *

There is no transfer to 1. Defective transfer switch coil 1. *
standby after utility 2. Defective transfer relay 2. *
source failure. 3. Transfer relay circuit open 3. *

4. Defective control logic board 4. *

Unit consumes large 1. Break-in procedure 1. *
amounts of oil. not followed

22

*Contact the nearest dealer for assistance.

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Section 6 — Mounting Dimensions

15 kW Generator

Drawing No. 0D3739-B

.

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46.2"

172.3

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+

Section 7 — Electrical Data

15 kW Generator
Wiring Diagram – Drawing No. 0E9016

ENGINE WIRIN

DIAGRAM KE

BA - BRUSH ASSEMBL

BCR - BATTERY CHARGE RELA

B1 - MAIN OUTPUT BREAKE

CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATIO

CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PUL
D - DIOD
DSW - PCB MOUNTED DIP SWIT

FS - FUEL SOLENOI

F1 - FUSE 15 AM

F2 - FUSE 7.5 AM

RD - CONTROL PANEL GROUN

HTO - HIGH OIL TEMPERATURE SWIT
IC - INLINE CONNECT
ICT - INTERCONNECTION TERMINAL

IM1 - IGNITION MODULE, CYLINDER #

IM2 - IGNITION MODULE, CYLINDER #

LOP - LOW OIL PRE

- STARTER CONTACT

R - STARTER CONTACTOR RELA

SP1, SP2 - SPARK PLUG

W1 - AUTO / OFF / MANUAL SWIT

W2 - SET EXERCISE SWIT

M - STARTER MOT

TB - INSULATED TERMINAL BL

TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.

RE SWIT

HARGE

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4 - SPAR

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G

Section 7 — Electrical Data

15 kW Generator

Wiring Diagram – Drawing No. 0E9016

22

22

22

NTROL PANEL B

T TO BEARIN

B

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22

22

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L

Section 7 — Electrical Data

15 kW Generator
Electrical Schematic – Drawing No. 0E9017

22

ELECTRONI

VOLTA

REGULAT

HARGE

1

2-1

2-1

1

STATOR

DIAGRAM KE

BA - BRUSH ASSEMBL
BCR - BATTERY CHARGE RELA
CB1 - CIRCUIT BREAKER, MAIN OUTPU

CB2 - CIRCUIT BREAKER, ALT. EXCITATIO

CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PUL
D - DIOD

FS - FUEL SOLENOI

F1 - FUSE 15 AM

F2 - FUSE 7.5 AM

HTO - HIGH OIL TEMPERATURE SWIT

IM1 - IGNITION MODULE, CYLINDER #

IM2 - IGNITION MODULE, CYLINDER #

LOP - LOW OIL PRE

- STARTER CONTACT

R - STARTER CONTACTOR RELA

SP1, SP2 - SPARK PLUG

W1 - AUTO / OFF / MANUAL SWIT

W2 - SET EXERCISE SWIT

M - STARTER MOT

TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.

RE SWIT

1

BATTERY CHARGE

WINDIN

22

1

ENGINE R

WINDIN
STATOR

HT

NTR

PRINTED CIRCUI

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B

2

1

1

1

L

2

1

1

1

1

22

22

1

1

1

2

1

2

1

26

SM

C1-1

5

0

8

C1-5

5618

5

5A

SCR

0

0

0

5

6

39

5

0

94

3

3

8

SP2

SP1

23

6

0

3

SC

0

SW1

5

5A

39

94

S

0

C2-1

G

(

)

R

CB1

33

56VA

3

5

5A

C2-5

C2-6

94

3

CUSTOMER

SU

D

CK

SC

0V

0V120V

CUSTOMER

CO

S

COIL

dc

U

Y

UT

C

R

SSO

SOCKET

+

0

5

3

94

GFCI

OU

T

GGG

CB3

0

5

515

3

5

5B

5B

0

39

Section 7 — Electrical Data

15 kW Generator

Electrical Schematic – Drawing No. 0E9017

24

240VA

TILIT

INP

12V

TRANSFE

NNECTION

12

22

22

12VDC ACCE

1

1

2

1

1

2

1

1

RY

1

1

1

1

1

POWE

WINDIN

1

1

1

2

1

2

2

STATOR

2

1

1

1

1

1

1

1

1

1

1

F

BLA

PPLIE

TLE

27

35

68

49

52

Y

0

9

3

37

33

5

35

34

6

9

35

9

82

80

51

6

8

80

2

87

5

86

8

39

92

89491

6315

69

0

52

9

35

51

9

6

7

0

214

5

9

9

8

1

Section 8 — Exploded Views and Parts Lists

15 kW Generator
Enclosure – Drawing No. 0F0080-C

PRE PACKAGED UNITS ONL

4

4

7

7

4

4

2

4

2

1

4

2

4

4

7

2

4

4

1

2

2

28

1

Section 8 — Exploded Views and Parts Lists

15 kW Generator

Enclosure – Drawing No. 0F0080-C

ITEM PART NO. QTY. DESCRIPTION

1 0C6140 1 ASSEMBLY, ENCLOSURE BASE

0D1901 1 ASSEMBLY, ENCLOSURE BASE (7KW)

2 0C6735 2 SUPPORT, ROOF FOLDING

3 0F0063 1 ENCLOSURE, FRONT

4 0C7062 1 ENCLOSURE, EXHAUST SIDE

0C7062A 1 ENCLOSURE, EXHAUST SIDE (7KW)

5 0E8811 1 ENCLOSURE, SIDE & BACK

0E8811A 1 ENCLOSURE, SIDE & BACK (7KW)

6 0E9873 1 ENCLOSURE, ROOF

7 0C7065 1 PANEL, ALTERNATOR DIVIDER

0C7065A 1 PANEL, ALTERNATOR DIVIDER (7KW)

8 0C8101A 1 PANEL, MUFFLER BOX SIDE

0C8861 1 PANEL, MUFFLER BOX SIDE (7KW)

9 0C8101B 1 COVER, MUFFLER BOX

0C8862 1 COVER, MUFFLER BOX (7KW)

10 0C8283 1 GASKET, DOOR SEAL

11 0C8284A 1 FOAM, BACK ENCLOSURE

12 0C8

13 0C8284C 1 FOAM, FRONT ENCLOSURE

14 0C8285 1 BRACKET, BATTERY SUPPORT

15 0C8899A 1 PAD, 24"X48" WITH MOUNTING HOLES

16 0D1128 1 PANEL, ENGINE DIVIDER

0D1128A 1 PANEL, ENGINE DIVIDER (7KW)

17 0E4244 1 BAFFLE, INTAKE

0D1605A 1 BAFFLE, INTAKE (7KW)

18 0D1606 1 HOUSING, FAN

0D5264 1 BAFFLE, EXHAUST (7KW)

19 0D1839 2 BRACKET, TOP SUPPORT

20 0D1840 2 BRACKET, BOTTOM SUPPORT

21 0D2425 1 DUCT, BASE AIR

22 0D2588 1 GASKET, FRONT DIVIDER

0D2588A 1 GASKET, FRONT DIVIDER (7KW)

23 0D2676 1 COVER, FRONT EXHAUST ENCLOSURE

24 0D2677 1 COVER, BACK EXHAUST ENCLOSURE

25 0D2979B 2 CLOTH, HARDWARE 266.7mm x 146mm

0D2979B 3 CLOTH, HARDWARE 266.7mm x 146mm (7KW)

26 0D2979C 1 CLOTH, HARDWARE 543mm x 146mm

27 0D297

0D2979E 1 CLOTH, HARDWARE (7KW)

28 0E4245 1 FOAM, FRONT INTAKE BAFFLE

0D3058A 1 FOAM, FRONT INTAKE BAFFLE (7KW)

29 0E4245A 1 FOAM, TOP INTAKE BAFFLE

30 0E4245B 1 FOAM, BACK INTAKE BAFFLE

0D3058C 1 FOAM, BACK INTAKE BAFFLE (7KW)

31 0D3057D 1 FOAM, BACK ENCL. STRIP

32 0D3059A 1 FOAM, EXHAUST SIDE ENCLOSURE END

33 0D3059B 1 FOAM, EXHAUST SIDE ENCLOSURE FRONT

34 0D3059C 1 FOAM, EXHAUST FAN HOUSING

35 0D7176 24 WASHER, SELF LOCKING

22 WASHER, SELF LOCKING (7KW)

36 0D3059D 1 FOAM, FRONT EXHAUST ENCLSURE COVER

37 0D3059

38 0C7781A 2 DOOR, PAWL

39 0D3037 1 LATCH, QUARTER TURN LOCKING

40 0F0164 1 HINGE TYPE A WITH STUDS, PIN

41 0F0165 1 HINGE TYPE B WITH STUDS, PIN

42 0D3037A 1 LATCH, QUARTER TURN NON-LOCKING

43 0A2115 4 WASHER NYLON .250"

44 022097 1 WASHER LOCK M6-1/4"

46 0F0710 18 RIVET POP 0.125 X 0.337

284B 1 FOAM, ROOF ENCLOSURE

9D 1 CLOTH, HARDWARE 266.7mm x 387.4mm

E 1 FOAM, BACK EXHAUST ENCLOSURE COVER

ITEM PART NO. QTY. DESCRIPTION

47 047411 6 SCREW HHC M6-1.0 X 16 G8.8

047411 4 SCREW HHC M6-1.0 X 16 G8.8 (7KW)

48 043116 5 SCREW HHC M6-1.0 X 12 G8.8

043116 6 SCREW HHC M6-1.0 X 12 G8.8 (7KW)

49 0D3700 26 NUT, LOCKING FLANGE M6-1.0

0D3700 24 NUT, LOCKING FLANGE M6-1.0 (7KW)

50 0D4662 11 SCREW HHTT M8-1.2 X 20 BP

51 090388 36 SCREW TAPTITE M6-1.0 X 12 BP

24 SCREW TAPTITE M6-1.0 X 12 BP (7KW)

52 092120 2 NUT LOCK TRIC M6 X 1.0 Y/ZNC

54 0D3167 1 GASKET, BATTERY SUPPORT BRACKET

55 0A3328 1 PLUG, PLASTIC 0.593

56 055414 1 LUG SLDLSS #2-#8X17/64 CU

57 092079 1 SCREW TAPTITE M6-1.0X25 BP

58 0A1658 2 L/WASH SPECIAL ¼

59 0C2

60 086729 1 CONTACTOR, STARTER (7KW)

61 0388040AJ0 1 CABLE, #6 RED BATTERY 38.5"

62 022127 2 NUT HEX 1/4-20 STEEL (7KW)

63 022129 6 WASHER LOCK 5/16

022129 7 WASHER LOCK 5/16 (7KW)

64 074908 8 SCREW TAPTITE M5-0.8 X 10 BP

65 0D2346 1 HARNESS, ENGINE

0D2345 1 HARNESS, ENGINE (7KW)

66 023484F 1 BUSHING, SNAP SB-1000-12

67 022142 1 SCREW HHC 5/16-18 X 3/4 G5 (7KW)

68 0A7836 2 RIVET,1/8" X 0.126" - 0.375" LSH POP

69 0A8475 2 L/WASH SPECIAL #10

70 0912970069 1 ASSEMBLY, ROOF / DOOR GROUND WIRE

71 09129

72 055450 2 PLUG PLASTIC 1.375

73 0E5968 11 GASKET, EXTRUDED TRIM

74 0D3701 1 PLATE, "HOT"

75 0D3472 1 GROMMET 2.75 X 1/16

76 0C8742 1 EXTERNAL CONNECTION BOX

77 0C8911 1 POWER BLOCK

78 0D8442 1 HARNESS GENERATOR TO EXT CONN BOX

0D8652 1 HARNESS GENERATOR TO EXT

79 036937 2 SCREW PPHM #10-32 X 1

80 022152 5 WASHER LOCK #10

81 051713 2 WASHER FLAT M5

82 022158 5 NUT HEX #10-32 STEEL

83 0D3031 1 FUEL LINE, 3/4"OUTDOOR (NOT SHOWN)

84 026850 1 WASHER SHAKPROOF EXT 1/4 STEEL

85 04981

86 0F0164A 1 HINGE TYPE A WITH STUDS, SOCKET

87 0F0165A 1 HINGE TYPE B WITH STUDS, SOCKET

89 0E2874 1 SCREW HHTR 1/4-20 X 3/4

90 043107 4 SCREW HHC M8-1.25 X 25

91 022145 10 WASHER FLAT 5/16

92 045771 4 NUT HEX M8-1.25

93 0C3906 2 SELF-ALIGN SCREW M6 HH

94 0E4321 1 PANEL, EXHAUST ALIGNMENT

95 0E1330A 1 GROMMET, 38.1 CROSS SLIT WITH HOLE

96 0E9692 1 BRACKET, REGULATOR MOUNTING

97 042907 2 SCREW HHC M8-1.25 X 16mm

98 0F5241 1 PLATE, COVER

99 0F594

937 1 BRACKET, BATTERY HOLD DOWN (7KW)

70070 2 ASSEMBLY, ROOF / DOOR GROUND WIRE

CONNECTION BOX (7KW)

3 1 NUT HEX M6-1.0 G8 YELLOW CHROME

3 1 GASKET, COVER

29

Section 8 — Exploded Views and Parts Lists

15 kW Generator
Control Panel – Drawing No. 0E9162-J

30

Section 8 — Exploded Views and Parts Lists

15 kW Generator

Control Panel – Drawing No. 0E9162-J

ITEM PART NO. QTY. DESCRIPTION

1 0E7886A 1 CIRCUIT BREAKER 30A X 2P 240V (7KW)
0E7886E 1 CIRCUIT BREAKER 50A X 2P 240V (12KW)
0E7886J 1 CIRCUIT BREAKER 65A X 2P 240V

(13/15KW)
2 0A1801 1 ASSEMBLY, BATTERY CHARGER ENGINE
3 083049 1 ASSEMBLY, POTTED REGULATOR
4 0C2174 1 RELAY, 12V 25A SPST
5 075210A 1 BLOCK 1 POSITION
6 0D3062 4 HEX STAND-OFF #6-32 x 3/8"
7 0D8615 1 ASSEMBLY, HOME STANDBY CONTROLLER
0D8615A 1 ASSEMBLY, HOME STANDBY CONTROLLER

(7KW)
8 032300 2 HOLDER, FUSE
9 022676 1 FUSE, 15AMP X AGC15
10 0E4494 1 SWITCH, ROCKER DPDT ON-OFF-ON
11 0E7890 1 CIRCUIT BREAKER MOUNTING BRACKET
12 023484E 1 SNAP BUSHING
13 075476 4 SCREW PPHM M4-0.7 x 16mm
15 0E6480 6 NUT HEX LOCK M4-0.7 NYLON IN
17 0C1085 6 SCREW PPHM M3-0.5 x 8mm
0C1085 4 SCREW PPHM M3-0.5 x 8mm (7KW)
19 054502 1 CIRCUIT BREAKER 3 X 1 ETA 46-500-P
053623 1 CIRCUIT BREAKER 2.5 X 1 ETA 46-500-P

(7KW)
20 0E7870 1 CONTROL, PANEL BOTTOM
0E7871 1 CONTROL, PANEL BOTTOM (7KW)
21 075235 4 SCREW HHC M5-0.8 x 30mm
22 0D5240 1 SWITCH, SPST (ON)-ON N/O
23 0D9784 6 NUT HEX LOCK M3-0.5 NYLON INSERT
0D9784 4 NUT HEX LOCK M3-0.5 NYLON INSERT

(7KW)
24 0D8502 1 NEUTRAL CONNECTOR
26 0E8956 1 HARNESS, CONTROL PANEL (NOT SHOWN)
0E8957 1 HARNESS, CONTROL PANEL WIRE (NOT

SHOWN) (7KW)
27 074908 4 SCREW TAPTITE, M5-0.8 x 10 BP
28 049226 6 WASHER LOCK M5

SERT

ITEM PART NO. QTY. DESCRIPTION

29 082025 6 NUT HEX LOCK M5-0.8 NYLON INSERT
30 0C3910 1 TRANSFORMER
31 022507 2 SCREW HHC 1/4"-20 x 1/2"
32 0A9611 1 FUSE 7.55A X AGC5
33 046689 1 BLOCK TERMINAL STRIP 20A 4 X 6 X 1100V
34 063617 1 RELAY PANEL 12VDC DPDT 10A 240VAC
35 075475 2 SCREW PPHM M4-0.7 x 10mm
36 043180 2 WASHER FLAT M4
37 0E8812 1 COVER, CONTROL PANEL COMPONENT
0E8895 1 COVER, CONTROL PANEL COMPONENT

(7KW)
38 092036 8 SCREW PPHMS/LW #6-32 x 1/4"
39 045770 2 SCREW HHC M5-0.8 x10mm
40 0E7866 1 COVER, CONTROL PANEL
0E7867 1 COVER, CONTROL PANEL (7KW)
41 0D3700 8 NUT FLANGE M6-1.0 NYLOK
42 0912970069 1 ASSEMBLY, ROOF/DOOR GROUND WIRE
43 0E2874 1 SCREW HHTR 1/4"-20 X 3/4"
44 0A1658 2 WASHER LOCK SPECIAL 1/4"
45 022473 3 WASHER FLAT 1/4"-M6
46 038750 1 SCREW HHC M6-1.0 x 30mm
47 022097 3 WASHER LOCK M6-1/4"
48 049813 1 NUT HEX M6-1.0
49 031879 6 WASHER FLAT #4
031879 4 WASHER FLAT #4 (7KW)
50 023897 2 WASHER FLAT #10
51 0E9056 1 SOCKET, 12VDC ACCESSORY
52 0E5840 1 CIRCUIT BREAKER 15A PUSH / PULL MAIN

RESET
53 036903 6 SCREW PPHM #6-32 X 5/
54 0E7833 1 PLATE, WEATHERPROOF GFCI
55 0E4261 1 OUTLET, 15A GFCI DUPLEX
56 022985 4 WASHER FLAT #6
57 082625 4 NUT LOCK HEX #6-32 NYL INSERT
58 0E9171 1 GASKET, WEATHERPROOF GFCI
59 0F4793 2 SCREW PPHM M3-0.5 x 10mm

8"

31

Section 8 — Exploded Views and Parts Lists

15 kW Generator
GT-990 Engine – Drawing No. 0F4715-B Part 1

9

4

5

143

6

7

2

2, 5, 19, 20, 39, 40, 47, 64, 93, 140

66

34

8, 11, 12, 13

67

16A, 16B, 17, 18

4, 5, 6

68

69

36

37

35

7, 47, 48, 49, 50, 51, 52, 53, 54, 56, 57, 58, 59, 60, 63, 64

70

143

47, 48, 49, 50, 51, 52, 53, 54, 56, 57, 58, 59, 60, 62, 63, 64

71

140

39

27, 28, 29

72

22

34

3, 32, 33, 34, 35, 36, 40, 72

73

33

32

10

1

11

12

8

65

13

14

20

64

62

63

61

60

59

21

15

16A

19

17

18

16B

16A

57

58

25

30

56

54

23

144

24

53

52

55

27

26

47

49

48

3

3

31

51

50

28

29

43

44

46

45

32

38

40

41

42

Section 8 — Exploded Views and Parts Lists

15 kW Generator

GT-990 Engine – Drawing No. 0F4715-B Part 1

ITEM PART NO. QTY. DESCRIPTION

1 0C5729 1 ASSEMBLY, CRANKCASE HOUSING WITH

SLEEVE

2 0E9843 1 SEAL, 38 I.D. CRANKSHAFT
3 090388 3 SCREW, TAPTITE M6-1.0 X 12 YC
4 0C5372 1 ASSEMBLY, BREATHER
5 0C3005 1 GASKET, BREATHER COVER
6 0E3372B 3 SEPARATOR, OIL BREATHER
7 0D8067A 1 ASSEMBLY, HEAD #1 G&S
8 071983 4 RETAINER, PISTON PIN 20
9 0C2981C 1 ROCKER, COVER NO OIL FILL
10 045761A 4 STUD M8-1.25/10MM X 30 G5 ZINC
11 0E2985 2 PISTON, HC
12 021533 2 SET, PISTON RING 90MM
13 0E1466 2 PIN PISTON
14 0D4041 1 ASSEMBLY, CAMSHAFT & GEAR
15 0C2
16A 0C2985A 2 ROLLER BEARING, GOVERNOR PLATE
16B 0C2985B 1 ROLLER BEARING, GOVERNOR
17 0D4042 1 ASSEMBLY,GOVERNOR GEAR
18 0A7811 1 SPOOL, GOVERNOR MACHINED
19 0C2977 1 GASKET, CRANK CASE
20 0C5943 1 SEAL, OIL PASSAGE
21 0E4357E 1 ASSEMBLY, CRANKSHAFT HORIZONTAL

22 0E3223 2 ASSEMBLY, CONNECTING ROD
23 0D2157 2 SCREW SHC M6-1.0 X 50 G8.8
24 0E6098 1 SCREEN, OIL PICKUP
25 0D4123A 1 ASSEMBLY, OIL PUMP
26 078699E 2 SLEEVE, SEAMED DOWEL 10 DIA.
27 0C3011 2 COVER, OIL RELIEF
28 0C3009 2 SPRING, OIL RELIEF
29 0C3010 2 BALL, 1/2D OIL RELIEF
30 093873 2 WASHER, LOCK RIB M6
31 0C5315 1 GEROTOR, OUTER
32 0C5998 1 CLAMP, OIL TUBE
33 0D1667 1 ARM, GOVERNOR
34 0C2991 2 E-RING, GOVERNOR ARM
35 0C2988 1 THRUST WASHER, GOVERNOR
36 0C2992 1 BUSHING, GOVERNOR LOWER

983 1 SHAFT, GOVERNOR

DIRECT DRIVE

ITEM PART NO. QTY. DESCRIPTION

37 0C3971C 1 ASSEMBLY, DIPSTICK WITH HANDLE
38 0C5305 1 TUBE, DIPSTICK
39 0C3027 1 O-RING, OIL CLR 3/8 X 1/2
40 0E9842 1 SEAL, 42 I.D. CRANKSHAFT
41 0C5731 1 ASSEMBLY, HOUSING COVER WITH

SLEEVE
42 0C3006 9 SCREW, HHFC M10-1.5 X 55
43 080318 8 SCREW HHFC M6-1.0 X 25
44 093064 1 ASSEMBLY, OIL FILL CAP
45 0C8808 2 HOOK, LIFTING
46 0D2723B 1 ROCKER, COVER WITH OIL FILL
47 0C2979 2 GASKET, VALVE COVER
48 086515 8 KEEPER, VALVE SPRING
49 0D2274 4 RETAINER, VALVE SPRING
50 0D3867 4 SPRING, VALVE
51 078672 2 SEAL, VALVE STEM D7
52 0C5371 4 WASHER, VALVE SPRING
53 072694 4 STUD, ROCKER ARM PIVOT
54 0D3998 4 NUT HEX M8-1.0 G8 YEL CHR
55 0C3027 2 O-RING, 3/8" X 1/2"
56 0D5313 4 ROCKER ARM
57 0D6024 2 PLATE, PUSH ROD GUIDE
58 0C2976 12 SCREW HHFC M8-1.25 X 65
59 086516 2 VALVE, EXHAUST
60 0C2229 2 VALVE, INTAKE
61 083897 4 TAPPET, SOLID
62 0D8067B 1 ASSEMBLY, HEAD #2 G&S
63 0D9853D 4 PUSHROD, 147
64 0C2978 2 GASKET, HEAD
65 043790 1 BARBED ELBOW 90 3/8NPT X 3/8
66 0D4010 1 KIT GASKET
67 0D4011 1 KIT PISTON & RINGS
68 0D4012 1 KIT BREATHER ASSEMBLY
69 0D4013 1 KIT GOVERNOR ASSEMBLY
70 0D8675A 1 KIT HEAD ASSEMBLY CYLINDER 1
71 0D8675B 1 KIT HEAD ASSEMBLY CYLINDER 2
72 0D4015 1 KIT OIL RELIEF
73 0D4016 1 KIT GEAR COVER

33

Section 8 — Exploded Views and Parts Lists

15 kW Generator
GT-990 Engine – Drawing No. 0F4715-B Part 2

82

83

81

79

80

74

117

143

76

77

96

75

95

78

130

114

122

119

118

97

121

98

124

99

100

124

125

123, 145

125

143

120

137

126

13

136

1

138

127

132

115

133

116

139

135

134

142

128

129

34

84

86

88

85

89

90

93

89

94

91

97

98

92

99

112

101

102

107

108

103

104

109

105

110

106

112

112

113

111

Section 8 — Exploded Views and Parts Lists

15 kW Generator

GT-990 Engine – Drawing No. 0F4715-B Part 2

ITEM PART NO. QTY. DESCRIPTION

74 0C5136A 2 KNOB, AIR CLEANER
75 0C3024 1 COVER, AIRBOX NG/LP
76 0C3040 1 PRE-CLEANER,
77 0C8127 1 ELEMENT, AIR CLEANER
78 0D8564A 1 ASSEMBLY, MIXER/AIRBOX 990
0D8564B 1 ASSEMBLY, MIXER/AIRBOX 760
79 0D2595 4 SCREW SHOULDER (8MM) M6-1.0 X 18
80 0D4417 4 WASHER,RUBBER 1/4" X 1/8" THICK
81 0C3025 1 SWITCH, OIL PRESS
82 0D3083 1 ASSEMBLY, OIL DRAIN HOSE
83 0C7292 1 NIPPLE, 3/4"-16 UNF
84 070185D 1 OIL FILTER
85 075281 1 SWITCH, THERMAL 284F
86 0F2094 2 SCREW, M3-0.5 X 6 SEMS
87 0F1338A 1 ASSY, IGN COIL W/DIODE NO ADV
88 035461 2 BARBED STR 1/4NPT X 3/8
89 0F6301 4 CLAMP, HOSE OETIKER 16.5mm
90 0C9806 2 HOSE, 3/8" I.D. X 6" LONG
91 0C3026 1 COOLER, OIL
92 0C9764 4 PLASTITE,1/4-15 X 3/4
93 0C3043 2 GASKET, MANIFOLD / PORT
94 0C7694 1 MANIFOLD CYLINDER 2
95 0C7693 1 MANIFOLD CYLINDER 1
96 0C3041A 2 SLEEVE, RUBBER
97 070008 4 WASHER FLAT M8 SS
98 070006 4 WASHER LOCK M8 SSTL
99 040976 4 SCREW SHC M
100 0F1170A 1 PLATE, BACKING WITH OIL COOLER
101 0E4997 1 GROUND WIRE CONNECTOR
102 0C3725B 1 FLYWHEEL ASSEMBLY
103 0C3031 1 FAN, NYLON
104 0C3032 1 PLATE, FAN
105 0A5992 2 WASHER SHAKEPROOF INT M8 SS
106 051754 2 SCREW HHC M8-1.25 X 12 G8.8
107 0C3033 1 WASHER, 25mm I.D.
108 0C3034 1 NUT,HEX M24
109 0C8549A 1 SNORKEL, AIR INTAKE

8-1.25 X 20 G12.9

ITEM PART NO. QTY. DESCRIPTION

110 0F1169A 1 HOUSING, BLOWER NG COOLER
111 0D1131 1 GUARD, FAN
112 045756 25 SCREW TAPTITE M6-1X10 YELLOW

CHROME
113 0C9763 4 NUT, GROMMET 1/4 PLUG
114 0C3036A 1 HOSE, BREATHER
115 022145 1 WASHER FLAT 5/16-M8 ZINC
116 022129 1 WASHER LOCK M8-5/16
117 0C3018 1 WRAPPER, UPPER CYLINDER 1
118 0C3019 1 WRAPPER, LOWER CYLINDER 1
119 0D1142A 1 WRAPPER, LOWER CYLINDER 2
120 0D1143 1 WRAPPER, UPPER CYLINDER 2
121 0E6043 2 SCREW TAPTITE M5-0.8 X 8 ZP
122 0F1177 1 ASSEMBLY, GROUND WIRE
123 0F1338B 1 ASSY, IGN COIL W/DIODE NO ADV
124 022097 4 WASHER LOCK M6-1/4
125 092079 4 SCREW TAPTITE M6-1.0 X 25 BP
126 0E4271 1 STARTER
127 0D4529 2 SPARKPLUG
128 022129 2 WAS
129 061906 2 SCREW HHC M8-1.25 X 85 G8.8
1 30 082774 1 KEY, WOODRFF 4 X 19D
1 31 0E5343 1 NUT HEX LOCK M10-1.50
1 32 0C8468 1 SPRING, ANTI-LASH
1 33 0C3048 1 ROD, GOVERNOR CONTROL
1 34 0D3754 1 ASSEMBLY, GOVERNOR LEVER
1 35 0D3742 1 SPRING, GOVERNOR
1 36 0C8482 1 ASSEMBLY, GOVERNOR ADJUSTER
1 37 0E0486 1 SCREW SHC M10-1.5 X 75 G10.9
1 38 0D3743 1 SPRING, GOVERNOR IDLE
1 39 0D3705 1 ASSEMBLY, GOVERNOR ADJUSTER

140 0C2993 1 SEAL, GOVERNOR SHAFT
142 045771 1 NUT HEX M8-1.25 G8
143 0D6147 7 SCREW HHFC M6-1.0 X 10mm
144 0E8152 1 O-RING 0.49" I.D. X 0.07" THICK

HER LOCK M8-5/16

BRACKET

35

41

42

Section 8 — Exploded Views and Parts Lists

15 kW Generator
15 kW Generator – Drawing No. 0D3417-L

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11

Section 8 — Exploded Views and Parts Lists

15 kW Generator – Drawing No. 0D3417-L

ITEM PART NO. QTY. DESCRIPTION

1 0C6934 1 ADAPTOR, ENGINE

2 0C7930 1 STATOR 12KW

0D2359 STAT O R 1 3KW / 15KW

3 0C7944 1 ROTOR 12KW

0D2356 ROTOR 13KW / 15KW

4 0C6043 1 CARRIER, REAR BEARING

5 0D2336 1 FAN, 12" CURVED BLADE

6 0D6634 1 MUFFLER

7 0D3220 1 TAIL PIPE, MUFFLER

8 0C8101 1 PANEL, MUFFLER BASE

9 056482 1 BEARING 1.1811-2.8346

10 0C3168 3 5/16 SPECIAL LOCK WASHER

11 0D1838 1 BOLT, HHCS 3/8"-24 x 15.50"

12 0D1846 4 BOLT, HHCS M8-1.25 x 345mm

13 0C7038 1 BRACKET, ALTERNATOR MOUNTING

14 0D1609 1 DUCT, ALTERNATOR AIR

15 0D2559 1 GASKET, ALTERNATOR AIR DUCT

16 0C7038A 1 BRACKET, ENGINE MOUNTING

17 0C775

18 0388050AD0 1 CABLE, #6 48" BLACK BATTERY

19 0C2417A 1 EARTH STRAP 3/8X 3/8

20 082121C 1 CLIP-J, VYNL COAT 0.625" ID

21 066386 1 ASSEMBLY BRUSH HOLDER

22 029451 2.6 FT TAPE ELEC UL FOAM 1/8 X 1/2

23 049451 1 WASHER FLAT .406ID X 1.62OD

24 022237 5 WASHER LOCK 3/8

25 022511 4 SCREW HHC 3/8-16 X 1-1/4 G5

26 022131 4 WASHER FLAT 3/8 ZINC

27 051731 4 SCREW HHC M8-1.25 X 50 G8.8

28 022145 12 WASHER FLAT 5/16 ZINC

29 049820 4 NUT LOCK HEX M8-1.25 NYL INSERT

30 045756 2 SCREW TAPTITE M6-1.0X10 BP

31 022129 10 WA

32 022259 8 NUT HEX 5/16-18 STEEL

33 059637 2 SCREW TAPTITE 3/8-16 X 3/4 BP

34 0D4662 4 SCREW 5/16-18X3/4" HH THD ROLL

35 0F7065 3 FT HOSE RES 1/2 LP GAS

36 048031M 4 HOSE CLAMP 3/4" I.D.

37 0F0462 4 NUT HEX W/TOOTH WSHR M8-1.25

38 0C2824 1 SCREW TAP-R #10-32 x 9/16

39 025145 1 U-BOLT 5/16"-18 X 1.25" WITH SADDLE

40 0C4138 2 GASKET, EXHAUST PORT

41 040173 2 CLAMP HOSE #5.5 0.62"-0.62"

42 074995 1.44 FT HOS

43 066849 2 SCREW HHTT M5-0.8 X 16

8 4 RUBBER MOUNT

SHER LOCK M8-5/16

E 1\4 ID LPG 350PSI UL21

15 kW Generator

37

Section 8 — Exploded Views and Parts Lists

15 kW Generator
Gas Regulator – Drawing No. 0D8720-G

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Section 8 — Exploded Views and Parts Lists

15 kW Generator

Gas Regulator – Drawing No. 0D8720-G

ITEM PART NO. QTY. DESCRIPTION

1 0D5694 1 CASTING, TWIN REGULATOR HOUSING
2 0F5022 1 SOLENOID COIL, 12VDC
3 0C4647 1 GASKET , SOLENOID
4 0D4166 1 PLUNGER, LP REGULATOR ASSEMBLY
5 0C6070 1 SPRING-SOLENOID, PLUNGER
8 0F4795 4 SCREW PPHM SEMS M4-0.7 X 10
9 0C5760J 1 JET, GN 410 ENGINE LP (7KW)
10 0C6606 2* BARBED STRAIGHT 1/2NPT x 1/2
11 097934 2* O-RING, CHECK VALVE
12 0C4645 2* ADJUSTER SCREW, TWIN REGULATOR
13 0C5761 2 LEVER, REGULATOR
14 0C5968 2 SUPPORT, INLET SEAL
15 0C6066 2 SEAL, INLET
16 0C5759 2 PIN, PIVOT ARM
17 0C5764 2 SPRING, REGULATOR
0C5764A 2 SPRING, REGULATOR (7KW)
18 070728 4 SCREW, PFHMS M3-0.5 x 5
19 0C6069 2 GASKET, DIAPHRAGM
20 0C5762 2 COVER, TWIN REGULATOR
21 045764 16 SCREW, TAPTITE M4X8 BP
22 0C673
23 0C6067 2 SUPPORT, DIAPHRAGM
24 0C4706 2 DIAPHRAGM, TWIN REGULATOR
25 0C6068 2 CAP, DIAPHRAGM SUPPORT
26 0C4643A 2 INLET, TWIN REGULATOR 11.11 DIA.
27 026073 1 PLUG, STANDARD PIPE 1/8" STEEL SQUARE HEAD
026073 2 PLUG, STANDARD PIPE 1/8" STEEL SQUARE HEAD (7KW)
28 0A4032 2* PIN, LIMITED ADJUSTMENT
29 0D3308 4 WASHER, FLAT M3 X 10mm O.D.
30 024310 1 PLUG, STANDARD PIPE 1/2" STEEL SQUARE HEAD (7KW)
31 028414A 1 BARBED STRAIGHT 1/8"NPT X 1/4"
32 0D5698A 1 JET IDLE PRIMER PHILLIPS HD (V-TWIN ONLY)
37 0D3973 1 PLUG, EXPANSION 16mm

1 2 RIVET, POP .118 X .125

* A QUANTITY OF 1 IS TO BE USED ON 7KW HOME STANDBY

39

Section 9 – Warranty

15 kW Generator

NOTE: This Emission Control Warranty Statement pertains to this product only IF the generator size is 15 kW or below.

CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with
Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control System Warranty on your new engine.*
New (small off road) engines must be designed, built and equipped to meet stringent anti-smog standards for the state of
California and the federal government. Generac will warrant the emission control system on your engine for the periods of
time listed below provided there has been no abuse, neglect, unapproved modification or improper maintenance of your
engine.

Your emission control system may include parts such as the carburetor, ignition and exhaust systems. Generac will repair your
engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.

MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

Emissions control systems on engines are warranted for two years as hereinafter noted. If, during such warranty period,
any emission-related component or system on your engine is found to be defective in materials or workmanship, repairs or
replacement will be performed by a Generac Authorized Warranty Service Facility.

PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:

As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory
supplied Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on
your engine. However, Generac cannot deny warranty solely because of the lack of receipts or for your failure to ensure the
completion of all scheduled maintenance.

As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or
responsibility if your engine, or a part/component thereof, has failed due to abuse, neglect, improper maintenance or unap­proved modifications, or the use of counterfeit and/or “grey market” parts not made, supplied or approved by Generac.

You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a
problem occurs. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility.
To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number:

1-800-333-1322

IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System Warranty
(ECS Warranty), which is provided to you by Generac pursuant to California and federal law. See also the “Generac Limited
Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you by Generac.
The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in terms between the
ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where the Generac Warranty
may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe important rights and obli­gations with respect to your new engine.

Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty ser­vice, evidence must be presented showing the date of the sale to the original purchaser/owner. The purchaser/owner shall
be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the
inspection or repair facilities. The purchaser/owner also shall be responsible for any and/or all damages or losses incurred while
the engine is being transported/shipped for inspection or warranty repairs.

If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at
the following address:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

P.O. BOX 297

WHITEWATER, WI 53190

Part 1

40

Section 9 – Warranty

15 kW Generator

EMISSION CONTROL SYSTEM WARRANTY

Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines:

(a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on the

date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for
24 consecutive months thereafter.

(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or

equipment, and to each subsequent purchaser/owner, that each of its engines is ...

(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the EPA and CARB pursuant to

their respective authority, and

(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a war-

ranted emissions-related part to fail to be identical in all material respects to the part as described in the engine manufac­turer’s application for certification.

(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:

(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s

Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall
be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the ECS
Warranty shall be warranted for the remainder of the ECS Warranty Period.

(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual

shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or replace
as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall
be warranted for the remainder of the ECS Warranty Period.

(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s Manual

shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part fails prior
to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection (4) below.
Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the
ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.

(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge

to the owner at a Generac Authorized Warranty Service Facility.

(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsible

for diagnostic costs if the repair is deemed warrantable.

(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused

by a failure under warranty of any emission-related part covered by the ECS Warranty.

(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to

meet the expected demand for such emission-related parts.

(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS

Warranty maintenance or repairs and will be provided without charge to the purchaser/owner. Such use shall not reduce
Generac’s ECS Warranty obligations.

(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac

engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac
shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an
unapproved, add-on, modified, counterfeit and/or “grey market” part.

EMISSION RELATED PARTS INCLUDE THE FOLLOWING:

1) Fuel Metering System:

1.1) Gasoline carburetor assembly and its
internal components (if so equipped).

a) Fuel filter (if so equipped)
b) Carburetor gaskets
c) Fuel pump (if so equipped)

1.2) LPG carburetion assembly and its
internal components (if so equipped).

a) Fuel controller (if so equipped)
b) Mixer and its gaskets (if so equipped)
c) Carburetor and its gaskets (if so equipped)
d) Primary gas regulator (if so equipped)
e) LP liquid vaporizer (if so equipped)

2) Air Induction System including:
a) Intake pipe/manifold
b) Air cleaner

3) Ignition System including:
a) Spark plug
b) Ignition module

4) Catalytic Muffler Assembly (if so equipped) including:
a) Muffler gasket
b) Exhaust manifold

5) Crankcase Breather Assembly including:
a) Breather connection tube

*Generac engine types covered by this warranty statement include the following:

1) Utility

2) Lawn and Garden Equipment

3) Recreational Vehicle (RV) Generator

4) Industrial Mobile (IM) Generator

Part 2

41

Section 9 – Warranty

15 kW Generator

BRYANT "TWO YEAR" LIMITED WARRANTY FOR

"PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"

For a period of two years from the date of original sale, warrants that its generator will be free from defects in material and workman­ship for the items and period set forth below. Bryant will, at its option, repair or replace any part which, upon examination, inspection
and testing by a Bryant Dealer, is found to be defective. All transportation costs under the warranty, including return to the factory, are
to be borne and prepaid by the purchaser/owner. This warranty applies only to Bryant prepackaged emergency automatic standby
generators sold and rated for use in "Standby" applications.

WARRANTY SCHEDULE

YEARS ONE AND TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed.
ENGINE - All Components
ALT ERNATOR - All Components
TRANSFER SYSTEM - All Components

Steel enclosures are warranted against rusting for the first year of ownership only. Damage caused after receipt of generator is the
responsibility of the owner and is not covered by this warranty. Nicks, scrapes, dents or scratches to the painted enclosure should be
repaired promptly by the owner.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

• Bryant generators that utilize non-Bryant replacement parts.

• Bryant generators utilizing non-Bryant automatic transfer switches.

• Any Bryant generators used as rental or trailer mounted applications.

• Air-cooled units used for prime power in place of existing utility power where utility power is present or in place of utility power where
utility power service does not normally exist.

• Costs of normal maintenance, adjustments, installation and start-up.

• Steel enclosures that are rusting due to the improper installation, location in a harsh or saltwater environment or scratched where
integrity of paint applied is compromised.

• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.

• Failures due, but not limited to, accident, misuse, abuse, negligence or improper installation. As with all mechanical devices, the
Bryant engines need periodic part(s) service and replacement to perform well.

• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire,
freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.

• Damage related to rodent and/or insect infestation.

• Products that are modified or altered in a manner not authorized by Bryant in writing.

• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or
replacement of the defective part(s).

• Failure due to misapplication.

• Telephone, cellular phone, facsimile, internet access or other communication expenses.

• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty
period.

• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.

• Rental equipment used while warranty repairs are being performed.

• Costs incurred for equipment used for removal and/or reinstallation of generator, (i.e.; cranes, hoists, lifts, etc.)

• Overnight freight costs for replacement part(s).

• Overtime labor.

• Starting batteries, fuses, light bulbs and engine fluids.

THIS WARRANTY IS IN

BRYANT MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

BRYANT 'S ONLY L I ABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL
BRYANT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT
RESULT OF BRYANT 'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages,
so the above limitation may not apply to you.
This warranty gives you specific legal rights. You also have other rights from state to state.

Part No. 0F7614 Rev. 0 (08/24/05) Printed in U.S.A.Catalog No. OM18-7

PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY,

Revision (10/01/04)