Generac ASPAS1CCL015 User Manual

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Owner’s Manual

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT

INSTALLATION!!

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!

This manual should remain with the unit.

Not intended for use in critical life support applications.

Liquid-cooled, Prepackaged

Standby Generators

Model Number:

ASPAS1CCL015

Carrier

INTRODUCTION

Thank you for purchasing a Carrier home standby generator system.

Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was written. However, the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any time without prior notice.

READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, contact the nearest Carrier 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 service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:

After this heading, read instructions that, if not strictly complied with, will result in serious personal injury, including death, or considerable property damage.

After this heading, read instructions that, if not strictly complied with, may result in 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 is as follows:

This symbol points out important safety information that, if not followed, could endanger personal safety and/or property of others.

This symbol points out potential explosion hazard.

This symbol points out potential fire hazard.

This symbol points out potential electrical shock hazard.

The operator is responsible for proper and safe use of the equipment. Carrier strongly recommends that the operator read this Owner's Manual and thoroughly understand all instructions before using this equipment. Carrier 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.

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 Carrier 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 ensure a minimum number of problems and keep operating expenses at a minimum. See a Carrier Dealer for service aids and accessories.

Operating instructions presented in this manual assume that the standby electric system has been installed by a Carrier Dealer or other competent, qualified contractor. Installation of this equipment is not a “do-it-yourself” project.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs, contact a Carrier Dealer for assistance. Service technicians are factory-trained and are capable of handling all of servicing needs.

When contacting a Carrier Dealer about parts and service, always supply the complete model number and serial number of the unit as given on the front cover of this manual and on the DATA LABEL affixed to the unit.



YOUR CARRIER DEALER IS:

___________________________________________

Model No.__________ Serial No.___________

Dealer Name

Address

City

State

Zip Code

Phone Number

DANGER

Table of Contents

Carrier Liquid-cooled 15 kW Generators

Carrier 1

INTRODUCTION ..................................IFC

SAFETY RULES ......................................2

Section 1 — GENERAL

INFORMATION..................4

1.1 Generator ......................................................4

1.2 Transfer Switch ............................................4

1.3 Automatic System Operation ........................4

1.4 Generator AC Connection Systems................4

1.5 Main Circuit Breaker ....................................4

1.6 Generator Fuel System ..................................5

1.7 Engine Protective Devices ..............................5

1.8 Unpacking ....................................................6

1.9 Lifting the Generator ....................................6

1.10 Specifications ................................................6

1.11 Fuel Consumption ........................................7

1.12 Reconfiguring the Fuel System ......................7

1.13 Torque Specifications ....................................7

1.14 Engine Oil Recommendations ......................8

1.15 Coolant Recommendations............................8

1.16 Before Installation ........................................8

Section 2 — INSTALLATION ................8

2.1 Standby Generator Installation ....................8

2.2 Generator Location ......................................9

2.3 Generator Mounting and Support ................9

2.4 Basic Standby Electric System ......................9

2.5 Emergency Circuit Isolation Method ..........10

2.6 Total Circuit Isolation Method ....................10

2.7 Grounding the Generator ............................10

2.8 Generator AC Neutral Connections ............10

2.9 Transfer Switch Signal Connections............10

2.10 Battery Installation ......................................11

2.11 Preparation Before Start-Up........................11

Section 3 — OPERATION....................12

3.1 Control Console Components......................12

3.2 Manual Transfer and Startup......................13

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

3.4 Weekly Exercise Cycle..................................13

Section 4 — MAINTENANCE ..............14

4.1 Maintenance Performed by Authorized

Service Facilities ..........................................14

4.2 Cooling System............................................14

4.3 Overload Protection for Engine DC

Electrical System ........................................14

4.4 Checking Fluid Levels ................................14

4.5 Maintenance Owner/Operator

Can Perform................................................15

4.6 Miscellaneous Maintenance ........................16

4.7 Scheduled Maintenance ..............................18

Section 5 — TROUBLESHOOTING......21

5.1 Troubleshooting Points................................21

Section 6 — NOTES............................22

Section 7 — INSTALLATION

DIAGRAM ......................23

Section 8 — ELECTRICAL DATA ........24

Section 9 — EXPLODED VIEWS AND

PARTS LISTS ................28

Section 10 — WARRANTY .................44

2 Carrier

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. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

Carrier cannot anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit are, therefore, not all-inclusive. If using a procedure, work method or operating technique that Carrier does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique utilized does not render the generator unsafe.

Despite the safe design of this generator, operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to install, operate 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.

GENERAL HAZARDS

• For safety reasons, Carrier recommends that this equipment be installed, serviced and repaired by a Carrier Dealer or other competent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations. The operator also must comply with all such codes, standards and regulations.

• Installation, operation, servicing and repair of this (and related) equipment must always comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure that the generator is installed, operated and serviced in accordance with the manufacturer’s instructions and recommendations. Following installation, do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes, standards, laws and regulations.

• The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. For that reason, adequate ventilation must be provided. Exhaust gases must be piped safely away from any building or enclosure that houses the generator to an area where people, animals, etc., will not be harmed. This exhaust system must be installed properly, in strict compliance with applicable 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 prevent buildup of explosive gases and to ensure 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.

• Keep the area around the generator clean and uncluttered. Remove any materials that could become hazardous.

• 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 promptly repair or replace all worn, damaged or defective parts using only factory-approved parts.

• 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 well as the standby generator. Avoid contact with bare wires, terminals, connections, etc., on the generator as well as the transfer switch, if applicable. Ensure all appropriate covers, guards and barriers are in

IMPORTANT SAFETY INSTRUCTIONS

Carrier Liquid-cooled 15 kW Generators

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, and service and repair technicians for this equipment.

SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries.

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

WARNING:

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

cancer, birth defects or other reproductive harm.

WARNING:

DANGER

Carrier 3

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.

• If people must stand on metal or concrete while installing, operating, servicing, adjusting or repairing this equipment, place insulative mats over a dry wooden platform. Work on the equipment only while standing on such insulative mats.

• The National Electrical Code (NEC), Article 250 requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground and/or grounding rods. This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator set or by static electricity. Never disconnect the ground wire.

• Wire gauge sizes of electrical wiring, cables and cord sets must be adequate to handle the maximum electrical current (ampacity) to which they will be subjected.

• Before installing or servicing this (and related) equipment, make sure that all power voltage supplies are positively turned off at their source. Failure to do so will result in hazardous and possibly fatal electrical shock.

• Connecting this unit to an electrical system normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distribution system when the generator is operating. Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy.

• Generators installed with an automatic transfer switch will crank and start automatically when normal (utility) source voltage is removed or is below an acceptable preset level. To prevent such automatic start-up and possible injury to personnel, disable the generator’s automatic start circuit (battery cables, etc.) before working on or around the unit. Then, place a “Do Not Operate” tag on the generator control panel and on the transfer switch.

• 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.

IRE HAZARDS

• Keep a fire extinguisher near the generator at all times. Do NOT use any carbon tetra-chloride type extinguisher. Its fumes are toxic, and the liquid can deteriorate wiring insulation. Keep the extinguisher properly charged and be familiar with its use. Consult the local fire department for any questions pertaining to fire extinguishers.

EXPLOSION HAZARDS

• Properly ventilate any room or building housing the generator to prevent build-up of explosive gas.

• 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.

• Carrier generator sets may operate using one of several types of fuels. All fuel types are potentially FLAMMABLE and/or EXPLOSIVE and should be handled with care. Comply with all laws regulating the storage and handling of fuels. Inspect the unit’s fuel system frequently and correct any leaks immediately. Fuel supply lines must be properly installed, purged and leak tested according to applicable fuel-gas codes before placing this equipment into service.

• Diesel fuels are highly FLAMMABLE. Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE. Natural gas is lighter than air, and LP gas is heavier than air. Install leak detectors accordingly.

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.

NOTE:

It is essential to use the latest version of any standard to ensure correct and current information.

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 SYS-

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

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

able same as Item 1.

4. NFPA No. 58, AMERICAN NATIONAL STANDARD

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

5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL

ELECTRIC CODE, available same as Item 1.

6. Article X, NATIONAL BUILDING CODE, available

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

7. AGRICULTURAL WIRING HANDBOOK, available

from the Food and Energy Council, 909 University Avenue, Columbia, MO 65201.

8. ASAE EP-3634, INSTALLATION AND MAINTE-

NANCE 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.

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IMPORTANT SAFETY INSTRUCTIONS

Carrier Liquid-cooled 15 kW Generators

4 Carrier

1.1 GENERATOR

This equipment is a liquid-cooled, engine-driven generator set. The generator is designed to supply electrical power that operates critical electrical loads during utility power failure. The unit has been factory-installed in a weather resistant, all metal enclosure and is intended for outdoor installation only. Use this generator as a source of electrical power for the operation of 120 and/or 240 volts, single phase loads.

These models are available. They are rated as follows:

Model ASPAS1CCL015: Provides 15,000 watts (15 kW) of single phase power.

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 electric system from the utility distribution system when the generator is operating (NEC 701). Failure to isolate an electrical system by such means results in damage to the generator and may also result in injury or even death to utility power workers due to backfeed of electrical energy.

1.2 TRANSFER SWITCH

This generator system includes a matched automatic transfer switch which is intended to be used in conjunction with the generator. It is supplied with a NEMA 3R enclosure. The NEMA 3R enclosure is weather proof and can be used indoors or outdoors. Follow these rules:

• Install the transfer switch on a firm, sturdy supporting structure.

• To prevent switch distortion, level the switch if necessary. This can be done by placing washers between the switch enclosure and the mounting surface.

• Never install the switch where water or any corrosive substance might drip onto the enclosure.

• Protect the switch at all times against excessive moisture, dust, dirt, lint, construction grit and corrosive vapors.

• Failure to utilize a Carrier transfer switch with this generator will void the warranty.

1.3 AUTOMATIC SYSTEM OPERATION

When this generator, along with its transfer switch, has been installed and interconnected, a circuit board in the generator panel constantly monitors utility power source voltage. Should that voltage drop below a preset value, and remain at such a low state for a preset amount of time, the generator cranks and starts. After the generator starts, the transfer switch transfers load circuits so the generator can power them.

When utility source voltage has been restored, the switch re-transfers back to the utility source voltage and the generator then shuts down.

Please reference the transfer switch manual for specific information.

1.4 GENERATOR AC CONNECTION SYSTEMS

The generator was shipped from the factory with its stator AC output leads connected in a single-phase, three-wire generator AC connection system (Figure

1.1). The stator assembly in this system consists of a

pair of stationary windings, with two leads brought out of each winding. Each single winding can supply 120 volts AC, 60 Hertz. When the two windings are connected in series, a 240 volts, 60 Hertz AC output results. Typically the two “hot” leads in the circuit are Wires No. 11 and 44. The “Neutral” leads are the junction of Wires 22 and 33.

Figure 1.1 - Generator AC Connection System

1.5 MAIN CIRCUIT BREAKER

The generator’s main circuit breaker is included with the unit as shipped from the factory. The breaker for each unit is described in Figure 1.2.

Section 1 - General Information

Carrier Liquid-cooled 15 kW Generators

Model Rating Phase Actual Current C/B Rating* % over rating Circuit Breaker

ASPAS1CCL015 15,000 1 62.5 70 112% 70A BQ2

* Amp Rating of CB structured under model.

Figure 1.2 - Main Circuit Breaker

Carrier 5

1.6 GENERATOR FUEL SYSTEM

The generator has been factory tested and adjusted using a natural gas fuel system. If propane (LP requirements) gas is preferred, refer to Section 1.12.

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

Fuel pressure for a natural gas set up should be five

inches to 14 inches of water column (0.18 to 0.5 psi) at all load ranges.

Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column (0.4 to 0.5 psi) at all load ranges.

NOTE:

A separate gas line and regulator may be needed to assure proper gas pressure to the generator. Improper gas pressure can cause hard starting and affect engine durability.

Gaseous fuels such as natural and LP (propane) 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.

1.7 ENGINE PROTECTIVE DEVICES

The engine has several safety switches which cause the engine to automatically shut down under the following conditions: low oil pressure, high coolant temperature, engine overspeed, low coolant level or overcrank (Figure 1.3).

Figure 1.3 - Engine Protective Devices

1.7.1 LOW OIL PRESSURE SWITCH

This switch is normally-closed (N.C.), but is held open by engine oil pressure during engine running. Should operating oil pressure drop below about 8-10 psi (55-68 kPa), the switch contacts close and the engine shuts down automatically (Figure 1.4).

Figure 1.4 - Low Oil Pressure Switch

1.7.2 HIGH COOLANT TEMPERATURE SWITCH

This normally open (N.O.), thermostatic switch has sensing tip which is immersed in captive coolant. Should coolant temperature exceed about 230°F (110°C), the switch contacts close, which causes the engine to shut down automatically (Figure 1.5).

Figure 1.5- High Coolant Temperature Switch

1.7.3 LOW COOLANT LEVEL SWITCH

Should engine coolant level drop below the level of the high coolant temperature switch, it is possible for the engine to overheat without automatic shutdown. To prevent such overheating without automatic shut down, the engine has a low coolant level sensor. If the engine coolant drops too low, the engine automatically shuts down (Figure 1.6 on page 6).

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Section 1 - General Information

Carrier Liquid-cooled 15 kW Generators

6 Carrier

Figure 1.6 - Low Coolant Level Sensor

1.7.4 OVERSPEED SHUTDOWN

The Pre-pack circuit board on liquid cooled units receives AC frequency (rpm) signals directly from the stator AC power windings, via sensing leads S15 and S16. Should AC frequency exceed about 72 Hz, circuit board action will automatically shutdown the engine (Figure 1.7).

Figure 1.7 - Control Module Assembly

Circuit Board

*Rated power of generator is subject to and limited by such factors as ambient temperature, altitude, engine condition, and other factors. Engine power will decrease about 3% for each 1000 feet above 3000 feet and will decrease an additional

1.5% for each 10°F above 77°F. Maximum output power of the generator is limited by maximum engine power.

1.7.5 PCB OPERATION LED’S

• LED 1 is RED. The LED is ON when utility sensing is NOT available to the circuit board. This LED will function only when the AUTO/OFF/MANUAL switch is set in the AUTO position.

• LED 2 is YELLOW. This LED is ON when the circuit board battery charger is on. This LED will cycle ON and OFF with the battery charger, 4.85 hours on the 4.85 hours OFF.

• LED 3 is GREEN. This LED will flash when the circuit board has load voltage available to it. This LED will function when voltage is available across T1 and T2.

1.7.6 OVERCRANK SHUTDOWN

After 90 seconds of crank-rest cycles, this function ends cranking if the engine fails to start in that 90-second span.

1.7.6 DC FUSE

This clearly labeled fuse is located on the front panel of the control system. It protects the panel wiring and components from damaging overload. Always

remove this fuse before commencing work on the generator. The unit will not start or crank if the fuse

is blown. Replace the fuse with one of the same size, type, and rating. Carrier normally uses an AGC fuse rated at 15 amps (part number 022676).

1.8 UNPACKING

Handle shipping cartons and crates with care. Use care to avoid damage from dropping, bumping, collision, etc. Store and unpack cartons with the proper side up, as noted on the shipping carton.

1.9 LIFTING THE GENERATOR

When lifting or hoisting equipment is used, be careful not to touch overhead power lines. The generators weight of more than 900 pounds requires proper tools, equipment, and qualified personnel to be used in all phases of handling and unpacking.

1.10 SPECIFICATIONS

1.10.1 GENERATOR SPECIFICATIONS

Model ..................................................................ASPAS1CCL015

Phase ..................................................................................Single

Rated Max. Cont. AC Power Output (kW) ................................15

Rated Voltage (volts) ........................................................120/240

No. of Rotor Poles ......................................................................4

Driven Speed of Rotor ..........................................................1800

Rotor Excitation System ........................Direct excited brush type

Rotor/Stator Insulation ......................................................Class F

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17 1

U12

U14

U13

U15

U10

U16

U17

C 3

CR16

9 CR1

CR7

C 8

9 C23

C24

C19

C20

C21

C13

R 6

R 1

R 3

R 7

R 8

R 2

R 3

R 4

R 5

R 6

R 7

R 9

R 0

R 1

R 2

R 3

R 5

R 6

R 7

R 8

R 9

R 0

R 1

R 2

R 3

R 4

R 6

R 7

R 0

R 1

R 2

R 3

R 7

R 9

R 1

R 2

R 3

R 5

R 7

R 9

R 0

R 1

R 2

R 4

R 5

R 6

R77

R 8

SW1

R 4

R 0

R 5

R 1

R 9

CR37

Q13

0 C25

R 2

Q11

Q12

MM C5

CR41

U18

U19

R 3

U20

C14

C15

C16

C10

C11C1

C17

C18

C12

C22

R 4

Q14

Q16

R 8

R 4

R 5

R 6

R 7

R 8

Q15

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Section 1 — General Information

Carrier Liquid-cooled 15 kW Generators

PRE-PACKAGED STANDB

LED

2002 GENERAC POWER SYSTEMS, ASSY #076009

T R

FOR 50H

1.10.2 ENGINE SPECIFICATIONS

Make..............................................................................Mitsubishi

Displacement ..............................................92 inches3(1.5 liters)

Cylinder Arrangement......................................................4, in-line

Valve Arrangement................................................Overhead Cam

Firing Order........................................................................1-3-4-2

Number of Main Bearings............................................................5

Compression Ratio ..............................................................9 to 1

No. of Teeth on Flywheel ........................................................104

Ignition Timing

at 1800 rpm ..................................................35 degrees BTDC

Spark Plug Gap ..................................................0.020-0.025 inch

Recommended Spark Plugs

Champion ....................................................................RN11YC4

Oil Pressure....................................................................30-50 psi

Crankcase Oil Capacity........................3.0 U.S. quarts (2.8 liters)

Recommended Engine Oil........................................SAE 15W-40

Type of Cooling System ..................Pressurized, closed recovery

Cooling Fan ..............................................................Pusher Type

Cooling System Capacity ......................2 U.S. gallons (7.6 liters)

Recommended Coolant ............................Use a 50-50 mixture of

ethylene glycol base.

1.11 FUEL CONSUMPTION

15 kW Models

Using Natural Gas ........................................277 cu. ft. per hour

Using LP Gas ..............................110 cubic ft.(3.1 gal.) per hour

NOTE:

Fuel consumption is given at rated maximum continuous power output when using natural gas rated at 1000 Btu per cubic foot and LP gas rated 2520 Btu per cubic foot. Actual fuel consumption obtained may vary depending on such variables as applied load, ambient temperature, engine conditions and other environmental factors.

Fuel pressure for a natural gas set up should be five inches to 14 inches of water column (0.18 to 0.5 psi) at all load ranges.

Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column (0.4 to 0.5 psi) at all load ranges.

1.12 RECONFIGURING THE FUEL SYSTEM

NOTE:

All models are configured for natural gas from the factory.

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

1. Turn the main gas supply off.

2. Remove the carburetor fuel hose from the outlet

port (Port 1) of the demand regulator (Figure

1.8).

3. Remove the brass hose fitting from the outlet port

(Port 1) of the demand regulator.

4. Remove pipe plug from Port 2.

5. Install brass hose fitting into Port 2.

6. Install pipe plug into Port 1.

7. Connect carburetor gas hose to brass fitting.

8. Tighten all clamps and plugs.

9. Make sure fuel supply is of the proper pressure

and type for configuration.

10. Reverse the procedure to convert back to natural

gas.

Figure 1.8 — Reconfigure the Fuel System

NOTE:

Port 1 is for NG only and Port 2 is for LP vapor only. No provision for simultaneous fuels has been made.

Serious injury or damage may occur if not configured properly. Please consult a dealer with any questions.

1.13 TORQUE SPECIFICATIONS

Cylinder Head ............................................15 (+ 90° + 90°) ft.lb.

Intake Manifold ................................................................13 ft.lb.

Exhaust Manifold..............................................................13 ft.lb.

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Section 1 — General Information

Carrier Liquid-cooled 15 kW Generators

Carrier 7

Port 2

PLUG

LP FUEL SYSTEM

PLUG

Port 1

NG FUEL SYSTEM

FUEL HOSE

BRASS HOSE FITTING

PORT 1

HOUSING PORTS

FUEL HOSE

BRASS HOSE FITTING

OUT

OUT PORT 2

HOUSING PORTS

DANGER

8 Carrier

1.14 ENGINE OIL RECOMMENDATIONS

The unit has been filled with 15W-40 engine oil at the factory. Use a high-quality detergent oil classified “For Service SJ or latest available.” Detergent oils keep the engine cleaner and reduce carbon deposits. Use oil having the following SAE viscosity rating, based on the ambient temperature range anticipated before the next oil change:

NOTE:

Synthetic oil is highly recommended when the generator will be operating in ambient temperatures which regularly exceed 90° F and/or fall below 30° F.

Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in an engine failure.

1.15 COOLANT RECOMMENDATIONS

Use a mixture of half low silicate ethylene glycol base anti-freeze and deionized water. Cooling system capacity is about 8 U.S. quarts (7.6 liters). Use only deionized water and only low silicate anti-freeze. If desired, add a high quality rust inhibitor to the recommended coolant mixture. When adding coolant, always add the recommended 50-50 mixture.

Do not use any chromate base rust inhibitor with ethylene glycol base anti-freeze or chromiumhydroxide (“green slime”) forms and will cause overheating. Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base anti-freeze. Using any high silicate anti-freeze boosters or additives will also cause overheating. It is also recommended that any soluble oil inhibitor is NOT used for this equipment.

1.16 BEFORE INSTALLATION

Before installing this equipment, check the ratings of both the generator and the transfer switch. Read “Emergency Isolation Method” and “Total Circuit Isolation Method” in Sections 2.5 and 2.6.

The generator’s rated wattage/amperage capacity must be adequate to handle all electrical loads that the unit will power. The critical (essential) loads may need to be grouped together and wired into a separate “emergency” distribution panel.

The standard transfer switch has no sensing or controlling circuit boards. Instead, the generator control console houses a “Printed Circuit Board Assembly”, which controls all phases of operation, including engine start up and load transfer.

2.1 STANDBY GENERATOR INSTALLATION

Connecting this generator to an electrical system normally supplied by an electric utility shall be by means of a transfer switch, so as to isolate the electric system from the utility distribution system when the generator is operating. Failure to isolate the electric system by these means will result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy.

If an open bottom is used, the engine-generator is to be installed over non-combustible materials and should be located such that combustible materials are not capable of accumulating under the generator set.

Only qualified, competent installation contractors or electricians thoroughly familiar with applicable codes, standards and regulations should install this standby electric power system. The installation must comply strictly with all codes, standards and regulations pertaining to the installation.

This genset must be installed on a level surface. The base frame must be level within 1/2 inch all around.

After the system has been installed, do nothing that might render the installation in noncompliance with such codes, standards and regulations.

2.1.1 NFPA STANDARDS

The following published standards booklets pertaining to standby electric systems are available form the National Fire Protection Association (NFPA), Batterymarch Park, Quincy, MA 02269:

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Section 2 — Installation

Carrier Liquid-cooled 15 kW Generators

Temperature Oil Grade (Recommended)

Above 80° F (27° C) SAE 30W or 15W-40

32° to 80° F (-1° to 27° C) SAE 20W-20 or 15W-40

Below 32° F (0° C) SAE 10W or 15W-40

DANGER

Carrier 9

NOTE:

It is essential to use the latest version of any standard to ensure correct and current information.

• NFPA No. 37, STATIONARY COMBUSTION ENGINES AND GAS TURBINES.

• NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES.

• NFPA No. 220, STANDARD TYPES OF BUILDING CONSTRUCTION

• NFPA No. 68, GUIDE FOR EXPLOSION VENTING

• NFPA No. 70, NATIONAL ELECTRICAL CODE.

• NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE.

• NFPA No. 10, INSTALLATION, MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS.

2.1.2 OTHER PUBLISHED STANDARDS

In addition to NFPA standards, the following information pertaining to the installation and use of standby electric systems is available:

NOTE:

It is essential to use the latest version of any standard to ensure correct and current information.

• Article X, NATIONAL BUILDING CODE, available from the American Insurance Association, 85 John Street, New York, N.Y. 10038.

• AGRICULTURAL WIRING HANDBOOK, obtainable from the Food and Energy Council, 909 University Avenue, Columbia, MO, 65201.

• ASAE EP-364.2, INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRIC POWER, available from the American Society of Agricultural Engineers, 2950 Niles Road, St. Joseph, MI 49085.

• A52.1, AMERICAN NATIONAL STANDARD FOR CHIMNEYS, FIREPLACES AND VENTING SYSTEMS, available from the American National Standard Institute, 1430 Broadway, New York, N.Y.

10018.

2.2 GENERATOR LOCATION

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

• Install the unit where air inlet and outlet openings will not become obstructed by leaves, grass, snow, etc. If prevailing winds will cause blowing or drifting, consider using a 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. Five feet allowance of space is recommended on all sides. Local codes may supercede this recommendation.

• Where strong prevailing winds blow from one direction, face the generator air inlet openings into the prevailing winds.

• Install the generator as close as possible to the transfer switch. This reduces the length of wiring and conduit.

• Install the generator as close as possible to the fuel supply, to reduce the length of piping. HOWEVER, REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE.

2.3 GENERATOR MOUNTING AND

SUPPORT

Retain the generator compartment to a concrete slab with 1/4-inch masonry type anchor bolts. Be sure the bolts are long enough to retain the compartment. The slab should be at least six inches thick and should extend beyond the enclosure to a distance of at least three inches on all sides. See Section 6, Installation Diagram.

2.4 BASIC STANDBY ELECTRIC

SYSTEM

Figure 2.1 shows a schematic diagram of a basic standby electric system. Both the UTILITY power supply and the STANDBY (generator) output are connected to an approved transfer switch. The transfer switch is required by electrical code and serves the following functions:

• Permits the LOAD circuits to be connected to only one power supply at a time.

• Prevents electrical backfeed between the generator and the UTILITY power circuits.

Notice that both the STANDBY and the UTILITY power supplies to the transfer switch are protected against overload by a main line circuit breaker.

Figure 2.1 – Basic Standby Electric System

Carrier recommends the use of a Carrier transfer switch in conjunction with this generator.

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Section 2 — Installation

Carrier Liquid-cooled 15 kW Generators

10 Carrier

2.5 EMERGENCY CIRCUIT ISOLATION METHOD

This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator. If the generator is powering only critical loads, within the wattage/amperage capacity, during utility power outages, consider using the emergency circuit isolation method.

Critical electrical loads are grouped together and wired into a separate “Emergency Distribution Panel.” Load circuits powered by that panel are within the wattage/amperage capacity of the generator set. When this method is used, it is difficult to overload the generator. The transfer switch must meet the following requirements:

• It must have an ampere rating equal to, or greater

than, the total amperage rating of the emergency distribution panel circuit.

• Have it installed between the building’s main dis-

tribution panel and the emergency distribution panel.

2.6 TOTAL CIRCUIT ISOLATION METHOD

When a generator capable of powering all electrical loads in the circuit is to be installed, use the “Total Circuit Isolation Method.” It is possible for the generator to be overloaded when this isolation method is employed. The following apply to the transfer switch in this type of system.

• Ampere rating of the transfer switch must be equal

to, or greater than, the ampere rating of the normal incoming utility service.

• The transfer switch is installed between the utility

service entrance and the building distribution panel.

2.7 GROUNDING THE GENERATOR

The National Electrical Code requires the frame and external electrically conductive parts of this equipment to be properly connected to an approved earth ground and/or grounding rods. For that purpose, a GROUND LUG (Figure 2.2) is provided on the generator mounting base. Consult a qualified electrician for grounding requirements in the area. Grounding procedures must meet local regulations.

Do not connect the ground wire to any pipe that carries a flammable or explosive substance – FIRE or an EXPLOSION may result.

Proper grounding helps protect personnel against electrical shock in the event of a ground fault condition in the generator or in connected electrical devices. In addition, grounding helps dissipate static electricity that often builds up in ungrounded devices.

Figure 2.2 – Generator Grounding Lug (typical)

2.8 GENERATOR AC NEUTRAL CONNECTIONS

Carrier uses an UNGROUNDED AC neutral. Grounding is recommended only at the main service entrance. If the neutral wire is grounded and one of the phase loads becomes grounded, the excessive current opens the load circuit breaker or collapses the generator field. The actual result depends on the electrical characteristics of the particular installed generator.

Failure to connect the generator neutral properly will result in unbalanced line-to-neutral voltages. Resulting high voltages will cause equipment damage.

2.9 TRANSFER SWITCH SIGNAL CONNECTIONS

It is necessary to connect the control wires between the generator and the transfer switch.

Control system interconnections consist of N1, N2, T1, T2, and leads 23 and 194. Control system interconnection leads must be run in a conduit that is separate from the AC power lead. Recommended wire gauge sizes for this wiring depends on the length of the wire, as recommended below:

Section 2 — Installation

Carrier Liquid-cooled 15 kW Generators

MAXIMUM WIRE LENGTH RECOMMENDED WIRE

SIZE

460 FEET (140M) No. 18 AWG.

461 TO 730 FEET (223M) No 16 AWG.

731 to 1,160 feet (354m) No 14 AWG.

1,161 to 1,850 feet (565m) No 12 AWG.

DANGER

Carrier 11

2.10 BATTERY INSTALLATION

Standby generators installed with automatic transfer switches will crank and start automatically when NORMAL (UTILITY) source voltage is removed or is below an acceptable preset level. To prevent such automatic start-up and possible injury to personnel, do not connect battery cables until the NORMAL source voltage at the transfer switch is correct and the system is ready to be put into operation.

Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing tools or equipment near the battery.

Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If the fluid is spilled, flush the affected area immediately with clear water.

Do not dispose of the battery in a fire. The battery is capable of exploding.

Do not open or mutilate the battery. Released electrolyte can be toxic and harmful to the skin and eyes.

The battery represents a risk of high short circuit current. When working on the battery, always remove watches, rings or other metal objects, and only use tools that have insulated handles.

2.10.1 VENTED BATTERIES

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, flush thoroughly and immediately 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 one pound (500 grams) bicarbonate of soda to one gallon (4 liters) of 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 procedure are to be followed:

• DO NOT SMOKE when near batteries,

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

• Discharge static electricity from body before touching batteries by first touching a grounded metal surface.

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

The recommended battery is Group 26, 12V negative ground, 525 CCA/75 AH minimum. All batteries must be at 100 percent state-of-charge before they are installed on the generator.

When using maintenance-free batteries, it is not necessary to check the specific gravity or electrolyte level. Have these procedures performed at the intervals specified in Section 4, “Maintenance.” A negative ground system is used. Battery connections are shown on the wiring diagrams. Make sure all batteries are correctly connected and terminals are tight. Observe battery polarity when connecting batteries to the generator set.

NOTE:

Damage will result if the battery connections are made in reverse.

2.11 PREPARATION BEFORE START-UP

The instructions in this section assume that the standby generator has been properly installed, serviced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor. Be sure to read the “Safety Rules” on pages 2 and 3, as well as all other safety information in this manual, before attempting to operate this (and related) equipment.

2.11.1 PRIOR TO INITIAL START-UP

Prior to initially starting the generator, it must be properly prepared for use. Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids (oil, coolant, fuel, etc.) may result in an engine failure.

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Section 2 — Installation

Carrier Liquid-cooled 15 kW Generators

DANGER

12 Carrier

Before starting the generator for the first time, the installer must complete the following procedures. For follow-up maintenance information and/or service intervals, please refer to Section 4, “Maintenance.”

2.11.2 TRANSFER SWITCH

If this generator is used to supply power to any electrical system normally powered by an electric utility, the National Electrical Code requires that a transfer switch be installed. The transfer switch prevents electrical backfeed between two different electrical systems. (For additional information, see the applicable transfer switch manual for this unit.) The transfer switch, as well as the generator and other standby components, must be properly located and mounted in strict compliance with applicable codes, standards and regulations.

2.11.3 FUEL SYSTEM

Make sure the fuel supply system to the generator (a) delivers the correct fuel at the correct pressure and (b) is properly purged and leak tested according to code. No fuel leakage is permitted. See “Specifications” (Section 1.10) for more information.

2.11.4 GENERATOR SET LUBRICATION

Check the engine crankcase oil level before operating and add oil to the proper level – the dipstick “FULL” mark. Never operate the engine with the oil level below the dipstick “ADD” mark. See “Specifications” (Section 1.10) and “Engine Oil Recommendations” (Section 1.14).

NOTE:

This engine is shipped from the manufacturer with 15W-40 oil. This oil should be changed after 30 hours of operation.

2.11.5 ENGINE COOLANT

Have the engine cooling system properly filled with the recommended coolant mixture. Check the system for leaks and other problems. See “Specifications” (Section 1.10) and “Coolant” (Section 1.15).

2.11.6 BELT TENSION

Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals. Belt tension is correct when a force of approximately 22 pounds (10 kg), applied midway between pulleys, deflects the belt about 3/8- to 5/8inch (10 to 16 mm).

2.11.7 ELECTRICAL SYSTEM

Make sure the generator is properly connected to an approved earth ground and/or ground rod.

Make sure the generator battery is fully charged, properly installed and interconnected, and ready for use.

Check to ensure that there are no loose electrical connections. Restrain any loose wires to keep them clear of any moving generator set components.

3.1 CONTROL CONSOLE

COMPONENTS

The components of a liquid-cooled generator control console (Figure 3.1) are as follows:

Figure 3.1 - Liquid-Cooled Generator Panel

3.1.1 AUTO/OFF/MANUAL SWITCH

Use this three-position switch as follows:

• Set the switch to AUTO for fully automatic operation. See “Automatic Operation”, Section 3.4.

• Set switch to MANUAL position to crank and start the generator engine.

• Set switch to OFF position to shut down an operating engine. With OFF selected, operation will not be possible.

With switch set to AUTO, engine can crank and start suddenly without warning. Such automatic start up normally occurs when UTILITY source voltage drops below a pre-set level. To prevent possible injury that might be caused by such sudden starts, set AUTO/OFF/MANUAL switch to OFF before working on or around the unit. Then, place a "DO NOT OPERATE" tag on control console.

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Section 3 — Operation

Carrier Liquid-cooled 15 kW Generators

HOUR METER

FUSE

15-A AGC

FAULT

INDICATOR

AUTO

SET

OFF

MANUAL

EXERCISE TIME

DANGER

Carrier 13

3.1.2 FAULT INDICATOR LAMP

The lamp goes ON when one or more of the following engine faults occurs and when engine shuts down.

• Low oil pressure • Overcrank

• High coolant temperature • Overspeed

• Low coolant level

3.1.3 15 AMP FUSE

The fuse protects the control console’s DC control circuit against electrical overload. If the fuse has melted open because of an overload, engine cranking and startup cannot occur. If replacement of the fuse is necessary, use only an identical 15-amp fuse. (Type AGC, part number 022676).

3.1.4 7.5 AMP INLINE FUSE

This inline fuse is connected in the 15A line that runs between the AUTO/OFF/MANUAL switch and position 10 of the 76009A PCB. This fuse protects the start, fuel, field boost, and transfer outputs from the PCB and will open if there is excessive current draw on any one of these outputs.

NOTE:

This fuse will not remove the positive (+) battery input power from the PCB when it opens. This means the exercise timer will not be reset. If this fuse does open, carefully check the wiring to the start, fuel, field boost and transfer outputs before replacing the fuse.

3.1.5 SET EXERCISE TIME SWITCH

This switch allows for programming the generator to start and exercise automatically. See “Weekly Exercise Cycle” (Section 3.5).

3.2 MANUAL TRANSFER AND START-UP

To transfer electrical loads to the STANDBY (GENERATOR) power source side and start the engine manually, refer to the Owner’s Manual of the particular transfer switch.

3.3 AUTOMATIC OPERATION

To set the system for fully automatic operation, proceed as follows:

• Check that load circuits are connected to the

utility power supply.

• Set the AUTO/OFF/MANUAL switch to its AUTO

position.

• Set the generator main circuit breaker to its ON or

CLOSED position.

3.4 WEEKLY EXERCISE CYCLE

The generator will start and exercise once every seven days. During this weekly exercise, the unit runs for about 20 minutes and shuts down. Transfer of loads to generator output does not occur during the exercise.

To select day and time for exercising, proceed as follows:

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

• Set generator main circuit breaker to OFF or OPEN.

• Locate the rocker switch on the control panel identified with the words “Set Exercise Time” (Figure

3.2).

• Push “Set Exercise Time” switch to ON position for 20 to 30 seconds and then release. Switch will spring back into its original position when released.

• Wait 30 seconds before setting the AUTO/OFF/ MANUAL switch to AUTO position.

If the AUTO/OFF/MANUAL switch is switched too soon, the engine may start. If engine does start, it will shut down automatically in about two (2) minutes.

• Set the generator main circuit breaker to its ON or CLOSED position.

• Generator is now programmed to start and exercise every seven days thereafter, on day and time of day the switch was actuated.

• Place a sign on the generator control panel and the transfer switch, indicating the day and time the generator will be exercising.

NOTE:

If battery terminals are disconnected, the exercise timer needs to be reset for correct automatic exercise operation.

Figure 3.2 - “Set Exercise” Switch

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Section 3 - Operation

Carrier Liquid-cooled 15 kW Generators

TER

OFF

FUSE

15-A AGC

FAULT

INDICATOR

SET EXERCISE TIME

14 Carrier

4.1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES

A. EVERY THREE MONTHS

1.Check battery state of charge and condition.

2.Inspect and test fuel system.

3.Check transfer switch.

4.Inspect exhaust system.

5.Check engine ignition system.

6.Check fan belts.

B. ONCE EVERY SIX MONTHS

1.Test Engine Safety Devices (low oil pressure, low coolant level, high coolant temperature).

C. ONCE ANNUALLY

1.Test engine governor. Adjust or repair, if needed.

2.Clean, inspect generator.

3.Flush cooling system.

D. FIRST 100 OPERATING HOURS

1.Change engine oil and oil filter. (After initial change, service engine oil and filter at 150 operating hours or six months, whichever comes first.)

2.Retorque cylinder head. (See Torque Specs, Section 1.13.)

3.Retorque intake and exhaust manifold. (See Torque Specs, Section 1.13.)

E. EVERY 500 OPERATING HOURS

1.Service air cleaner.

2.Check starter.

3.Check engine DC alternator.

F. EVERY 800 OPERATING HOURS

1.Retorque cylinder head. (See Torque Specs, Section 1.13.)

2.Retorque intake and exhaust manifold. (See Torque Specs, Section 1.13.)

3.Check engine compression.

4.Check valve clearance.

4.2 COOLING SYSTEM

Air intake 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 shut down. (See Section 7 for installation drawings and vent locations.)

The exhaust system parts from this product get 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.

4.3 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM

Engine cranking, start up and running are controlled by a solid state Engine Controller circuit board. Battery voltage is delivered to that circuit board via a 15 amp fuse. These overcurrent protection devices will open if the circuit is overloaded.

If a circuit breaker opens or a fuse element melts, find the cause of the overload before resetting the circuit breaker or replacing the fuse.

4.4 CHECKING FLUID LEVELS

4.4.1 CHECK ENGINE OIL

Check engine crankcase oil level (Figure 4.1) at least every 20 hours of operation, or prior to use.

• Remove oil dipstick and wipe dry with a clean,

lint-free cloth.

• Install oil dipstick, then remove again.

• Oil should be between FULL and ADD marks.

• If oil level is below the dipstick ADD mark, remove

oil fill cap. Add the recommended oil to bring oil level up to the FULL mark. DO NOT FILL ABOVE THE “FULL” MARK. See Section 1.14 for recommended oils.

Figure 4.1 - Oil Dipstick and Oil Fill Cap

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Section 4 — Maintenance

Carrier Liquid-cooled 15 kW Generators

OIL DIPSTIC

Carrier 15

4.4.2 BATTERY FLUID

Check battery electrolyte fluid at least once a month. Fluid should cover separators in all battery cells. If fluid level is low, add distilled water to cover tops of separators. DO NOT USE TAP WATER IN BATTERY.

4.4.3 ENGINE COOLANT

Check coolant level in coolant recovery bottle. See Specifications, Section 1.10.

• Add recommended coolant mixture as necessary.

• Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly. Coolant should be at bottom of radiator filler neck. If coolant level is low, inspect gasket in radiator pressure cap. Replace cap, if necessary. To have pressure cap tested, contact a dealer. Inspect cooling system and coolant recovery system for leaks.

4.5 MAINTENANCE OWNER/

OPERATOR CAN PERFORM

4.5.1 CHECK ENGINE OIL LEVEL

Refer to “Checking Fluid Levels” in Section 4.4.

4.5.2 CHECK BATTERY

• Check battery fluid level each week as outlined under “Check Fluid Levels”.

• Check battery cables for condition, tightness, corrosion or damage. Clean, tighten or replace as necessary.

4.5.3 EXERCISE SYSTEM

Start the generator engine at least once every seven days and let it run at least 20 minutes. See Section

3.5, “Weekly Exercise Cycle”.

4.5.4 INSPECT COOLING SYSTEM

• Inspect engine cooling system at least once each month.

• Check hoses for damage, deterioration, leaks, etc. Correct any discrepancies found.

• Check hose clamps for tightness.

4.5.5 CHECK ENGINE COOLANT LEVEL

See “Checking Fluid Levels” in Section 4.4.

4.5.6 PERFORM VISUAL INSPECTION

Complete a thorough visual inspection of the entire engine-generator monthly. Look for obvious damage, loose, missing or corroded nuts, bolts and other fasteners. Look for fuel, oil or coolant leaks.

4.5.7 INSPECT EXHAUST SYSTEM

Inspect the exhaust system at least once every three months. Check all exhaust system pipes, mufflers, clamps, etc. for condition, tightness, leaks, security, damage.

4.5.8 CHECK FAN BELT

• Inspect fan belts every three months. Replace any damaged, deteriorated, worn or otherwise defective belt.

• Check fan belt tension. Thumb pressure, exerted midway between pulleys, should deflect about 3/8 to 3/4 inch. Adjust belt tension as required.

4.5.9 INSPECT ENGINE GOVERNOR

Visually inspect electronic governor.

Do not attempt to adjust the governor. Only qualified service facilities should adjust the governor. Excessively high operating speeds are dangerous and increase the risk of personal injury. Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life. Correct rated frequency and voltage are supplied only at the proper governed speed. Some connected electrical load devices may be damaged by incorrect frequency and/or voltage. Only qualified service technicians should adjust the governed speed.

4.5.10 CHANGING ENGINE OIL

Refer to maintenance performed by authorized service facilities for engine oil and filter change frequencies.

Drain the oil while the engine is still warm from running. This means warm up the engine, shut it down and drain immediately as follows:

1. Remove OIL DRAIN HOSE from its retaining clip.

2. Loosen and remove OIL DRAIN HOSE CAP.

Drain oil completely into suitable container.

3. When all oil has drained, install and tighten OIL

DRAIN HOSE CAP, and re-install into its retaining clip.

4. Turn OIL FILTER (Figure 4.2) counterclockwise

and remove. Dispose of old filter.

5. Apply light coating of new engine oil to seal of new

oil filter. Install FILTER and tighten by hand only. DO NOT OVERTIGHTEN.

6. Remove OIL FILL CAP. Add recommended oil (see

SPECIFICATIONS). DO NOT FILL ABOVE THE DIPSTICK “FULL” MARK. Crankcase oil capacity is 4.0 U.S. quarts (3.8 liters).

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Section 4 — Maintenance

Carrier Liquid-cooled 15 kW Generators

DANGER

16 Carrier

Figure 4.2 - Oil Filter

After refilling the crankcase with oil, always check oil level on dipstick. NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK “ADD” MARK.

7. Start engine and check for oil leaks.

4.5.11 CHANGING THE ENGINE AIR CLEANER

To replace the engine air cleaner, (part number

059402), simply remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover (Figure 4.3).

Figure 4.3 – Engine Air Cleaner

See the “Scheduled Maintenance,” Section 4.7, for air cleaner maintenance.

4.5.12 SPARK PLUGS

Reset the spark plug gap or replace the spark plugs as necessary. See Section 4.7.

1. Clean the area around the base of the spark plugs

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 plugs to clean.

2. Remove the spark plugs and check the condition.

Replace the spark plugs if worn or if reuse is questionable. See the “Scheduled Maintenance,” Section 4.7, for recommended inspection.

3. Check the spark plug gap using a wire feeler

gauge. Adjust the gap to 0.5-0.6 mm (0.020-0.025 inch) by carefully bending the ground electrode (Figure 4.4).

Figure 4.4 – Setting the Spark Plug Gap

4.5.13 COOLANT CHANGE

Every year, have a dealer drain, flush and refill the cooling system. See SPECIFICATIONS (Section 1.10) for cooling system recommendations.

4.6 MISCELLANEOUS MAINTENANCE

4.6.1 CLEANING THE GENERATOR

Keep the generator as clean and as dry as possible. Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation resistance.

Periodically clean generator exterior surfaces. A soft brush may be used to loosen caked on dirt. Use a vacuum system or dry, low pressure air to remove any accumulations of dirt. The generator is housed inside an all-weather enclosure, clean the enclosure with a soft, damp cloth or sponge and water. Apply a coat of automotive type wax once a year to help prevent corrosion.

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Section 4 — Maintenance

Carrier Liquid-cooled 15 kW Generators

SET PLUG GAP AT 0.5-0.6 mm

(0.020-0.025 inch)

OIL FILTER

Air Cleaner

(Doors Removed for Clarity)

Carrier 17

Once each year, have the generator cleaned and inspected by a dealer. That dealer will use dry, low pressure air to clean internal windings. Parts inside the control console should be cleaned and inspected at this time as well.

Finally, have the insulation resistance of stator and rotor windings checked. If insulation resistances are excessively low, the generator may require drying.

4.6.2 BATTERY

All lead-acid storage batteries discharge when not in use. Refer to specific instructions and warnings that accompany the battery. If such information is not available, observe the following precautions when handling a battery:

• DO NOT use jumper cables and a booster battery to crank or start the generator engine.

• DO NOT recharge a weak battery while it is installed in the generator. Remove battery from generator and recharge in a well-ventilated area, away from fuel vapors, sparks, heat or flames.

• Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns. DO NOT permit fluid to contact eyes, skin, clothing, painted surfaces, wiring insulation, etc. If any battery fluid is spilled, flush the affected area with clear water immediately.

• Always wear safety glasses, rubber apron and gloves when handling a battery.

• Batteries give off explosive hydrogen gas while charging. The gas can form an explosive mixture around the battery for several hours after charging. Any spark, heat or flames can ignite the gas and cause an explosion which can shatter the battery, causing blindness or other serious injury.

4.6.3 BATTERY MAINTENANCE

The battery should be inspected per the “Scheduled Maintenance,” Section 4.7. 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.

Do not use any jumper cables or booster battery to crank and start the generator engine. If the battery has completely discharged, remove it from the generator for recharging.

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.

4.6.4 BATTERY REPLACEMENT

When replacing batteries, use the same number and the type of battery that follows:

NOTE:

The BCI number should be located directly on the battery.

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Section 4 — Maintenance

Carrier Liquid-cooled 15 kW Generators

BCI Group No. CCA

26 525 @ 0 deg. F

PERIODIC REPLACEMENT PARTS

Part Name Part Number

Oil Filter # 0A4531A244 Radiator Cap # 046627 Air Cleaner # 059402 Spark Plug # 0A45310275

DANGER

18 Carrier

Section 4 — Maintenance

Carrier Liquid-cooled 15 kW Generators

4.7 SCHEDULED MAINTENANCE

The following is a recommended maintenance schedule for small standby and residential generator sets. The established intervals in the schedule are the maximum

recommended when the unit is used in an average service application. They will need to be decreased (performed more frequently) if the unit is used in a severe application. Use the unit hour meter or calendar time, whichever occurs first, from the previous maintenance interval to determine the next required maintenance interval.

Service Maintenance Interval Information:

The various service maintenance intervals are designated by interval numbers as follows:

1 An early inspection of the generator set to insure it is ready to operate when required and to identify any poten-

tial problem areas.

Performed monthly or following each 10 hours of operation of the unit and requires approximately .5 manhours per unit to complete.

This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning:

To prevent injury, perform the following steps in the order indicated before starting any maintenance:

• Disable the generator set from starting and/or connecting to the load by setting the control panel AUTO-OFF-MANUAL switch to the OFF position.

• Remove the control panel fuse.

• Turn off utility supply to engine water heater.

• Turn off the battery charger by turning off utility supply to the transfer switch.

• Remove the negative battery cable.

The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition fr

om burning out sensitive control panel components and circuits

Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal operation when required.

2 A break-in service inspection of the generator set to insure it is ready to operate and carry the load when

required, and to identify any potential problem areas.

Performed ONL

Y ONCE following the first three months or the first 30 hours of operation after purchase of

the unit and requires approximately 2.5 man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by a dealer.

3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required,

and to identify any potential problem areas.

Performed semi-annually or following each 50 hours of operation of the unit and requires approximately 1.5 man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by a dealer.

4 A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required, and

to identify any potential problem areas.

Performed annually or following each 100 hours of operation of the unit and requires approximately 4.0 man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by a dealer.

Carrier 19

Section 4 — Maintenance

Carrier Liquid-cooled 15 kW Generators

Maintenance Level 1 Level 2 Level 3 Level 4

Tasks

Recom- Task Required Task Required Task Task

mended Comp. to be done Comp. to be done Comp. Required Comp.

to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date-

monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials)

10 hrs. 30 hrs. 50 hrs. 100 hrs.

1. Disable the unit from operating per the first page warning.

2. Check the engine oil level. Adjust as necessary.

3. Check the engine coolant level. Adjust as necessary.

4. Check the engine coolant thermal protection level. Correct as necessary.

5. Check the natural gas delivery system on gas engine driven units. Tighten connections as necessary.

6. Check the air inlets and outlets for debris. Clean as necessary.

7. Check the battery electrolyte level if accessible. Adjust as necessary.

8. Check the battery posts, cables, and charger for loose connections, corrosion, and proper operation. Correct as necessary.

9. Check the unit wiring for loose connections, corrosion, and damage. Correct as necessary.

10. Check the engine accessory drive belts for wear, weather cracking, and damage. Replace as necessary.

11. Visually inspect the unit looking for leaks, wear or damage, loose connections or components, and corrosion. Correct as necessary.

12. Test the engine and transfer switch safety devices. Correct and/or adjust as necessary.

20 Carrier

Section 4 — Maintenance

Carrier Liquid-cooled 15 kW Generators

Maintenance Level 1 Level 2 Level 3 Level 4

Tasks

Recom- Task Required Task Required Task Task mended Comp. to be done Comp. to be done Comp. Required Comp.

to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date-

monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials)

10 hrs. 30 hrs. 50 hrs. 100 hrs.

13. Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks, loose connections or components, and abnormal operating conditions. Correct as necessary.

14. Start and exercise the unit at full rated load (use a load bank if the site load is not enough) for at least 2 hours looking for leaks, loose connections or components, and abnormal operating conditions. Correct as necessary.

15. Change the engine oil.

16. Replace the engine oil filter(s).

17. Replace the engine air filter(s).

18. Check the engine spark plugs on gas engine driven units. Clean and re-gap or replace as necessary.

19. Perform a 5 minute no-load operational run of the unit looking for any post service problems.

20. Return the unit to standby setup for operation when required.

Carrier 21

Section 5 — Troubleshooting

Carrier Liquid-cooled 15 kW Generators

5.1 TROUBLESHOOTING POINTS

PROBLEM CAUSE CORRECTION

Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse.

2. 7.5 amp fuse blown. 2. Replace fuse.

3. Loose or corroded or defective 3. Tighten, clean or replace battery cables. battery cables as necessary.

4. Defective starter contactor. 4. Replace contactor.

5. Defective starter motor. 5. Replace starter motor.

6. Dead or Defective Battery. 6. Remove, change or replace battery.

Engine cranks but won't start 1. Out of fuel. 1. Replenish fuel.

2. Fuel solenoid (FS) is defective 2. Replace solenoid.

3. Open Wire #14 from Engine Control 3. Reconnect wire. circuit board.

4. Spark plugs defective. 4. Clean, regap or replace plugs.

Engine starts hard, runs rough. 1. Flame arrestor (air cleaner) plugged or 1. Clean or replace as needed.

damaged.

2. Plugged fuel line. 2. Unclog fuel line.

3. Defective spark plugs. 3. Clean, regap or replace plugs.

Engine starts then shuts down. 1. Engine oil level is low. 1. Check oil and add oil as needed.

2. Engine is overheated. 2. Check cooling system for leaks.

3. Defective Low Oil Pressure Switch 3. Replace switch.

4. Defective Coolant Temperature Switch 4. Replace switch.

5. Defective Control Module circuit board. 5. Replace board.

6. Coolant Level is Low. 6. Repair leak - Add coolant.

7. Defective Low Coolant Level Switch 7. Replace Switch.

AUTO/OFF/MANUAL Switch at OFF, 1. Defective AUTO/OFF/MANUAL switch 1. Replace switch. engine continues to run 2. Open/disconnected wire #15A between 2. Reconnect/close wire.

AUTO/OFF/MANUAL switch and Control Module circuit board.

3. Defective Control Module circuit board 3. Replace board.

No AC output from generator. 1. Check main line circuit breaker. 1. Reset to ON or CLOSED.

2. Check circuit breaker & fuses. 2. Reset and replace, if necessary.

3. Transfer switch set to NORMAL position 3. Set to GENERATOR position.

4. Generator internal failure. 4. Contact a dealer facility.

5. Thermal circuit breaker open. 5. Auto-reset - Wait five min. and

attempt restart.

NOTE:

Under normal operating conditions, if repair of generator set or replacement of any parts is necessary during the warranty period, you must contact a dealer. Failure to have the repair or replacement performed by a Carrier dealer will result in non-coverage of warranty repair cost.

Section 6 - Notes

Carrier Liquid-cooled 15 kW Generators

22 Carrier

Carrier 23

Section 7 - Installation Diagram

Carrier Liquid-cooled 15 kW Generators

Drawing No. 0E1533-B

RED

) C

)

TR1

) )

RED

BLACK

A 8

A A

A E 6

E 6

CK O

N CK

O/O

OS.

PB2 S

OCK

BREAKER

2 S1

1 CB

1 S

24 Carrier

Section 8 - Electrical Data

Carrier Liquid-cooled 15 kW Generators Wiring Diagram — Control Panel —Drawing No. 0F5243

NNE

E2 240

240V. 1- PHA

VERN

TUAT

RAN

YELL

UTPUT

BLA

E1 T

E2 T

E1 T

120

151

161

LDE

H H

UNTIN

BRU

BEARIN

T T E

BLA

225

BLA

WIT

TRIP 2 P

FRMR, UTILITY

TERMINAL

TRN

LLE

NTR

FAULT LI

VERN

APA

UIT BREAKE

ULAT

TRIP 7 P

E RE

LTA V

TERMINAL

UIT B

NEUTRAL BL

PRE-PA

NNE

INE

WIT

EMBL

N A I

MANUAL

UPRE

AUT

E 15 AMP

E, INLINE 7.5 AM

E I

ET EXER

WIT

FER

TRAN

NNE

LED

TAT

ALTERNAT

BLA

K TRAN

NNE

R PRE-PA

WIT

225

TAR

225

YELL

225

BLA

RED

BLUE

(BLA

Carrier 25

Section 8 - Electrical Data

Carrier Liquid-cooled 15 kW Generators

Electrical Schematic — Control Panel — Drawing No. 0F5244

) )

O/O

C O

O C

0 9 9

CK 9

5 5C

8 3

E L

A 2

WN IN

. .

ITI

FF P

A 2

BLA

TART

FER

TANDARD

TRAN

ENERA

TEM

NNE

V L-L

R 2

R 24

WIT

W WIRE F

E WIRE F

E BL

YELL

ED WIRE

LATE

ELL

RAN

BLUE

RED

ELL

BLACK

WIT

N T

FER

NNE

REPA

RAN

LLER

NIT

NTR

VERN

NTR

ARD

IT B

B -

EMBLY

N A I

PRE

A -

WIT

UTILITY SENSING

E I

MAN

ET EXER

3 - TERMINAL BOARDS 2

W2 -

W1 - A

R1 -TRANSFORMER

LAT

E RE

LTA

R - V

END E

R T

TAT

R R

BLA

APA

2 - CIRCUIT BREAKERS

- ALTERNAT AP -

R - ALTERNAT

N WINDIN

NNE

ITATI

INE

- EN

PE - EX

AMP

E 1

- F

IN LINE

LT INDI

AMP

E 7.

HT FA

1 - F

L - LI

1-14

-1

-12

-5-4

NNE

V 1-PHA

MER T

24 2

26 Carrier

Section 8 - Electrical Data

Carrier Liquid-cooled 15 kW Generators Wiring Diagram — 1.5L Engine — Drawing No. 0E0343-B

813

SSU

SOR

DC-VR

NTR

NNECTI

LEGEN

- CONTROL CONTACT DIS - DISTRIBUT

DCA - DC ALTERNAT

FS - FUEL SOLENOI

RD - GROUN

LOS - LOW OIL PRE

M - STARTER MOT

WTS - WATER TEMPERATURE SWIT

WLS - WATER LEVEL SEN

RE SWIT

BLA

DC-

ELECTRONI

VERN

NTROLLE

ACTUAT

NNECT

VERN

ACTUAT

Carrier 27

Section 8 - Electrical Data

Carrier Liquid-cooled 15 kW Generators

Electrical Schematic — 1.5L Engine — Drawing No. 0A7182-C

U O

TRIP

)

L PANEL

NTR

ERMINAL

LAT

E RE

LTA

BLA

LEGEN

- CONTROL CONTACT

NIT

L PANEL

VERN

NTR

ACTUAT

NNECT

VERN

DCA - DC ALTERNAT

FS - FUEL SOLENOI

RD - GROUN

ISC - IGNITION SYSTEM CONTA LOS - LOW OIL SWIT

M - STARTER MOT

WTS - WATER TEMPERATURE SWIT WLS - WATER LEVEL SWIT

ITEM PART NO. QTY. DESCRIPTION

1098290 1 ASM MOTOR STEPPER 2098941A 1 HOUSING GOVERNOR CONNECTOR 3098958A REF CONNECTOR INTERFACE ASSEMBLY 4098942A 1 COVER CONNECTOR HOUSING 5098225 2 SCREW FHM #2 X 5/8 SELF TAP 6 043146 3 SCREW HHC M6-1.0 X 10 G8.8 7 022097 5 WASHER LOCK M6-1/4 8 084543A 1 SCREW PHM M3-0.5 X 12MM

9 098783 1 LEVER STEPPER MOTOR 10 037398 2 NUT LOCK HEX #10-32 NYL INS 11 0E1326 1 ASSY. CARBURETOR LINKAGE ROD 12 0A7106 1 BRACKET STEPPER MOTOR 13 074031 AR LIQUID NEOPRENE 14 029333A 10 TIE WRAP 7.4"X.19" BLK UL 15 022507 2 SCREW HHC 1/4-20 X 1/2 G5 16 022473 2 WASHER FLAT 1/4 ZINC 17 064526 1 SCREW TAP HWH #6-25 X 3/8 ZINC 18 0E1694 1 SPRING,ANTI LASH

(

)

28 Carrier

Section 9 - Exploded Views and Parts

Carrier Liquid-cooled 15 kW Generators Governor Assembly — Drawing No. 0E1331-B

ITEM

ATIN

NEOPREN

ARB

REF.

RET

R AR

INTAKE MANIF

REF.

WIRE HARNE

RE WIRE HARNE

WITH TIE WRAP A

ITEM PART NO. QTY. DESCRIPTION

1 0D8656 1 BASE MOUNTING 1.5L STNRD & ACSTC

2 027482 2 WASHER SHAKEPROOF EXT 5/16 STL

3 070936 2 DAMPENER VIBRATION

4 070936C 2 VIB. ISO. 70-75 DURO

5039253 8 SCREW HHC M8-1.25 X 20 G8.8

6 022145 12 WASHER FLAT 5/16 ZINC

7 022129 16 WASHER LOCK M8-5/16

8 045771 4 NUT HEX M8-1.25 G8 YEL CHR

9 071956 4 WASHER FLAT M8 10 051730 4 SCREW HHC M8-1.25 X 60 G8.8 11 021991 1 EARTH STRAP 13 0D9335 2 PANEL SUPPORT 14 0D9336 2 PANEL BRACKET 15 0C2454 16 SCREW TH-FRM M6-1 X 16 N WA Z/JS 16 047411 1 SCREW HHC M6-1.0 X 16 G8.8 17 022097 1 WASHER LOCK M6-1/4 18 022473 1 WASHER FLAT 1/4-M6 ZINC 19 055414 1 LUG SLDLSS #2-#8 X 17/64 CU 20 049813 5 NUT HEX M6 X 1.0 G8 YEL CHR 21 026850 1 WASHER SHAKEPROOF EXT 1/4 STL 22 0A1694 2 1-1/2" BUTTON PLUG

Section 9 - Exploded Views and Parts

Carrier Liquid-cooled 15 kW Generators

Mounting Base — Drawing No. 0E0768-B

Carrier 29

30 Carrier

OOF

Section 9 - Exploded Views and Parts

Carrier Liquid-cooled 15 kW Generators Enclosure — Drawing No. 0F4490

WELD

PANEL F

R A

ABL

NDER R

E D

R LAT

TENER T

ND WIRE

TITE

E L

ITEM #2

ITEM PART NO. QTY. DESCRIPTION

1 0D8666 1 ROOF ACSTC&STND CMPRTMNT 1.5L

2 0D8664C 1 DUCT CENTER 1.5L

3 0D8657 1 SUPPORT RADIATOR 1.5L MITSU

4 0D8660 2 BRACE SIDE 1.5L MITSU

5 0A7568 2 DOORWELDMENT 1.5EPS

6 0D8659 1 CORNER POST REAR RH SIDE 1.5L

7 0D8662 1 DOOR REAR COMPARTMENT 1.5L

8 0D8661 1 BRACE REAR 1.5L MITSU

9 0D8658 1 CORNER POST REAR LH SIDE 1.5L 10 067042 2 LATCH & CAM 11 0C2454 40 SCREW TH-FRM M6-1 X 16 N WA Z/JS 12 033530 3 SCREW PHM #10-32 X 5/8 ZINC 13 051716 3 NUT HEX M5-0.8 G8 YEL CHR 14 022152 3 WASHER LOCK #10 15 0912970064 3 ASSEMBLY BASE-DOOR GROUND WIRE 16 023762 3 WASHER SHAKEPROOF EXT #10 STL 17 0912970063 3 GRD WIRE ASS'Y 99HSB 18 022264 6 WASHER LOCK #8-M4 19 067035 6 SCREW PPHM #8-32 X 5/16 20 022127 1 NUT HEX 1/4-20 STEEL 21 0F4487A 1 ASSEMBLY COVER ACCESS 22 022473 1 WASHER FLAT 1/4 ZINC 23 022097 1 WASHER LOCK M6-1/4 24 0D2023 3 GASKET CLIP-ON SELF GRIPPING 25 0F3390 1 LATCH AND CAM 26 037337 6 NUT HEX JAM 3/8-24 SS 27 0D2023 21 GASKET CLIP-ON SELF GRIPPING 28 0D8664A 1 DUCT LH SIDE 1.5L 29 0D8664B 1 DUCT RH SIDE 1.5L

Section 9 - Exploded Views and Parts

Carrier Liquid-cooled 15 kW Generators

Enclosure — Drawing No. 0F4490

Carrier 31

32 Carrier

Section 9 - Exploded Views and Parts

Carrier Liquid-cooled 15 kW Generators Control Panel — Drawing No. 0F5240

0 0

229

'A'

Carrier 33

ITEM PART NO. QTY. DESCRIPTION

10D9322 1 PANEL BACK & BOTTOM 20D9332 1 PANEL LH SIDE 3 0F5246A 1 PANEL FRONT W/SILKSCREEN 40D9330 1 PANEL RH SIDE C-PANEL SML BRK 5 0E3783 1 DECAL WARNING REMOVE FUSE 6 064009 1 LIGHT 12VDC .02A LED RED PILOT 7 032300 1 HOLDER FUSE 8 022676 1 FUSE 15A X AGC15

9 0E4494 1 SWITCH ROC DPDT ON-OFF-ON 10 082573 1 SWITCH ROCKER DPST 125V SPD 11 083048 1 ASSEMBLY REGULATOR POTTED 12 083264 1 TFMR ASM CMA 240/12V 13 076009A 1 PP LOGIC ASM 50/60HZ 14 0E0331A 1 HARN CONTROL PANEL 1.5L MITSU

(NOT SHOWN) 15 056739 1 RELAY SOLENOID 12VDC PNL MNT 16 049350 1 CIRCT BRK 4 X 1 ETA 46-500-P 17 047822 1 BLOCK TERM 20A 7 X 6 X 1100V 18 048766 1 BLOCK TERM 20A 2 X 6 X 1100V 19 057335 1 BLOCK TERM 20A 20 X 6 X 1100V 20 098647 1 ASSY L.C. ELECT GOV 21 0E1454 1 DECAL CUST. CONNT. PRE-PACK1.5L 22 0E1459 1 DECAL TERMINAL STRIP PRE-PACK 23 072566 4 NUT SPACER.250 PCB 24 080882 8 SCREW PPH TAPPING #6 X 5/8 SS 25 0A8955 2 SCREW PHM M6-1.0 X 20MM 26 022097 3 WASHER LOCK M6-1/4 27 022473 2 WASHER FLAT 1/4-M6 ZINC 28 0C2212 10 SCREW PHTT M4-0.7 X 16 ZYC 29 023762 2 WASHER SHAKEPROOF EXT #10

STL

ITEM PART NO. QTY. DESCRIPTION

30 0C2267 14 SCREW HHTT M5-0.8 X 12 BP 31 023897 15 WASHER FLAT #10 ZINC 32 0C2454 4 SCREW TH-FRM M6-1X16 N WA Z/JS 33 054199 1 DECAL HIGH VOLTAGE 34 081988 1 DECAL EXERCISE INFO 35 0E2514 1 STRAIGHT WIRE CONNECTOR 1 1/2" 36 0A1354A 1 REGULATOR - DC ALT 37 074908 4 SCREW HHTT M5-0.8 X 10 BP 38 020911 4 SCREW PPHM M5-0.8 X 30 ZINC 39 051713 5 WASHER FLAT M5 40 049226 5 WASHER LOCK M5 41 051716 5 NUT HEX M5-0.8 G8 YEL CHR 42 036261 4 RIVET POP .125 X .129-.133/#30 43 0D9334 1 PANEL, TOP 44 061979 1 BUS BAR 45 022237 1 WASHER LOCK 3/8 46 022241 1 NUT HEX 3/8-16 STEEL 47 057073 1 JUNCTION BLOCK 3/8-16 48 055440 1 SCREW HHC M5-0.8 X 25 G8.8 49 0D8671 1 HINGE CONTINUOUS 1.5L CNTL PNL 50 0912970080 1 WIRE ASSEMBLY 51 049813 1 NUT HEX M6 X 1.0 G8 YEL CHR 52 033121 1 SCREW HHC #10-32 X 1/2 53 026850 1 WASHER SHAKEPROOF EXT 1/4

STL 54 022158 1 NUT HEX #10-32 STEEL 55 022152 1 WASHER LOCK #10 56 0A3968 1 CAPACITOR FILTER ASY 57 0C2323 2 SCREW PHTT #6-32 X 5/8 ZYC

Section 9 - Exploded Views and Parts

Carrier Liquid-cooled 15 kW Generators

Control Panel — Drawing No. 0F5240

Section 9 - Exploded Views and Parts

Carrier Liquid-cooled 15 kW Generators Engine — Drawing No. 0F5273

34 Carrier

ITEM PART NO. QTY. DESCRIPTION

1 0A4531 1 ENGINE-1.5L 2 022473 2 WASHER FLAT 1/4 ZINC 3 057822 1 CLAMP HOSE #8 .53-1.00 4 0A45310258 1 GASKET-EXHAUST MANIFOLD 5 0A4355 1 MANIFOLD-EXHAUST 6 0E2632 1 HEAT SHIELD EXH 1.5L 7 022097 8 WASHER LOCK M6-1/4 8 022507 2 SCREW HHC 1/4-20 X 1/2 G5

9 052212 2 SCREW HHC M10-1.25 X 25 G8.8 10 046526 4 WASHER-LOCK-M10 11 022131 20 WASHER FLAT 3/8 ZINC 12 0C2499 2 STAMPING ENG FOOT 13 055993 1 SPACER .41 X .75 X .12 STL/ZNC 14 045772 1 NUT HEX M10-1.5 G8 YEL CHR 15 023586 2 SCREW SHC 5/16-18 X 2 G8.8 NZ 16 020692 1 STARTER-12V 17 0A7005 2 SPACER .56 X 1 X .37 ST/ZNC 18 052243 1 SCREW HHC M10-1.5 X 60 G8.8 19 0A4772 1 ENGINE PLATE 20 070901 2 SLEEVE DOWEL BLHSG 21 051735 3 SCREW HHC M10-1.5 X 70 G8.8 22 056768 3 SCREW HHC M10-1.5 X 90 G8.8 23 022145 9 WASHER FLAT 5/16 ZINC 24 022129 18 WASHER LOCK M8-5/16 25 022259 2 NUT HEX 5/16-18 STEEL 26 052213 11 SCREW HHC M10-1.25 X 20 G8.8 27 047411 2 SCREW HHC M6-1.0 X 16 G8.8 28 052830 1 SCREW HHC M10-1.25 X 45 G8.8 29 0F3856 1 GUARD, CRANKSHAFT 1.5L 30 045771 12 NUT HEX M8-1.25 G8 YEL CHR 31 058306 5 SCREW SHC M8-1.25 X 25 G12.9 32 030795 2 SCREW HHC 5/16-18 X 1 G5 33 0A2711A 1 ADAPTER-THERMOSTAT 34 048665 1 GASKET THERMOSTAT 35 075885 1 THERMOSTAT 195 DEG 36 0A45310257 1 GASKET INLET MANIFOLD 37 0E1100 1 MANIFOLD INTAKE MACHINED

ITEM PART NO. QTY. DESCRIPTION

38 0E0561 1 ASSY WATER LEVEL SENSOR C/E

PL 39 0A6751 1 SW-TMP 245 DEG 3/8 NPT 40 077996 1 CAP ANTIFREEZE RUBBER 41 026925 2 PLUG STD PIPE 3/8 STEEL SQ HD 42 061012 1 PLUG STD PIPE 1/8 SCKT HD 43 039253 4 SCREW HHC M8-1.25 X 20 G8.8 44 0A5110 1 PIPE WATER-INLET 45 0A7006 1 O-RING 1-1/16 X 1-5/16 X 1/8 46 025507 2 WASHER SHAKEPROOF EXT 7/16

STL 47 022500B 2 SPACER .41 X .75 X .25 ST/ZNC 48 0A8584 1 SWITCH OIL PRESSURE 49 036277 1 ELBOW 90D STREET 1/8 50 042574 1 ADAPTOR 1/8 NPTF TO 1/8-28 51 026073A 1 PLUG STD PIPE 1/4 STEEL SQ HD 52 0A6701 1 SCREW HHC M10-1.5 X 110 G8.8 53 039414 1 SCREW HHC M8-1.25 X 35 G8.8 54 0A5568 1 SCREW HHC M12-1.25 X 55 G8.8 55 051769 1 WASHER LOCK M12 56 0A4804A 1 PULLY,CRANKSHAFT 1800 RPM 1.5L 57 0A5839 1 BRACKET - ALT SUPPRT 58 0A1354B 1 DC ALTERNATOR-12V 59 0A4839 1 ARM ADJUST ALTERNATOR 60 055816 4 SCREW HHC M6-1.0 X 70 G8.8 61 049811 9 WASHER FLAT M6 62 0E1936 1 FAN COOLING 15" 63 0A2628 1 PULLEY - FAN 95 DIA 64 0A5275 1 V-BELT 3/8 X 32-1/8 1.5L 65 0A4814 1 SPACER PULLEY 66 0A45310244 1 FILTER OIL 67 0C1852 1 ADAPTER DRAIN OIL 68 0912970066 1 GROUND WIRE (STARTER) 69 070928 1 CLAMP HOSE - OIL DRAIN 70 069860C 1 HOSE ASM.-OIL DRAIN 71 069811 1 CAP HEX 1/4NPT BRASS 72 075443 2 SCREW CRMPTIT 1/4-20 X 5/8

Section 9 - Exploded Views and Parts

Carrier Liquid-cooled 15 kW Generators

Engine — Drawing No. 0F5273

Carrier 35

)

Section 9 - Exploded Views and Parts

Carrier Liquid-cooled 15 kW Generators Radiator — Drawing No. 0F5274

36 Carrier

TAT

THERM

BOTTOM ONLY

ITEM PART NO. QTY. DESCRIPTION

1 0D8657 1 SUPPORT RADIATOR 1.5L MITSU 2 0A5734 1 RADIATOR 1.5L 3 0A6237 1 VENTURI 1.5L MODINE

4 * 0A6238 1 GUARD FAN 1.5L MODINE

5 047290A 1 ASSY. RAD. DRAIN HOSE 6 065852 2 SPRING CLIP HOLDER .37-.62 7 0A2111 2 SCREW SWAGE 10-32 X 5/16 Z/YC 8099502 4 CLAMP HOSE #24 B1.06 - 2.00

9 083709 1 CLAMP WIRE HOSE .573 - .551 10 052250 2 TAPE FOAM 1 X 1 (12" LG) 11 0A7275 3 FOAM 1.5 X 1 ADH BAK 12 022097 4 WASHER LOCK M6-1/4 13 035461 1 BARBED STR 1/4 NPT X 3/8 14 022473 7 WASHER FLAT 1/4 ZINC 15 0E0726 1 BRACKET WATER BOTTLE 1.5L MIT 16 076749 1 TANK COOLANT RECOVERY

17 * 075443 6 SCREW CRMPTIT 1/4-20 X 5/8

18 056892 4 SCREW CRIMPTITE 10-24 X 3/8 19 0A6284 1 HOSE - LOWER RADIATR 20 0A6258 1 HOSE - UPPER RADIATR 21 029032 1 HOSE 9/32 ID (36" LG) 22 031669 4 BOLT CARR 1/4-20 X 1-3/4 JS500 23 060035 4 SPACER .41 X .75 X .87 ST/ZNC 24 022127 4 NUT HEX 1/4-20 STEEL 26 046627 1 CAP RADIATOR 27 0C7649 1 CLAMP HOSE .38-.87 28 0C2454 4 SCREW TH-FRM M6-1 X 16 N WA Z/JS

* FAN GUARD KIT 0E3596 (NOT USED WITH LEVEL ONE GUARDING)

Section 9 - Exploded Views and Parts

Carrier Liquid-cooled 15 kW Generators

Radiator — Drawing No. 0F5274

Carrier 37

38 Carrier

)

Section 9 - Exploded Views and Parts

Carrier Liquid-cooled 15 kW Generators Fuel System — Drawing No. 0E0774-E

T 1

NATURAL GAS

T 2

L.P. VAP

Carrier 39

ITEM PART NO. QTY. DESCRIPTION

1 * --------- 1 WELDMENT MOUNTING BASE

2 075580 1 FLANGE FUEL INLET

3 0E1006 1 ASSY REGULATOR 1.5L N.G.OR LPV

4039253 2 SCREW HHC M8-1.25 X 20 G8.8

5 022145 2 WASHER FLAT 5/16 ZINC

6 022129 6 WASHER LOCK M8-5/16

7 045771 2 NUT HEX M8-1.25 G8 YEL CHR

8 0A7040 1 BRACKET-RAD HOSE

9 032552 1 BARBED EL 90 5/16 X 1/8 NPT 10 029032 1 HOSE 9/32 ID 11" 11 0E1056 1 FUEL HOSE ASSM. NAT.GAS/L.P.V. 12 029032 1 HOSE 9/32 ID 6.5" 13 0A5547 1 COVER AIR CLEANER 14 048031C 4 CLAMP HOSE BAND 1/4 15 0D1509 1 DECAL INLET PRESSURE

16 ** 0E0591 1 ADAPTER,CARB.TO AIR CLNR

17 059402 1 FILTER ELEMENT 18 037561 1 NUT WING 1/4-20 NYLK 19 0E1028 1 CARBURETOR ASSY. 1.5L 20 059401 1 CARBURETOR GASKET

21 ** 091526 4 SCREW PPHM M5-0.8 X 12 ZNC 22 ** 049226 4 WASHER LOCK M5

23 026307 1 ELBOW 90D STREET 3/4 24 062522 1 STUD TH 1/4-20 X 3 G2 ZNC FULL 25 022127 1 NUT HEX 1/4-20 STEEL 26 022259 2 NUT HEX 5/16-18 STEEL 27 050279 1 DECAL FUEL INLET NG 28 0A6125 2 STUD 5/16-18 X 1.25 F THR 29 0D8492T 1 DECAL EMISSION CTRL 1.5 NG 2005 (10-15KW NATURAL GAS)

30 ** 0E1104 1 GASKET AIR CLEANER ADAPTER 31 ** 0E0668 1 O-RING 2-028 1.38 X 1.50 X .06 32 ** 0E0590 1 VENTURI 18MM 33 ** 0C5133 1 O-RING 29.82 X 2.62 34 ** 0E0665 1 SCREW THROTTLE PIN STOP 35 ** 0E1108 1 THROTTLE ARM REWORK 36 ** 033138 1 SCREW HHM #10-32 X 5/8 37 ** 022152 1 WASHER LOCK #10 38 ** 0E0645 1 LEVER THROTTLE STOP 39 ** 063463A 1 BARBED STR 3/8NPT X 1/2 W/VS

40 0E1558 1 HOSE LPG & NAT GAS 1/2 ID (23"LG) 41 057823 2 CLAMP HOSE #10 .56 - 1.06 42 0E1111 1 PLATE, GAS REGULATOR MOUNTING 43 042907 2 SCREW HHC M8-1.25 X 16 G8.8 44 0C2454 2 SCREW TH-FRM M6-1 X 16 N WA Z/JS

* SHOWN IN OTHER VIEW ** INCLUDED IN ITEM 19 (CARBURETOR ASY. )

Section 9 - Exploded Views and Parts

Carrier Liquid-cooled 15 kW Generators

Fuel System — Drawing No. 0E0774-E

40 Carrier

e g

Section 9 - Exploded Views and Parts

Carrier Liquid-cooled 15 kW Generators Alternator — Drawing No. 0A9348-F

ine

rankshaf

o En

ousin

o Blow

Carrier 41

ITEM PART NO. QTY. DESCRIPTION

1098671 1 ASSY ROTOR 10KW

098681 1 ASSY ROTOR 15KW 098675 1 ASSY ROTOR 20KW

098936 1 ASSY ROTOR 25KW 2 0A5336A 1 HOUSING BLOWER 3 0A1659 1 SCREEN AIR OUTLET 4 071912 4 SCREW PPHM M5-0.8 X 8 SS 5049226 4 WASHER LOCK M5 6 051713 4 WASHER FLAT M5 7 022129 4 WASHER LOCK M8-5/16 8098672 1 ASSY STATOR 10KW A

098673 1 ASSY STATOR 10KW D

098674 1 ASSY STATOR 10KW GJK

098682 1 ASSY STATOR 15KW 1PH A

098683 1 ASSY STATOR 15KW 3PH D

098684 1 ASSY STATOR 15KW 1PH GJK

098676 1 ASSY STATOR 20KW 1PH A

098677 1 ASSY STATOR 20KW 1PH D

098678 1 ASSY STATOR 20KW 1PH GJK

097620 1 ASSY STATOR 25KW 1PH A

098937 1 ASSY STATOR 25KW 1PH D

097621 1 ASSY STATOR 25KW 3PH D 9 0A5382 1 BEARING CARRIER REAR

10 075591 1 ASSY HOLDER BRUSH 11 075476 4 SCREW PPHM M4-0.7 X 16 12 0A5601 1 COVER REAR BEARING CARRIER 13 075554B 4 BOLT STATOR X 16" LG 14 0A9375 4 SCREW RHM #10-24 X 2 15 022152 4 WASHER LOCK #10 16 097146 1 FAN & RING GEAR ASSEM. 17 042558 1 KEY SQ 3/8 X 1 STEEL 18 0A5061 1 SPACER-FLEX PLATE 19 0A4989 1 PLATE, FLEX 20 053557 1 SCREW HHC M12-1.75 X 40 G8.8 21 051769 6 WASHER LOCK M12 22 049541 4 SCREW HHC M10-1.5 X 35 G8.8 23 046526 4 WASHER LOCK M10 24 045772 4 NUT HEX M10-1.5 G8 YEL CHR

26 * 087599 1 PLUG PLASTIC 3/8 NPT

27 077043E 1 FLEX CONDUIT 1" BLACK (NOT SHOWN) 28 022131 4 WASHER FLAT 3/8-M10 ZINC 29 072578 1 SPACER ROTOR SHAFT 30 0A7043 5 SCREW HHC M12-1.25 X 25 G8.8 31 049808 5 WASHER FLAT M12 32 058589 1 DECAL WARN ENG START 33 023365 4 WASHER SHAKEPROOF INT #8 35 0A8830 4 WASHER FLAT .34 ID X .75 OD 36 072080 1 DECAL, DANGER STANBY UNITS

* USED ON PRE-PACKAGED UNITS ONLY

Section 9 - Exploded Views and Parts

Carrier Liquid-cooled 15 kW Generators

Alternator — Drawing No. 0A9348-F

ITEM PART NO. QTY. DESCRIPTION

1 077483 REF BATT 12VDC 75-AH 26 (NOT INCLUDED) 2 038804D 1 CABLE BATT RED #4 X 20.00 3 038805B 1 CABLE BATT BLK #4 X 23.00 4 0742600131 1 ASSY,WIRE#16 RED 1.6 5 022131 1 WASHER FLAT 3/8 ZINC 6 046526 1 WASHER LOCK M10 7 052213 1 SCREW HHC M10-1.25 X 20 G8.8 8 075763 3 BOOT, BATTERY CABLE 9 0D8668 1 BRACKET, BATTERY HOLD DOWN 1.5

13 050331A 1 BATTERY POST COVER (RED+) 14 050331 1 BATTERY POSTCOVER (BLACK-) 15 0C2454 2 SCREW TH-FRM M6-1X16 N WA Z/JS 16 025507 1 WASHER SHAKEPROOF EXT 7/16 STL 17 027482 2 WASHER SHAKEPROOF EXT 5/16 STL

OCK

42 Carrier

Section 9 - Exploded Views and Parts

Carrier Liquid-cooled 15 kW Generators Battery — Drawing No. 0E0770-B

TARTE

LEN

T BL

Carrier 43

ITEM PART NO. QTY. DESCRIPTION

1 0A4355 1 MANIFOLD EXHAUST 1.5L 2 0E2844 1 NIPPLE TOE 1.5NPTX5.5 BLK IRON 3 036434 3 BOLT U 5/16-18 X 2.09

036449 3 SADDLE 2 INCH 4 0E0109 1 PIPE,EXHAUST 1.5L STNDRD&ACSTC 5 0C1318 1 FLEX PIPE EXHAUST 6 0D8657 1 SUPPORT, RADIATOR 1.5L MITSU 7 0E0170 1 BLANKET, EXHAUST 1.5L MITSU 80D9437 1 MUFFLER,1.5L ACOUSTIC&STANDARD 9 060366 2 STRAP MUFFLER 6" DIA

10 039253 4 SCREW HHC M8-1.25 X 20 G8.8 11 022145 4 WASHER FLAT 5/16 ZINC 12 022129 4 WASHER LOCK M8-5/16 13 045771 4 NUT HEX M8-1.25 G8 YEL CHR 14 0A8974 1 CAP RAIN 2" 15 027837 2 SCREW RHM 1/4-20 X 2-1/4

Section 9 - Exploded Views and Parts

Carrier Liquid-cooled 15 kW Generators

Muffler — Drawing No. 0E0773-A

44 Carrier

Section 10 – Warranty

Carrier Liquid-cooled 15 kW Generators

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new engine.* In California, new utility, and lawn and garden equipment engines must be designed, built and equipped to meet the state’s stringent anti-smog standards. 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 system and exhaust system. 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 1995 and later model year 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 due to 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.

Warranty service can be arranged by contacting Generac Power Systems, Inc..

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 law. See also the “Carrier Two Year Limited Warranty for Prepackaged Emergency Automatic Standby Generators” 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 Carrier 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 Carrier 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.

To arrange for emissions equipment warranty or 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

www.generac.com

Part 1

Carrier 45

EMISSION CONTROL SYSTEM WARRANTY

Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines:

(a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on

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

(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 CARB pursuant to its

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.

(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 responsi-

ble 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 owner. Such use shall not reduce Generac 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:

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

1) Prepackaged Standby Generator

2) Auxiliary Power Unit (APU) Generator

3) Standby Generator

Part 2

Section 10 – Warranty

Carrier Liquid-cooled 15 kW Generators

1) Fuel Metering System:

1.2) LPG/Natural Gas carburetion assembly and its internal components.

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

Part No. 0F4163 Rev. 0 (01/20/05) Printed in U.S.A.

Section 10 – Warranty

Catalog No. 03AS-PA4 Form No. OMASPASL1507-1

Carrier Liquid-cooled 15 kW Generators

CARRIER "TWO YEAR" LIMITED WARRANTY FOR

"PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"

For a period of two years from the date of original sale, Carrier warrants that its generator will be free from defects in material and workmanship for the items and period set forth below. Carrier will, at its option, repair or replace any part which, upon examination, inspection and testing by a Carrier 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 Carrier 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 ALTERNATOR - 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:

• Carrier generators that utilize non-Carrier replacement parts.

• Carrier generators utilizing non-Carrier automatic transfer switches.

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

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

CARRIER 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.

CARRIER 'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL CARRIER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF CARRIER '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.

Revision (10/01/04)

Generac ASPAS1CCL015 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual