CARRIER Home Generator Manual L0520292

User Manual: CARRIER CARRIER Home Generator Manual CARRIER Home Generator Owner's Manual, CARRIER Home Generator installation guides

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I

Air-coo_ed Automatic

Standby Generators

Mode_: ASPA×I CCA015

(13 kW NG, 15 kW LP)

©

*This manua_ should remain with the unit.*

Not intended for use as Primary Power in place of utility

or in life=support applications.

DEADLY EXHAUST FUMES. OUTDOOR iNSTALLATiON ONLY!

Thank you for purchasing this model of tile Carrier

product line. This model is a compact, high per%f-

inance, air-cooled, engine-driven generator designed

to automatically supply electrical power to operate

critical loads during a utility power failure.

This unit is factory installed in an all-weather, metal

enclosure that is intended exclusively for outdoor

installation. This generator will operate using either

vapor withdrawn liquid propane (LP) or natural gas

(NG).

This unit meets the 1998 and later California

emissions regulations. To ensure that the engine

continues to meet these regulations, refer to the

following information and instructions in this

owner's manual.

@R[AD Tills MANUAl THOROUGHLY

If any portion of this manual is not understood,

contact the nearest dealer for starting, operating and

servicing procedures.

ThrolNllout tiffs publication, and on tags and decals

affixed to tlle generator, DANGER, WARNING,

CAUTION and NOTE blocks are used to alert person-

nel to special instructions about a particular opera-

tion that may be hazardous if performed incorrectly

or carelessly. Observe them carefully. Tlleir defini-

tions are as lhllows:

After this heading, read instructions that, if not

strictly complied with, wilt resuR in serious per-

sonal injury, including death, in addition to severe

propertydamage.

WARNING

After this heading, read instructions that, if not

strictly complied with, may resuJt in serious per-

sonal injury or property damage.

CAUTION

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 haz-

ards 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 sy_nbols accompany the

[)ANGER, WARNING and CAUTION blocks. The type

of inlhrmation each indicates follows:

Z_ This symbol points out important safety infor-

mation that, if not followed, could endanger

personal safety and/or property of others.

This symbol points out potential explosion haz-

ard,

/_k This symbol points out potential fire hazard,

Z_ This symbol points out potential electrical shock

hazard.

The operator is responsible for proper and sale use

f the equipment. The manufacturer strongly recom-

mends that the operator read this Oumeis Manua_

and thoroughly understand all instructions belbre

using this equipment. The manufi_eturer also strong-

ly recommends instructing other users to properly

start and operate the unit. This prepares thenl if they

need to operate the equipment in an emergene_t

This manual contains pertinent owner's information,

including warranty; electrical diagrams, exploded

views and lists of repair parts, for modeh

o Model ASPAXICCA015 - 13 kW NG, 15 kW LP, V;

hvin G_ft990 Engine

OPERATION AND MAINTENANCE

It is the operator's responsibility to perlorm all salety

checks, to make sure that all maintenance for sale

operation is perlormed promptly; and to have the

equipment checked periodically by a dealen Normal

maintenance service and replacement of parts are the

responsibility of the owner/operator and, as such, are

not considered deicers in materials or workmanship

within the terms of the warranty. Individual operating

habits and usage contribute to the need for mainte-

nance service.

Proper maintenance and care of the generator ensures

a mininmm number of problems and keep operating

expenses at a mmimunL See a dealer for service aids

and accessories.

When the generator requires servicing or repairs,

simply contact a dealer for assistance. Service teelmi-

eians are factory-trained and are capable of handling

all service needs.

When contacting a dealer about parts and service,

always supply the complete model number and serial

number of the unit as given on its data decal, which

is located on the generaton

The Carrier Dealer is:

Dealer Name

Address

City State Zip

Model No, Serial No,

Table of Contents

15 kW Generator

TABLE 1

Untroduction ........................ Unside Front Cover

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

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

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

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

Safety RuRes ........................................................ 2

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

Section 1 -General information ................... 4

1.1 Unpaekin_Inspeetion .................................... 4

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

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

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

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

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

1.O. 1 Generator ........................................... (3

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

1.7 Fuel Requirements and Recommendations ... 6

1.8 Fuel Consumption ......................................... G

1.9 Reeonfiguring the Fuel System ...................... 7

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

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

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

1.10.2 Trans%r Switch .................................. 8

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

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

Section 2 - Post lnstaRation Start-up

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

2.1 Before Initial Star_-up .................................... 9

2.2 Cheek Transfer Switch Operation ................. 9

2.3 Electrical Cheeks .......................................... 9

2.4 Generator _[_sts Under Load ....................... 10

2.5 CheeRing Automatic Operation .................... 10

2.G Adjusting the Regulator (Natural Gas Only).. 11

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

2.7.1 15kWUnits ..................................... 12

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

Section 3- Operation .................................... 12

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

3.2 Using the Auto/Ol1/Manual Switch ............... 13

3.2.1 "Auto" Position .................................. 13

3.2.2 "Off" Position .................................... 13

3.2.3 "Manual" Position ............................. 13

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

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

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

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

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

3.5.1 Transler to Generator

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

3.5.2 Transter Back to Utility

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

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

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

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

3.7.2 High _[_mperature Switch ................. 15

3.7.3 Overerank ........................................ 1G

3.7.4 Overspeed ........................................ 1G

Section 4 - Maintenance ............................... 16

4.1 _51ses ........................................................... 16

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

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

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

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

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

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

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

4.6 Spark Plug{s) .............................................. 17

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

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

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

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

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

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

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

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

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

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

Section 5 - Troubleshooting ........................ 22

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

Section 6 - Mounting Dimensions ............. 23

Section 7- ElectricM Data ........................... 24

Section 8 -Exploded Views and

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

Section 9-Warranty ..................................... 40

SAFETYRULES IMPORTANT SAFETY iNSTRUCTIONS

1SkW Generator

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

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

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

Study these SAFETY RULES carefully betore

installing, operating or servicing this equipment.

Become familiar with this Owner's Manual and with

the unit. The generator can operate safely; efficiently

and reliably only if it is properly installed, operated

and maintained.

The manulacmrer cannot anticipate every possible

circumstance that might involve a hazard. The warn-

ings in this manual, and on tags and decals affixed to

the unit are, therefore, not all-inclusive. Any personal

injury or property damage resulting from the use of a

procedure, work method or operating technique not

specifically recommended by the manufacturer, shall

be the sole responsibility of the operator. Operators

who deviate from manufacturer recommended safety

procedures and operating techniques, or fail to take

the necessary precautions, do so at their own risk.

/_ Despite the safe design of this generator, oper-

ating this equipment imprudentJy, neglecting its

maintenance or being careless can cause pos-

sible injury or death, Permit onJy responsiMe

and capable persons to operate or maintain this

equipment

Z_ 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.

z_ Parts of the generator are rotating and/or hot

during operation. Exercise care near running

generators.

2

iN GENERALHAZARDS/5

.For satety reasons, the manuihemrer recommends

that the installation, initial start-up and mainte-

nance of this equipment is carried out by a deal-

en

o The engine exhaust Imnes contain carbon monox-

ide, which can be DEADLY. This dangerous gas, if

breathed in sufiieient concentrations, can cause

unconsciousness or even death. This exhaust

system must be installed properly; in strict com-

pliance with applicable codes and standards.

Following installation, do nothing that might ren-

der the system unsafe or in noncompliance with

such codes and standards.

o 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.

o Adequate, unobstructed flow of cooling and venti-

lating air is critical to correct generator operation.

Do not alter the installation or permit even partial

blockage of ventilation provisions, as this can seN-

ously affect safe operation of the generator. The

generator MUST be installed outdoors.

o When working on this equipment, remain alert

at all times. Never work on the equipment when

physically or mentally fatigued.

o Inspect the generator regularly, and contact the

nearest dealer for parts needing repair or replace-

ment.

o Before performing any maintenance on the gen-

erator, disconnect its battery cables to prevent

accidental start up. Disconnect the cable from the

battery post indicated by a NEGATIVE, NEG or (-)

iirst. Reconnect that cable last.

o 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 con-

ditions from leaking exhaust gases, fllel leakage,

oil leakage, etc.

ELECTRICAL HAZARDS /5,

All generators covered by this manual produce

dangerous electrical voltages and can cause fatal

electrical shoek. Utility power delivers extremely

high and dangerous voltages to the transfer switch

as does the standby generator when it is in opera-

tion. Avoid contact with bare wires, terminals,

connections, etc., while the unit is running. Ensure

all appropriate covers, guards and barriers are in

place beibre operating the generaton If work must

IMPORTANT SAFETY INSTRUCTIONS

15 kW Generator

SAFETYRULES

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 watch while barefoot or whife hands or

%et are wet DANGEROUS ELECTRICAL SHOCK

MAY RESULT.

"The National Electrical Code (NEC) requires the

Irame and external electrically conductive parts of

tile generator to be connected to an approved earth

ground. Local electrical codes also may require

proper grounding of tile generator electrical syso

tern.

.After installing this home standby electrical sys-

tem, the generator may crank and start at any tirne

without warning. When this occurs, load circuits

are trans%rred to tile STANDBY (GENERATOR)

power source. To prevent possible injury if such a

start and trans%r occur, always set tile generator's

AUTO/OFF/MANUAL switch to its OFF position

be%re working on equipment and rernove the 7.5A

and 15A fuses lrorn the generator control panel.

.In case of accident caused by electric shock, imme-

diately shut down the source of electrical power.

If this is not possible, attempt to free tile victim

Irorn tile live conductor. AVOID DIRECT CONTACT

WITH THE VICTIM. Use a nonconducting imple-

ment such as a dry rope or board, to free the vie-

tim from the live conductor. If the victim is uncon-

scious, apply tirst aid and get irnmediate medical

help.

°Never wear jewelry when working on this equip-

ment Jewelry can conduct electricity resulting in

electric shock, or may get caught in moving com-

ponents causing injury.

/g, NRENAZARDS/g,

°For fire safe_; tile generator nmst be installed

and maintained properly. Installation always nmst

eornply with applicable codes, standards, laws

and regulations. Adhere strictly to local, state and

national electrical and building codes. Comply

with regulations tile Occupational Safety and

Health Administration (OSHA) has established.

Also, ensure that the generator is installed in

accordance with the manufacturer's instructions

and recommendations. Following proper installa-

tion, do nothing that might alter a safe installation

and render tile unit in noncompliance with tile

aforementioned codes, standards, laws and regula-

tions.

o Keep a tire extinguisher near the generator at all

times. Extinguishers rated 'ABC" by the National

Fire Protection Association are appropriate Ior

use on tile standby electric system. Keep the extin-

guisher properly charged and be familiar with its

use. Consult tile local fire department with any

questions pertaining to fire extinguishers.

A [XPLOSlON NAZARDS A

Do not smoke around the generaton Wipe up any

fuel or oil spills immediately. Ensure that no corn-

bustible materials are left in tile generator com-

partment or on or near tile generaton as FIRE or

EXPLOSION may result. Keep tile area surround-

ing the generator clean and free from debris.

Gaseous fluids such as natural gas and liquid pro-

parle (LP) gas are extremely EXPLOSIVE. Install

the fuel supply system according to applicable

fliel-gas codes. Before placing the home standby

electric system into service, Iilel system lines must

be properly purged and leak tested according to

applicable code. After installation, inspect tile fuel

system periodically Ior leaks. No leakage is permit-

ted.

@STANDARDS INDEX

In the absence of pertinent standards, codes, regu-

lations and laws, the published intormation listed

below may be used as installation guide for this

equipment

1. NFPA No. 37, STATIONARY COMBUSTION

ENGINES AND (_]AS TURBINES, available Korn

the National Fire Protection Association, 470

Atlantic Avenue, Boston, MA 02210.

2. NFPA No. 76A, ESSENTIAL ELECTRICAL

SYSTEMS FOR HEAUFH CARE FACILITIES,

aw_ilable same as Item 1.

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

aw_ilable 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, aw_ilable 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.

80 ASAE EP-3634, INSTALLATION AND

MAINTENANCE OFFARM STANDBYELECTRICAL

SYSTEMS, aw_ilable Irorn the Arneriean Society

of Agricultural Engineers, 2950 Niles Road, St.

Joseph, MI 49085.

9. NFPA No. 30, FLAMIVlABLE AND COMBUSTIBLE

LIQUIDS CODE, awlilable sarne as Item 1.

3

"GENERAL°

NFORMATON

Section 1 - Genera[ information

1S kW Generator

/_ Only qua[ified electricians or contractors should

attempt such installations, which must comply

stdctJy with applkabIe codes, standards and

reguJationso

1.1 UNPACRING/INSPECTMON

After unpacking, earet_flly inspect tile contents

lbr damage.

This standby generator set has been laetory sup-

plied with a weatller protective enclosure that is

intended for outdoor installation only.

-A waRmnaA-

z_ tf this generator is used to power eIectrica[ [oad

circuits normaIIy powered by a utiIity power

source, it is required by code to install a trans-

fer switch, The transfer switch must effectiveJy

isolate the electrical system from the utility

distribution system when the generator is oper-

ating (NEC 700, 701 and 702}. Failure to [soJate

an electdca[ system by such means will result in

damage to the generator and also may resuIt in

injury or death to utility power workers due to

backfeed of eJectr[ca[ energy.

If any loss or damage is noted at time of delivery, have

tile person(s} making tile delivery note all damage on

the lreigllt bill or affix his or her signature under tile

consignor's memo of loss or damage.

If a loss or damage is noted after delivery, separate

tile damaged materials and contact the carrier lbr

claim procedures.

"Concealed damage" is understood to mean damage

to tile contents of a package that is not in evidence at

tile time of delivery, but is discovered later.

1.2 LOCATION

To lift tile generator, insert pipe imving sufIieient

strengtil and diameter througil the lifting holes which

are located near the unit's base (see Figure 1.1). Tile

unit may also be lifted by using a llook and hoist

metllod provided a spreader bar is used to ensure

tile lifting lines clear the roof panel.

Z_ When tilting or hoisting equipment is used, be

carefu[ not to contact overhead power Hneso

/_ The generator's weight of more than 300

pounds requires proper toots, equipment and

qua[flied personnel to be used in a[[ phases of

handling and unpacking.

1.3 PROTECTION SYSTEMS

Unlike an automobile engine, the generator may have

to run for long periods of time with no operator pres-

ent 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. Overerank

2. Higil Temperature Sensor 4. Overspeed

There are LED readouts on the control panel to indi-

cate that one of these iimlts has occurred. There is

also a "System Set" LED that is described below.

1.4 SYSTEM SET [.ED

The "System Set" LED is lit when all of the lhllowing

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 ligilt

will flash rapidl> This indicates that if the AUTO/

OFF/MANUAL switch is placed in the Auto posi-

tion, the generator will start.

3. Tile "Not In Auto" dip switeil is set to tile OFF

position on the control board.

4. No alarms are present, for example, low oil pres-

sure, higil temperature, etc.

4

Section I - Genera[ Information

1SkW Generator GENERAL

NFORMATON

1°5 THE GENERATOR

Figure 1.1 -15 kW, V-twin 67"=990

Exhaust

Enclosure

Oil Data

Dipstick \ Decal \

\\\ \\\

\\\ \\

\\\\\

\\\\\\\ \

\\

\

_r.

Control

Panel

GFCI

_ Outlet

Fuel

/Regulator

Fuel

Inlet

LiftingHoles Oil Filter Battery

Compartment

CompositeBase

5

"GENERAL°

NFORMATON

Section 1 - General information

1S kW Generator

1.6

1.6.1 GENERATOR

Rated Maw Cont Power Capacity (Watts _) ..... 13,000 NG/

15,000 LP+

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

Rated Max. Conthmous Load Current (Amps)

120 Volts + ...................................... 108.3 NG/125_0 LP

240 VoRs ............................................ 54.2 NG/62.5 LP

Main Line Circuit Breaker .................................... 65 Atnp

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

Nmnber of Rotor Poles ................................................... 2

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

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

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

Battery Requirement at

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

525 Cold<ranking Amperes Mhlhnmn

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

Output Sound Level (_ 23 ft (7m)

at fldl load ................................................... 71.5 db (A}

Normal Operating Ran,_e ........................... -20°F (-28.8"C)

to 104°E 140"C)

* Maxiiyll/ill w_th_e aIld (;llrreza are Slit)jeer to _ti]d lhl]ited by Slid] l'z_<:tOrS

as fuel Btu (;oIlteIlt, aI]]l)ieI][ teI]]l)eratllre, altitllde, eI]_hle power alld COn-

ditiom etc. Maximum power decreases about 3.5 percent fl_r each lnOO

feet above sea level: and also will deele_se about 1 pereenl for each 6 '_ ¢

(IfYF)abovei(¢_( (60_F).

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

exceed the value staledh>r 240V

1.6.2 ENGINE

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

Nmnber of Cylinders ...................................................... 2

Rated Horsepower .................................. 30 %3,¢;00 rpm

Displacement .......................................................... 992ec

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

_&dve Arrangement .................................. Overhead Valves

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

Reeonimended Spark Plug ................................... 0D4529

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

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

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

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

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

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

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

1o7 FUEL REQUIREMENTS

AND RECOMMENDATIONS

With LP gas, use only the vapor withdrawal sys-

tem. Tllis type of system uses the vapors %treed

above tile liquid lilel in tile storage tank.

The engine has been fitted witll a fllel earburetion

system that meets tile specifications of the 1997

California Air Resources Board for tamper=proof

dual fllel systems. The unit will run on natural gas or

LP gas, but it has been factory set to run on natural

gas. Should tile primary ihel need to be changed to

LP gas, the fllel system needs to be reeonfigured. See

instructions in the "Reeonfiguring the iSlel Systenf'

seetion.

Recommended fuels should lmve a Btu content of at

least 1,000 Btus per cubic loot for natural gas; or at

least 2,520 Btus per cubic toot lot LP gas. Ask the

fllel supplier for tile Btu content of the thee

Required fllel pressure for natural gas is 5 inches

to 7 inches water column (0.18 to 0.25 psi); and

for liquid propane, 11 inches to 14 inches of water

column (0.4 to 0.5 psi).

NOTE:

Any piping used to connect the generator to the

fuel supply should be of adequate size to ensure

the fuel pressure NEVER drops below 4 inches

water column for natural gas or 10 inches water

column for liquid propane for all load ranges.

1o8 FUEL CONSUMPTION

Model # Nat. Gas {*} LP Vapor {**}

1/2 Load Full Load 1/2 Load Full Load

05207 156 220 1.58/58 2,40/88

* Nalmal _as is in cubic feet per hour.

** LP is in gallons per hour/cubi( feet per hour.

** _ Values _ivell al-e at)t)l OXillla(e.

Gaseous fuels such as natural gas and liquid

propane (LP) gas are highly explosive. Even the

slightest spark can ignite such fuels and cause

an explosion. No leakage of fuel is permitted.

NaturM gas, which is lighter than air, tends to

collect in high areas. LP gas is heavier than air

and tends to settle in low areas.

6

Section I - General Information

1SkW Generator GENERAL

NFORIVlATON

1.9 RECONNGURING THE

FUEL SYSTEM

109.1 15KW, 990CC ENGINES

To reeonligure tile fuel system lrom NO to LR

these steps: NOTE:

follow

The primary regulator for the propane supply is

NOT INCLUDED with the generator. A fuel pres-

sure of 11 to 14 inehes of water column (0.4 to

0.5 psi) to the fuel inlet of the generator MUST

BE SUPPLIED.

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

2. Open the roof and remove the door.

3. Remove the battery. (if installed)

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

hand side of the battery compartment. _[\vo M6

screws are located on top of the bane and two

M6 screws are located on the inside of the baNe

towards the back.

5. Remove the small hose clamp and hose from the

filel regulator. It may be necessary to pry the hose

off of the brass fitting using a screwdriver to gen-

tly lilt up the hose edge.

(3. Remove the small brass hose fitting from the

regulator casting.

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

threaded hole originally occupied by the brass

hose fitting (Figure 1.2).

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

the small fuel jet into the regulator casting. Do

not over tighten.

9. Apply thread sealant to the threads of the hose

fitting and replace it into the regulator body.

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

tighten as necessary.

1 1. Replace the engine air in baNe using the ibur 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 fiat 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 ibr maximmn

power and best performance. DO NOT, UNDER

ANY CIRCUMSTANCES, REMOVE THE SET

PINS FROM THE REGULATOR HOUSING.

THIS WILL VOID THE WARRANTY.

Figure 1.2 -Demand Regulator

}

IDLE OIROUIT

PORT _. 0

FUEL JET

"_ REGULATOR

HOUSING SORT

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

maximmn power, follow the procedure in Section

2.6 (Adjusting the ]_51elRegulator).

1.10

ENERAT0

Install the generator set, in its protective enclosure,

outdoors, where adequate cooling and ventilating air

is always available. Consider these factors:

e

e

e

e

Install the unit where air inlet and outlet open-

ings will not become obstructed by leaves, grass,

snow, etc. If prevailing winds will cause blowing or

driiling, 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 fllel

supply, to reduce the length of piping.

Install the generator as close as possible to

the transfer switch. HOWEVER, REMEMBER

THAT LAWS OR CODES MAY REGULATE THE

DISTANCE.

The genset must be installed on a level surface.

The base frame nmst be level within two (2) inches

all around.

7

Section 1 - Genera[ Information

GENERAL

INFORMATION 15 kW Generator

1=103=1 15 kW Units

Transfer switches for use with this generator are sold

separately and can be purchased from dealers.

o Install any transter switch in accordance with the

instructions supplied with the transfer switch.

o Failure to utilize a the manufacturer's transfer

switch with this generator will void the warranty,

1ol 1 BATTERY[NSTALLATIGN

Fill the battery with the proper electrolyte fluid if

necessary and have the battery fully charged betbre

installing it.

Beibre installing and connecting the battery, complete

the iollowing steps:

1. Set the generator's ALJTO/OFF/NLa_NUAL switch to

OFE

2. _fffu-n off utility power supply to the transfer

switch.

3. Remove the 7.5 amp and 15 amp Iilses Kom the

generator control panel.

Battery cables were iaetory connected at the genera-

tor (Figure 1.3). Connect cables to battery posts as

Ihllows:

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 {IYom frame

ground) to the battery post indicated by a nega-

tive, NEG or (--).

6. Replace the 7.5 amp and 15 amp fuses in the

generator control panel.

NOTE:

Damage will result if battery connections are made

in reverse.

Figure 1.3 -Battery Cable Connections

BLACKLEAD

FROMFRAME)

--.I-

BATTERY

BEDLEAD

(FROMSTARTER

COHTACTOR)

-RED

+

BLACK

8

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 maintain-

ing the battery when the unit is not running. The

trickle charge feature cannot be used to recharge

a discharged battery.

1.12 THE BATTERY

Servicing of the battery is to be performed or super-

vised by personnel knowledgeable of batteries and

the required precautions. Keep unauthorized person-

ne] away Kom batteries.

%_]e]] replacing the battery; use the following type of

battery: Group 2G/26R 12-volt battery with a rating

of 525 coldocranking amps mininmm Ibr 15 kW at

-17.8 ° C (0 ° F) minimun]. When using a maintenance_

I]*ee battery, it is not necessary to cheek the specific

gravity or electrolyte level. Have these procedures

pertormed 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 seL

Do not dispose of the battery in a fire. The

battery is capabJe of expIodingo

Z_ A battery presents a risk of electrica[ shock

and high short circuit current. The following pre-

cautions are to be observed when working on

batteries:

• Remove the 7.5A and 15A fuses from the genera-

tor contro] panel;

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

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

battery; and

• Disconnect charging source prior to connecting or

disconnecting battery terminaJs.

-A wAH.c A-

/_ Do not open or mutilate the battery. ReJeased

electrolyte has been known to be harmfut to the

skin and eyes, and to be toxic.

Z_ The electrolyte is a dilute suJfur[c acid that is

harmful to the skin and eyes. it is electrically

conductive and corrosive.

Section 1 - Post InstMIation Start-up and Adiustments

1SkW Generator

POS%@

iNSTALLATiON

STAR%UP

ADJUSTMENTS

The following procedures are to be observed:

• Wear full eye protection and protective clothing;

• Where eJectrolyte contacts the skin, wash it off

immediately with water;

• Where eJectro[yte contacts the eyes, immediately

flush thorougNy with water and seek medical

attention; and

• Spilled electrolyte is to be washed down with an

acid neutrMizing agent. A common practice is to

use a solution of ! pound (500 grams) bicarbonate

of soda to 1 galIon (4 liters) or water. The bicar-

bonate of soda soJution is to be added untit the

evidence of reaction (foaming) has ceased. The

resulting liquid is to be flushed with water and the

area dried.

Z_ 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 touch-

ing the battery by first touching a grounded metal

surface.

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

the OFF position before connecting the battery

caMes. Jf the switch is set to AUTO or MANUAL,

the generator can crank and start as soon as the

battery cables are connected.

Be sure the utility power supply is turned off, or

sparking may occur at the battery posts as the

cables are attached and cause an explosion.

2.1 BEFOREINITIAL START-UP

Betbre starting, complete the following:

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

OFF (or open) position.

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

the OFF position.

3. Turn OFF the utility power supply to the transfer

switcil using the means provided (such as the

utility main line circuit breaker).

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

sary, till to tile dipstick FULL mark witil the rec-

ommended oil. Do not fill above the FULL mark.

5. Cileck the file] supply. Gaseous fuel lines must

imve been properly purged and leak tested in

accordance witil applicable fuel-gas codes. All

file] simtoff valves in tile I_lel supply lines must

be open.

"_ CAUTION

z_ Never operate the engine with the oil level

below the "Add" mark on the dipstick. Doing

this could damage the engine.

2.2 CHECK TRANSFER SWITCH

Reter to Section 3.5, of tile owner's manual lbr man-

ual operation procedures.

A Ak-

Z_ Do not attempt manual transfer switch opera-

tion until aH 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 possibIy

fatat electrical shock.

2.3 ELECTRICAL CHECKS

Complete electrical checks as follows:

1. Set tile generator's main circuit breaker to its

OFF (or open} position.

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

the OFF position.

3. Turn OFF the utility power supply to tile transfer

switcil using tile means provided (sucil as the

utility main line circuit breaker).

4. _[hlrn on tile utility power supply to the transfer

switcil using the means provided (sucil as a utility

main line circuit breaker).

AxThe transfer switch is now electrically "hot."

Contact with "hot" parts will result in extremely

hazardous and possibly fatal electrical shock.

Proceed with caution.

5. Use an accurate AC voltmeter to check utility

power source voltage across terminals N1 and

N2. Nominal line-toqine voltage should be 240

volts AC.

G. Check utility power source voltage across termi-

nals N1 and the transfer switch neutral lug; then

across terminal N2 and neutral. Nominal line-to-

neutral voltage silould be 120 volts AC.

7. Wilen certain that utility supply voltage is compat-

ible with transfer switch and load circuit ratings,

tm-n OFF the utility power supply to the transfer

switcil.

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

OFF (or open) position. Initial tests will be con-

ducted at no-load condition.

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

MANUAL switch to MANUAL. The engine should

crank and start.

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

allow internal temperatures to stabilize. Then, set

the generator's main circuit breaker to its ON (or

closed) position.

9

iNSTALLATiON

START-UP

ADJUSTMENTS

Section 2 - Post Installation Start-up and Adiustments

1S kW Generator

Z_ Proceed with caution! Generator power voltage

Jsnow supplied to the transfer switch, Contact

with live transfer switch parts will result in dan-

gerous and possibly fatal electrkal shock,

11. Connect an accurate AC voltmeter and a fre-

quency meter across transfer switch terminal

lugs E 1 and E2. Voltage should be 242-252 volts;

Kequency should read about 61-63 Hertz.

12. Connect the AC voltmeter test leads across ter-

minal lug E1 and neutral; then across E2 and

neutral. In both cases, voltage reading should be

121-126 volts AC.

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

OFF (or open) position. Let the engine run at no-

load tot a few minutes to stabilize internal engine

generator temperatures.

14. Set the generator's AUTO/OFF/MANUAL swifeh to

OFE 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. Oenerally_ if both AC

frequency and voltage are high or lo_; the engine

governor requires adjustment. If frequency is cor-

rect, but voltage is high or low, the generator's

voltage regulator requires adjustment.

2.4 GENERATOR TESTS UNDER LOAD

To test the generator set with electrical loads applied,

proceed as follows:

1. Set generator's main circuit breaker to its OFF

(or open) position.

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

switch to OFE

3. Turn OFF the utility power supply to the transfer

swifeh, using the means provided {such as a util-

ity main line circuit breaker).

wA.NINc

Z_ Do not attempt manual transfer switch opera-

tion until aH power voltage supplies to the

transfer switch have been positiveJy turned off.

Failure to turn off aH power vottage supplies

will result in extremely hazardous and possibly

fatal electrical shock,

4. Manually set the transfer swifeh to the STANDBY

position, i.e., load terminals connected to the

generator's E 1/E2 terminals. The transfer switch

operating lever should be down.

5. Set the generator's AUTO/OFF/iVlANUAL switch

to MANUAL. The engine should crank and start

irmnediatel_t

lo

G. Let the engine stabilize and warm tip 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 fllll rated wattage/amperage capacity

of the installed generator.

9. Connect an accurate AC voltmeter and a frequen-

cy meter across terminal lugs E 1 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 tot 20-30

minutes. Listen for unusual noises, vibration or

other indications of abnormal operation. Check

ibr oil leaks, evidence of overheating, etc.

11. When testing tinder load is complete, turn OFF

electrical loads.

12. Set the generator's nmin circuit breakers to their

OFF (or open) positions.

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

14. Set the AUTO/OFF/MANUAL switch to OFE The

engine should shut down.

2.5 CHECKINGAUTOMATIC

OPERATmON

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 OFE

3. Turn OFF the utilitypower supply to the transfer

switch using the means provided (such as a utility

main line circuit breaker).

4. Manually set the transfer switch to the UTILITY

position, i.e., load terminals connected to the util-

ity power source side.

5. 7him ON the utility power supply to the transfer

swifeh, using the means provided {such as a util-

ity mata line circuit breaker).

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

Then set the generator's mata circuit breaker to

its ON (or closed) position. The system is now

ready for autonmtic operation.

7. Turn OFF the utility power supply to the transfer

swifeh.

With the AUTO/OFF/MANUAL swifeh at AUTO, the

engtae should crank and start when the utility source

power is turned OFE AAer starting, the transfer

swifeh should connect load circuits to the standby

side. Let the system go through its entire automatic

sequence of operation.

Section 2 - Post Installation Start-up and Adjustments

15 kW Generator

POS_@

iNSTALLATiON

STAR.UP

ADJUSTMENTS

With the generator running and loads powered by

generator AC output, turn ON tile utility power supply

to the transfer switch. Tile ibllowing should occur:

.Alter about six seconds, the switch should transler

loads back to tile utility power source.

.About one minute after retransfer, tile engine

should shut down.

2.5 ADJUSTING THE REGULATOR

{NATURAL(;AS ONLY}

Although the generator has been Nctory set to pro-

vide rnaxirnum powen it may be necessary in some

areas to a(_just this setting. Because natural gas has

difthrent BTU or power content across tile country

the engine may not per%rm as designed.

If experiencing engine problerns at high or flfll load

conditions %llow these steps, it will require a tre-

queney meter to per%tin this procedure.

1. Turn off utility power to tile main distribution

panel in the house. This earl be done by switching

tile service main breaker to tile off or open posi-

tion.

2, Allow the generator to start beIbre loading tile

generator. Confirm tile no-load fl-equency with

the roof open and door off is set at 63-63.5 Hz.

Transfer load to emergency circuits.

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

on the emergency circuits in an attempt to fully

load the generator. Be cautious not to overload

the generator. Use tile tallowing chart as a guide:

U_it [ 120 Volts | 240 Volts

15 kW I 108.3 amps I 54.2 anlps

4. When lhll load has been achieved. Connect a lYe-

queney meter to the output lugs of tile generator's

main line circuit breaker.

5. Tile i_lel regulator is fitted with two adjustment

screws. While watching tile Kequency meter,

slowly turn the adjustment screw clockwise or

counterclockwise one at a time until highest Ke-

queney is read on the meter. Only limited adjust-

ment is available between the set pins. Under no

circumstances should any of tile pins be removed

(Figures 2.1 and 2.2).

Figure 2.1 -- Dual Fuel Regulators

V-twin 410

Adjustment

(BothSides}

(Beth Sides)

Adjustment

Screw

(OneSide

Only}

Pin

6. When the highest lrequeney is reached maximum

power has been set. Then turn both adjustment

screws 1/4 turn counterclockwise. Regulator is

now set.

Figure 2.2 -- Placement of Regulator

7_ _[?lrn utility power to the main distribution panel

back on. This can be done by switching tile ser-

vice main breaker to the on or closed position.

Allow tile generator to shut down.

wARNINc

Z_ Do not make any unnecessary adjustments.

Factory settings are correct for most applica-

tions. However, when making adjustments, be

careful to avoid overspeeding the engine.

If this procedure or equipment are not awlilable,

locate the nearest Dealer and they earl perform tile

adjustments.

NOTE:

A service fee may be charged for this adjustment.

11

OPERATION Section 3- Operation

IS kW Generator

2°7 ENGINE GOVERNORADJUSTMENT

If both AC l_-equeney and voltage are eorrespondtagly

high or low, adjust tile engine governor as follows:

2.7,1 15 KW UMTS

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

Figure 2,3 -- V-twin Engine Governor

Adjustment

Gevemor Clamp £Nt

2. Completely remove the idle spring.

3. With governor arm at wide open throttle position,

rotate governor shaft ikflly clockwise. Tighten

clamp bolt to 84 taeh-pounds.

4. Start unit and apply frill load. Use full load speed

adjust screw {Figure 2.4) to adjust frequency to

58 Hz.

5. Remove load, stop engtae, loosen the idle adjust

screw and reconnect the idle sprtag.

(3. Push the governor arm to the closed throttle posi-

tion. Make sure the idle spring does not stretch at

all.

7. Restart the unit.

8. Slowly turn the idle adjust screw to adjust the no-

load idle fi-equeney to 63-63.5 Hz.

9. The governor is now set.

Figure 2,4 -- V-twin Fuff Load Speed Adjust

Screw

12

2.8 VOLTAGEREGULATOR

With the Irequeney between 62-63.5 Hertz, slowly

turn the slotted potentiometer (Figure 2.5) until line

voltage reads 244-252 volts.

NOTE:

Remove the access panel on top of the control

panel to adjust the voltage regulator.

Figure 2.5 -Voltage A djustmen t Po ten tiometer

HHHHHHI

[]

o

_©'

i

L

NOTE:

The voltage reg_ator is housed above the generator's

control panel. The regulator maintains a voltage in

direct proportion to frequency. For example, at 62

Hertz, line-to-neutral voltage will be 124 volts.

3.1 BREAK4N PROCEDURE

Once the unit has been tastalfed and all electrical

cheeks have been made, it is strongly recommended

that the followtag "Break-ta Procedure" be completed

to ensure correct generator operation ta the future.

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

AUTO.

2. Turn OFF the utility power supply to the transfer

switch ustag the means provided (such as a utility

mata ltae circuit breaker).

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

transfer to standby.

4. Ustag the transfer swifeifs built-ta emergency

load center, mrn on circuits to load the generator

to approximately 25% rated load and run the unit

%r one hour.

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

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

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

8. _[_lrn ON the utility power supply to the transfer

switch, which will allow the transfer switch to

transfer back to utility powen The unit will con-

tinue to run for one mtaute and then shut down.

Section 3 - Operation

15 kW Generator

OPERATION

9. Allow tile unit to cool.

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

OFF (or OPEN) position.

1 1. Set the generator's AUTO/OFF/MANUAL swifeh

to OFE Remove the 7.5A and 15A Iilses Irom the

generator control panel. Disconnect the battery

cables as outlined in "General Hazards" {page

2).

12. Drain tile oil and remove the oil tilter. Replace

the oil iilter according to Section 3.4, "Changing

the Oil Filter". Replace the oil with s_lthetic oil

as reconunended in Section 3.3, "Changing the

Engine Oil".

13. Reconnect the battery cables as outlined in

"General Hazards" {page 2) and insert the 7.5A

and 15A fllses into the generator control panel.

The generator is now ready for service.

3.2 USINGTHEAUm/OFF/MANUAL

SWITCH(FIGURE3J)

3o2ol "AUTO" POSITION

Selecting this switch position activates t_llly auto-

matic system operation. It also permits starting and

exercising the engine every seven days with the set-

ting of the exercise timer (see "Setting the Exercise

Timer" section). This position also is used thr remote

starting, when it is set up.

¢' 3,2,2 "OFF" POSITION

This switch position shuts down the engine. This

position also prevents automatic operation.

3,2,3 "MANUAL" POSITION

Set the switch to MANUAL to crank and start the

engine. Transfer to standby power will not occur

unless there is a utility failure.

Figure 3.1 -Generator Contro! Panel

OUTLETFUSE

?; AUTO OFF

SYSTEM FUSE

15A SET

EXERCISE

TIME

EXTERNAL

GFCJ

©

CIRCUIT

MAN BREAKER _SYSTEM SET

12VDC /" _LOW OIL

HIGH TEMR

OVER CRANK

ACCESSORY ..... RHclNa_ RREND0 _ED _T

-_ WARNING _-

2xWith the switch set to AUTO, the engine may

crank and start at any time without warning.

Such automatic starting normally occurs when

utility power source voltage drops bMow a pre-

set level or during the normal exercise cycle. To

prevent possible injury that might be caused by

such sudden starts, always set the switch to OFF

and remove both fuses before working on or

around the generator or transfer switch. Then,

place a "Do Not Operate" tag on the generator

panel and on the transfer switch.

3.3 AUTOMATIC TRANSFER

To select automatic operation, do the following:

1. Make sure the transfer switch main contacts are

set to their UTILITY position, i.e., loads con-

nected to the utility power source (Figure 3.2).

2. Be sure that normal utility power source voltage

is available to transfer switch terminal lugs N1

and N2.

3. Set the generator's A2UTO/OFF/MANUAL switch to

AUTO.

4. Set the generator's main circuit breaker to its ON

(or CLOSED) position.

With the preceding steps complete, the generator will

start automatically when utility source voltage drops

below a preset level. After the unit starts, loads are

transferred to the standby power source. Refer to

Section 3.4, "Sequence of Automatic Operation."

@3,3,1 12 VDC ACCESSORYOUTLET

The generator is equipped with a 12 VDC accessory

outlet in the generator control panel {Figure 3.1).

With the generator running or in standby mode, this

outlet may be used to temporarily power low power

accessories such as a work ligM, cell phone, radio or

any other automotive style accessory. This outlet is

capable of delivering a MAXIMUM of 7.5 amps. If the

accessory to be used through this circuit demands

too nmch power, the fuse that protects this circuit

will melt open and the circuit will not be flmctional.

-_ WARNING _-

Z_ This 12 VDC outlet draws power from the

generator's starting battery and extended use of

this outlet may drain the battery and the engine

may not start. This outlet should NOT be used

for battery charging.

13

OPERATION Section 3 - Operation

1S kW Generator

Tile generator is equipped with an external 15 amp,

120 volt, GFCI convenience outlet that is located in

tile right rear of the generator enclosure. _rhen tile

generator is running, in the absence of utility power,

this outlet may be used to power items outside a

home such as lights or power tools. This outlet may

also be used when utility power is present by run-

ning the generator in manual mode. This outlet does

not provide power if the generator is not running.

This outlet is protected by a 15 amp circuit breaker

located in the generator control panel {Figure 3.1 ).

3.4 SEQUENCEOF AUTOMATIC

OPERATION

The generator's control panel houses a control logie

circuit board. This board constantly monitors util-

ity 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 acti-

vate and connect load circuits to the standby power

supply (load terminal lugs T l/T2 connect to terminal

lugs E l/E2).

Upon restoration of utility source voltage above a

preset level, generator circuit board action signals the

transter switch to transfer loads back to that power

supply. After retranster, the engine is signalled to shut

down.

The actual sequence of operation is controlled by

sensors anti 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 tip for

about 10 seconds before the load is transferred

to a standby source.

C. Standby Voltage Sensor

* This sensor monitors generator AC output volt-

age. When the voltage has reached 50 percent of

the nominal rated voltage, transfer to standby

ear occur.

D. Utility Voltage Pickup Sensor

* This sensor monitors utility power supply volt-

age. When that voltage is restored to above 70

percent of the nominal source voltage, a retrans-

ter time delay starts timing.

14

E.Retransfer Time Delay

. This timer runs for about 15 seconds.

° At end of a 15-second delay, circuit board action

de-energizes the transfer relay in the transfer

switch.

° Retransfer to utility power source then occurs.

E Engine Cool-down Timer

° When the load is transferred back to utility power

source, the engine cool-down timer starts tin>

ing.

° The timer will run for about one minute, and the

generator will then shut down.

3.5 MANUAt.TRANSFEROPERATION

@3.5.1 TRANSFERTO GENERATORPOWER

To start the generator and activate the transfer switch

manually, proceed as lbllows:

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

OFE

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

OFF (or OPEN) position.

3. %lrn OFF the utility power supply to the transfer

switch using the means provided {such as a utility

main line circuit breaker).

A

4_

Do not attempt to activate the transfer switch

manually unti[ all power voltage supplies to the

switch have been positively turned off. FaiJure

to turn off all power vottage supplies may result

in extremely hazardous and possibly fataJ etec-

tricaJ shock.

Use the manual transfer handle inside the trans-

fer switch to move the main contacts to their

"Standby"position, i.e., loads connected to the

standby power source (Figure 3.2).

Figure 3.2 - ManuM Transfer Switch Operation

i

LOADCONNECTEDTO UTiLiTY POWERSOURCE

LOADCONNECTEDTO STANDBYPOWERSOURCE

i

MANUAL TRANSFER

HANDLE

TRANSFER SWITCH

OPERATING LEVER

5. _[b crank and start the engine, set the/KJTO/OFF/

MANUAL switch to MANUAL.

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

minutes.

7. Set tile generator's main circuit breaker to its ON

(or CLOSED) position. Tile standby power source

now powers the loads.

@3.5.2 TRANSFER BACK TO UTILITY POWER

SOURCE

When utility power has been restored, transfer back

to that source and shut down the generaton This can

be accomplished as Iollows:

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

OFF (or OPEN) position.

2. Let the engine run for a minute or two at noqoad

to stabilize the internal temperatures.

3. Set the generator's AUTO/OFF/MANUAL switch

to its OFF (or OPEN) position. The engine should

shut down.

4. Check that utility power supply to the transfer

switch is turned OFE

Z_ Do not attempt to activate the transfer switch

manually until all power voltage supplies to the

switch have been positively turned off, Failure

to turn off all power voltage supplies may result

[n extremMy hazardous and possibly fatal elec-

trical shock,

5. Use the manual transfer handle inside the trans-

fer switch to move the main contacts back to their

UTILITY position, i.e., loads connected to tile util-

ity power source (Figure 3.2).

6. Turn ON the utility power supply to the transfer

switch using the means provided.

7. Set the system to automatic operation as outlined

in %utomatic Transfer Operation," Section 2.3.

3.6 SETTING THE EXERCISE TIMER

Tile 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 lhllowing sequence is completed.

During this exercise period, the unit runs lhr approx-

imately 12 minutes and then shuts down. Transfer of

loads to the generator output does not occur during

the exercise cycle.

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

selection of the day and time for system exercise. To

select the desired day and time of day; the Iollowing

sequence must be performed at that time.

1. V_ril_ _that the AUTO/OFF/MANUAL switch is set

to AUTO.

Sedion 3-- Operation

15 kW Generator

OPERATION

2_

3_

Hold down the set timer switch until the genera-

tor starts (approximately 10 seconds) and then

release.

Tile generator will start and run tbr approximate-

ly 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 per-

formed. 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 hoard is ON.

3.7 PROTECTION SYSTEMS

3.7,1 LOW OiL PRESSURESWITCH

This switch (Figure 3.3) has normally closed contacts

that are held open by engine oil pressure during

cranking and operating. Should oil pressure drop

below the 8 psi range, switch contacts close, and the

engine shuts down. The unit should not be restarted

until oil is added, and tile AUTO/OFF/IVIANUAL swifeh

nmst be turned to OFF and then back to AUTO.

TEMPERAT_

This switch's contacts (Figure 3.3) close if tile tem-

perature should exceed approximately 140 ° C (284"

F), initiating an engine shutdown. Tile generator will

automatically restart and the LED will reset once tile

temperature has returned to a safe operating level.

Figure 3.3 -Low Oil Pressure and

High Tempera lure Switches

Low Oil Switch

Drain

Hose

15

MAINTENANCE

Section 4-Maintenance

15 kW Generator

_RANK

This ieature prevents tlle generator irom damaging

itself when it continually attempts to start and anoth-

er problem, such as no fllel supply, prevents it from

starting. Tile unit will crank and rest Ihr a preset time

limit. Then, it will stop cranking, and the LED will

light indicating an overcrank failure. The AUTO/OFF/

MANUAL switch will need to be set to OFF and then

back to AUTO to reset the generator control board.

NOTE:

If the fault is not repaired, the overcrank feature

will continue to activate.

3.7,3.1 Approximate Crank Cyde Times

* 15 seconds ON

. 7 seconds OFF

. 7 seconds ON

. 7 seconds OFF

. Repeat Ior 45 seconds

Approximately 90 seconds total

3.Z4 OVERSPEED

This ieature protects the generator from damage by

shutting it down if it happens to ruts faster than the

preset limit. This protection also prevents the genera-

tor from supplying an output that could potentially

damage appliances connected to the generator cir-

cuit. Contact the nearest dealer if this failure occurs.

4.1 FUSES

The generator panel's 15 amp fuse (Figure 4.1) pro-

tects the DC control circuit against overload. The fllse

is wired its series with the battery output lead to the

panel. If the fllse element has melted open, the engine

cannot crank or start. Replace the fuse using only an

identical 15-amp replacement.

The generator panel's 7.5 amp fllse protects the 12

VDC accessory socket. If the fllse element has melted

open, the 12 VDC socket will not provide power to

any accessories. Replace the/ilse using only an iden-

tical 7.5 amp replacement. To remove fuse, push the

Iuse holder cap down and rotate counterclockwise.

Figure 4. ! -Generator Contro! Pane!

0UTLETFUSE

?;

AUTO OFF

SYSTEM FUSE

O

15A SET

EXERCISE

TIME

16

4.2 CHECKING THE ENGINE

OiL LEVEL

For oil capacities, see the "Specifications," Section.

For engine oil recommendations, see Section 4.3.1.

_[% check the engine oil level, proceed as iollows

{Figure 4.2):

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

MANUAL switch to the IVIANUAL position. Allow

it to run for a short while and then shut it down

by moving the switch to the OFF position.

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

cloth.

3. Install the dipstick; then, remove it again. The oil

level should be at the dipstick "l_5lll" mark. If nec-

essary, add oil to the "b)lll" mark only. DO NOT

FILL ABOVE THE "FULE' MARK.

CAUTION

/_ Never operate the engine with the oil JevM

bMow the "Add" mark on the dipstick. Doing

this could damage the engine.

4. Install the dipstick.

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

nal position.

Figure 4.2 -- Oi[ Dipstick and Fill, !5 kW

Oil Dipstick

4.3 CHANGING THE ENGINE OIL

4.3.1 ENGINE OIL RECOMMENDATIONS

Use oil of American Petroleum Institute (API) Service

Class SG, SH or SJ. Use all season SAE 5W-30

Synthetic oil. Organic break-in oil is required before

using sy_sthetic oil.

NOTE:

The unit is supplied with "break-in" oil. See the

"Break-in Procedure" Section for the first required

oil change.

Section 4 - Maintenance

15 kW Generator MAINTENANCE

"_ CAUTION

//_ Any attempt to crank or start the engine before

it has been properly serviced with the recom-

mended oil may resuJt in an engine failure.

4°3°2 OIL CHANGE PROCEDURE

To change tile 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 OFE pull the

oil drain hose (Figure 4.3) free of its retaining

clip. Remove the cap from the hose and drain the

oil into a suitable container.

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

end of the oil drain hose. Retain the hose in the

clip.

4. Refill with the proper recommended oil (see

"Engine Oil Recommendations"). See the

"Speciiications" Section fhr oil capacities.

Figure 4.3 -Oil Drain Hose and Filter

oil Filter

4.4 CHANGING THE OIL FILTER

Change the engine oil filter as follows:

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

turning it counterclockwise.

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

gasket of the new filter. See the "Specifications"

Section for recommended filter.

3. Screw the new filter on by hand until its gasket

lightly contacts the oil filter adapter. Then, tighten

the filter an additional 3/4 to one turn {Figure

4.4).

4. Refill with the proper recommended oil (see

"Engine Oil Recommendations"}. See the

"Specifications" Section for oil capacities.

5. Start the engine and check for leaks.

4.5 CHANGING THE ENGINE

AIR CLEANER

4.5.1 15 KW GENERATORS

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

the fbllowing procedure:

1. Turn the two screws counterclockwise to loosen.

2. Remove the cover and air filter.

3. Wipe away dust or debris from inside of the air

box and around edges.

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

5. Install the cover. Turn the two cover screws clock-

wise to tighten.

See the "Service Schedule," Section for air cleaner

maintenance. See the "Specii?cations" Section for air

filter replacement part nmnber.

Figure 4.4 -- 15 kW Engine Air Cleaner

S0rew

over

Filter

4.6 SPARKPLUG(S)

Reset the spark plug(s) gap or replace the spark

plug(s) as necessary. See the "Service Schedule"

Section for maintenance requirements.

1. Clean the area around the base of the spark

plug(s) to keep dirt and debris out of the engine.

Clean by scraping or washing using a wire brush

and commercial solvent. Do not blast the spark

plug(s) to clean.

2. Remove the spark plug(s) and check the con-

dition. Replace the spark plug(s) if worn or if

reuse is questionable. See the "Service Schedule"

Section for recommended inspection.

3. Check the spark plug gap using a wire feeler

gauge. Adjust the gap to 0.50 mm (0.020 inch) for

15 kW by careflflly bending the ground electrode

(Figure 4.5). 17

MAINTENANCE

Section 4-Maintenance

1S kW Generator

Figure 4.5 -Setting the Spark Plug Gap

SET PLUG GAP AT

0.050 ram/0.020 inch

4.7 BATTERY MAINTENANCE

The battery should be inspected per the "Service

Schedule," Section 4.13. The ibllowing procedure

should be ibllowed ibr inspection:

1. inspect tile battery posts and cables tbr 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 B_a'TER-

IES.

3. Have the state of charge and condition checked.

This should be done with an automotbze-type bat-

tery hydrometer.

Do not dispose of the battery in a fire. The

battery is capable of exploding,

Z_ A battery presents a risk of eJectrical shock

and high short circuit current. The following pre-

cautions 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 terminaJs;

Remove the 7.5A and 15A fuses from the generator

control panel. -A wAR.m.c&

/_ Do not open or mutilate the battery. Released

electrolyte has been known to be harmful to the

skin and eyes, and to be toxic.

Z_ The electrolyte is a dilute sulfuric acid that is

harmfuJ to the skin and eyes. Jt is eJectrically

conductive and corrosive. The following

procedures are to be observed:

18

• Wear full eye protection and protective clothing;

• Where electroJyte contacts the skin, wash it off

immediately with water;

• Where eJectroJyte contacts the eyes, immediately

flush thoroughly with water and seek medical

attention; and

Spilted electrolyte is to be washed down with an

acid neutralizing agent. A common practice is to

use a sotution of ! pound (500 grams} bicarbonate

of soda to 1 gallon (4 liters) or water. The bicar-

bonate of soda solution is to be added untit the

evidence of reaction (foaming) has ceased. The

resulting Jiquid is to be flushed with water and the

area dried.

z_ 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 eJectricity from body before touch-

ing the battery by first touching a grounded metaJ

surface.

2x

A

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

the OFF position before connecting the battery

tames, ff the switch is set to AUTO or MANUAL,

the generator can crank and start as soon as the

battery caMes are connected.

Be sure the UTILITY power supply is turned

OFF, and the 7.5A and 15A fuses are removed

from the generator control panel, or sparking

may occur at the battery posts as the cables are

attached, causing an explosion.

4.8 ADJUSTING VALVE CLEARANCE

After the first six (G) months of operation, adjust

the valve clearance in the engine.

Important: if feeling uneomibrtable about doing

this procedure or the proper tools are not available,

please contact the dealer for service assistance. This

is a very important step to insure longest li% lhr the

engine.

To adjust valve clearance:

* Make sure the engine is at room temperature.

* Make sure that the spark plug wire is removed

irom the spark plug and out of the way.

* Remove the four screws attaching the valve cover

with a #2 or #3 phillips screwdriver.

Section 4 = Maintenance

1SkW Generator MAINTENANCE

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

of its compression stroke (both valves closed). To

get tlle piston at TDC, remove the intake screen at

tlle front of the engine to gain access to the flywheel

nut. Use a large socket and socket wrench to rotate

the nut and hence tile engtae. While watching the

piston through the spark plug hole. Tile piston

should move up and down. Tile piston is at TDC

when it is up as high as it can go.

o Loosen tile rocker jam nut. Use an 10ram allen

wrench to turn the pivot ball stud while checking

clearance between tile rocker arm and the valve

stem with a Ieeler gauge. Correct clearance is

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

NOTE:

Hold the rocker arm jam nut in place as the pivot

ball stud is turned.

When valve clearance is correct, hold tile pivot ball

stud ta place with the allen wrench and tighten tile

rocker arm jam nut. Tighten tile jam nut to 174

ta/lbs, torque. After tightening tile jam nut, recheck

valve clearance to make sure it did slot change.

Figure 4.6 -Valve Clearance Adjustment

Jam Nut

Pivot Ball

Stud

Rocker

Arm

Valve

Stem

4,9 C00UNG SYSTEM

Air talet and outlet openings ta tile generator eo!n-

partment must be open and unobstructed for con-

ttaued proper operation. This includes such obstruc-

tions as high grass, weeds, brush, leaves and snow.

Without sufficient eooltag and ventilating air flow, the

engine/generator quickly overheats, which causes it

to qtaekly shut down. (See Figure 4.7 lhr vent loca-

tions. )

-_ WARNING _-

/_ The exhaust from this product gets extremely

hot and remains hot after shutdown. High grass,

weeds, brush, leaves, etc. must remain dear of

the exhaust. Such materiMs may ignite and burn

from the heat of the exhaust system.

Figure 4.7- Cooling Vent Locations

t/dR INTAKE

°Install slew valve cover gasket.

o Re-attach the valve cover.

NOTE:

Start all four screws before tightening or it will not

be possible to get them in place. Make sure the

valve cover gasket is in place,

oRe-attach the spark plug wire to tile spark plug.

, Repeat the process lot the other cylinder.

CAUTION

Z_ The maximum ambient temperature for the

generator [s 48.9 ° C (104 ° F).

4.10 ATTENTION AFTER SUBMERSION

If the generator has been submerged ta water, it MUST

NOT be started and operated. Followtag any submer-

sion in water, have a dealer thorolNhly clean and dry

the generator.

4,11 CORROSIONPROTECTION

Periodically wash and wax tile enclosure using auto-

motive type products. Frequent washing is recom-

mended in salt water/coastal areas. Spray engtae

linkages with a light oil such as WD-40.

19

MAINTENANCE

Section 4-Maintenance

1S kW Generator

@4.11.1 ADDITIONAL CORROSION

PROTECTION

Periodically spray all engine linkage parts and brack-

ets with corrosion inhibiting spray such as WD=40 or

a comparable product.

4.12 OUT OF SERVICE PROCEDURE

@ 4o12.1REMOVAL FROM SERVICE

If the generator cannot be exercised every seven days,

and will be out of service longer than 90 days, pre-

pare tile generator Ior storage as Iollows:

1. Start the engine and let it warm tip.

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

and allow the unit to shut down.

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

oil fault.

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

OFF (or open) position.

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

turn off the utility power to the transfer switch.

Remove the 7.5A and 15A fllses from the genera=

tor control panel. Disconnect the battery cables

as outlined in "General Hazards" {page 2). Turn

on the utility power supply to the transfer switch

in order to power the emergency load centers cir-

cuits while utility" power is awJilable.

G. While the engine is still warm from running,

drain the oil completely. ReIill the crankcase with

oil. See "Engine Oil Recommendations," Section.

7. Attach a tag to the engine indicating the viscosity"

and classification of the oil in the crankcase.

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

agent into the spark plug(s) threaded openings.

Reinstall and tighten the spark plug(s).

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

room on a wooden board. Never store the battery

on any concrete or earthen floor.

10. Clean and wipe the entire generator.

4o12o2 RETURN TO SERVICE

To return the unit to service after storage, proceed

as follows:

1. Verify that utility power is turned off and that the

Auto/Off/Manual switch is set to OFF

2. Check the tag on the engine for oil viscosity- and

classification. Verify" that the correct reeom=

mended oil is used in the engine (see "Engine Oil

Recommendations"). If necessary, drain and refill

with the proper oil.

3. Cheek the state of the battery. Fill all cells of

unsealed batteries to the proper level with dis°

tilled water. DO NOT USE TAP WATER IN THE

BATTERY. Recharge the battery to I00 percent

state of charge, or, if defective, replace the bat=

tery. See the "Specifications" Section, ior type and

size.

4. Clean and wipe the entire generator.

5. Remove the 7.5A and 15A fuses Kom the genera=

tor control panel. Reconnect the battery. Observe

battery polarity. Damage may occur if the battery

is connected incorrectly.

6. Open the iuel shutoff valve.

7. Insert the 7.5A and 15A fuses into the generator

control panel. Start the unit by moving the Auto/

Off/Manual switch to MANUAL. Allow the unit to

warm up thoroughly.

8. Stop the unit by setting the Auto/Off/Manual

switch to OFF

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

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

1 1. The generator is now ready Ior service.

NOTE:

If the battery was dead or disconnected, the exer-

cise timer must be reset,

2O

Section 4 = Maintenance

15 kW Generator MAINTENANCE

4.13 SERVICESCHEDULE

ATTENTION: _t is recommended that all service

work be performed by the nearest Dealer.

SYSTEM[COMPONENT

X=Action

R=Replace as Necessary

* = Notify Dealer

if Repair is Needed.

FUEL

PROCEDURE

Inspect Change Clean

FRE_qUENCY

W = Weekly

M = Monthly

Y = Yearly

Fuel lines and connections* X M

LUBRICATION

Off level X M

Off X AFTER BREAK-IN,

AND Y

Off filter X AFTER BREAK-IN,

AND Y

COOLING

Enclosure ]ouvers X X W

BATTERY

Remove corrosiolL X X M

ensllre dl%ness

X X M

bagel T terminals

Check charge state X R EVERY G M

Electrolyte level X R EVERY 6 M

(unsealed batteries only}*

ENGINE AND MOUNTING

Air cleaner X R Y

Spark plu_{s} X R Y

GENERAL CONDITION

Vfl)ration, Noise, Leakage, X M

COMPLETE TUNE-UP* TO BE COMPLETED BY A DEALER

21

TROUBLESHOOTING Section 5=Troubleshooting

1S kW Generator

5.1 TROUBLESHOOTING GUmDE

Cause

Tile engine will not crank. 1. Fuse blown

2. Loose, corroded or detective

battery cables

3. Defective starter eontaetor (7 kW) 3.

4. Defective starter motor 4.

5. Dead Battery 5.

Correction

1. Replace 15A fllse oil generator

control panel.

2. Tighten, clean or replace

as necessary.

Charge or replace battery.

Tile engine cranks but

will not start.

1. Out offllel

2. Defective fllel solenoid (FS)

3. Open #14 wire flom

engine control board

4. Defective spark plug{s)

5. Valve lash out of adjustment.

1. Replenish fuel.

2. *

3. *

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

5. Reset valve lash.

Tile engine starts hard

and runs rough.

1. Air cleaner

plugged or damaged

2. Detective spark plug(s) 2.

3. Fuel regulator not set. 3.

4. Fuel pressure incorrect. 4.

1. Cheek, replace air cleaner.

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

Set fllel regulator.

Confirm fllel pressure is at (0.4-

0.5 psi) ti)r LR and 5-7" water

eohmm (0.18-0.25 psi) for natural

gas.

Tile AUTO/OFF/I_NUAL switch

is set to OFR but tile engine

continues to run.

1. Deleetive switch 1. *

2. AUTO/OFF/MANUAL switch 2. *

wired incorrectly

3. Defective control board 3. *

There is no AC output from

the generator.

1. Main line circuit breaker open 1. Reset circuit breaker

to ON (or closed).

2. Generator internal l_tilure 2. *

There is no transfer to

standby alter utility

source failure.

1. Defective transler switch coil 1. *

2. Defective transfer relay 2. *

3. Transfer relay circuit open 3. *

4. Defective control logic board 4. *

Unit consumes large 1. Breakqn procedure 1. *

amounts of oil. not followed

*Contact the nearest Dealer for assistance,

22

743

/2s ',i

716tze

308

i iI

7O4

i [27,7"j

-. v

207 [8.14"]

TRANSFER SWITCH

(IF SUPPLIED)

604 [23,5"] _-

622 [24,5'_J

LEFT S_DE VEW 76,2mm [300]

pEAGRAVEL

M]NUMUM

L

UFT[NG HOLES 4-CORNERS

"DO NOT LEFT BY THE ROOF"

1193 [47"] _'

FRONT VIEW

AIR

OUTLET 1_

i_- ,_ F_...................___11_

030.2; nt n [Ol19"1 ; /' _ - ¢°°F_

t

..... 1172.3 [462"1

I

#14ram [ 24_0" _,_

M_NIMUMOPEN AREA

ALL AROUND UNiT

A:'_ N lAKE

94 NPT FUEL iNLET

GAS PRESSUREOF 11 14'

WATER COLUMN REQUIRED

// i E•\

\: CABLE ACCESS HOLES•

_/:;', ' [REMOVE PLUG FOR ACCESS/

_==_

260

_ {_°_"_ )I,'\\

149

L5.9"]

RIGHT SIDE VIEW REAR VIEW

**ALL DIMENSIONS IN:

MILLIMETERS [INCHES]

t#

s=.

I

No

N

Section 7 - Electrical Data

ms kW Generator

Wiring Diagram = Drawing No. 0E9016

ENGINE WIRING

DIAGRAM KEY

BA -BROBR ASSEMBLY

RCR- BATTERY CRAROB RELAY

CR1 -fv'AINOL_PUT BREAKER

CR2- CIRCUIT RRBAKBR, ALTERNATOR BXCI FATION

CR3- CIRCUIT RRBAKER, EXTERNAL OUTLET, RUSH/PULL

D-DIODE

DSW kPCR fv'OBNTBD DIP SWITCH

FB -FUEL SOLENOID

F1 kFUSE 15AMP

F2 kFUSE75 AMP

ORB- CONTROL PANEL GROUNB

HTO kNIGH OIL TEMPERATURE SW[TOH

IC kINL[NB CONNECTOR

ICT- INTEROONNECTIONTERMINALS

IM1k IGNITION MODULE, CYUNBBR #1

IN2 _ IGNITION PODULB, CYUNBBR #2

LOP- LOWOIL PRESSURE SWITCH

SC- STARTER CONTACTOR

SCR -STARTER CONTACTOR RELAY

SPl_ SP2 kSPARK PLUGS

SW1 kAUTO /OFF /MANUAL SWITCR

SW2 kBET EXERCISE SWITOR

SM -STARTER MOTOR

_B -INSULATEDTERMIBAL BLOCK

TX- TRANSFORMER, 16 Vac 56 VA & 1_ Vac 1 VA (DUAL SBC)

SP1

SP2 D

IC

RED

OUSTOMERSUPPLIED

19--

0

224B

225B

o

14

_ e >_o

18 >5 }18

TB

OR 16

_ u

85

J2

CONTROL

PRINTED CIRCUIT BOARD

DSW

1234

1

2RemoteNotAuto

3 SOHz Oneration

4 SPARE

13

15

........... 66A ..........................................................................

--28g

--15A

17

15

--0

--225

-- 224

LED- ALARM INDICA'_RB

24

Section 7 = Emectrical Data

1S kW Generator

Wiring Diagram = Drawing No. 0E9016

194

--66A

CONTROLPANELBOX

224A

BCR

225A

CB2

11

22

4

o

6

162

VOLTAGE

REGULATOR

77 66

194

23

N2

N1

551

/

15B

CLOSEST TO BEARING

BA

STATOR

240V GENERATOR

OUTPUTTO TRANSFER

SWITCHCONTACTOR z

E

12VDCACCESSORYSOCKET

CUSTOMER

CONNECTION

25

Section 7 m Electrical Data

1S kW Generator

EmectricamSchematic_ Drawing No. 0E9017

ELECTRONIC

VOLTAGE

REGULATOR

7_ BATTERY CHARGE

162 qo 6

C2-8 2

DPE WINDING

(STATOB)

DIAGRAMKEY

BA - BRUSHASSEMBLY

BCR- BATTERYCHARGERELAY

CB1- CIRCUITBREAKER,MAINOUTPUT

CB2- QRCU]T BREAKER,ALT EXCITATION

CB3- CIRCUITBREAKER,EXTERNALOUTLET,PUSH/PULL

D- DIODE

FB - FUELSOLENOID

F1 - FUSE 15AMP

F2 - FUSE 75 AMP

HTO- HIGHOIL TEMPERATURESWITCH

]M1-IGNITIONMODULE,CYLINDER#1

]M2-]GNmON MODULE,CYLINDER#2

LOP- LOWOIL PRESSURESWITCH

SC- STARTERCONTACTOB

SCR- STARTERCONTACTORRELAY

BP1,BP2 - SPARKPLUGS

BW1- AUTO/OFF /MANUALSWITCH

BW2- SET EXERCISESdITCH

SM -STARTERMOTOR

TX- TRANSFORMER,16Vac_ VA & 16Vac 1VA (DUALSEC)

I1

22 ..........................................................................................................................................................................................................................................................................................................................................22

WINDING

02-2

6

6

sw2 L

BTO

ENGINE RUN

WINDING

(STATOR)

C2-3

CONTROL

PRINTEDCIRCUIT

BOARD

LOP

14

01-3

23

-- 194

--- 56 --

_o

--14

w_ 68A

239

15A

17

15

6

.............................225 ......................................

-- 224

j225A

224A

226

224 --

--13 --

O

15A

26

Section 7 - Emectrical Data

15 kW Generator

£mectricamSchematic -Drawing No. 0E9017

224A

..............................225

..............................224

13

56VA

C2_6

-- 15A

23

194

--13

0

15

i

.............18

17

...........15

0

239

14

--_3 --<<

C2q

C1-1

<(

02-5

0

T

G

L

194 23

239

23

194

N ....

POWER i ! 120V 1201V

WENDENG

(STATOR)u_

11

N

BLACK

-- BATTERY

12V

CUSTONER

SUPPLIED

b E

I _

--G

I EXTERNAL

GFCE

OUTLET

240V

CUSTOMER

CONNECTIONS

-<_18

01 5

27

_@ RTSISTS Section 8-E×ploded Views and Parts lists

15 kW Generator

Encmosure= Drawing No. oFooso-c

PREPACKAGED UNITS ONLY

7_

40 \\

69

7I

30 17

< <

35_ 49

26 ,\

47

2O

31 50 r44 60

_11

8 _. 57

51 9 35 27

< 56

49 1 58

\

34

35

52

25

63

92

<

g3 13

39

_S........42

10

.)

f

/

P

28

Section 8- E×pIoded Views and Parts Lists

15 kW Generator

Enclosure = Drawing No. eFO080-C

_(_,_ RTtmSTS

iTEM PART NO. QTY.

1 006140 1

0D1901 1

2 006735 2

3 0F0063 1

4 007062 1

007062A 1

5 0E8811 1

0E8811A 1

6 0E9873 1

7 007065 1

007066A 1

8 008101A 1

008861 1

9 008101B 1

008862 1

10 008283 1

11 008284A 1

12 008284B 1

13 0082840 1

14 008285 1

15 008899A 1

16 0Dl128 1

0D1128A 1

17 0E4244 1

0D1605A 1

18 0D1606 1

0D5264 1

19 0D1839 2

20 0D1840 2

21 0D2425 1

22 0D2588 1

0D2588A 1

23 0D2676 1

24 0D2677 1

25 0D2979B 2

0D2979B 3

26 0D29790 1

27 0D2979D 1

0D2979E 1

28 0E4245 1

0D3058A 1

29 0E4245A 1

30 0E4245B 1

0D30680 1

31 0D3057D 1

32 0D3069A 1

33 0D3069B 1

34 0D30590 1

35 0D7176 24

22

36 0D3059D 1

37 0D3059E 1

38 007781A 2

39 0D3037 1

40 0F0164 1

41 0F0165 1

42 0D3037A 1

43 0A2115 4

44 022097 1

46 0F0710 18

DESCBIPTION

ASSEMBLY,ENCLOSUREBASE

ASSEMBLY,ENCLOSUREBASE(7KW)

SUPPORT, ROOFFOLDING

ENCLOSURE,FRONT

ENCLOSURE,EXHAUSTSIDE

ENCLOSURE,EXHAUSTSIDE(7KW)

ENCLOSURE,SIDE& BACK

ENCLOSURE,SIDE& BACK(7KW)

ENCLOSURE,ROOF

PANEL,ALTERNATORDIVIDER

PANEL,ALTERNATORDIVIDER(7KW)

PANEL,MUFFLERBOXSIDE

PANEL,MUFFLERBOXSIDE (7KW)

COVER,MUFFLERBOX

COVER,MUFFLERBOX (7KW)

GASKET,DOOR SEAL

FOAM,BACKENCLOSURE

FOAM,ROOFENCLOSURE

FOAM,FRONTENCLOSURE

BRACKET,BATTERYSUPPORT

PAD,24"X48"WITHMOUNTINGHOLES

PANEL,ENGINEDIVIDER

PANEL,ENGINEDIVIDER(7KW)

BAFFLE,INTAKE

BAFFLE,INTAKE(7KW)

HOUSING,FAN

BAFFLE,EXHAUST(7KW)

BRACKET,TOP SUPPORT

BRACKET,BOTTOMSUPPORT

DUCT,BASEAIR

GASKET,FRONT DIVIDER

GASKET,FRONT DIVIDER(7KW)

COVER FRONTEXHAUSTENCLOSURE

COVER BACKEXHAUSTENCLOSURE

CLOTH HARDWARE266.7mmx 146mm

CLOTH HARDWARE266.7mmx 146mm(7KW)

CLOTH HARDWARE543mmx 146mm

CLOTH HARDWARE266.7mmx 387.4mm

CLOTH HARDWARE(7KW)

FOAM FRONTINTAKEBAFFLE

FOAM FRONTINTAKEBAFFLE(7KW)

FOAM TOP INTAKEBAFFLE

FOAM BACKINTAKEBAFFLE

FOAM BACKINTAKEBAFFLE(7KW)

FOAM BACKENCL STRIP

FOAM EXHAUSTSIDEENCLOSUREEND

FOAM EXHAUSTSIDEENCLOSUREFRONT

FOAM EXHAUSTFANHOUSING

WASHER,SELFLOCKING

WASHER,SELFLOCKING(7KW)

FOAM,FRONTEXHAUSTENCLSURECOVER

FOAM,BACKEXHAUSTENCLOSURECOVER

DOOR,PAWL

LATCH,QUARTERTURNLOCKING

HINGETYPE A WITH STUDS,PIN

HINGETYPE B WITH STUDS,PIN

LATCH,QUARTERTURNNON-LOCKING

WASHERNYLON.250"

WASHERLOCKM6d/4"

RIVET POP 0,125X 0,337

|YEM PART NO. QTY. DESCRIPTION

52

54

55

56

57

58

59

60

61

62

63

66

67

68

69

70

71

72

73

74

75

76

77

78

79

80

81

82

83

84

85

86

87

89

9O

91

92

93

94

95

96

97

98

99

047411 6 SCREW RRCM6A.0 X 16 G8.8

047411 4 SCREWHHCM6d .0 X 16 G8.8(7KW)

043116 5 SCREWHHCMSd.0 X 12 G8.8

043116 6 SCREWHHCM6d .0 X 12 G8.8(7KW)

0D3700 26 NUT,LOCKINGFLANGEM6A.0

0D3700 24 NUT,LOCKINGFLANGE M6A.0 (7KW)

0D4662 11 SCREW HHTTM8-1.2X 20 BP

090388 36 SCREWTAPTITEMTd .0 X 12 BP

24 SCREWTAPTITEM6d .0 X 12 BP(7KW)

092120 2 NUT LOCKTRIO M6 X 1.0Y/ZNC

0D3167 1 GASKET,BATTERYSUPPORTBRACKET

0A3328 1 PLUG,PLASTIC0.593

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

092079 1 SCREWTAPTFE M6d .0X25BP

0A1658 2 L/WASHSPECIAL_A

002937 1 BRACKET,BATTERYHOLD DOWN(7KW)

086729 1 CONTACTOR,STARTER(7KW)

0388040AJ0 1 CABLE,#6 RED BATTERY38.5"

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

022129 6 WASHERLOCK5/16

022129 7 WASHERLOCK5/16(7KW)

074908 8 SCREWTAPTITEM5-0.8X 10 BP

0D2346 1 HARNESS,ENGINE

0D2345 1 HARNESS,ENGINE(7KW)

023484F 1 BUSHING,SNAPSB-1000A2

022142 1 SCREWHHC5/16-18X 3/4G5 (7KW)

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

0A8475 2 L/WASHSPECIAL#10

0912970069 1 ASSEMBLY,ROOF/DOORGROUNDWIRE

0912970070 2 ASSEMBLY,ROOF/DOORGROUNDWIRE

055450 2 PLUG PLASTIC1.375

0E5968 11 GASKET,EXTRUDEDTRIM

0D3701 1 PLATE,"HOT"

0D3472 1 GROMMET2.75 X 1/16

008742 1 EXTERNALCONNECTIONBOX

008911 1 POWERBLOCK

0D8442 1 HARNESSGENERATORTO EXT CONNBOX

0D8652 1 HARNESSGENERATORTO EXT

CONNECTIONBOX (7KW)

036937 2 SCREWPPHM#10-32X 1

022152 5 WASHERLOCK#10

051713 2 WASHERFLATM5

022158 5 NUT HEX#10-32 STEEL

0D3031 1 FUEL LINE,3/41'OUTDOOR(NOT SHOWN)

026850 1 WASHERSHAKPROOFEXT 1/4 STEEL

049813 1 NUT HEXM6d .0 G8YELLOWCHROME

0F0164A 1 HINGETYPE A WITH STUDS,SOCKET

0F0165A 1 HINGETYPE B WITH STUDS,SOCKET

0E2874 1 SCREW HHTR1/4-20 X 3/4

043107 4 SCREWHHCMSd.25 X 25

022145 10 WASHERFLAT5/16

045771 4 NUT HEX M8-1.25

003906 2 SELF-ALIGNSCREW M6 HH

0E4321 1 PANEL,EXHAUSTALIGNMENT

0E1330A 1 GROMMET,38.1 CROSSSLIT WITH HOLE

0E9692 1 BRACKET,REGULATORMOUNTING

042907 2 SCREWHHCMSd.25 X 16ram

0F5241 1 PLATE,COVER

0F5943 1 GASKET,COVER

29

_<_ RTSISTS Section 8-E×ploded Views and Parts lists

15 kW Generator

ContromPanem- Drawing No. 0E91624

22

8,9

\\ 8,32

i

38

27

\

23

4

i 48

\27 47 \ _ 29

I 2

44 17_

L

43

_- 45

47

30

2_ \31

55 58

/

/54

/

/

53

3o

Section 8- E×pIoded Views and Parts Lists

15 kW Generator

CentromPanem=Drawing No. eE9162-_

)_RTtmSTS

mTEM

1

PART NO. QTY.

0E7886A 1

0E7886E 1

0E7886J 1

2 0A1801 1

3 083049 1

4 0C2174 1

5 075210A 1

6 0D3062 4

7 0D8815 1

0D8815A 1

8 032300 2

9 022678 1

10 0E4494 1

11 0E7890 1

12 023484E 1

13 075478 4

15 0E6480 6

17 0C1085 6

0C1088 4

19 054502 1

053623 1

20 0E7870 1

0E7871 1

21 075235 4

22 0D5240 1

23 0D9784 8

0D9784 4

24 0D8802 1

28 0E8956 1

0E8957 1

27 074908 4

28 049226 6

DESCRIPTION |YEM PART NO. QTY. DESCRiPTiON

CIRCUITBREAKER30AX 2P 240V (7KW) 29 082025

CIRCUITBREAKER50A X 2P 240V (12KW) 30 0C3910

CIRCUITBREAKER85AX 2P240V 31 022507

(13/15KW) 32 0A9611

ASSEMBLY,BATTERYCHARGERENGINE 33 046689

ASSEMBLY,POTTEDREGULATOR 34 063617

RELAY,12V25ASPST 35 075475

BLOCK1 POSITION 38 043180

HEXSTAND-OFF#8-32x 3/8" 37 0E8812

ASSEMBLY,HOMESTANDBYCONTROLLER 0E8895

ASSEMBLY,HOMESTANDBYCONTROLLER

(7KW) 38 092036

HOLDER,FUSE 39 045770

FUSE,15AMPX AGC15 40 0E7866

SWITCH,ROCKERDPDTON-OFF-ON 0E7887

CIRCUITBREAKERMOUNTINGBRACKET 41 0D3700

SNAPBUSHING 42 0912970069

SCREWPPHMM4-0.7x 16mm 43 0E2874

[',JUTHEX LOCKM4-0.7NYLONINSERT 44 0A1658

SCREWPPHMM3-0.5x 8ram 45 022473

SCREWPPHMM3-0.5x 8mm (7KW) 46 038750

CIRCUITBREAKER3 X 1 ETA48-500-P 47 022097

CIRCUITBREAKER2.5 X 1 ETA48-500-P 48 049813

(7KW) 49 031879

CONTROL,PANELBOTTOM 031879

CONTROL,PANELBOTTOM(7KW) 80 023897

SCREWHHCM5-0.8x 30mm 51 0E9056

SWITCH,SPST (ON)-ONN/O 52 0E5840

[`,JUTHEX LOCKM3-0.5NYLONINSERT

[`,JUTHEX LOCKM3-0.5NYLONINSERT 83 036903

(7KW) 54 0E7833

NEUTRALCONNECTOR 55 0E4261

HARNESS,CONTROLPANEL(NOTSHOWN) 88 022985

HARNESS,CONTROLPANELWIRE (NOT 87 082825

SHOWN)(7KW) 58 0E9171

SCREWTAPTITE,M5-0.8x 10 BP 59 0F4793

WASHERLOCK M5

6 NUT HEXLOCKM5-0.8 NYLONINSERT

1 TRANSFORMER

2 SCREWHHC1/4"-20x 1/2"

1 FUSE7.55AX AGC8

1 BLOCKTERMINALSTRIP20A 4 X 6 X 1100V

1 RELAYPANEL12VDCDPDT10A240\/AC

2 SCREWPPHMM4-0.7x 10mm

2 WASHERFLATM4

1 COVER,CONTROLPANELCOMPONENT

1 COVER,CONTROLPANELCOMPONENT

(7KW)

8 SCREWPPHMS/LW#6-32x 1/4"

2 SCREWHHCM5-0.8xl0mm

1 COVER,CONTROLPANEL

1 COVER,CONTROLPANEL(7KW)

8 NUT FLANGEM6-1.0 NYLOK

1 ASSEMBLY,ROOF/DOORGROUNDWIRE

1 SCREWHHTR1/4"-20X 3/4"

2 WASHERLOCKSPECIAL1/4"

3 WASHERFLAT1/4"-M8

1 SCREWHHCM6-1.0x 30mm

3 VVASHERLOCKM8-1/4"

1 NUT HEXM6-1.0

8 WASHERFLAT#4

4 WASHERFLAT#4 (7KW)

2 WASHERFLAT#10

1 SOCKET,12VDCACCESSORY

1 CIRCUITBREAKER15APUSH/PULLMAIN

RESET

6 SCREWPPHM#6-32X 5/8"

1 PLATE,WEATHERPROOFGFCI

1 OUTLET,15AGFC!DUPLEX

4 WASHERFLAT#6

4 NUT LOCKHEX#6-32 NYLINSERT

1 GASKET,WEATHERPROOFGFC!

2 SCREWPPHMM3-0.5x 10mm

31

4O

41

42

37

44

45

140

26

46

47

48

49

50

51

52

34

36

35

34

33

22

66 2,5,19,20,39,40,47,64,93,I40

67 8,11,12,13

68 4,5,6

69 16A,16B,17,18

70 7,47,48,49,50,51,52,53,54,56,57,58,59,60,63,64

71 47,48,49,50,51,52,53,54,56,57,58,59,60,62,63,64

72 27,28,29

73 3,32,33,34,35,36,40,72

21

25

23 16B

16A

16A 15

13

14

12

10

58

63 64

\

65

60 61

7

6

143

Section 8= E×pIoded Views and Parts Lists

1skw Generator

GT=990 Engine =Drawing No. OF4715=B Part I

F_,_RTtmSTS

iTEM PART NO. QTY.

1 005729 1

2 0E9843 1

3 090388 3

4 0C5372 1

5 0C3005 1

6 0E3372B 3

7 0D8067A 1

8 071983 4

9 0C29810 1

10 045781A 4

11 0E2985 2

12 021533 2

13 0E1486 2

14 0D4041 1

15 002983 1

16A 002985A 2

16B 002985B 1

17 0D4042 1

18 0A7811 1

19 002977 1

20 005943 1

21 0E4357E 1

22 0E3223 2

23 0D2157 2

24 0E6098 1

25 0D4123A 1

26 078699E 2

27 003011 2

28 003009 2

29 0C3010 2

30 093873 2

31 0C5315 1

32 005998 1

33 0D1667 1

34 0C2991 2

35 0C2988 1

36 002992 1

DESCRIP_|QN

ASSEMBLY,CRANKCASEHOUSINGWITH

SLEEVE

SEAL,38 !.D.CRANKSHAFT

SCREW,TAPTITEM6-1.0X 12YC

ASSEMBLY,BREATHER

GASKET,BREATHERCOVER

SEPARATOR,OILBREATHER

ASSEMBLY,HEAD#1 G&S

RETAINER,PISTONPIN20

ROCKER,COVERNOOIL FILL

STUDM8-1.25/10MMX 30 G5 ZINC

PISTON,HO

SET,PISTONRING90MM

PIN PISTON

ASSEMBLY,CAMSHAFT& GEAR

SHAFT,GOVERNOR

ROLLERBEARING,GOVERNORPLATE

ROLLERBEARING,GOVERNOR

ASSEMBLY,GOVERNORGEAR

SPOOL,GOVERNORMACHINED

GASKET,CRANKCASE

SEAL,OILPASSAGE

ASSEMBLY,CRANKSHAFTHORIZONTAL

DIRECTDRIVE

ASSEMBLY,CONNECTINGROD

SCREWSHC M6-1.0X 50 G8.8

SCREEN,OILPICKUP

ASSEMBLY,OIL PUMP

SLEEVE,SEAMEDDOWEL10 DIA.

COVER,OIL RELIEF

SPRING,OIL RELIEF

BALL,1/2DOILRELIEF

WASHER,LOCKRIBM6

GEROTOR,OUTER

CLAMP,OILTUBE

ARM,GOVERNOR

E-RING,GOVERNORARM

THRUSTWASHER,GOVERNOR

BUSHING,GOVERNORLOWER

|YEM PABY NO. QTY. DESCRiPTiON

37 0039710 1 ASSEMBLY,DIPSTICKWITHHANDLE

38 005305 1 TUBE, DIPSTICK

39 003027 1 O-RING,OILCLR3/8X 1/2

40 0E9842 1 SEAL,42 !.D.CRANKSHAFT

41 005731 1 ASSEMBLY,HOUSINGCOVERWITH

SLEEVE

42 003006 9 SCREW,HHFCM10-1.5X 55

43 080318 8 SCREWHHFCM6-1.0X 25

44 093064 1 ASSEMBLY,OILFILL CAP

45 008808 2 HOOK,LIFTING

46 0D2723B 1 ROCKER,COVERWITH OILFILL

47 002979 2 GASKET,\,'AWECOVER

48 086515 8 KEEPER,VALVESPRING

49 0D2274 4 RETAINER,VALVESPRING

50 0D3867 4 SPRING,VALVE

51 078672 2 SEAL,VALVESTEMD7

52 005371 4 WASHER,VALVESPRING

53 072694 4 STUD,ROCKERARM PIVOT

54 0D3998 4 NUT HEXM8-1.0G8YEL CHR

55 003027 2 O-RING,3/8"X 1/2"

56 0D5313 4 ROCKERARM

57 0D8024 2 PLATE,PUSHRODGUIDE

58 0C2976 12 SCREWHHFOM8-1.25X 65

59 086516 2 VALVE,EXHAUST

60 002229 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 BARBEDELBOW90 3/8NPTX 3/8

66 0D4010 1 KIT GASKET

67 0D4011 1 KIT PISTON& RINGS

68 0D4012 1 KIT BREATHERASSEMBLY

89 0D4013 1 KIT GOVERNORASSEMBLY

70 0D8875A 1 KIT HEADASSEMBLYCYLINDER1

71 0D8675B 1 KIT HEADASSEMBLYCYLINDER2

72 0D4015 1 KITOIL RELIEF

73 0D4016 1 KIT GEARCOVER

33

RTSIsTS Section 8 - E×ploded Views and Parts Lists

15 kW Generator

GT=990Engine = Drawing No. 0F4715=BPart 2

122 124 125

123, 145

25

124 143

119__,_

120

138

139

136 _ 135

137

134

132

142

81

1114

128

95

97

126

84

86 85

88 89

90 89

91 92

99

112

103

105

107

108

112

110

112

111

34 GenePac ® Power' SVstems _ Inc,

Section 8 - E×ploded Views and Parts Lists

1skw Generator

GT-990 Engine _Drawing No. 0F471S-B Part 2

_)_ RTtmSTS

iTEM PART NO, QTY.

74 0C5138A 2

75 0C3024 1

78 0C3040 1

77 008127 1

78 0D8584A 1

0D8584B 1

79 0D2595 4

80 0D4417 4

81 003025 1

82 0D3083 1

83 0C7292 1

84 070185D 1

85 075281 1

86 0F2094 2

87 0F1338A 1

88 035461 2

89 0F6301 4

90 0C9808 2

91 0C3026 1

92 009764 4

93 0C3043 2

94 0C7694 1

95 0C7893 1

96 003041A 2

97 070008 4

98 070006 4

99 040978 4

100 0F1170A 1

101 0E4997 1

102 003725B 1

103 003031 1

104 0C3032 1

105 0A5992 2

108 051754 2

107 0C3033 1

108 0C3034 1

109 008549A 1

DESCRIPTION

KNOB,AIRCLEANER

COVER,AIRBOXNG/LP

PRE-CLEANER,

ELEMENT,AIR CLEANER

ASSEMBLY,MIXER/AIRBOX990

ASSEMBLY,MIXER/AIRBOX760

SCREWSHOULDER(8MM)M6-1.0X 18

WASHER,RUBBER1/4"X 1/8"THICK

SWITCH,OIL PRESS

ASSEMBLY,OIL DRAINHOSE

NIPPLE,3/4"-16UNF

OILFILTER

SWITCH,THERMAL284F

SCREW,M3-0.5X 8 SEMS

ASSY,IGNCOiLW/DIODENOADV

BARBEDSTR 1/4NPTX 3/8

CLAMP,HOSEOETIKER16.5mm

HOSE,3/8" I.D.X 6" LONG

COOLER,OIL

PLASTITE,1/4-15X 3/4

GASKET,MANIFOLD/PORT

MANIFOLDCYLINDER2

MANIFOLDCYLINDER1

SLEEVE,RUBBER

WASHERFLATM8SS

WASHERLOCK M8SSTL

SCREWSHC M8-1.25X 20G12.9

PLATE,BACKINGWITHOILCOOLER

GROUNDWIRECONNECTOR

FLYWHEELASSEMBLY

FAN,NYLON

PLATE,FAN

WASHERSHAKEPROOFINTM8SS

SCREWHHCM8-1.25X 12G8.8

WASHER,25mmI.D.

NUT,HEX M24

SNORKEL,AIR INTAKE

ITEM PART NO, QTY.

110 0F1169A 1

111 0Dl131 1

112 045758 25

113 009783 4

114 003036A 1

115 022145 1

116 022129 1

117 0C3018 1

118 003019 1

119 0D1142A 1

120 0Dl143 1

121 0E8043 2

122 0Fl177 1

123 0F1338B 1

124 022097 4

125 092079 4

128 0E4271 1

127 0D4529 2

128 022129 2

129 061906 2

130 082774 1

131 0E5343 1

132 008488 1

133 003048 1

134 0D3754 1

135 0D3742 1

136 0C8482 1

137 0E0488 1

138 0D3743 1

139 0D3705 1

140 0C2993 1

142 045771 1

143 0D6147 7

144 0E8152 1

DESCRIPTION

HOUSING,BLOWERNGCOOLER

GUARD,PAN

SCREWTAPTITEM8-1Xl0YELLOW

CHROME

NUT,GROMMET1/4PLUG

HOSE,BREATHER

WASHERFLAT5/16-M8ZINC

WASHERLOCKM8-5/16

WRAPPER,UPPERCYLINDER1

WRAPPER,LOWERCYLINDER1

WRAPPER,LOWERCYLINDER2

WRAPPER,UPPERCYLINDER2

SCREWTAPTITEM5-0.8X 8 ZP

ASSEMBLY,GROUNDWIRE

ASSY,IGNCOILW/DIODENOADV

WASHERLOCKM8-1/4

SCREWTAPTITEM6-1.0X 25 BP

STARTER

SPARKPLUG

WASHERLOCKM8-5/16

SCREWHHCM8-1.25X 85 G8.8

KEY,WOODRFF4 X 19D

NUT HEXLOCKM10-1.50

SPRING,ANTI-LASH

ROD,GOVERNORCONTROL

ASSEMBLY,GOVERNORLEVER

SPRING,GOVERNOR

ASSEMBLY,GOVERNORADJUSTER

SCREWSHC M10-1.5X 75G10.9

SPRING,GOVERNORIDLE

ASSEMBLY,GOVERNORADJUSTER

BRACKET

SEAL,GOVERNORSHAFT

NUT HEXM8-1.25G8

SCREWHHFCM6-1.0X 10mm

O-RING0.49"I.D.X 0.07"THICK

Generac ®Power' Systems_ mnc, 35

34 40

36

36

35

11

5

23

24

21

43

33

13

37

8

9

31

32

28

2

3

20

38

15

\

30

17

10

32

25

32

19\

26

16

29

28

27

35 36

36

31

32

H

6'€

Z

o

0

t#

¢0

x

E

&

##

Section 8- E×pIoded Views and Parts Lists

15 kW Generator

15 kW Generator =Drawing No. 0D3417=L

'_(_ _RTtISTS

iTEM

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

2O

21

22

23

24

25

26

27

28

29

3O

31

32

33

34

35

36

37

38

39

40

41

42

43

PART NO.

0C6934

007930

0D2359

0C7944

0D2356

006043

0D2336

0D6634

0D3220

008101

056482

003168

0D1838

0D1846

007038

0D1609

0D2559

007038A

007758

0388050AD0

002417A

082121C

066386

029451

049451

022237

022511

022131

051731

022145

049820

045756

022129

022259

059637

0D4662

0F7065

048031M

0F0462

002824

025145

004138

040173

074995

066849

QTY', DESCRIPTION

1

1

1

1

1

1

3

1

4

1

1

1

1

4

1

1

1

1

2.6 FT

1

5

4

4

4

12

4

2

10

8

2

4

3 FT

4

4

1

1

2

2

1.44FT

2

ADAPTOR,ENGINE

STATOR12KW

STATOR13KW/15KW

ROTOR12KW

ROTOR13KW/15KW

CARRIER,REARBEARING

FAN,12" CURVEDBLADE

MUFFLER

TAILPIPE, MUFFLER

PANEL,MUFFLERBASE

BEARING1.1811-2.8346

5/16 SPECIALLOCKWASHER

BOLT,HHCS3/8"-24x 15.50"

BOLT,HHCS M8-1.25x 345mm

BRACKET,ALTERNATORMOUNTING

DUCT,ALTERNATORAIR

GASKET,ALTERNATORAIR DUCT

BRACKET,ENGINEMOUNTING

RUBBERMOUNT

CABLE,#6 48" BLACKBATTERY

EARTHSTRAP3/8X 3/8

CLIP-J,VYNLCOAT0.625"ID

ASSEMBLYBRUSHHOLDER

TAPEELECULFOAM1/8X 1/2

WASHERFLAT.4061DX 1.62OD

WASHERLOCK3/8

SCREWHHC3/8-16 X 1-1/4G5

WASHERFLAT3/8ZINC

SCREWHHC M8-1.25X 50 G8.8

WASHERFLAT5/16ZINC

NUT LOCKHEX M8-1.25NYL INSERT

SCREWTAPTITEM6-1.0X10BP

WASHERLOCKM8-5/16

NUT HEX5/16-18STEEL

SCREWTAPTITE3/8-16X 3/4BP

SCREW5/16-18X3/4"HHTHD ROLL

HOSE RES1/2 LP GAS

HOSE CLAMP3/4" I.D.

NUT HEXW/TOOTHWSHRM8-1.25

SCREWTAP-R#10-32x 9/16

U-BOLT5/16"-18X 1.25"WITHSADDLE

GASKET,EXHAUSTPORT

CLAMPHOSE#5.5 0.62"-0.62"

HOSE 1\4 ID LPG350PSIUL21

SCREWHHTTM5-0.8X 16

37

20

./

25 24

23

10

12

J

/

/

/

17

12

8

2

10_

3

10

30 "0

J

\

37

J_

J26 16 _ 29

_14 19

13

23

11

24

12

25

28

2O

z _

o _

?

/

21

Section 8 - E×ploded Views and Parts Lists

1S kW Generator

Gas Regumator= Drawing No. OD8720=G

_(_ RTtmSTS

iTEM PART NO, QTY.

1 0D5694

2 0F5022

3 004647

4 0D4166

5 006070

8 0F4795

9 005760J

10 006606

11 097934

12 004645

13 005761

14 005968

15 006066

16 005759

17 005764

005764A

18 070728

19 006069

20 005762

21 045764

22 006731

23 006067

24 0C4706

25 0C6068

26 004643A

27 026073

026073

28 0A4032

29 0D3308

30 024310

31 028414A

32 0D5698A

37 0D3973

1

1

1

1

1

4

1

2*

2*

2*

2

2

2

2

2

2

* A QUANTITYOF 1 ISTO BE USEDON 7KW

DESCRIPTION

4

2

2

16

2

2

2

2

2

1

2

2*

4

1

1

1

1

CASTING,TWIN REGULATORHOUSING

SOLENOIDCOIL, 12VDC

GASKET, SOLENOID

PLUNGER,LP REGULATORASSEMBLY

SPRING-SOLENOID,PLUNGER

SCREWPPHMSEMS M4-0.7X 10

JET,GN410 ENGINELP (7KW)

BARBEDSTRAIGHT1/2NPTx 1/2

O-RING,CHECKVALVE

ADJUSTERSCREW,TWINREGULATOR

LEVER,REGULATOR

SUPPORT,INLETSEAL

SEAL, INLET

PIN, PIVOTARM

SPRING,REGULATOR

SPRING,REGULATOR(7KW)

SCREW,PFHMSM3-0.5x 5

GASKET,DIAPHRAGM

COVER,TWIN REGULATOR

SCREW,TAPTITEM4X8BP

RIVET,POP .118X.125

SUPPORT,DIAPHRAGM

DIAPHRAGM,TWIN REGULATOR

CAP,DIAPHRAGMSUPPORT

INLET,TWINREGULATOR11.11DIA.

PLUG,STANDARDPIPE1/8"STEELSQUAREHEAD

PLUG,STANDARDPIPE1/8"STEELSQUAREHEAD(7KW)

PIN, LIMITEDADJUSTMENT

WASHER,FLATM3X 10ramO.D.

PLUG,STANDARDPIPE1/2"STEELSQUAREHEAD(7KW)

BARBEDSTRAIGHT1/8"NPTX 1/4"

JET IDLEPRIMERPHILLIPSHD (\,'-TWINONLY)

PLUG,EXPANSION16ram

HOMESTANDBY

39

Section 9 - Warranty

15 kW Generator

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

CALiFORNiA AND FEDERALEMiSSiONCONTROLWARRANTYSTATEMENT

YOURWARRANTYRIGHTSAND OBLIGATIONS

The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with

Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control System Warranty on your new' engine.*

New (small off road) engines must be designed, built and equipped to meet stringent anti-smog standards for the state of

California and the federal government. Generac will warrant the emission control system on your engine for the periods of

time listed below provided there has been no abuse, neglect, unapproved modification or improper maintenance of your

engine.

Your emission control system may include parts such as the carburetor, ignition and exhaust systems. Generac will repair your

engine at no cost to you for diagnosis, replacement parts and labor_ should a warrantable condition occur.

MANUFACTURER'S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

Emissions control systems on engines are warranted for two years as hereinafter noted, if, during such warranty period,

any emission-rebted component or system on your engine is found to be defective in materiaB or workmanship, repairs or

repbcement will be performed by a Generac Authorized Warranty Service Facility.

PURCNASER'SIOWNER'S WARRANTY RESPONSIBILITIES:

As the engine purchaser/owners you are responsible for the completion of all required maintenance as listed in your factory

supplied Owner's Manual For warranty purposes, Generac recommends that you retain all receipts covering maintenance on

your engine. However; Generac cannot deny warranty solely because of the lack of receipts or for your failure to ensure the

completion of all scheduled maintenance.

As the engine purchaser/owners 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 unap-

proved modifications, or the use of counterfeit and/or "grey market" parts not made, supplied or approved by Generac.

You are responsible for presenting your engine to a Generac Authorized Warranty Service Fadlity as soon as a

prebJem 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 tolPfree number:

1-800-333-1322

iMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System Warranty

(ECS Warranty), which is provided to you by Generac pursuant to California and federal law. See also the "Generac Limited

Warranties for Generac Power Systems, Inc," which is enclosed herewith on a separate sheet, also provided to you by Generac.

The ECS Warranty applies only to the emission control system of your new' engine. If there is any conflict in terms between the

ECS Warranty and the Generac Warranty,, the ECS Warranty shall apply except in circumstances where the Generac Warranty

may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe important rights and obli-

gations with respect to your new engine.

Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty ser-

vice, evidence must be presented showing the date of the sale to the original purchaser/owner. The purchaser/owner shall

be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to!from the

inspection or repair facilities. The purchaser!owner also shall be responsible for any and/or all damages or losses incurred while

the engine is being transported/shipped for inspection or warranty repairs.

if you have any questions regarding your warranty rights and responsibilities, you should contact Generac at

the followingaddress:

ATTENTIONWARRANTYDEPARTMENT

GENERACPOWERSYSTEMS,INC.

P.O.BOX297

WHITEWATER,WI53190

Part 1

40

Section 9 - Warranty

15 kW Generator

EMISSION CONTROL SYSTEM WARRANTY

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

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

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

24 consecutive months thereafter.

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

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

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

their respective authority, and

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

ranted emissionsorelated part to fail to be identical in all material respects to the part as described in the engine manufac-

turer's application for certification.

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

(1) Any warranted, emissionsorelated parts that are not scheduled for replacement as required maintenance in the Owners

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 EC5

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 Owners 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, emissionsorelated part that is scheduled for replacement as required maintenance in the Owner's Manuai

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 replacement0 the part shall be repaired or replaced by Generac according to Subsection (4) below.

Any such emissionsorelated 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 emissionsorelated part.

(4) Repair or replacement of any warranted, emissionsorelated 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 wiil be provided without charge to the purchaser/owner. Such use shall not reduce

Generac's ECS Warranty obligations.

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

engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac

shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an

unapproved, add-on, modified, counterfeit and/or "grey market" part.

EMISSION RELATED PARTS INCLUDE THE FOLLOWING:

1) Fuel Metering System:

1.1) Gasoline carburetor assembly and its

internal components (if so equipped).

a) Fuel filter (if so equipped)

b) Carburetor gaskets

c) Fuel pump (if so equipped)

1.2) LPG carburetion assembly and its

internal components (if so equipped).

a) Fuel controller (if so equipped)

b) Mixer and its gaskets (if so equipped)

c) Carburetor and its gaskets (if so equipped)

d) Primary gas regulator (if so equipped)

e) LP liquid vaporizer (if so equipped)

2) Air Induction System including:

a) Intake pipe/manifold

b) Air cleaner

3) Ignition System including:

a) Spark plug

b) Ignition module

4) Catalytic Muffler Assembly (if so equipped) including:

a) Muffler gasket

b) Exhaust manifold

5) Crankcase Breather Assembly including:

a) Breather connection tube

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

1) Utility

2) Lawn and Garden Equipment

3) Recreational Vehicle (RV) Generator

4) Industrial Mobile 0M) Generator

Part 2

41

Section 9-Warranty

1S kW Generator

CARRIER "TWO YEAR" LIMITED WAR_NTY FOR

"PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENEPJ_TORS"

For a period of two years from the date of original sale, Carrier warrants that its generator will be free from defects in material and

workmanship for the items and period set forth below. Carrier will, at its option, repair or replace any part which, upon examination,

inspection and testing by' a Carrier Dealer, is found to be defective. AiI transportation costs under the warranty, including return to the

factory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to Carrier prepackaged emergency automatic

standby generators sold and rated for use in "Standby" applications.

WARRANTY SCHEDULE

YEARS ONE AND TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed.

ENGINE - All Components

ALTERNATOR - All Components

TRANSFER SYSTEM - AII Components

Steel enclosures are warranted against rusting for the first year of ownership only. Damage caused after receipt of generator is the

responsibility of the owner and is not covered by this warranty. Nicks, scrapes, dents or scratches to the painted enclosure should be

repaired promptly by the owner.

THiS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

Carrier generators that utilize non-Carrier replacement parts.

Carrier generators utilizing non-Carrier automatic transfer switches.

Any Carrier generators used as rental or trailer mounted appiications.

Units used for prime power in place of existing utility power where utility power is present or in place of utility power where utility

power service does not normally exist.

Costs of normal maintenance, adiustments, instailation and start-up.

Steel enclosures that are rusting due to the improper installation, location in a harsh or saltwater environment or scratched where

integrity of paint applied is compromised.

Failures caused by any contaminated fuels, oils, cootants or Iack of proper fluid amounts.

Failures due, but not limited to, accident, misuse, abuse, negligence or improper instailation. As with all mechanicaI devices, the

Carrier engines need periodic part(s) service and replacement to perform wetL

Failures caused by any externat cause or act of God, such as collision, theft, vandaiism, riot or wars, nuclear holocaust, fire,

freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.

Damage related to rodent and/or insect infestation.

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

Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or

replacement of the defective part(s).

Failure due to misapplication.

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

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

period.

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

Rental equipment used while warranty repairs are being performed.

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

Overnight freight costs for replacement part(s).

Overtime labor.

Starting batteries, fuses, light bulbs and engine fluids.

rHIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY,

CARRIER MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABiLiTY OR FITNESS FOR A PARTICULAR PURPOSE.

Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

CARRIER'S ONLY LiABiLiTY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT

SHALL CARRIER BE LIABLE FOR ANY iNCiDENTAL OR CONSEQUENTIAL DAMAGES, EVEN iF SUCH DAMAGES ARE A

DIRECT RESULT OF CARRIER'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential

damages, so the above limitation may not apply to you.

This warranty gives you specific legal rights. You also have other rights from state to state.

Revision (10/01/04)

Part No. 0F7551 Rev. 0 (08/24/05) Catalog No. OMASPAXI5ol Printed in U.S,A,