Generac Power Systems 05176-0 User Manual

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POWER SYSTEMS, INC.

Installation and

Owner’s Manual

Air-cooled Automatic

Standby Generators

Model: 05176-0 (13 kW NG, 15 kW LP)



GENERAC

POWER SYSTEMS, INC.

*This manual should remain with the unit.*

Not intended for use as Primary Power in place of utility

or in life-support applications.

DANGER

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!



INTRODUCTION

Thank you for purchasing this model by Generac Power Systems Inc.. This model is a compact, high performance, air-cooled, engine-driven generator designed to automatically supply electrical power to operate critical loads during a utility power failure.

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 This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG).

READ THIS MANUAL THOROUGHLY



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

Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their defini-

tions are as follows:

DANGER

After this heading, read instructions that, if not

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

After this heading, read instructions that, if not

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

After this heading, read instructions that, if not

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

NOTE:

After this heading, read explanatory statements

that require special emphasis.

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

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

This symbol points out important safety informa-



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

This symbol points out potential explosion hazard.



This symbol points out potential fire hazard.



This symbol points out potential electrical shock



hazard.

The operator is responsible for proper and safe use of the equipment. The manufacturer strongly recommends that the operator read this Owner's Manual and thoroughly understand all instructions before using this equipment. The manufacturer also strongly recommends instructing other users to properly start and operate the unit. This prepares them if they need to operate the equipment in an emergency.

CONTENTS

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This manual contains pertinent owner’s information, including warranty, electrical diagrams, exploded views and lists of repair parts, for model:

• 05176-0 – 13 kW NG, 15 kW LP, V-twin GT-990 Engine



OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment checked periodically by an Authorized Dealer. Normal maintenance service and replacement of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.

Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expenses at a minimum. See the Authorized Dealer for service aids and accessories.



HOW TO OBTAIN SERVICE

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

When contacting an Authorized Dealer about parts and service, always supply the complete model number and serial number of the unit as given on its data decal, which is located on the generator. See "The Generator" section for decal location.

Model No. ____________ Serial No. ______________

AUTHORIZED

DEALER LOCATION

To locate the nearest AUTHORIZED

DEALER, please call this number:

1-800-333-1322

or locate us on the web at

www.generac.com

Table of Contents

Air-cooled 15 kW Generators

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

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

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

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

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

Authorized Dealer Locator Number ................... IFC

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

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

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

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

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

1.3 System Set LED ............................................ 4

1.4 The Generator ...............................................5

1.5 Specifications ................................................ 6

1.5.1 Generator ........................................... 6

1.5.2 Engine ................................................ 6

1.6 Fuel Requirements and Recommendations ...6

1.7 Fuel Consumption ......................................... 6

1.8 Reconfiguring the Fuel System ......................6

Section 2 – Installation ....................................7

2.1 Installation .................................................... 7

2.1.1 Remote Monitoring Connections ........7

2.1.2 Roof Open Alarm ...............................8

2.1.3 Transfer Switch Connection ............... 8

2.2 Battery Installation ........................................9

2.3 The Battery .................................................10

Section 3 – Post Installation Start-up

and Adjustments .......................10

3.1 Before Initial Start-up ..................................10

3.2 Check Transfer Switch Operation ............... 10

3.3 Electrical Checks ........................................10

3.4 Generator Tests Under Load ....................... 11

3.5 Checking Automatic Operation .................... 12

3.6 Adjusting the Regulator (Natural Gas Only) .. 12

3.7 Engine Governor Adjustment ...................... 13

3.7.1 Additional Corrosion Protection ....... 13

3.8 Voltage Regulator Adjustment ...................... 13

Section 4 – Operation ....................................14

4.1 Using the Auto/Off/Manual Switch ............... 14

4.1.1 “Auto” Position ..................................14

4.1.2 “Off” Position....................................14

4.1.3 “Manual” Position ............................. 14

4.2 Automatic Transfer Operation ..................... 14

4.3 Sequence of Automatic Operation ............... 14

4.4 Manual Operation .......................................15

4.4.1 Close to Normal Source Side .............15

4.4.2 Close to Emergency Source Side .......16

4.4.3 Return to Normal Source Side ...........16

4.5 Voltage Checks ............................................ 16

4.6 Generator Tests Under Load ....................... 16

4.7 Setting the Exercise Timer .......................... 17

4.8 Protection Systems ...................................... 17

4.8.1 Low Oil Pressure Switch .................. 17

4.8.2 High Temperature Switch .................17

4.8.3 Overcrank ........................................17

4.8.4 Overspeed ........................................ 18

Section 5 – Maintenance ...............................18

5.1 Fuse .............................................................18

5.2 Checking the Engine Oil Level ..................... 18

5.3 Changing the Engine Oil .............................. 18

5.3.1 Engine Oil Recommendations .......... 18

5.3.2 Oil Change Procedure ....................... 18

5.4 Changing the Oil Filter ................................ 19

5.5 Changing the Engine Air Cleaner .................19

5.6 Spark Plug(s) .............................................. 19

5.7 Battery Maintenance ....................................20

5.8 Adjusting Valve Clearance ........................... 20

5.9 Cooling System ........................................... 21

5.10 Attention After Submersion .........................21

5.11 Corrosion Protection ................................... 21

5.12 Out of Service Procedure ............................. 21

5.12.1 Removal From Service......................21

5.12.2 Return to Service ............................. 22

Section 6 – Troubleshooting .........................27

6.1 Troubleshooting Guide ................................27

Section 7 – Mounting Dimensions ............. 28

Section 8 – Electrical Data ........................... 29

Section 9 – Exploded Views and

Parts Lists ................................... 34

Section 10 – Warranty ................................... 48

IMPORTANT SAFETY INSTRUCTIONS

Air-cooled 15 kW Generators

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

operation be copied and posted near the unit’s installation site. Safety should be stressed to



all operators and potential operators of this equipment.



The engine exhaust from this product

contains chemicals known to the state

defects or other reproductive harm.



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

cancer, birth defects or other reproductive harm.

Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit are, therefore, not all-inclusive. If using a procedure, work method or operating technique the manufacturer 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.

WARNING:

of California to cause cancer, birth

WARNING:



DANGER

Despite the safe design of this generator, operat-



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

Potentially lethal voltages are generated by



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

Parts of the generator are rotating and/or hot



during operation. Exercise care near running generators.

Please read all hazards carefully!



GENERAL HAZARDS



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

• The engine exhaust fumes contain carbon monoxide, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. This exhaust system must be installed properly, in strict compliance with applicable codes and standards. Following installation, do nothing that might render the system unsafe or in noncompliance with such codes and standards.

• Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.

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

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

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

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

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



ELECTRICAL HAZARDS



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

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

• The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground. Local electrical codes also may require proper grounding of the generator electrical system.

• After installing this home standby electrical system, the generator may crank and start at any time without warning. When this occurs, load circuits are transferred to the STANDBY (generator) power source. To prevent possible injury if such a start and transfer occur, always set the generator’s AUTO/OFF/MANUAL switch to its OFF position before working on equipment and remove the 5A and 15A fuses from the generator control panel.

• In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting implement, such as a rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help.

• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving components causing injury.

FIRE HAZARDS



• For fire safety, the generator must be installed and maintained properly. Installation always must comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure that the generator is installed in accordance with the manufacturer’s instructions and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes, standards, laws and regulations.





IMPORTANT SAFETY INSTRUCTIONS

Air-cooled 15 kW Generators

• Keep a fire extinguisher near the generator at all times. Extinguishers rated “ABC” by the National Fire Protection Association are appropriate for use on the standby electric system. Keep the extinguisher properly charged and be familiar with its use. If there are any questions pertaining to fire extinguishers, consult the local fire department.

EXPLOSION HAZARDS



• Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.

• Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE. Install the fuel supply system according to applicable fuel-gas codes. Before placing the home standby electric system into service, fuel system lines must be properly purged and leak tested according to applicable code. After installation, inspect the fuel system periodically for leaks. No leakage is permitted.

STANDARDS INDEX



In the absence of pertinent standards, codes, regulations and laws, the published information listed below may be used as installation guide for this equipment.

1. NFPA No. 37, STATIONARY COMBUSTION

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

2. NFPA No. 76A, ESSENTIAL ELECTRICAL

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

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

available same as Item 1.

4. NFPA No. 58, AMERICAN NATIONAL STANDARD

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

5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL

ELECTRIC CODE, available same as Item 1.

6. Article X, NATIONAL BUILDING CODE, available

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

7. AGRICULTURAL WIRING HANDBOOK, avail-

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

8. ASAE EP-3634, INSTALLATION AND

MAINTENANCE OF FARM STANDBY ELECTRICAL SYSTEMS, available from the American Society of Agricultural Engineers, 2950 Niles Road, St. Joseph, MI 49085.

9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE

LIQUIDS CODE, available same as Item 1.



Section 1 — General Information

Air-cooled 15 kW Generators

DANGER

Only qualified electricians or contractors should



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

1.1 UNPACKING/INSPECTION

After unpacking, carefully inspect the contents for damage.

• This standby generator set has been factory supplied with a weather protective enclosure that is intended for outdoor installation only.

If this generator is used to power electrical load



circuits normally powered by a utility power source, it is required by code to install a transfer switch. The transfer switch must effectively isolate the electrical system from the utility distribution system when the generator is operating (NEC 700, 701 and 702). Failure to isolate an electrical system by such means will result in damage to the generator and also may result in injury or death to utility power workers due to backfeed of electrical energy.

If any loss or damage is noted at time of delivery, have the person(s) making the delivery note all damage on the freight bill or affix his or her signature under the consignor's memo of loss or damage.

If there is loss or damage after delivery, separate the damaged materials and contact the carrier for claim procedures.

“Concealed damage” is understood to mean damage to the contents of a package that is not in evidence at the time of delivery, but is discovered later.

1.2 PROTECTION SYSTEMS

Unlike an automobile engine, the generator may have to run for long periods of time with no operator present to monitor engine conditions. For that reason, the engine is equipped with the following systems that protect it against potentially damaging conditions:

1. Low Oil Pressure Sensor 3. Overcrank

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

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

1.3 SYSTEM SET LED

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

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

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

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

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

1.4 THE GENERATOR

aust

uel

ecal

Oil

uel

Figure 1.1 – 15 kW, V-twin GT-990 Engine

Dipstic

Exh

Enclosur

Section 1 — General Information

Air-cooled 15 kW Generators

ontro

Dat

Pan

F Regulato

F Inl

il Filte

Figure 1.2 – 15 kW, V-twin GT-990 Engine Rear View

Batter

Compartmen

Composite Bas

AUTOMATIC TRANSFE

WIT

Section 1 — General Information

Air-cooled 15 kW Generators

1.5 SPECIFICATIONS

1.5.1 GENERATOR



Rated Max. Continuous Power

Capacity (Watts*) .......................... 13,000 NG/15,000 LP

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

Rated Max. Continuous Load Current (Amps)

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

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

Main Line Circuit Breaker .................................... 70 Amp

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

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

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

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

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

Battery Requirement ...... Group 26/26R at -17.8° C ( 0° F)

12 Volts and 525 Cold-cranking Amperes Minimum

Weight ............................................................ 640 Pounds

Output Sound Level

@ 23 ft (7m) at full load ............................... 71.5 db (A)

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

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

factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc. Maximum power decreases about 3.5 percent for each 1,000 feet above sea level; and also will decrease about 1 percent for each 6° C (42° F) above 16° C (60° F).

+ Total current in two separate curcuits. Current in each curcuit must

not exceed the value stated for 240V.

1.5.2 ENGINE



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

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

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

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

Cylinder Block ...................................... Aluminum w/Cast

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

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

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

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

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

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

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

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

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

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

to 104°F (40°C)

Iron Sleeve

1.6 FUEL REQUIREMENTS AND RECOMMENDATIONS

With LP gas, use only the vapor withdrawal system. This type of system uses the vapors formed

above the liquid fuel in the storage tank.

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

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

Required fuel pressure for natural gas is five inches

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

NOTE:

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

1.7 FUEL CONSUMPTION

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

05176 156 220 1.58/58 2.40/88

*Natural gas is in cubic feet per hour. **LP is in gallons per hour/cubic feet per hour.

1.8 RECONFIGURING THE FUEL SYSTEM

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

NOTE:

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

0.5 psi) to the fuel inlet of the generator MUST

BE SUPPLIED.

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

2. Open the roof and remove the door.

3. Remove the battery. (if installed)

OSE

OUSING PORT

JUSTER

OOR

COMMON

OPEN

OWFUEL

Section 2 — Installation

Air-cooled 15 kW Generators

4. Remove the engine air in baffle located on the lefthand side of the battery compartment. Two M6 screws are located on top of the baffle and two M6 screws are located on the inside of the baffle towards the back.

5. Remove the small hose clamp and hose from the fuel regulator. It may be necessary to pry the hose off of the brass fitting using a screwdriver to gently lift up the hose edge.

6. Remove the small brass hose fitting from the regulator casting.

7. Place the small fuel jet, thread side first, into the threaded hole originally occupied by the brass hose fitting (Figure 1.3).

Figure 1.3 - Demand Regulator

TLET PORT

FUEL H

BRASS HOSE FITTIN

IDLE CIRCUI

POR

1/8 NP

BRASS HOSE

FITTIN

REW

REGULAT H

MAL

FUEL JE

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

2.1 INSTALLATION

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

• Install the unit where air inlet and outlet openings

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

• Install the generator on high ground where water

levels will not rise and endanger it.

• Allow sufficient room on all sides of the generator

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

• Where strong prevailing winds blow from one

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

• Install the generator as close as possible to the fuel

supply, to reduce the length of piping.

8. Using a short No. 2 Phillips screw driver, thread the small fuel jet into the regulator casting. Do not over tighten.

9. Apply thread sealant to the threads of the hose fitting and replace it into the regulator body.

10. Re-attach the small hose and hose clamp and tighten as necessary.

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

12. Identify both brass adjustment screws on the regulator.

NOTE:

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

13. To adjust the system to run on LP fuel, turn BOTH adjuster screws 1/2 TURN CLOCKWISE. The system should now be set for maximum power and best perfomance. DO NOT, UNDER

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

2.1.1 REMOTE MONITORING CONNECTIONS



Mounted in the transfer switch is relay contact board (Figure 2.1) that can be used to remotely monitor various functions of the generator system.

The contacts are rated as shown below. Failure to follow these ratings will cause unit failure.

• Arrangement: SPCT (Form C)

• Ratings: Resistive Load, 4Amp max switching current at 30VDC; 2Amp max switching current at 125VAC

• Wire Range: 26-14Awg

• Terminal tightening torque: 5 in/lb.

Figure 2.1 — Remote Monitoring Connections

ENGIN

WITCH I

EMERGEN

RELAY

WITCH I

AUT

ALAR

RELAY

Section 2 — Installation

Air-cooled 15 kW Generators

Remote monitoring functions are only available with the AUTO/OFF/MANUAL switch in the Auto or Manual position. Since the contacts are SPDT, it is possible to monitor either state of each alarm function.

Relay 1: Engine running, normally closed.

Engine not running, normally open

Relay 2: Transfer Switch in Emergency, normally

closed

Transfer Switch in Utility, normally open

Relay 3: Control panel switch in Auto, normally

open

Control panel switch in Manual or Off, nor-

mally closed

Relay 4: The common alarm is activated by any of

the following shutdown faults Low Oil Pressure High Engine Temperature Overspeed Overcrank Common alarm active, normally open No Common alarm, normally closed

Relay 5: Spare, not used on this model

Relay 6: Enclosure door open, normally closed

Enclosure door closed, normally open

2.1.2 ROOF OPEN ALARM



This generator is equipped with an alarm to detect when the roof of the enclosure is open. A limit switch that is installed in the generator enclosure controls this alarm. During shipping, the generator's enclosure panels may have shifted and this limit switch may require adjustment. Simply loosen the two screws and adjust the placement of the limit switch. The arm of the limit switch should be in the depressed position when the enclosure roof is closed and the door latch is secure (see Figure 2.2).

Figure 2.2 — Limit Switch

2.1.3 TRANSFER SWITCH CONNECTION



These switches (Figure 2.3) are used with a singlephase system, when the single-phase NEUTRAL line is to be connected to a Neutral Lug and is not to be switched.

Figure 2.3 — Typical 2-Pole Transfer Mechanism

(200 Amp Shown)

UTILITY LUGS

UTILITY CLOSING COIL

GENERATOR LUGS (E1 & E2)

GENERATOR CLOSING COIL

LOAD LUGS (T1 & T2)

Solderless, screw-type terminal lugs are standard.

Switch Wire Conductor Tightening Rating Range Torque

200A #6-250 MCM 275 in-lbs.

Conductor sizes must be adequate to handle the maximum current to which they will be subjected to, based on the 75°C column of tables, charts, etc. used to size conductors. The installation must comply fully with all applicable codes, standards and regulations.

Before connecting wiring cables to terminals, remove any surface oxides from the cable ends with a wire brush. All power cables should enter the switch next to transfer mechanism terminals. If ALUMINUM conductors are used, apply corrosion inhibitor to conductors. Tighten terminal lugs to the torque values as noted on the decal located on the inside of the door. After tightening terminal lugs, carefully wipe away any excess corrosion inhibitor.

All power cables should enter the switch next to the transfer mechanism terminals.

Down

Slots

Use a torque wrench to tighten the conductors,



being sure not to over tighten, or damage to the switch base could occur. If not tightened enough, a loose connection would result, causing excess heat which could damage the switch base.

Section 2 — Installation

Air-cooled 15 kW Generators

Connect power source load conductors to clearly marked transfer mechanism terminal lugs as follows

1. Connect UTILITY (NORMAL) power source cables

to switch terminals N1, N2.

2. Connect customer LOAD leads to switch termi-

nals T1, T2.

Conductors must be properly supported, of approved insulative qualities, protected by approved conduit, and of the correct wire gauge size in accordance with applicable codes.

Be sure to maintain proper electrical clearance between live metal parts and grounded metal. Allow at least 1/2 inch for 100-400 amp circuits.

2.2 BATTERY INSTALLATION

DANGER

Do not dispose of the battery in a fire. The



battery is capable of exploding.

A battery presents a risk of electrical shock



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

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

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

battery; and

• Disconnect charging source prior to connecting or

disconnecting battery terminals.

Do not open or mutilate the battery. Released



electrolyte has been known to be harmful to the skin and eyes, and to be toxic.

The electrolyte is a dilute sulfuric acid that is



harmful to the skin and eyes. It is electrically conductive and corrosive.

The following procedures are to be observed:

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off

immediately with water;

• Where electrolyte contacts the eyes, immediately

flush thoroughly with water and seek medical attention; and

• Spilled electrolyte is to be washed down with an

acid neutralizing agent. A common practice is to use a solution of 1 pound (500 grams) bicarbonate of soda to 1 gallon (4 liters) or water. The bicarbonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried.

Lead-acid batteries present a risk of fire because



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

• DO NOT SMOKE when near the battery;

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

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

Be sure the AUTO/OFF/MANUAL switch is set to



the OFF position before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected.

Be sure the utility power supply is turned off, or



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

Fill the battery with the proper electrolyte fluid if necessary and have the battery fully charged before installing it.

Before installing and connecting the battery, complete the following steps:

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

OFF.

2. Turn off utility power supply to the transfer

switch.

3. Remove the 5 amp fuse from the generator con-

trol panel.

If the AUTO/OFF/MANUAL switch is not set to its



OFF position, the generator can crank and start as soon as the battery cables are connected. If the utility power supply is not turned off, sparking can occur at the battery posts and cause an explosion.

Battery cables were factory connected at the generator (Figure 2.4). Connect cables to battery posts as follows:

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

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

5. Connect the black battery cable (from frame

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

6. Replace the 5 amp fuse in the generator control

panel.

NOTE:

Damage will result if battery connections are made in reverse.

Section 3 — Post Installation Start-up and Adjustments

Air-cooled 15 kW Generators

Figure 2.4 – Battery Cable Connections

NOTE:

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

3.1 BEFORE INITIAL START-UP

Before starting, complete the following:

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

OFF (or open) position.

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

the OFF position.

3. Turn OFF the utility power supply to the transfer

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

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

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

5. Check the fuel supply. Gaseous fuel lines must

have been properly purged and leak tested in accordance with applicable fuel-gas codes. All fuel shutoff valves in the fuel supply lines must be open.

Never operate the engine with the oil level



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

3.2 CHECK TRANSFER SWITCH

OPERATION

Refer to the "Manual Operation" section of the owner’s manual for manual operation procedures.

2.3 THE BATTERY

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

When replacing the battery, use the following type of battery: Group 26/26R 12-volt battery with a rating of 525 cold-cranking amps minimum at -17.8º C (0º F) minimum. When using a maintenance-free battery, it is not necessary to check the specific gravity or electrolyte level. Have these procedures performed at the intervals specified in the “Service Schedule.” A negative ground system is used. Battery connections are shown on the wiring diagrams. Make sure the battery is correctly connected and terminals are tight. Observe battery polarity when connecting the battery to the generator set.

DANGER

Do not attempt manual transfer switch opera-



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

3.3 ELECTRICAL CHECKS

Complete electrical checks as follows:

1. Turn on the utility power supply to the transfer

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

DANGER

The transfer switch is now electrically “hot.”



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

2. Use an accurate AC voltmeter to check utility

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

Section 3 — Post Installation Start-up and Adjustments

Air-cooled 15 kW Generators

3. Check utility power source voltage across terminals N1 and the transfer switch neutral lug; then across terminal N2 and neutral. Nominal line-toneutral voltage should be 120 volts AC.

4. When certain that utility supply voltage is compatible with transfer switch and load circuit ratings, turn OFF the utility power supply to the transfer switch.

5. Set the generator's main circuit breaker to its OFF (or OPEN) position. Initial tests will be conducted at no-load condition.

6. On the generator panel, set the AUTO/OFF/ MANUAL switch to MANUAL. The engine should crank and start.

7. Let the engine warm up for about five minutes to allow internal temperatures to stabilize. Then, set the generator’s main circuit breaker to its ON (or closed) position.

DANGER

Proceed with caution! Generator power voltage



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

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

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

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

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

NOTE:

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

3.4 GENERATOR TESTS UNDER LOAD

Do not attempt manual transfer switch opera-



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

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

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

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

4. Manually set the transfer switch to the STANDBY position, i.e., load terminals connected to the generator's E1/E2 terminals. The transfer switch operating lever should be down.

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

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

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

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

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

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

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

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

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

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

Section 3 — Post Installation Start-up and Adjustments

Air-cooled 15 kW Generators

3.5 CHECKING AUTOMATIC OPERATION

To check the system for proper automatic operation, proceed as follows:

1. Set the generator’s main circuit breaker to it’s

OFF (or open) position.

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

to OFF.

3. Manually set the transfer switch to the UTILITY

position, i.e., load terminals connected to the utility power source side.

4. Turn ON the utility power supply to the transfer

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

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

Then set the generator’s main circuit breaker to its ON (or closed) position. The system is now ready for automatic operation.

6. Turn OFF the utility power supply to the transfer

switch.

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

With the generator running and loads powered by generator AC output, turn ON the utility power supply to the transfer switch. The following should occur:

• After about 15 seconds, the switch should transfer

loads back to the utility power source.

• About one minute after retransfer, the engine

should shut down.

3.6 ADJUSTING THE REGULATOR (NATURAL GAS ONLY)

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

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

1. Turn off utility power to the main distribution

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

2. Allow the generator to start before loading the

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

3. Turn on electrical loads. Be cautious not to overload the generator. Use the following chart as a guide:

Model 120 Volts 240 Volts

005176 108.3 amps 54.1 amps

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

5. The fuel regulator is fitted with two adjustment screws. While watching the frequency meter, slowly turn the adjustment screw clockwise or counterclockwise one at a time until highest frequency is read on the meter. Only limited adjustment is available between the set pins. Under no circumstances should any of the pins be removed (Figures 3.1 and 3.2).

Figure 3.1 — Dual Fuel Regulators

V-twin Engine

Adjustment Screw

(Both Sides)

Set Pin

(Both Sides)

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

Adjustment Screw

(One Side Only)

410cc

Figure 3.2 — Placement of Regulator

Adjustment Screw

Section 3 — Post Installation Start-up and Adjustments

Air-cooled 15 kW Generators

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

Do not make any unnecessary adjustments.



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

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

NOTE:

A service fee may be charged for this adjustment.

3.7 ENGINE GOVERNOR ADJUSTMENT

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

1. Loosen governor clamp bolt (See Figure 3.3).

Figure 3.3 — V-twin Engine Governor

Adjustment

Figure 3.4 — V-twin Full Load Speed Adjust

Screw

Full Load Speed Adjust Screw

3.7.1 ADDITIONAL CORROSION



PROTECTION

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

3.8 VOLTAGE REGULATOR

Idle Spring

Governor Shaft

(Rotate

Clockwise)

Governor Clamp Bolt

2. Completely remove the idle spring.

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

4. Start unit and apply full load. Use full load speed adjust screw (Figure 3.4) to adjust frequency to 58 Hz.

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

6. Using a hand, push the governor arm to the closed throttle position. Make sure the idle spring does not stretch at all.

7. Restart the unit.

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

9. The governor is now set.

No Load Idle Adjustment Screw

ADJUSTMENT

With the frequency between 62-63.5 Hertz, slowly turn the slotted potentiometer (Figure 3.5) until line voltage reads 244-252 volts.

NOTE:

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

Figure 3.5 – Voltage Adjustment Potentiometer

Turn to adjust voltage.

NOTE:

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

Section 4 — Operation

Air-cooled 15 kW Generators

4.1 USING THE AUTO/OFF/MANUAL

SWITCH (FIGURE 4.1)

4.1.1 “AUTO” POSITION



Selecting this switch position activates fully automatic system operation. It also permits starting and exercising of the engine every seven days with the exercise timer (see "Generator Test Under Load"). This position also is used for remote starting, when it is set up.

4.1.2 “OFF” POSITION



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

4.1.3 “MANUAL” POSITION



Set the switch to MANUAL to crank and start the engine. Transfer to standby power will not occur unless there is a utility failure.

Figure 4.1 – Generator Control Panel

FUSE

15A

With the switch set to AUTO, the engine may



crank and start at any time without warning.

OFFAUTO

SET

EXERCISE

TIME

MAN.

Locat e your near est dealer at :

POWER SYSTEMS, INC.

FLA SHING GR EEN LED=

4FLASHINGREDLEDS=

Such automatic starting normally occurs when utility power source voltage drops below a preset level or during the normal exercise cycle. To prevent possible injury that might be caused by such sudden starts, always set the switch to OFF and remove both fuses before working on or around the generator or transfer switch. Then, place a “Do Not Operate” tag on the generator panel and on the transfer switch.

SYSTEM SET

LOW OIL

HIGH TEMP.

OVER SPEED

OVER CRANK

N O UT IL IT Y S E N S E

EX ERCISER NOT SET

4.2 AUTOMATIC TRANSFER

OPERATION

To select automatic operation, do the following:

1. Make sure the transfer switch main contacts are set to their “Utility” position, i.e., loads connected to the utility power source (Figure 4.2).

2. Be sure that normal utility power source voltage is available to transfer switch terminal lugs N1

and N2.

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

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

With the preceding steps complete, the generator will start automatically when utility source voltage drops below a preset level. After the unit starts, loads are transferred to the standby power source. Refer to “Sequence of Automatic Operation.”

4.3 SEQUENCE OF AUTOMATIC

OPERATION

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

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

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

A. Utility Voltage Dropout Sensor

• This sensor monitors utility source voltage.

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

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

B. Engine Warm-up Time Delay

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

C. Standby Voltage Sensor

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

D. Utility Voltage Pickup Sensor

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

E. Retransfer Time Delay

• This timer runs for about 15 seconds.

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

Section 4 — Operation

Air-cooled 15 kW Generators

• Retransfer to utility power source then occurs.

F. Engine Cool-down Timer

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

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

4.4 MANUAL OPERATION

DANGER

Do NOT manually transfer under load.



Disconnect transfer switch from all power sources by approved means, such as a main circuit breaker(s).

A manual HANDLE is shipped with the transfer switch. Manual operation must be checked BEFORE the transfer switch is operated electrically. To check manual operation, proceed as follows:

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

2. Turn OFF both UTILITY and EMERGENCY power supplies to the transfer switch, with whatever means provided (such as the main line circuit breakers).

3. Note position of transfer mechanism main contacts by observing the moveable contact carrier arm.

• Manual operation handle towards the top of switch mechanism - LOAD terminals (T1, T2) are connected to UTILITY terminals (N1, N2).

• Manual operation handle towards the bottom of switch mechanism - LOAD terminals (T1, T2) are connected to EMERGENCY terminals (E1, E2).

Do not use excessive force when operating the



transfer switch manually or damage could be done to the manual handle.

4.4.1 CLOSE TO NORMAL SOURCE SIDE



Before proceeding, verify the position of the switch by observing the position of manual operation handle in Figure 4.2. If the handle is UP, the contacts are closed in the NORMAL position, no further action is required. If the handle is DOWN, proceed with Step

Step 1: With the handle inserted into the actuating

shaft, move handle UP. Be sure to hold on to the handle as it will move quickly after the center of travel.

Figure 4.2 — Actuating Transfer Switch

Attach handle to actuating shaft.

Move handle

UP for the

NORMAL

(UTILITY)

position.

NOTE: Return handle to storage position in enclosure when finished with manual transfer.

Move handle

DOWN for the

EMERGENCY

(STANDBY)

position.

Section 4 — Operation

Air-cooled 15 kW Generators

4.4.2 CLOSE TO EMERGENCY SOURCE SIDE



Before proceeding, verify the position of the switch by observing the position of the manual operation handle in Figure 4.2. If the handle is DOWN, the contacts are closed in the EMERGENCY (STANDBY) position. No further action is required. If the handle is UP, proceed with Step 1.

Step 1: With the handle inserted into the actuating

shaft, move the handle DOWN. Be sure to hold on to the handle as it will move quickly after the center of travel.

4.4.3 RETURN TO NORMAL SOURCE SIDE



Manually actuate switch to return manual operating handle to the UP position.

4.5 VOLTAGE CHECKS

1. Turn ON the UTILITY power supply to the transfer switch with whatever means provided (such as the UTILITY main line circuit breaker).

DANGER

PROCEED WITH CAUTION. THE TRANSFER



SWITCH IS NOW ELECTRICALLY HOT. CONTACT WITH LIVE TERMINALS RESULTS IN EXTREMELY HAZARDOUS AND POSSIBLY FATAL ELECTRICAL SHOCK.

2. With an accurate AC voltmeter, check for correct voltage.

Single-phase utility supply:

Measure across ATS terminal lugs N1 and N2. Also

check N1 to NEUTRAL and N2 to NEUTRAL.

3. When certain that UTILITY supply voltage is correct and compatible with transfer switch ratings, turn OFF the UTILITY supply to the transfer switch.

4. On the generator panel, set the AUTO/OFF/ MANUAL switch to MANUAL position. The generator should crank and start.

5. Let the generator stabilize and warm up at noload for at least five minutes.

6. Set the generator's main circuit breaker (CB1) to its ON or CLOSED position.

DANGER

PROCEED WITH CAUTION. GENERATOR



OUTPUT VOLTAGE IS NOW BEING DELIVERED TO TRANSFER SWITCH TERMINALS. CONTACT WITH LIVE TERMINALS RESULTS IN EXTREMELY DANGEROUS AND POSSIBLY FATAL ELECTRICAL SHOCK.

7. With an accurate AC voltmeter and frequency meter, check the no-load, voltage and frequency.

Single-phase generator supply:

Measure across ATS terminal lugs E1 to E2. Also

check E1 to NEUTRAL and E2 to NEUTRAL.

a. Frequency ....................................... 60-62 Hertz

b. Terminals E1 to E2 ........................ 240-246 VAC

c. Terminals E1 to NEUTRAL .............120-123 VAC

d. Terminals E2 to NEUTRAL ............. 120-123 VAC

8. Set the generator’s main circuit breaker (CB1) to its OFF or OPEN position.

9. Set the AUTO/OFF/MANUAL switch to the OFF position to shut down the generator.

NOTE:

Do NOT proceed until generator AC output voltage and frequency are correct and within stated limits. If the no-load voltage is correct but noload frequency is incorrect, the engine governed speed probably requires adjustment. If no-load frequency is correct but voltage is not, the voltage regulator may require adjustment.

4.6 GENERATOR TESTS UNDER LOAD

1. Set the generator's main circuit breaker to its OFF or OPEN position.

2. Manually actuate the transfer switch main contacts to their EMERGENCY (STANDBY) position. Refer to "Manual Operation".

3. To start the generator, set the AUTO/OFF/MANUAL switch to MANUAL. When engine starts, let it stabilize for a few minutes.

4. Turn the generator's main circuit breaker to its ON or CLOSED position. The generator now powers all LOAD circuits. Check generator operation under load as follows:

• Turn ON electrical loads to the full rated wattage/amperage capacity of the generator. DO NOT OVERLOAD.

• With maximum rated load applied, check voltage and frequency across transfer switch terminals E1 and E2. Voltage should be greater than 230 volts and frequency should be greater than 59 Hertz.

• Let the generator run under rated load for at least 30 minutes. With unit running, listen for unusual noises, vibration, overheating, etc., that might indicate a problem.

5. When checkout under load is complete, set main circuit breaker of the generator to its OFF or OPEN position.

6. Let the generator run at no-load for several minutes. Then, shut down by setting the AUTO/OFF/ MANUAL switch to its OFF position.

Section 4 — Operation

Air-cooled 15 kW Generators

7. Move the switch's main contacts back to their UTILITY position. For example, load connected to UTILITY power supply. Refer to "Manual Operation". Handle and operating lever of transfer switch should be in UP position.

8. Turn on the UTILITY power supply to transfer switch, using whatever means provided (such as a UTILITY main line circuit breaker). The UTILITY power source now powers the loads.

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

its AUTO position. The system is now set for fully automatic operation.

4.7 SETTING THE EXERCISE TIMER

The generator is equipped with an exercise timer. Once it is set, the generator will start and exercise once every seven days, on the day of the week and at the time of day the following sequence is completed. During this exercise period, the unit runs for approximately 12 minutes and then shuts down. Transfer of loads to the generator output does not occur during the exercise cycle.

A switch on the control panel (see Figure 4.1) allows for selection of the day and time for system exercise. To select the desired day and time of day, the following sequence must be done at that time.

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

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

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

NOTE:

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

4.8 PROTECTION SYSTEMS

4.8.1 LOW OIL PRESSURE SWITCH



This switch (Figure 4.3) has normally closed contacts that are held open by engine oil pressure during cranking and operating. Should oil pressure drop below the 8 psi range, switch contacts close, and the engine shuts down. The unit should not be restarted until oil is added, and the AUTO/OFF/MANUAL switch must be turned to OFF and then back to AUTO.

4.8.2 HIGH TEMPERATURE SWITCH



This switch’s contacts (Figure 4.3) close if the temperature should exceed approximately 140º C (284º F), initiating an engine shutdown. The generator will automatically restart and the LED will reset once the temperature has returned to a safe operating level.

Figure 4.3 – Low Oil Pressure and

High Temperature Switches

Low Oil Switch

Oil Drain Hose

Oil Filter

4.8.3 OVERCRANK



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

NOTE:

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

High Temp Switch

Section 5 — Maintenance

Air-cooled 15 kW Generators

4.8.3.1 Approximate Crank Cycle Times

• 15 seconds ON

• 7 seconds OFF

• 7 seconds ON

• 7 seconds OFF

• Repeat for 45 seconds

Approximately 90 seconds total

4.8.4 OVERSPEED



This feature protects the generator from damage by shutting it down if it happens to run faster than the preset limit. This protection also prevents the generator from supplying an output that could potentially damage appliances connected to the generator circuit. Contact the nearest Authorized Dealer if this failure occurs.

5.1 FUSE

The generator panel’s 15 amp fuse (Figure 5.1) protects the DC control circuit against overload. The fuse is wired in series with the battery output lead to the panel. If the fuse element has melted open, the engine cannot crank or start. Replace the fuse using only an identical 15-amp replacement.

The generator panel’s 5 amp fuse protects the battery charge circuit against overload. If the fuse element has melted open, battery charging will not be possible. Replace the fuse using only an identical 5 amp replacement. To remove fuse, push cap down and rotate counterclockwise.

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

Figure 5.2 — Oil Dipstick and Fill

Oil Dipstick

Oil Fill

3. Install the dipstick; then, remove it again. The oil level should be at the dipstick “Full” mark. If necessary, add oil to the “Full” mark only. DO NOT FILL ABOVE THE “FULL” MARK.

Never operate the engine with the oil level



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

4. Install the dipstick.

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

Figure 5.1 – Generator Control Panel

FUSE

15A

OFFAUTO

SET

EXERCISE

TIME

MAN.

Locat e your nearest dealer at :

FLA SHING GR EEN L ED=

4FLASHINGREDLEDS=

POWER SYSTEMS, INC.

SYSTEM SET

LOW OIL

HIGH TEMP.

OVER SPEED

OVER CRANK

N O U T IL IT Y S E N S E

EX ERCISER N OT S ET

5.2 CHECKING THE ENGINE OIL LEVEL

For oil capacities, see “Specifications”. For engine oil recommendations, see "Changing the Engine Oil". To check the engine oil level, proceed as follows (Figure

5.2):

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

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

5.3 CHANGING THE ENGINE OIL

5.3.1 ENGINE OIL RECOMMENDATIONS



Use all season SAE 5W-30 synthetic oil or use SAE 30 oil of American Petroleum Institute (API) Service Class SG, SH, SJ or SL.

 Any attempt to crank or start the engine before

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



5.3.2 OIL CHANGE PROCEDURE

To change the oil, proceed as follows:

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

2. Immediately after the engine shuts OFF, pull the oil drain hose (Figure 5.3) free of its retaining clip. Remove the cap from the hose and drain the oil into a suitable container.

Section 5 — Maintenance

Air-cooled 15 kW Generators

Figure 5.3 – Oil Drain Hose and Filter

Oil Drain Hose

Oil Filter

3. After the oil has drained, replace the cap onto the end of the oil drain hose. Retain the hose in the clip.

4. Refill with the proper recommended oil (see "Changing the Engine Oil"). See the "Specifications" section for oil capacities.

5.4 CHANGING THE OIL FILTER

Change the engine oil filter as follows:

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

2. Apply a light coating of clean engine oil to the gasket of the new filter. See the "Specifications" section for recommended filter.

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

5.3).

4. Refill with the proper recommended oil (see "Changing the Engine Oil"). See the "Specifications" section for oil capacities.

5. Start the engine and check for leaks.

5.5 CHANGING THE ENGINE

AIR CLEANER

See Figures 1.1 and 1.2, for the location of the air cleaner. Use the following procedure (Figure 5.4):

1. Turn the two screws counterclockwise to loosen.

2. Remove the cover and air filter.

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

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

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

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

Figure 5.4 — Engine Air Cleaner

Screw

Cover

Filter

5.6 SPARK PLUG(S)

Reset the spark plugs gap or replace the spark plugs as necessary. See the “Service Schedule” section for maintenance requirements.

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 “Service Schedule” section for recommended inspection.

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

5.5).

Figure 5.5 – Setting the Spark Plug Gap

SET PLUG GAP AT 0.50 mm (0.020 inch)

Section 5 — Maintenance

Air-cooled 15 kW Generators

5.7 BATTERY MAINTENANCE

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

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

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

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

DANGER

Do not dispose of the battery in a fire. The



battery is capable of exploding.

A battery presents a risk of electrical shock



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

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

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

battery; and

• Disconnect charging source prior to connecting or

disconnecting battery terminals.

Do not open or mutilate the battery. Released



electrolyte has been known to be harmful to the skin and eyes, and to be toxic.

The electrolyte is a dilute sulfuric acid that is



harmful to the skin and eyes. It is electrically conductive and corrosive. The following procedures are to be observed:

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off

immediately with water;

• Where electrolyte contacts the eyes, immediately

flush thoroughly with water and seek medical attention; and

• Spilled electrolyte is to be washed down with an

Lead-acid batteries present a risk of fire because



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

• DO NOT SMOKE when near the battery;

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

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

Be sure the AUTO/OFF/MANUAL switch is set to



the OFF position before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected.

Be sure the utility power supply is turned off,



and the 5A fuse is removed from the generator control panel, or sparking may occur at the battery posts as the cables are attached, causing an explosion.

5.8 ADJUSTING VALVE CLEARANCE

After the first 50 hours of operation, adjust the valve clearance in the engine.

Important: If feeling uncomfortable about doing this

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

To adjust valve clearance:

• Make sure the engine is at room temperature.

• Make sure that the spark plug wire is removed

from the spark plug and out of the way.

• Remove the four screws attaching the valve cover

with a #2 or #3 phillips screwdriver.

• Make sure the piston is at Top Dead Center (TDC)

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

• Loosen the rocker jam nut. Use an 10mm allen

wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge. Correct clearance is

0.002-0.004 inch (0.05-0.1 mm). See Figure 5.6.

NOTE:

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

Section 5 — Maintenance

Air-cooled 15 kW Generators

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

Figure 5.6 - Valve Clearance Adjustment

Pivot Ball

Jam Nut

• Install new valve cover gasket.

• Re-attach the valve cover.

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

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

• Repeat the process for the other cylinder.

Stud

NOTE:

Rocker

Arm

Valve Stem

5.9 COOLING SYSTEM

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

Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to quickly shut down. (See Figure 5.7 for vent locations.)

The exhaust from this product gets extremely



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

The maximum ambient temperature for the



generator is 48.9° C (104° F).

Figure 5.7 – Cooling Vent Locations

5.10 ATTENTION AFTER SUBMERSION

If the generator has been submerged in water, it MUST NOT be started and operated. Following any submersion in water, have an Authorized Dealer thoroughly clean and dry the generator.

5.11 CORROSION PROTECTION

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

5.12 OUT OF SERVICE PROCEDURE

5.12.1 REMOVAL FROM SERVICE



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

1. Start the engine and let it warm up.

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

and allow the unit to shut down.

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

oil fault.

4. Set the AUTO/OFF/MANUAL switch to OFF and

turn off the utility power to the transfer switch.

5. While the engine is still warm from running,

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

6. Attach a tag to the engine indicating the viscosity

and classification of the oil in the crankcase.

7. Remove the spark plugs and spray fogging agent

into the spark plugs threaded openings. Reinstall and tighten the spark plugs.

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

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

9. Clean and wipe the entire generator.

Section 5 — Maintenance

Air-cooled 15 kW Generators

5.12.2 RETURN TO SERVICE



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

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

2. Verify that utility power is turned off and that the AUTO/OFF/MANUAL switch is set to OFF.

3. Check the tag on the engine for oil viscosity and classification. Verify that the correct recommended oil is used in the engine (see "Enging Oil Requirements"). If necessary, drain and refill with the proper oil.

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

5. Clean and wipe the entire generator.

6. Remove the 5A fuse from the generator control panel.

7. Reconnect the battery. Observe battery polarity. Damage may occur if the battery is connected incorrectly. Replace the 5A fuse in the generator control panel.

8. Open the fuel shutoff valve.

9. Start the unit by moving the AUTO/OFF/MANUAL switch to MANUAL. Allow the unit to warm up thoroughly.

10. Stop the unit and set the AUTO/OFF/MANUAL switch to AUTO. Set the generator’s main circuit breaker to its ON (or CLOSED) position.

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

12. The generator is now ready for service.

NOTE:

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

Section 5 — Maintenance

Air-cooled 15 kW Generators

7 KW - 40 KW SMALL STANDBY GENERATOR SETS



Following is a recommended maintenance schedule for small standby and residential generator sets from 7 kW to 40 kW in size, and applies to gas engine driven units. 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 calendar time 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 man-

hours 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 the battery charger.

• Remove the negative battery cable.

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

from 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 wear-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 ONLY 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 an Authorized Service 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 an Authorized Service 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 an Authorized Service Dealer.

5 A comprehensive inspection of the generator set to insure it is properly serviced and ready to operate and carry

the load when required, and to identify any potential problem areas.

Performed annually or following each 250 hours of operation of the unit and requires approximately 6.0

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 an Authorized Service Dealer.

Section 5 — Maintenance

Air-cooled 15 kW Generators

Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks

mended Comp. Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- Required (Date- Semi- (Date- to be done (Date- Bi- (Date monthly/ Initials) to be done Initials) annually/ Initials) Annually/ Initials) annually/ Initials) 10 hrs. 6 months 50 hrs. 100 hrs. 250 hrs.

1. Disable the unit

from operating per the first page warning.

2. Check the engine

oil level. Adjust as necessary.

3. Check the natural

gas delivery system for leaks and correct pressure on gas engine driven units. Tighten connections as necessary.

4. Check the air

inlets and outlets for debris. Clean as necessary.

5. Check the battery

electrolyte level and specific gravity if accessible. Adjust as necessary.

6. Check the battery

posts, cables, and charger for loose connections, corrosion, and proper operation. Correct as necessary.

7. Check the unit

wiring for loose connections, corrosion, and damage. Correct as necessary.

8. Check the engine

valve clearance. Adjust as necessary.

9. Visually inspect

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

Recom- Task Task Required Task Task Required Task

Section 5 — Maintenance

Air-cooled 15 kW Generators

Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks

10. Test the engine

and transfer switch safety devices. Correct and/or adjust as necessary.

11. 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.

12. 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.

13. Perform an

engine oil analysis (send a sample to a lab for results). Change the engine oil and filters if the analysis results indicate this is required.

14. Change the *

engine oil.

15. Replace the *

engine oil filter(s).

Recom- Task Task Required Task Task Required Task

* Change oil and ﬁ lter after ﬁ rst eight (8) hours of operation and then every 100 hours thereafter. Change sooner when operating under a heavy load or in

a dusty or dirty environment or in high ambient temperatures.

Section 5 — Maintenance

Air-cooled 15 kW Generators

Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom- Task Task Required Task Task Required Task

16. Replace the

engine air filter(s).

17. Perform a 5

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

18. Return the unit

to standby setup for operation when required.

Section 6 — Troubleshooting

Air-cooled 15 kW Generators

6.1 TROUBLESHOOTING GUIDE

Problem Cause Correction

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

control panel.

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

3. Defective starter motor 3. *

4. Dead Battery 4. Charge or replace battery.

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

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

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

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

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

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

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

4. Fuel pressure incorrect. 4. Confirm fuel pressure is at 11-14” water column (0.4-0.5 psi) for LP, and 5-7” water column (0.18-0.25 psi) for natural gas.

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

continues to run. wired incorrectly

3. Defective control board 3. *

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

2. Generator internal failure 2. *

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

4. Defective control logic board 4. *

*Contact the nearest Authorized Dealer for assistance.

Section 7 — Mounting Dimensions

Air-cooled 15 kW Generators Drawing No. 0F5927

CUSTO

SP2

SP1

868585

DIAGRAM KE

GTS

OCK

SSU

1 - 20 Vac Sense Transformer

316

CIC

SCR

66A

OLDSW

55686

013A

351

229

66A

239

225

SW3

)

BA - BRUSH ASSEMBL

BCR - BATTERY CHARGE RELA

1 - 8 POSITION CONNECT

2 - 12 POSITION CONNECT

- 4 POSITION CONNECT

4 - 6 POSITION CONNECTI

B1 - MAIN OUTPUT BREAKE

CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATIO

D - DIOD DSW - PCB MOUNTED DIP SWIT

FS - FUEL SOLENOI

F1 - FUSE 5A BATTERY CHARGE

F2 - FUSE 15 AMP SYSTE

F3, F4 - FUSE 5A SENSIN

RD - CONTROL PANEL GROUN

- TRANSFER SWITCH CONTACT

HTO - HIGH OIL TEMPERATURE SWITC IC - INLINE CONNECT IM1 - IGNITION MODULE, CYLINDER #

IM2 - IGNITION MODULE, CYLINDER #

LOP - LOW OIL PRE

- STARTER CONTACT

R - STARTER CONTACTOR RELA

SP1, SP2 - SPARK PLUG

W1 - AUTO / OFF / MANUAL SWIT

W2 - SET EXERCISE SWIT

- DOOR ALARM SWIT

M - STARTER MOT

TB - INSULATED TERMINAL BL

TR - RELAY, TRANSFE

TS - TERMINAL STRI

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

VR1, VR2 - VARISTOR

XA1, XB1, XC1 - LIMIT SWITCHE

RE SWIT

Section 8 — Electrical Data

Air-cooled 15 kW Generators

Wiring Diagram – Drawing No. 0F5643-B Part 1

ENGINE WIRIN

HARGE

BLA

MER SUPPLIE

L.E.D - ALARM INDICATOR

PRINTED CIRCUIT BOAR

2 - Remote Not Aut

3 - 50 Hz Operatio

4 - SPAR

NTR

GRD

225

0239

66A

CLOSES

66A

351

162

66A

SW2

SW1

351

CB1

CB2

9229

66A

GRD

5A15A

910

Section 8 — Electrical Data

Air-cooled 15 kW Generators Wiring Diagram – Drawing No. 0F5643-B Part 2

NTROL PANEL B

T TO BEARIN

TAT

VOLTA

REGULAT

AUT

MANUA

TRAL

NNE

Section 8 — Electrical Data

GRD

COM+

RY5-

SIG

194

GRD

5A15A

COIL

GTS

COIL

2T1

Air-cooled 15 kW Generators

Wiring Diagram – Drawing No. 0F5643-B Part 3

TRANSFER SWIT

NEUTRA

BOAR

COM

REMOT

NAL

RY1 - ENGINE R

RY2 - SWITCH IN EMERGEN

RY3 - SWITCH IN AUT

RY4 - COMMON ALAR

RY6 - DOOR OPE

Section 8 — Electrical Data

(

)

C2-8

C2-7

CB2

C2-1

C1-3

C2-3

C1-6

C2-9

)

095J15

66A

351

C1-4

C2-2

SW2

66A

9423

66A

3A663

3A13

56VA

351

)

SW3

SSU

GTS

OCK

Air-cooled 15 kW Generators Electrical Schematic – Drawing No. 0F5844-B

ELECTRONI

VOLTA

REGULAT

224

HARGE

BATTERY CHAR

WINDIN

ENGINE R

WINDIN

TATOR

DPE WINDIN

STATOR

DIAGRAM KE

BA - BRUSH ASSEMBL

BCR - BATTERY CHARGE RELA

1 - 8 POSITION CONNECT

2 - 12 POSITION CONNECT

- 4 POSITION CONNECT

4 - 6 POSITION CONNECTI

B1 - MAIN OUTPUT BREAKE

CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATIO

D - DIOD FS - FUEL SOLENOI F1 - FUSE 5A BATTERY CHARGE F2 - FUSE 15 AMP SYSTE

F3, F4 - FUSE 5A SENSIN

- TRANSFER SWITCH CONTACT HTO - HIGH OIL TEMPERATURE SWIT IM1 - IGNITION MODULE, CYLINDER #

IM2 - IGNITION MODULE, CYLINDER #

LOP - LOW OIL PRE

NB - NEUTRAL BL

- STARTER CONTACT

R - STARTER CONTACTOR RELA

SP1, SP2 - SPARK PLUG

W1 - AUTO / OFF / MANUAL SWIT

W2 - SET EXERCISE SWIT

- DOOR ALARM SWIT

M - STARTER MOT

TR - RELAY, TRANSFE

TS - TERMINAL STRI

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

VR1, VR2 - VARISTOR

XA1, XB1, XC1 - LIMIT SWITCHE

RE SWIT

PRINTED CIRCUI

BOAR

NTR

Section 8 — Electrical Data

C1-1

C1-5

SCR

SP2

SP1

0SC0

SW115A

94FS

(

)

CB1

C2-5

C2-6

CUSTOMER

COM

COIL

COM

ONCNC

COIL

GTS

5239

COM+

SIG

COM-

COM

CNO

515

SW3

COM

0239

C1-2

C3-5

C3-1

C3-4

C3-2

C3-6

C3-3

C4-3

C4-2

515

Air-cooled 15 kW Generators

Electrical Schematic – Drawing No. 0F5844-B

AUT

152

POWE WINDIN STATOR

BOAR

REMOT

NAL

RY1 - ENGINE R

RY2 - SWITCH IN EMERGEN

RY3 - SWITCH IN AUT

RY4 - COMMON ALAR

RY6 - DOOR OPE

BLA

PPLIE

37253532

6315

214

Section 9 — Exploded Views and Parts Lists

Air-cooled 15 kW Generators Enclosure – Drawing No. 0F5845

Section 9 — Exploded Views and Parts Lists

Air-cooled 15 kW Generators

Enclosure – Drawing No. 0F5845

ITEM PART NO. QTY. DESCRIPTION

1 0C6140 1 ASSEMBLY, ENCLOSURE BASE 2 0C6735 2 SUPPORT, ROOF FOLDING 3 0F0063 1 ENCLOSURE, FRONT 4 0C7062 1 ENCLOSURE, EXHAUST SIDE 5 0F5629 1 ENCLOSURE, SIDE & BACK 6 0E9873 1 ENCLOSURE, ROOF 7 0C7065 1 PANEL, ALTERNATOR DIVIDER 8 0C8101A 1 PANEL, MUFFLER BOX SIDE 9 0C8101B 1 COVER, MUFFLER BOX 10 0C8283 1 GASKET, DOOR SEAL 11 0C8284A 1 FOAM, BACK ENCLOSURE 12 0C8284B 1 FOAM, ROOF ENCLOSURE 13 0C8284C 1 FOAM, FRONT ENCLOSURE 14 0C8285 1 BRACKET, BATTERY SUPPORT 15 0C8899A 1 PAD, 24"X48" WITH MOUNTING HOLES 16 0F5630 1 PANEL, ENGINE DIVIDER 17 0E4244 1 BAFFLE, INTAKE 18 0D1606 1 HOUSING, FAN 19 0D1839 2 BRACKET, TOP SUPPORT 20 0D1840 2 BRACKET, BOTTOM SUPPORT 21 0D2425 1 DUCT, BASE AIR 22 0D2588 1 GASKET, FRONT DIVIDER 23 0D2676 1 COVER, FRONT EXHAUST ENCLOSURE 24 0D2677 1 COVER, BACK EXHAUST ENCLOSURE 25 0D2979B 2 CLOTH, HARDWARE 266.7mm x 146mm 26 0D2979C 1 CLOTH, HARDWARE 543mm x 146mm 27 0D2979D 1 CLOTH, HARDWARE 266.7mm x 387.4mm 28 0E4245 1 FOAM, FRONT INTAKE BAFFLE 29 0E4245A 1 FOAM, TOP INTAKE BAFFLE 30 0E4245B 1 FOAM, BACK INTAKE BAFFLE 31 0D3057D 1 FOAM, BACK ENCL. STRIP 32 0D3059A 1 FOAM, EXHAUST SIDE ENCLOSURE END 33 0D3059B 1 FOAM, EXHAUST SIDE ENCLOSURE

FRONT

34 0D3059C 1 FOAM, EXHAUST FAN HOUSING 35 0D7176 24 WASHER, SELF LOCKING 36 0D3059D 1 FOAM, FRONT EXHAUST ENCLOSURE

COVER

37 0D3059E 1 FOAM, BACK EXHAUST ENCLOSURE

COVER 38 0C7781A 2 DOOR, PAWL 39 0D3037 1 LATCH, QUARTER TURN LOCKING 40 0F0164 1 HINGE TYPE A WITH STUDS, PIN

ITEM PART NO. QTY. DESCRIPTION

41 0F0165 1 HINGE TYPE B WITH STUDS, PIN 42 0D3037A 1 LATCH, QUARTER TURN NON-LOCKING 43 0A2115 4 WASHER NYLON .250" 44 022145 8 WASHER FLAT 5/16 45 042907 4 SCREW HHC M8-1.25 X 16 G8.8 46 0F0710 14 RIVET POP 0.125 X 0.337 47 047411 6 SCREW HHC M6-1.0 X 16 G8.8 48 043116 4 SCREW HHC M6-1.0 X 12 G8.8 49 0D3700 26 NUT, LOCKING FLANGE M6-1.0 50 0D4662 11 SCREW HHTT M8-1.2 X 20 BP 51 090388 36 SCREW TAPTITE M6-1.0 X 12 BP 52 092120 2 NUT LOCK TRIC M6 X 1.0 Y/ZNC 53 0F5633 1 ASSEMBLY, TRANSFER SWITCH 54 0D3167 1 GASKET, BATTERY SUPPORT BRACKET 55 0A3328 1 PLUG, PLASTIC 0.593 56 055414 1 LUG SLDLSS #2-#8X17/64 CU 57 092079 1 SCREW TAPTITE M6-1.0X25 BP 58 0A1658 2 L/WASH SPECIAL ¼ 59 042907 2 SCREW HHC M8-1.25 X 16mm 60 0E9692 1 BRACKET, REGULATOR MOUNTING 61 0E1330A 1 GROMMET, 38.1 CROSS SLIT WITH HOLE 62 0E4321 1 PANEL, EXHAUST ALIGNMENT 63 022129 10 WASHER LOCK 5/16 64 074908 8 SCREW TAPTITE M5-0.8 X 10 BP 65 0D2346 1 HARNESS, ENGINE 66 023484F 1 BUSHING, SNAP SB-1000-12 67 0C3906 2 SELF-ALIGN SCREW M6 HH 68 0A7836 2 RIVET,1/8" X 0.126" - 0.375" LSH POP

0A8475 2 L/WASH SPECIAL #10

69 70 0912970069 1 ASSEMBLY, ROOF / DOOR GROUND WIRE 71 0912970070 2 ASSEMBLY, ROOF / DOOR GROUND WIRE 72 055450 1 PLUG PLASTIC 1.375 73 0E5968 11 GASKET, EXTRUDED TRIM 74 0D3701 1 PLATE, "HOT" 75 0D3472 1 GROMMET 2.75 X 1/16 76 0E2874 1 SCREW HHTR 1/4-20 X 3/4 77 043107 4 SCREW HHC M8-1.25 X 25 78 0F5681 1 HARNESS 79 0F0164A 1 HINGE TYPE A WITH STUDS, SOCKET 80 0F0165A 1 HINGE TYPE B WITH STUDS, SOCKET 81 045771 4 NUT HEX M8-1.25 82 0D3031 1 FUEL LINE, 3/4"OUTDOOR (NOT SHOWN)

Section 9 — Exploded Views and Parts Lists

Air-cooled 15 kW Generators Control Panel – Drawing No. 0F5846

Section 9 — Exploded Views and Parts Lists

Air-cooled 15 kW Generators

Control Panel – Drawing No. 0F5846

ITEM PART NO. QTY. DESCRIPTION

1 0E7886G 1 CIRCUIT BREAKER 70A X 2P 240V (15KW) 2 0A1801 1 ASSEMBLY, BATTERY CHARGER ENGINE 3 083049 1 ASSEMBLY, POTTED REGULATOR 4 0C2174 1 RELAY, 12V 25A SPST 5 075210A 2 BLOCK 1 POSITION 6 0D3062 4 HEX STAND-OFF #6-32 x 3/8" 7 0D8615 1 ASSEMBLY, HOME STANDBY CONTROLLER 8 032300 2 HOLDER, FUSE 9 022676 1 FUSE, 15AMP X AGC15 10 0E4494 1 SWITCH, ROCKER DPDT ON-OFF-ON 11 0E7890 1 CIRCUIT BREAKER MOUNTING BRACKET 12 023484E 1 SNAP BUSHING 13 075476 4 SCREW PPHM M4-0.7 x 16mm 14 0F4793 2 SCREW PPHM M3-0.5 x 10mm 15 0E6480 6 NUT HEX LOCK M4-0.7 NYLON INSERT 16 023897 2 WASHER FLAT #10 17 0C1085 4 SCREW PPHM M 18 0D8443 1 DECAL, CONTROL PANEL (NOT SHOWN) 19 054502 1 CIRCUIT BREAKER 3 X 1 ETA 46-500-P 20 0F5747 1 CONTROL, PANEL BOTTOM 21 075235 4 SCREW HHC M5-0.8 x 30mm 22 0D5240 1 SWITCH, SPST (ON)-ON N/O 23 0D9784 6 NUT HEX LOCK M3-0.5 NYLON INSERT 24 0D8502 1 NEUTRAL CONNECTOR 25 031879 6 WASHER FLAT #4 26 0F5679 1 HARNESS, CONTROL PANEL (NOT SHOWN) 27 074908 4 SCREW TAPTITE, M5-0.8 x 10 BP 28 049813 1 NUT HEX M6-1.0 29 082025 6 NUT HEX LOCK M5-0.8 NYLON INSERT 30 0C3910 1 TRANSFORMER 31 022507 2 SCREW HHC 1/4"-20 x 1/2" 32 099727 1 FUSE 5A X AGC5 33 046689 1 BLOCK TERMINAL STRIP 20A 4 X 6 X 1100V 34 063617 1 RELAY PANEL 12VDC DPDT 10A 240VAC 35 075475 2 SCREW PPHM M4-0.7 x 10mm 36 043180 2 WASHER FLAT M4 37 0D8439 1 COVER, CONTROL PANEL COMPONENT 38 092036 8 SCREW PPHMS/LW #6-32 x 1/4" 39 045770 2 SCREW HHC M5-0.8 x10mm 40 0E7866 1 COVER, CONTROL PANEL 41 0D3700 8 NUT FLANGE M6-1.0 NYLOK 42 0912970069 1 ASSEMBLY, ROOF/DOOR GROUND WIRE 43 0E2874 1 SCREW HHTR 1/4"-20 X 3/4" 44 0A1658 2 WASHER LOCK SPECIAL 1/4" 45 022473 3 WASHER FLAT 1/4"-M6 46 038750 1 SCREW HHC M6-1.0 x 30mm 47 022097 3 WASHER LOCK M6-1/4" 48 027770 2 SCREW RHM #4-40 X 5/8" 49 027771 2 NUT HEX #4-40 50 043182 2 WASHER LOCK M3 51 084464 1 LIMIT SWITCH OPERATION 52 042632 1 GROMMET 1/2 X 1/16 X 3/8

3-0.5 X 8mm

Section 9 — Exploded Views and Parts Lists

Air-cooled 15 kW Generators GT-990 Engine – Drawing No. 0E8774-Q Part 1

Section 9 — Exploded Views and Parts Lists

Air-cooled 15 kW Generators

GT-990 Engine – Drawing No. 0E8774-Q Part 1

ITEM PART NO. QTY. DESCRIPTION

1 0C5729 1 ASSEMBLY, CRANKCASE HOUSING WITH

SLEEVE

2 0E9843 1 SEAL, 38 I.D. CRANKSHAFT 3 090388 3 SCREW, TAPTITE M6-1.0 X 12 YC 4 0C5372 1 ASSEMBLY, BREATHER 5 0C3005 1 GASKET, BREATHER COVER 6 0E3372B 1 SEPARATOR, OIL BREATHER 7 0D8067A 1 ASSEMBLY, HEAD #1 G&S 8 071983 4 RETAINER, PISTON PIN 20 9 0C2981C 1 ROCKER, COVER NO OIL FILL 10 045761A 4 STUD M8-1.25/10MM X 30 G5 ZINC 11 0E2985 2 PISTON, HC 12 021533 2 SET, PISTON RING 90MM 13 0E1466 2 PIN PISTON 14 0D4041 1 ASSEMBLY, CAMSHAFT & GEAR 15 0C2983 1 SHAFT, GOVERNOR 16A 0C2985A 2 ROLLER BEARING, GOVERNOR PLATE 16B 0C2985B 1 ROLLER BEARING, GOVERNOR 17 0D4042 1 ASSEMBLY,GOVERNOR GEAR 18 0A7811 1 SPOOL, GOVERNOR MACHINED 19 0C2977 1 GASKET, CRANK CASE 20 0C5943 1 SEAL, OIL PASSAGE 21 0G0140E 1 ASSEMBLY, CRANKSHAFT HORIZONTAL

DIRECT DRIVE 22 0E3223 2 ASSEMBLY, CONNECTING ROD 23 0D2157 2 SCREW SHC M6-1.0 X 50 G8.8 24 0E6098 1 SCREEN, OIL PICKUP 25 0G1536 1 ASSEMBLY, OIL PUMP 26 0E8152 1 O-RING .49 ID X .07 THICK 27 0C3011 2 COVER, OIL RELIEF 28 0C3009 2 SPRING, OIL RELIEF 29 0C3010 2 BALL, 1/2D OIL RELIEF 30 093873 2 WASHER, LOCK RIB M6

31 0F5458 1 SCREW, PLASTITE HI-LOW #10 32 0C5998 1 CLAMP, OIL TUBE 33 0D1667 1 ARM, GOVERNOR 34 0C2991 2 E-RING, GOVERNOR ARM 35 0C2988 1 THRUST WASHER, GOVERNOR

ITEM PART NO. QTY. DESCRIPTION

36 0C2992 1 BUSHING, GOVERNOR LOWER 37 0C3971C 1 ASSEMBLY, DIPSTICK WITH HANDLE 38 0C5305 1 TUBE, DIPSTICK 39 0C3027 1 O-RING, OIL CLR 3/8 X 1/2 40 0E9842 1 SEAL, 42 I.D. CRANKSHAFT 41 0C5731 1 ASSY, HS COVER W/SLV 42 0C3006 9 SCREW, HHFC M10-1.5 X 55 43 080318 8 SCREW HHFC M6-1.0 X 25 44 093064 1 ASSEMBLY, OIL FILL CAP 45 0G1839 2 LIFT HOOK, GT990/760 46 0D2723B 1 ROCKER, COVER WITH OIL FILL 47 0C2979 2 GASKET, VALVE COVER 48 086515 8 KEEPER, VALVE SPRING 49 0D2274 4 RETAINER, VALVE S 50 0D3867 4 SPRING, VALVE 51 078672 2 SEAL, VALVE STEM D7 52 0C5371 4 WASHER, VALVE SPRING 53 072694 4 STUD, ROCKER ARM PIVOT 54 0D3998 4 NUT HEX M8-1.0 G8 YEL CHR 55 0C3027 2 O-RING, 3/8” X 1/2” 56 0D5313 4 ROCKER ARM 57 0D6024 2 PLATE, PUSH ROD GUIDE 58 0C2976 12 SCREW HHFC M8-1.25 X 65 59 086516 2 VALVE, EXHAUST 60 0C2229 2 VALVE, INTAKE 61 083897 4 TAPPET, SOLID 62 0D8067B 1 ASSEMBLY, HEAD #2 G&S 63 0D9853D 4 PUSHROD, 147 64 0C2978 2 GASKET, HEAD 65 043790 1 BARBED ELBOW 66 0D4010 1 KIT GASKET 67 0D4011 1 KIT PISTON & RINGS 68 0D4012 1 KIT BREATHER ASSEMBLY 69 0D4013 1 KIT GOVERNOR ASSEMBLY 70 0D8675A 1 KIT HEAD ASSEMBLY CYLINDER 1 71 0D8675B 1 KIT HEAD ASSEMBLY CYLINDER 2 72 0D4015 1 KIT OIL RELIEF 73 0D4016 1 KIT GEAR COVER

PRING

90 3/8NPT X 3/8

Section 9 — Exploded Views and Parts Lists

Air-cooled 15 kW Generators GT-990 Engine – Drawing No. 0E8774-Q Part 2

Section 9 — Exploded Views and Parts Lists

Air-cooled 15 kW Generators

GT-990 Engine – Drawing No. 0E8774-Q Part 2

ITEM PART NO. QTY. DESCRIPTION

74 0C5136A 2 KNOB, AIR CLEANER 75 0C3024 1 COVER, AIRBOX NG/LP 76 0C3040 1 PRE-CLEANER, 77 0C8127 1 ELEMENT, AIR CLEANER 78 0D8564A 1 ASSEMBLY, MIXER/AIRBOX 990 0D8564B 1 ASSEMBLY, MIXER/AIRBOX 760 79 0D2595 4 SCREW SHOULDER (8MM) M6-1.0 X 18 80 0D4417 4 WASHER,RUBBER 1/4" X 1/8" THICK 81 0C3025 1 SWITCH, OIL PRESS 82 0D3083 1 ASSEMBLY, OIL DRAIN HOSE 83 0C7292 1 NIPPLE, 3/4"-16 UNF 84 070185B 1 OIL FILTER 85 075281 1 SWITCH, THERMAL 284F 86 0F2094 2 SCREW, M3-0.5 X 6 SEMS 87 88 035461 2 BARBED STR 1/4NPT X 3/8 89 0F6301 4 CLAMP, HOSE OETIKER 16.5mm 90 0G0286 2 HOSE, 3/8" I.D. X 6" LG SAE J30R9 91 0C3026 1 COOLER, OIL 92 0C9764 4 PLASTITE,1/4-15 X 3/4 93 0C3043 2 GASKET, MANIFOLD / PORT 94 0C7694 1 MANIFOLD CYLINDER 2 95 0C7693 1 MANIFOLD CYLINDER 1 96 0C3041A 2 SLEEVE, RUBBER 97 070008 4 WASHER FLAT M8 SS 98 070006 4 WASHER LOCK M8 SSTL 99 040976 4 SCREW S 100 0C3016A 1 PLATE, BACKING WITH OIL COOLER 101 0E4997 1 GROUND WIRE CONNECTOR 102 0C3725B 1 FLYWHEEL ASSEMBLY 103 0C3031 1 FAN, NYLON 104 0C3032 1 PLATE, FAN 105 0A5992 2 WASHER SHAKEPROOF INT M8 SS 106 051754 2 SCREW HHC M8-1.25 X 12 G8.8 107 0C3033 1 WASHER, 25mm I.D. 108 0C3034 1 NUT,HEX M24 109 0C8549A 1 SNORKEL, AIR INTAKE

HC M8-1.25 X 20 G12.9

ITEM PART NO. QTY. DESCRIPTION

110 0C3022A 1 HOUSING, BLOWER NG COOLER 111 0D1131 1 GUARD, FAN 112 045756 25 SCREW TAPTITE M6-1X10 YELLOW

CHROME 113 0C9763 4 NUT, GROMMET 1/4 PLUG 114 0C3036A 1 HOSE, BREATHER 115 022145 1 WASHER FLAT 5/16-M8 ZINC 116 022129 1 WASHER LOCK M8-5/16 117 0C3018 1 WRAPPER, UPPER CYLINDER 1 118 0C3019 1 WRAPPER, LOWER CYLINDER 1 119 0D1142A 1 WRAPPER, LOWER CYLINDER 2 120 0D1143 1 WRAPPER, UPPER CYLINDER 2 121 0E6043 2 SCREW TAPTITE M5-0.8 X 8 ZP 122 0F1177 1 ASSEMBLY, GROUND WIRE 123 0C3052 1 ASSY, IGNITION COIL GV-990 CYLINDER 2 124 022097 4 WASHER LOCK M6-1/4 125 092079 4 SCREW TAPTITE M6-1.0 X 25 BP 126 0E4271 1 STARTER 127 0D4529 2 SPARKPLUG 128 022129 2 WASHER LOCK M8-5/16 129 061906 2 SCREW HHC M8-1.25 X 85 G8.8 1 30 082774 1 KEY, WOODRFF 4 X 19D 1 31 0E5343 1 NUT HEX LOCK M10-1.50 1 32 0C8468 1 SPRING, ANTI-LASH 1 33 0C3048 1 ROD, GOVERNOR CONTROL 1 34 0D3754 1 ASSEMBLY, GOVERNOR LEVER 1 35 0D3742 1 SPRING, GOVERNOR 1 36 0C8482 1 ASSEMBLY, GOVERNOR ADJUSTER 1 37 0E0486 1 SCREW SHC M10-1.5 X 75 G10.9 1 38 0D3743 1 SPRING, GOVERNOR IDLE 1 39 0D3705 1 ASS

140 0C2993 1 SEAL, GOVERNOR SHAFT 142 045771 1 NUT HEX M8-1.25 G8 143 0D6147 7 SCREW HHFC M6-1.0 X 10mm 144 0E8152 1 O-RING 0.49” I.D. X 0.07” THICK 145 0E7743 1 ASSY, IGNITION COIL 270mm CYLINDER 1

EMBLY, GOVERNOR ADJUSTER

BRACKET

Section 9 — Exploded Views and Parts Lists

Air-cooled 15 kW Generators 15 kW Generator – Drawing No. 0D3417-L

498

Section 9 — Exploded Views and Parts Lists

Air-cooled 15 kW Generators

15 kW Generator – Drawing No. 0D3417-L

ITEM PART NO. QTY. DESCRIPTION

1 0C6934 1 ADAPTOR, ENGINE 2 0C7930 1 STATOR 12KW 0D2359 STAT O R 1 3KW / 15KW 3 0C7944 1 ROTOR 12KW 0D2356 ROTOR 13KW / 15KW 4 0C6043 1 CARRIER, REAR BEARING 5 0D2336 1 FAN, 12” CURVED BLADE 6 0D6634 1 MUFFLER 7 0D3220 1 TAIL PIPE, MUFFLER 8 0C8101 1 PANEL, MUFFLER BASE 9 056482 1 BEARING 1.1811-2.8346 10 0C3168 3 5/16 SPECIAL LOCK WASHER 11 0D1838 1 BOLT, HHCS 3/8”-24 x 15.50” 12 0D1846 4 BOLT, HHCS M8-1.25 x 345mm 13 0C7038 1 BRACKET, ALTERNATOR MOUNTING 14 0D1609 1 DUCT, ALTERNATOR AIR 15 0D2559 1 GASKET, ALTERNATOR AIR DUCT 16 0C7038A 1 BRACKET, ENGINE MOUNTING 17 0C775 18 0388050AD0 1 CABLE, #6 48” BLACK BATTERY 19 0C2417A 1 EARTH STRAP 3/8X 3/8 20 082121C 1 CLIP-J, VYNL COAT 0.625” ID 21 066386 1 ASSEMBLY BRUSH HOLDER 22 029451 2.6 FT TAPE ELEC UL FOAM 1/8 X 1/2 23 049451 1 WASHER FLAT .406ID X 1.62OD 24 022237 5 WASHER LOCK 3/8 25 022511 4 SCREW HHC 3/8-16 X 1-1/4 G5 26 022131 4 WASHER FLAT 3/8 ZINC 27 051731 4 SCREW HHC M8-1.25 X 50 G8.8 28 022145 12 WASHER FLAT 5/16 ZINC 29 049820 4 NUT LOCK HEX M8-1.25 NYL INSERT 30 045756 2 SCREW TAPTITE M6-1.0X10 BP 31 022129 10 WA 32 022259 8 NUT HEX 5/16-18 STEEL 33 059637 2 SCREW TAPTITE 3/8-16 X 3/4 BP 34 0D4662 4 SCREW 5/16-18X3/4” HH THD ROLL 35 0F7065 3 FT HOSE RES 1/2 LP GAS 36 048031M 4 HOSE CLAMP 3/4” I.D. 37 0F0462 4 NUT HEX W/TOOTH WSHR M8-1.25 38 0C2824 1 SCREW TAP-R #10-32 x 9/16 39 025145 1 U-BOLT 5/16”-18 X 1.25” WITH SADDLE 40 0C4138 2 GASKET, EXHAUST PORT 41 040173 2 CLAMP HOSE #5.5 0.62”-0.62” 42 074995 1.44 FT HOSE 1\4 ID LPG 350PSI UL21 43 066849 2 SCREW HHTT M5-0.8 X 16

8 4 RUBBER MOUNT

SHER LOCK M8-5/16

Section 9 — Exploded Views and Parts Lists

Air-cooled 15 kW Generators Gas Regulator – Drawing No. 0D8720-H

7KW

Section 9 — Exploded Views and Parts Lists

Air-cooled 15 kW Generators

Gas Regulator – Drawing No. 0D8720-H

ITEM PART NO. QTY. DESCRIPTION

1 0D5694 1 CASTING, TWIN REGULATOR HOUSING 2 0F5022 1 SOLENOID COIL, 12VDC 3 0C4647 1 GASKET , SOLENOID 4 0D4166 1 PLUNGER, LP REGULATOR ASSEMBLY 5 0C6070 1 SPRING-SOLENOID, PLUNGER 8 0F4795 4 SCREW PPHM SEMS M4-0.7 X 10 9 0C5760J 1 JET, GN 410 ENGINE LP (7KW) 10 0C6606 2* BARBED STRAIGHT 1/2NPT x 1/2 11 097934 2* O-RING, CHECK VALVE 12 0C4645 2* ADJUSTER SCREW, TWIN REGULATOR 13 0C5761 2 LEVER, REGULATOR 14 0C5968 2 SUPPORT, INLET SEAL 15 0C6066 2 SEAL, INLET 16 0C5759 2 PIN, PIVOT ARM 17 0C5764 2 SPRING, REGULATOR 0C5764A 2 SPRING, REGULATOR (7KW) 18 070728 4 SCREW, PFHMS M3-0.5 x 5 19 0C6069 2 GASKET, DIAPHRAGM 20 0C5762 2 COVER, TWIN REGULATOR 21 045764 16 SCREW, TAPTITE M4X8 BP 22 0C67 23 0C6067 2 SUPPORT, DIAPHRAGM 24 0C4706 2 DIAPHRAGM, TWIN REGULATOR 25 0C6068 2 CAP, DIAPHRAGM SUPPORT 26 0C4643A 2 INLET, TWIN REGULATOR 11.11 DIA. 27 026073 1 PLUG, STANDARD PIPE 1/8” STEEL SQUARE HEAD 026073 2 PLUG, STANDARD PIPE 1/8” STEEL SQUARE HEAD (7KW) 28 0A4032 2* PIN, LIMITED ADJUSTMENT 29 0D3308 4 WASHER, FLAT M3 X 10mm O.D. 30 024310 1 PLUG, STANDARD PIPE 1/2” STEEL SQUARE HEAD (7KW) 31 028414A 1 BARBED STRAIGHT 1/8”NPT X 1/4” 32 0D5698A 1 JET IDLE PRIMER PHILLIPS HD (V-TWIN ONLY) 37 0D3973 1 PLUG, EXPANSION 16mm

31 2 RIVET, POP .118 X .125

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

Section 9 — Exploded Views and Parts Lists

Air-cooled 15 kW Generators Transfer Switch – Drawing No. 0F5633$-A

Section 9 — Exploded Views and Parts Lists

Air-cooled 15 kW Generators

Transfer Switch – Drawing No. 0F5633$-A

ITEM PART NO. QTY. DESCRIPTION

1 0D9618 1 TR SW-HSB 200A 2P 250V 2 0E3375 6 LUG SLDLSS 250-#6 AL/CU 3 0F1252 6 SCREW BHSC 1/4-20 X 3/8 4 022097 6 WASHER LOCK M6-1/4 5 074908 5 SCREW HHTT M5-0.8 X 16 BP 6 045771 1 NUT HEX M8-1.25 G8 YEL CHR 7 057329 1 LUG SLDLSS 350-#6 X 13/32 AL/CU 8 027482 1 WASHER SHAKEPROOF EXT 5/16 STL 9 022129 1 WASHER LOCK M8-5/16 10 073590A 2 FUSE 5A X BUSS 11***** 073591 2 FUSE HOLDER 12 090388 2 S 13 0A1495 4 SCREW HHTT M4-0.7 X 10 BP 14***** 063617 1 RELAY PNL 12VDC DPDT 10A@240VA 15 0C2454 2 SCREW TH-FRM M6-1 X 16 N WA Z/JS 16 0A1661 2 RIVET POP .156 X .675 AL 17 0C4449A 1 ASS’Y-NTRL BL150-200A 18 0F5634 1 WELDMENT XFER SW BOX HSB 19 0E6056 1 COVER TRANSFER SWITCH BOX HSB 20**** 0F0668 1 DECAL TRANSFER SWITCH 21 0C2262 1 DECAL TERMINAL STRIP 22*** 095282 1 DECAL-LIVE CIRCUIT 23 027770 2 SCREW RHM #4-40 x 5/8 24 064101 4 NUT LOCK FL 3/8-16 25 0F5694 1 SUBPLT TRANSFER SWITCH HSB 26***** 063378 3 HOLDER CABLE TIE 27***** 028739 5 TIE WRAP UL 3.9” X .10” NATL 28 0F5893 1 DECAL TRANSFER SWITCH DATA 200

9 067210A 1 DECAL GROUND LUG

2 30 0A9457 1 DECAL NEUTRAL 31 0A9517 1 DECAL MANUAL 5A FUSE 32 * 0E6190 1 DECAL TEST SEQUENCE 2P TS 3R 33 081221 1 DECAL-UL LIST HSB 34 0E6193 1 BRACKET ARM EXTENDER 35 064526 2 SCREW HWHS #6-25 X 3/8 ZNC 36 ** 0E6155 1 ARM EXTENDER PIN 37 0F5748 1 HARN 100/200A 2P HS 38 ** 0E6033 2 90 DEGREE DN SPADE CONNECTOR 39 0E6303B 1 WIRE E1 40 0E6303 1 WIRE A 41 0E6303A 1 WIRE B 42 0F5770 1 DECAL TERMINAL STRIP 43 020757 1 ALARM PCB 44 0D3062 4 HEX PCB SUPPORT, SCREW-IN 45 092036 8 #6-32 x 0.25” PPH W/ LOCK 46 048850 1 ASSY. TERM. BLOCK 20A 5 x 1100VAC 47 084464 1 LIMIT SW-SW OPERATION 48 043182 2 WASHER LOCK M3

CREW HHTT M6-1.0 X 12 ZINC

* CENTER DECAL ON INSIDE OF THE COVER (ITEM #19) ** SUPPLIED WITH TRANSFER SWITCH (ITEM #1). *** PLACE DECAL ON OUTSIDE OF COVER, LOWER RIGHT CORNER. **** NOT SHOWN ON THIS ASSEMBLY, CENTER DECAL ON FRONT OF COVER, 7” FROM TOP OF ENCLOSURE. ***** SUPPLIED WITH HARNESS (P/N 0F5748)

Section 10 – Warranty

Air-cooled 15 kW Generators

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

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new engine.* 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.

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

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

1-800-333-1322

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

Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service, evidence must be presented showing the date of the sale to the original purchaser/owner.

If there are any questions regarding the warranty rights and responsibilities, contact Generac at the following address:

ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS, INC. P.O. BOX 340 EAGLE, WI 53119

Part 1

Section 10 – Warranty

Air-cooled 15 kW Generators

EMISSION CONTROL SYSTEM WARRANTY

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

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

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

(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

warranted 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 responsible

for diagnostic costs if the repair is deemed warrantable.

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

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

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

to meet the expected demand for such emission-related parts.

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

Warranty maintenance or repairs and will be provided without charge to the 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:

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

* 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

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

Section 10 – Warranty

Air-cooled 15 kW Generators

GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR

HOME STANDBY/LIGHT COMMERCIAL PRODUCT 45kW AND BELOW

For a period of two (2) years from the date of sale, or start-up by Authorized/Certified Generac Power Systems Dealer, or branch thereof, Generac Power Systems, Inc. will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or an Authorized/Certified Generac Power Systems Dealer, or branch thereof, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Authorized/ Certified Generac Power Systems Dealer, or branch thereof. This warranty applies only to Generac Power Systems Generators used in "Standby" applications, as Generac Power Systems, Inc. has defined Standby, provided said generator has been properly installed and inspected on-site by appropriate personnel. Scheduled maintenance, as outlined by the generator owner's manual, is highly recommended. This should be performed by an Authorized/Certified Generac Power Systems Dealer, or branch thereof. This will verify service has been performed on the unit throughout the warranty period.

WARRANTY SCHEDULE

YEARS ONE and TWO — Limited comprehensive coverage on mileage, labor, and parts listed.

• - ALL COMPONENTS *Start-up and/or On-line Registration, or Registration Card, along with Proof of Purchase, must be performed and/or sent in.

Guidelines:

• Any and all warranty repairs and/or concerns, must be performed and/or addressed by an Authorized/Certified Generac Power Systems Dealer, or branch thereof.

• A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a Non - Generac Power Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the genset, no warranty coverage shall apply.

• All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty, Policies, and Procedures Flat Rate Manual.

• Units that have been resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable.

• Unit enclosure is only covered against rust or corrosion the first year of the warranty provision.

• Use of Non-Generac replacement part(s) will void the warranty in its entirety.

• Engine coolant heaters (block-heaters), heater controls and circulating pumps are only covered during the first year of the warranty provision (If applicable).

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

1. Any unit built/manufactured prior to January 1, 2005.

2. Costs of normal maintenance (i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up).

3. Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze.

4. Units sold, rated or used for "Prime Power", "Trailer Mounted" or "Rental Unit" applications as Generac Power Systems have defined Prime Power,

Trailer Mounted or Rental Unit. Contact a Generac Power Systems Distributor for Prime Power, Trailer Mounted or Rental Unit definition and warranty.

5. Units used for prime power in place of existing utility power where utility is present or in place of utility power where utility power service does not

normally exist.

6. Failures caused by any external cause or act of God such as, but not limited to, collision, fire, theft, freezing, vandalism, riot or wars, lightning,

earthquake, windstorm, hail, volcanic eruption, water or flood, tornado, hurricane, terrorist acts or nuclear holocaust.

7. Products that are modified or altered in a manner not authorized by Generac Power Systems in writing.

8. Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing.

9. 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).

10. Failure due to misapplication, misrepresentation, or bi-fuel conversion.

11. Telephone, facsimile, cell phone, satellite, internet, or any other communication expenses.

12. Rental equipment used while warranty repairs are being performed (i.e. rental generators, cranes, etc.).

13. Overtime, holiday, or emergency labor.

14. Planes, ferries, railroad, busses, helicopters, snowmobiles, snow-cats, off-road vehicle or any other mode of transportation deemed abnormal.

15. Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct

cause of the problem.

16. Starting batteries, fuses, light bulbs, engine fluids, and overnight freight cost for replacement part(s).

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC POWER SYSTEMS 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 purchaser/owner.

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

Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/ owner. Purchaser/owner agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gives purchaser/owner specific legal rights. Purchaser/owner also may have other rights that vary from state to state.

Generac Power Systems, Inc. • P.O. Box 8 • Waukesha, WI 53187

Part No. 0F5631 Revision C (12/07/06) Printed in U.S.A.

Ph: (262) 544-4811 • Fax: (262) 544-4851

Bulletin 0171360SVE / Printed in U.S.A. 7.05

Generac Power Systems 05176-0 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual