®
POWER SYSTEMS, INC.
Installation and
Owner’s Manual
Air-cooled Automatic
Standby Generators
Model:
05176-0 (13 kW NG, 15 kW LP)
*This manual should remain with the unit.*
Not intended for use as Primary Power in place of utility
or in life-support applications.
DANGER
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!
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Table of Contents
Air-cooled 15 kW Generators
4.2 Automatic Transfer Operation.....................14
4.3 Sequence of Automatic Operation ...............14
4.4 Manual Operation .......................................15
4.4.1 Close to Normal Source Side.............15
4.4.2 Close to Emergency Source Side .......16
4.4.3 Return to Normal Source Side...........16
4.5 Voltage Checks ............................................16
4.6 Generator Tests Under Load.......................16
4.7 Setting the Exercise Timer ..........................17
4.8 Protection Systems......................................17
4.8.1 Low Oil Pressure Switch ..................17
4.8.2 High Temperature Switch.................17
4.8.3 Overcrank ........................................17
4.8.4 Overspeed ........................................18
Introduction ........................Inside Front Cover
Read This Manual Thoroughly........................ IFC
Contents.......................................................... IFC
Operation and Maintenance ............................ IFC
How to Obtain Service..................................... IFC
Authorized Dealer Locator Number................... IFC
Safety Rules ........................................................2
Standards Index..................................................3
Section 1 – General Information...................4
1.1 Unpacking/Inspection....................................4
1.2 Protection Systems........................................4
1.3 System Set LED ............................................4
1.4 The Generator...............................................5
1.5 Specifications................................................6
1.5.1 Generator...........................................6
1.5.2 Engine................................................6
1.6 Fuel Requirements and Recommendations ...6
1.7 Fuel Consumption.........................................6
1.8 Reconfiguring the Fuel System ......................6
Section 2 – Installation....................................7
2.1 Installation....................................................7
2.1.1 Remote Monitoring Connections ........7
2.1.2 Roof Open Alarm ...............................8
2.1.3 Transfer Switch Connection...............8
2.2 Battery Installation........................................9
2.3 The Battery .................................................10
Section 5 – Maintenance...............................18
5.1 Fuse.............................................................18
5.2 Checking the Engine Oil Level.....................18
5.3 Changing the Engine Oil..............................18
5.3.1 Engine Oil Recommendations ..........18
5.3.2 Oil Change Procedure.......................18
5.4 Changing the Oil Filter ................................19
5.5 Changing the Engine Air Cleaner.................19
5.6 Spark Plug(s) ..............................................19
5.7 Battery Maintenance....................................20
5.8 Adjusting Valve Clearance ...........................20
5.9 Cooling System ...........................................21
5.10 Attention After Submersion.........................21
5.11 Corrosion Protection...................................21
5.12 Out of Service Procedure.............................21
5.12.1 Removal From Service......................21
5.12.2 Return to Service .............................22
Section 3 – Post Installation Start-up
and Adjustments .......................10
3.1 Before Initial Start-up..................................10
3.2 Check Transfer Switch Operation ...............10
3.3 Electrical Checks ........................................10
3.4 Generator Tests Under Load.......................11
3.5 Checking Automatic Operation....................12
3.6 Adjusting the Regulator (Natural Gas Only)..12
3.7 Engine Governor Adjustment......................13
3.7.1 Additional Corrosion Protection.......13
3.8 Voltage Regulator Adjustment......................13
Section 4 – Operation ....................................14
4.1 Using the Auto/Off/Manual Switch...............14
4.1.1 “Auto” Position..................................14
4.1.2 “Off” Position....................................14
4.1.3 “Manual” Position.............................14
Section 6 – Troubleshooting.........................27
6.1 Troubleshooting Guide................................27
Section 7 – Mounting Dimensions............. 28
Section 8 – Electrical Data........................... 29
Section 9 – Exploded Views and
Parts Lists................................... 34
Section 10 – Warranty................................... 48
1
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IMPORTANT SAFETY INSTRUCTIONS
Air-cooled 15 kW Generators
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe
operation be copied and posted near the unit’s installation site. Safety should be stressed to
all operators and potential operators of this equipment.
WARNING:
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
The engine exhaust from this product
Please read all hazards carefully!
GENERAL HAZARDS
WARNING:
• For safety reasons, the manufacturer recommends
that the installation, initial start-up and main-
tenance of this equipment is carried out by an
Authorized Dealer.
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
• The engine exhaust fumes contain carbon monox-
ide, which can be DEADLY. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death. This exhaust
system must be installed properly, in strict 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.
• Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit
is operating.
• Adequate, unobstructed flow of cooling and 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 seri-
ously affect safe operation of the generator. The
generator MUST be installed outdoors.
• When working on this equipment, remain alert
at all times. Never work on the equipment when
physically or mentally fatigued.
Study these SAFETY RULES carefully before install-
ing, operating or servicing this equipment. Become
familiar with this Owner’s Manual and with the
unit. The generator can operate safely, efficiently and
reliably only if it is properly installed, operated and
maintained. Many accidents are caused by failing to
follow simple and fundamental rules or precautions.
The manufacturer cannot anticipate every possible
circumstance that might involve a hazard. The warn-
ings in this manual, and on tags and decals affixed
to the unit are, therefore, not all-inclusive. If using
a procedure, work method or operating technique
the manufacturer does not specifically recommend,
ensure that it is safe for others. Also make sure the
procedure, work method or operating technique uti-
lized does not render the generator unsafe.
DANGER
Despite the safe design of this generator, operat-
ing this equipment imprudently, neglecting its
maintenance or being careless can cause possible
injury or death. Permit only responsible and capa-
ble persons to operate or maintain this equip-
ment.
• Inspect the generator regularly, and contact the
nearest Authorized Dealer for parts needing repair
or replacement.
• 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 (–)
first. Reconnect that cable last.
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.
• 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, fuel leakage,
oil leakage, etc.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
2
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IMPORTANT SAFETY INSTRUCTIONS
Air-cooled 15 kW Generators
• Keep a fire extinguisher near the generator at all
times. Extinguishers rated “ABC” by the National
Fire Protection Association are appropriate for
use on the standby electric system. Keep the extin-
guisher properly charged and be familiar with its
use. If there are any questions pertaining to fire
extinguishers, consult the local fire department.
ELECTRICAL HAZARDS
• All generators covered by this manual produce
dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely
high and dangerous voltages to the transfer switch
as does the standby generator when it is in 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 before operating the generator. If work must
be done around an operating unit, stand on an
insulated, dry surface to reduce shock hazard.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
EXPLOSION HAZARDS
• Do not smoke around the generator. Wipe up any
fuel or oil spills immediately. Ensure that no com-
bustible materials are left in the generator com-
partment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surround-
ing the generator clean and free from debris.
• Gaseous fluids such as natural gas and liquid pro-
pane (LP) gas are extremely EXPLOSIVE. Install
the fuel supply system according to applicable
fuel-gas codes. Before placing the home standby
electric system into service, fuel system lines must
be properly purged and leak tested according to
applicable code. After installation, inspect the fuel
system periodically for leaks. No leakage is permit-
ted.
• The National Electrical Code (NEC) requires the
frame and external electrically conductive parts of
the generator to be connected to an approved earth
ground. Local electrical codes also may require
proper grounding of the generator electrical sys-
tem.
• After installing this home standby electrical sys-
tem, the generator may crank and start at any
time without warning. When this occurs, load cir-
cuits are transferred to the STANDBY (generator)
power source. To prevent possible injury if such a
start and transfer occur, always set the generator’s
AUTO/OFF/MANUAL switch to its OFF position
before working on equipment and remove the 5A
and 15A fuses from the generator control panel.
• In case of accident caused by electric shock, imme-
diately shut down the source of electrical power. If
this is not possible, attempt to free the victim from
the live conductor. AVOID DIRECT CONTACT WITH
THE VICTIM. Use a nonconducting implement,
such as a rope or board, to free the victim from the
live conductor. If the victim is unconscious, apply
first aid and get immediate medical help.
‹
STANDARDS INDEX
In the absence of pertinent standards, codes, regu-
lations and laws, the published information listed
below may be used as installation guide for this
equipment.
1. NFPA No. 37, STATIONARY COMBUSTION
ENGINES AND GAS TURBINES, available from
the National Fire Protection Association, 470
Atlantic Avenue, Boston, MA 02210.
2. NFPA No. 76A, ESSENTIAL ELECTRICAL
SYSTEMS FOR HEALTH CARE FACILITIES,
available same as Item 1.
3. NFPA No. 54, NATIONAL FUEL GAS CODE,
• 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.
available same as Item 1.
4. NFPA No. 58, AMERICAN NATIONAL STANDARD
FOR STORAGE AND HANDLING OF LIQUEFIED
PETROLEUM GAS, available same as Item 1.
5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL
ELECTRIC CODE, available same as Item 1.
6. Article X, NATIONAL BUILDING CODE, available
from the American Insurance Association, 85
John Street, New York, N.Y. 10038.
FIRE HAZARDS
• For fire safety, the generator must be installed
and maintained properly. Installation always must
comply with applicable codes, standards, laws
and regulations. Adhere strictly to local, state and
national electrical and building codes. Comply
with regulations the Occupational Safety and
Health Administration (OSHA) has established.
Also, ensure that the generator is installed in
accordance with the manufacturer’s instructions
and recommendations. Following proper installa-
tion, do nothing that might alter a safe installation
and render the unit in noncompliance with the
aforementioned codes, standards, laws and regula-
tions.
7. AGRICULTURAL WIRING HANDBOOK, avail-
able from the Food and Energy Council, 909
University Avenue, Columbia, MO 65201.
8. ASAE
EP-3634,
INSTALLATION
AND
MAINTENANCEOFFARMSTANDBYELECTRICAL
SYSTEMS, available from the American Society
of Agricultural Engineers, 2950 Niles Road, St.
Joseph, MI 49085.
9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE, available same as Item 1.
3
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Section 1 — General Information
Air-cooled 15 kW Generators
1.2 PROTECTION SYSTEMS
DANGER
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:
Only qualified electricians or contractors should
attempt such installations, which must comply
strictly with applicable codes, standards and
regulations.
1. Low Oil Pressure Sensor
2. High Temperature Sensor
There are LED readouts on the control panel to notify
personnel that one of these faults has occurred. There
is also a “System Set” LED that is described below.
3. Overcrank
4. Overspeed
1.1 UNPACKING/INSPECTION
After unpacking, carefully inspect the contents for
damage.
• This standby generator set has been factory sup-
plied with a weather protective enclosure that is
intended for outdoor installation only.
1.3 SYSTEM SET LED
The “System Set” LED is lit when all of the following
conditions are true:
If this generator is used to power electrical load
1. The AUTO/OFF/MANUAL switch is set to the
AUTO position.
circuits normally powered by a utility power
source, it is required by code to install a trans-
fer switch. The transfer switch must effectively
isolate the electrical system from the utility
distribution system when the generator is oper-
ating (NEC 700, 701 and 702). Failure to isolate
an electrical system by such means will result in
damage to the generator and also may result in
injury or death to utility power workers due to
backfeed of electrical energy.
2. The utility voltage being supplied to the unit is
being sensed by the Control PCB. If the utility
sense voltage is not connected to the unit or if it
is below 168 volts AC, then the system set light
will flash rapidly. This indicates that if the AUTO/
OFF/MANUAL switch is placed in the Auto posi-
tion , the generator will start.
3. The “Not In Auto” dip switch is set to the OFF
position on the control board.
If any loss or damage is noted at time of delivery, have
the person(s) making the delivery note all damage on
the freight bill or affix his or her signature under the
consignor's memo of loss or damage.
4. No alarms are present, for example, low oil pres-
sure, high temperature, etc.
If there is loss or damage after delivery, separate the
damaged materials and contact the carrier for claim
procedures.
“Concealed damage” is understood to mean damage
to the contents of a package that is not in evidence at
the time of delivery, but is discovered later.
4
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Section 1 — General Information
Air-cooled 15 kW Generators
1.4 THE GENERATOR
Figure 1.1 – 15 kW, V-twin GT-990 Engine
Control
Panel
Oil
Dipstick
Data
Decal
Exhaust
Enclosure
Fuel
Regulator
Fuel
Inlet
Composite Base
Battery
Compartment
Oil Filter
Figure 1.2 – 15 kW, V-twin GT-990 Engine Rear View
AUTOMATIC TRANSFER
SWITCH
5
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Section 1 — General Information
Air-cooled 15 kW Generators
1.5 SPECIFICATIONS
1.6 FUEL REQUIREMENTS
AND RECOMMENDATIONS
‹
1.5.1 GENERATOR
With LP gas, use only the vapor withdrawal sys-
tem. This type of system uses the vapors formed
above the liquid fuel in the storage tank.
Rated Max. Continuous Power
Capacity (Watts*).......................... 13,000 NG/15,000 LP
Rated Voltage........................................................120/240
Rated Max. Continuous Load Current (Amps)
The engine has been fitted with a fuel carburetion
system that meets the specifications of the 1997
California Air Resources Board for tamper-proof
dual fuel systems. The unit will run on natural gas or
LP gas, but it has been factory set to run on natural
gas. Should the primary fuel need to be changed to
LP gas, the fuel system needs to be reconfigured. See
"Reconfiguring the Fuel System" for instructions on
reconfiguration of the fuel system.
120 Volts +...................................... 108.3 NG/125.0 LP
240 Volts.............................................. 54.2 NG/62.5 LP
Main Line Circuit Breaker.................................... 70 Amp
Phase ..............................................................................1
Number of Rotor Poles....................................................2
Rated AC Frequency................................................ 60 Hz
Power Factor ...................................................................1
Recommended Air Filter ........................... Part # 0C8127
Battery Requirement......Group 26/26R at -17.8° C ( 0° F)
12 Volts and 525 Cold-cranking Amperes Minimum
Weight ............................................................640 Pounds
Recommended fuels should have a Btu content of at
least 1,000 Btus per cubic foot for natural gas; or at
least 2,520 Btus per cubic foot for LP gas. Ask the
fuel supplier for the Btu content of the fuel.
Output Sound Level
@ 23 ft (7m) at full load ...............................71.5 db (A)
Required fuel pressure for natural gas is five inches
to seven inches water column (0.18 to 0.25 psi);
and for liquid propane, 11 inches to 14 inches of
water column (0.4 to 0.5 psi).
Normal Operating Range............................-20°F (-28.8°C)
to 104°F (40°C)
* Maximum wattage and current are subject to and limited by such
factors as fuel Btu content, ambient temperature, altitude, engine
power and condition, etc. Maximum power decreases about 3.5 per-
cent for each 1,000 feet above sea level; and also will decrease about
1 percent for each 6° C (42° F) above 16° C (60° F).
NOTE:
Any piping used to connect the generator to the
fuel supply should be of adequate size to ensure
the fuel pressure NEVER drops below 4 inches
water colum for natural gas or 10 inches water
column for liquid propane for all load ranges.
+ Total current in two separate curcuits. Current in each curcuit must
not exceed the value stated for 240V.
‹
1.5.2 ENGINE
Type of Engine ...................................................... GT-990
Number of Cylinders.......................................................2
Rated Horsepower...................................30 @ 3,600 rpm
Displacement .......................................................... 992cc
Cylinder Block ......................................Aluminum w/Cast
Iron Sleeve
1.7 FUEL CONSUMPTION
Model #
Nat. Gas (*)
LP Vapor (**)
1/2 Load Full Load 1/2 Load
Full Load
2.40/88
05176
156
220
1.58/58
Valve Arrangement .................................. Overhead Valves
Ignition System ...............................Solid-state w/Magneto
Recommended Spark Plug...................................RC12YC
Spark Plug Gap............................ 0.508 mm (0.020 inch)
Compression Ratio....................................................9.5:1
Starter.....................................................................12Vdc
Oil Capacity Including Filter.....................Approx. 1.7 Qts
Recommended Oil Filter ......................... Part # 070185B
Recommended Air Filter ........................... Part # 0C8127
Operating RPM.........................................................3,600
*Natural gas is in cubic feet per hour.
**LP is in gallons per hour/cubic feet per hour.
1.8 RECONFIGURING THE
FUEL SYSTEM
To reconfigure the fuel system from NG to LP, follow
these steps:
NOTE:
The primary regulator for the propane supply is
NOT INCLUDED with the generator. A fuel pres-
sure of 11 to 14 inches of water column (0.4 to
0.5 psi) to the fuel inlet of the generator MUST
BE SUPPLIED.
1. Turn off the gas supply. (if connected)
2. Open the roof and remove the door.
3. Remove the battery. (if installed)
6
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Section 2 — Installation
Air-cooled 15 kW Generators
4. Remove the engine air in baffle located on the left-
hand side of the battery compartment. Two M6
screws are located on top of the baffle and two
M6 screws are located on the inside of the baffle
towards the back.
5. Remove the small hose clamp and hose from the
fuel regulator. It may be necessary to pry the hose
off of the brass fitting using a screwdriver to gen-
tly lift up the hose edge.
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 produc-
ing maximum power, follow the procedure in
"Adjusting the Fuel Regulator".
2.1 INSTALLATION
Install the generator set, in its protective enclosure,
outdoors, where adequate cooling and ventilating air
is always available. Consider these factors:
6. Remove the small brass hose fitting from the
regulator casting.
• Install the unit where air inlet and outlet openings
will not become obstructed by leaves, grass, snow,
etc. If prevailing winds will cause blowing or drift-
ing snow, consider using a windbreak to protect
the unit.
7. Place the small fuel jet, thread side first, into the
threaded hole originally occupied by the brass
hose fitting (Figure 1.3).
Figure 1.3 - Demand Regulator
• Install the generator on high ground where water
OUTLET PORTS
FUEL HOSE
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.
BRASS HOSE
FITTING
IDLE CIRCUIT
PORT
BRASS HOSE
FITTING
SMALL
FUEL JET
1
NP
• Where strong prevailing winds blow from one
direction, face the generator air inlet openings to
the prevailing winds.
REGULATOR
HOUSING PORT
ADJUSTER
SCREWS
• Install the generator as close as possible to the fuel
supply, to reduce the length of piping.
‹
2.1.1 REMOTE MONITORING CONNECTIONS
Mounted in the transfer switch is relay contact board
(Figure 2.1) that can be used to remotely monitor
various functions of the generator system.
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.
The contacts are rated as shown below. Failure to fol-
low these ratings will cause unit failure.
• Arrangement: SPCT (Form C)
• Ratings: Resistive Load, 4Amp max switching
current at 30VDC; 2Amp max switching
current at 125VAC
11. Replace the engine air in baffle using the four M6
screws.
12. Identify both brass adjustment screws on the
regulator.
• Wire Range: 26-14Awg
• Terminal tightening torque: 5 in/lb.
NOTE:
Figure 2.1 — Remote Monitoring Connections
One adjustment screw can be accessed from the
front of the unit and the second can be accessed
from the back of the unit enclosure by removing
the plastic hole plug. The screw can be turned
with a long flat blade screwdriver.
RELAY KEY
RELAY 1
C
NC
NO
C
ENGINE
RUN
RELAY 2
NC
NO
C
SWITCH IN
EMERGENCY
13. To adjust the system to run on LP fuel, turn
BOTH adjuster screws 1/2 TURN CLOCKWISE.
The system should now be set for maximum
power and best perfomance. DO NOT, UNDER
ANY CIRCUMSTANCES, REMOVE THE SET
PINS FROM THE REGULATOR HOUSING.
THIS WILL VOID THE WARRANTY.
RELAY 3
NC
NO
C
SWITCH IN
AUTO
RELAY 4
NC
NO
C
COMMON
ALARM
RELAY 5
NC
NO
C
LOW
FUEL
RELAY 6
NC
NO
DOOR
OPEN
7
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Section 2 — Installation
Air-cooled 15 kW Generators
Remote monitoring functions are only available with
the AUTO/OFF/MANUAL switch in the Auto or Manual
position. Since the contacts are SPDT, it is possible
to monitor either state of each alarm function.
‹
2.1.3 TRANSFER SWITCH CONNECTION
These switches (Figure 2.3) are used with a single-
phase system, when the single-phase NEUTRAL line
is to be connected to a Neutral Lug and is not to be
switched.
Relay 1: Engine running, normally closed.
Engine not running, normally open
Figure 2.3 — Typical 2-Pole Transfer Mechanism
(200 Amp Shown)
Relay 2: Transfer Switch in Emergency, normally
closed
Transfer Switch in Utility, normally open
UTILITY LUGS
Relay 3: Control panel switch in Auto, normally
open
UTILITY
CLOSING
COIL
Control panel switch in Manual or Off, nor-
mally closed
Relay 4: The common alarm is activated by any of
the following shutdown faults
Low Oil Pressure
High Engine Temperature
GENERATOR
LUGS (E1 & E2)
GENERATOR
CLOSING
COIL
Overspeed
Overcrank
Common alarm active, normally open
No Common alarm, normally closed
Relay 5: Spare, not used on this model
Relay 6: Enclosure door open, normally closed
Enclosure door closed, normally open
LOAD LUGS (T1 & T2)
Solderless, screw-type terminal lugs are standard.
Switch
Rating
200A
Wire
Range
#6-250 MCM
Conductor Tightening
Torque
275 in-lbs.
‹
2.1.2 ROOF OPEN ALARM
This generator is equipped with an alarm to detect
when the roof of the enclosure is open. A limit switch
that is installed in the generator enclosure controls
this alarm. During shipping, the generator's enclosure
panels may have shifted and this limit switch may
require adjustment. Simply loosen the two screws
and adjust the placement of the limit switch. The arm
of the limit switch should be in the depressed posi-
tion when the enclosure roof is closed and the door
latch is secure (see Figure 2.2).
Conductor sizes must be adequate to handle the
maximum current to which they will be subjected to,
based on the 75°C column of tables, charts, etc. used
to size conductors. The installation must comply fully
with all applicable codes, standards and regulations.
Before connecting wiring cables to terminals, remove
any surface oxides from the cable ends with a wire
brush. All power cables should enter the switch next
to transfer mechanism terminals. If ALUMINUM con-
ductors are used, apply corrosion inhibitor to con-
ductors. Tighten terminal lugs to the torque values as
noted on the decal located on the inside of the door.
After tightening terminal lugs, carefully wipe away
any excess corrosion inhibitor.
Figure 2.2 — Limit Switch
All power cables should enter the switch next to the
transfer mechanism terminals.
Up
Use a torque wrench to tighten the conductors,
Down
being sure not to over tighten, or damage to
the switch base could occur. If not tightened
enough, a loose connection would result, caus-
ing excess heat which could damage the switch
base.
Slots
8
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Section 2 — Installation
Air-cooled 15 kW Generators
Connect power source load conductors to clearly
marked transfer mechanism terminal lugs as fol-
lows
Lead-acid batteries present a risk of fire because
they generate hydrogen gas. The
following procedures are to be followed:
1. Connect UTILITY (NORMAL) power source cables
to switch terminals N1, N2.
• 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.
2. Connect customer LOAD leads to switch termi-
nals T1, T2.
Conductors must be properly supported, of approved
insulative qualities, protected by approved conduit,
and of the correct wire gauge size in accordance with
applicable codes.
Be sure the AUTO/OFF/MANUAL switch is set to
the OFF position before connecting the battery
cables. If the switch is set to AUTO or MANUAL,
the generator can crank and start as soon as the
battery cables are connected.
Be sure to maintain proper electrical clearance
between live metal parts and grounded metal. Allow
at least 1/2 inch for 100-400 amp circuits.
Be sure the utility power supply is turned off, or
sparking may occur at the battery posts as the
2.2 BATTERY INSTALLATION
DANGER
cables are attached and cause an explosion.
Fill the battery with the proper electrolyte fluid if
necessary and have the battery fully charged before
installing it.
Do not dispose of the battery in a fire. The
battery is capable of exploding.
Before installing and connecting the battery, complete
the following steps:
A battery presents a risk of electrical shock
and high short circuit current. The following pre-
1. Set the generator's AUTO/OFF/MANUAL switch to
cautions are to be observed when working on
batteries:
OFF.
2. Turn off utility power supply to the transfer
• 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
switch.
3. Remove the 5 amp fuse from the generator con-
trol panel.
• Disconnect charging source prior to connecting or
disconnecting battery terminals.
If the AUTO/OFF/MANUAL switch is not set to its
OFF position, the generator can crank and start
as soon as the battery cables are connected. If
the utility power supply is not turned off, spark-
ing can occur at the battery posts and cause an
explosion.
Do not open or mutilate the battery. Released
electrolyte has been known to be harmful to the
skin and eyes, and to be toxic.
Battery cables were factory connected at the genera-
tor (Figure 2.4). Connect cables to battery posts as
follows:
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
conductive and corrosive.
4. Connect the red battery cable (from starter con-
tactor) to the battery post indicated by a positive,
POS or (+).
5. Connect the black battery cable (from frame
ground) to the battery post indicated by a nega-
tive, NEG or (—).
The following procedures are to be observed:
• Wear full eye protection and protective clothing;
• Where electrolyte contacts the skin, wash it off
immediately with water;
• Where electrolyte contacts the eyes, immediately
flush thoroughly with water and seek medical
attention; and
6. Replace the 5 amp fuse in the generator control
panel.
• Spilled electrolyte is to be washed down with an
acid neutralizing agent. A common practice is to
use a solution of 1 pound (500 grams) bicarbonate
of soda to 1 gallon (4 liters) or water. The bicar-
bonate of soda solution is to be added until the
evidence of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water and the
area dried.
NOTE:
Damage will result if battery connections are made
in reverse.
9
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Section 3 — Post Installation Start-up and Adjustments
Air-cooled 15 kW Generators
Figure 2.4 – Battery Cable Connections
3.1 BEFORE INITIAL START-UP
Before starting, complete the following:
1. Set the generator’s main circuit breaker to its
OFF (or open) position.
2. Set the generator's AUTO/OFF/MANUAL switch to
the OFF position.
3. Turn OFF the utility power supply to the transfer
switch using the means provided (such as the
utility main line circuit breaker).
4. Check the engine crankcase oil level and, if neces-
sary, fill to the dipstick FULL mark with the rec-
ommended oil. Do not fill above the FULL mark.
5. Check the fuel supply. Gaseous fuel lines must
have been properly purged and leak tested in
accordance with applicable fuel-gas codes. All
fuel shutoff valves in the fuel supply lines must
be open.
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.
Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
this could damage the engine.
3.2 CHECK TRANSFER SWITCH
OPERATION
Refer to the "Manual Operation" section of the owner’s
manual for manual operation procedures.
2.3 THE BATTERY
DANGER
Servicing of the battery is to be performed or super-
vised by personnel knowledgeable of batteries and
the required precautions. Keep unauthorized person-
nel away from batteries.
Do not attempt manual transfer switch opera-
tion until all power voltage supplies to the
transfer switch have been positively turned off.
Failure to turn off all power voltage supplies
will result in extremely hazardous and possibly
fatal electrical shock.
When replacing the battery, use the following type of
battery: Group 26/26R 12-volt battery with a rating
of 525 cold-cranking amps minimum at -17.8º C (0º
F) minimum. When using a maintenance-free battery,
it is not necessary to check the specific gravity or
electrolyte level. Have these procedures performed
at the intervals specified in the “Service Schedule.” A
negative ground system is used. Battery connections
are shown on the wiring diagrams. Make sure the
battery is correctly connected and terminals are tight.
Observe battery polarity when connecting the battery
to the generator set.
3.3 ELECTRICAL CHECKS
Complete electrical checks as follows:
1. Turn on the utility power supply to the transfer
switch using the means provided (such as a utility
main line circuit breaker).
DANGER
The transfer switch is now electrically “hot.”
Contact with “hot” parts will result in extremely
hazardous and possibly fatal electrical shock.
Proceed with caution.
2. Use an accurate AC voltmeter to check utility
power source voltage across terminals N1 and
N2. Nominal line-to-line voltage should be 240
volts AC.
10
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Section 3 — Post Installation Start-up and Adjustments
Air-cooled 15 kW Generators
3. Check utility power source voltage across termi-
3.4 GENERATOR TESTS UNDER LOAD
nals N1 and the transfer switch neutral lug; then
across terminal N2 and neutral. Nominal line-to-
neutral voltage should be 120 volts AC.
4. When certain that utility supply voltage is compat-
ible with transfer switch and load circuit ratings,
turn OFF the utility power supply to the transfer
switch.
Do not attempt manual transfer switch opera-
tion until all power voltage supplies to the
transfer switch have been positively turned off.
Failure to turn off all power voltage supplies
will result in extremely hazardous and possibly
fatal electrical shock.
5. Set the generator's main circuit breaker to its
OFF (or OPEN) position. Initial tests will be con-
ducted at no-load condition.
6. On the generator panel, set the AUTO/OFF/
MANUAL switch to MANUAL. The engine should
crank and start.
7. Let the engine warm up for about five minutes to
allow internal temperatures to stabilize. Then, set
the generator’s main circuit breaker to its ON (or
closed) position.
To test the generator set with electrical loads applied,
proceed as follows:
1. Set generator’s main circuit breaker to its OFF
(or OPEN) position.
2. Set the generator's AUTO/OFF/MANUAL
switch to OFF.
3. Turn OFF the utility power supply to the transfer
switch, using the means provided (such as a util-
ity main line circuit breaker).
4. Manually set the transfer switch to the STANDBY
position, i.e., load terminals connected to the
generator's E1/E2 terminals. The transfer switch
operating lever should be down.
5. Set the generator's AUTO/OFF/MANUAL switch
to MANUAL. The engine should crank and start
immediately.
DANGER
Proceed with caution! Generator power voltage
is now supplied to the transfer switch. Contact
with live transfer switch parts will result in dan-
gerous and possibly fatal electrical shock.
8. Connect an accurate AC voltmeter and a fre-
quency meter across transfer switch terminal
lugs E1 and E2. Voltage should be 242-252 volts;
frequency should read about 61-63 Hertz.
9. Connect the AC voltmeter test leads across ter-
minal lug E1 and neutral; then across E2 and
neutral. In both cases, voltage reading should be
121-126 volts AC.
10. Set the generator’s main circuit breaker to its
OFF (or open) position. Let the engine run at no-
load for a few minutes to stabilize internal engine
generator temperatures.
6. Let the engine stabilize and warm up for a few
minutes.
7. Set the generator’s main circuit breaker to its ON
(or closed) position. Loads are now powered by
the standby generator.
8. Turn ON electrical loads. Apply an electrical load
equal to the full rated wattage/amperage capacity
of the installed generator.
9. Connect an accurate AC voltmeter and a frequen-
cy meter across terminal lugs E1 and E2. Voltage
should be greater than 230 volts; frequency
should be greater than 58 Hertz.
10. Let the generator run at full rated load for 20-30
minutes. Listen for unusual noises, vibration or
other indications of abnormal operation. Check
for oil leaks, evidence of overheating, etc.
11. When testing under load is complete, turn OFF
electrical loads.
11. Set the generator's AUTO/OFF/MANUAL switch to
OFF. The engine should shut down.
NOTE:
It is important not to proceed until certain that
generator AC voltage and frequency are correct
and within the stated limits. Generally, if both AC
frequency and voltage are high or low, the engine
governor requires adjustment. If frequency is cor-
rect, but voltage is high or low, the generator’s
voltage regulator requires adjustment.
12. Set the generator's main circuit breakers to their
OFF (or open) positions.
13. Let the engine run at no-load for a few minutes.
14. Set the AUTO/OFF/MANUAL switch to OFF. The
engine should shut down.
11
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Section 3 — Post Installation Start-up and Adjustments
Air-cooled 15 kW Generators
3. Turn on electrical loads. Be cautious not to over-
3.5 CHECKING AUTOMATIC
load the generator. Use the following chart as a
guide:
OPERATION
To check the system for proper automatic operation,
proceed as follows:
Model
005176
120 Volts
108.3 amps
240 Volts
54.1 amps
1. Set the generator’s main circuit breaker to it’s
OFF (or open) position.
4. When full load has been achieved. Connect a fre-
quency meter to the output lugs of the generator’s
main line circuit breaker.
2. Check that the AUTO/OFF/MANUAL switch is set
to OFF.
3. Manually set the transfer switch to the UTILITY
position, i.e., load terminals connected to the util-
ity power source side.
4. Turn ON the utility power supply to the transfer
switch, using the means provided (such as a util-
ity main line circuit breaker).
5. Set the AUTO/OFF/MANUAL switch to AUTO.
Then set the generator’s main circuit breaker to
its ON (or closed) position. The system is now
ready for automatic operation.
5. The fuel regulator is fitted with two adjustment
screws. While watching the frequency meter,
slowly turn the adjustment screw clockwise or
counterclockwise one at a time until highest fre-
quency is read on the meter. Only limited adjust-
ment is available between the set pins. Under no
circumstances should any of the pins be removed
(Figures 3.1 and 3.2).
Figure 3.1 — Dual Fuel Regulators
6. Turn OFF the utility power supply to the transfer
switch.
V-twin Engine
With the AUTO/OFF/MANUAL switch at AUTO, the
engine should crank and start when the utility source
power is turned OFF. After starting, the transfer
switch should connect load circuits to the standby
side. Let the system go through its entire automatic
sequence of operation.
Adjustment
Screw
(Both Sides)
With the generator running and loads powered by
generator AC output, turn ON the utility power supply
to the transfer switch. The following should occur:
Set Pin
(Both Sides)
• After about 15 seconds, the switch should transfer
loads back to the utility power source.
• About one minute after retransfer, the engine
should shut down.
6. When the highest frequency is reached maximum
power has been set. Then turn both adjustment
screws 1/4 turn counterclockwise. Regulator is
now set.
3.6 ADJUSTING THE REGULATOR
(NATURAL GAS ONLY)
Although the generator has been factory set to pro-
vide maximum power, it may be necessary in some
areas to adjust this setting. Because natural gas has
different BTU or power content across the country
the engine may not perform as designed.
Figure 3.2 — Placement of Regulator
If experiencing engine problems at high or full load
conditions follow these steps. It will require a fre-
quency meter to perform this procedure.
1. Turn off utility power to the main distribution
panel in the house. This can be done by switching
the service main breaker to the off or open posi-
tion.
2. Allow the generator to start before loading the
generator. Confirm the no-load frequency with
the roof open and door off is set at 63-63.5 Hz.
Transfer load to emergency circuits.
Adjustment Screw
12
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Section 3 — Post Installation Start-up and Adjustments
Air-cooled 15 kW Generators
7. Turn utility power to the main distribution panel
Figure 3.4 — V-twin Full Load Speed Adjust
Screw
back on. This can be done by switching the ser-
vice main breaker to the on or closed position.
Allow the generator to shut down.
Full Load Speed Adjust Screw
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 available,
locate the nearest Service Dealer and they can per-
form the adjustments.
NOTE:
A service fee may be charged for this adjustment.
3.7 ENGINE GOVERNOR ADJUSTMENT
If both AC frequency and voltage are correspondingly
high or low, adjust the engine governor as follows:
‹
3.7.1 ADDITIONAL CORROSION
PROTECTION
Periodically spray all engine linkage parts and brack-
ets with corrosion inhibiting spray such as WD-40®
or a comparable product.
1. Loosen governor clamp bolt (See Figure 3.3).
Figure 3.3 — V-twin Engine Governor
Adjustment
3.8 VOLTAGE REGULATOR
ADJUSTMENT
Idle Spring
With the frequency between 62-63.5 Hertz, slowly
turn the slotted potentiometer (Figure 3.5) until line
voltage reads 244-252 volts.
Governor
Shaft
(Rotate
Clockwise)
NOTE:
Remove the access panel on top of the control
panel to adjust the voltage regulator.
Figure 3.5 – Voltage Adjustment Potentiometer
No Load Idle
Adjustment Screw
Governor Clamp Bolt
2. Completely remove the idle spring.
3. With governor arm at wide open throttle position,
rotate governor shaft fully clockwise. Tighten
clamp bolt to 84 inch-pounds.
4. Start unit and apply full load. Use full load speed
adjust screw (Figure 3.4) to adjust frequency to
58 Hz.
Turn to
adjust voltage.
5. Remove load, stop engine, loosen the idle adjust
screw and reconnect the idle spring.
6. Using a hand, push the governor arm to the
closed throttle position. Make sure the idle spring
does not stretch at all.
NOTE:
7. Restart the unit.
The voltage regulator is housed above the generator's
control panel. The regulator maintains a voltage in
direct proportion to frequency. For example, at 62
Hertz, line-to-neutral voltage will be 124 volts.
8. Slowly turn the idle adjust screw to adjust the no-
load idle frequency to 63-63.5 Hz.
9. The governor is now set.
13
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Section 4 — Operation
Air-cooled 15 kW Generators
and N2.
4.1 USING THE AUTO/OFF/MANUAL
SWITCH (FIGURE 4.1)
3. Set the generator’s AUTO/OFF/MANUAL switch to
AUTO.
4. Set the generator’s main circuit breaker to its ON
(or closed) position.
‹
4.1.1 “AUTO” POSITION
With the preceding steps complete, the generator will
start automatically when utility source voltage drops
below a preset level. After the unit starts, loads are
transferred to the standby power source. Refer to
“Sequence of Automatic Operation.”
Selecting this switch position activates fully automatic
system operation. It also permits starting and exercising
of the engine every seven days with the exercise timer
(see "Generator Test Under Load"). This position also is
used for remote starting, when it is set up.
4.3 SEQUENCE OF AUTOMATIC
‹
4.1.2 “OFF” POSITION
This switch position shuts down the engine. This
position also prevents automatic operation.
OPERATION
The generator’s control panel houses a control logic
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 T1/T2 connect to terminal
lugs E1/E2).
‹
4.1.3 “MANUAL” POSITION
Set the switch to MANUAL to crank and start the
engine. Transfer to standby power will not occur
unless there is a utility failure.
Figure 4.1 – Generator Control Panel
Upon restoration of utility source voltage above a
preset level, generator circuit board action signals the
transfer switch to transfer loads back to that power
supply. After retransfer, the engine is signalled to shut
down.
The actual sequence of operation is controlled by
sensors and timers on a control logic circuit board,
as follows:
FUSE
R
L o c a t
e
y o u r n e a r e s t
d e a le r a t
:
R
POWER SYSTEMS, INC.
5A
AUTO OFF MAN.
SYSTEM SET
LOW OIL
HIGH TEMP.
OVER SPEED
OVER CRANK
FUSE
F L A
S
H
IN
N
H
G
O
IN
G R E E N L E D
=
SET
EXERCISE
TIME
15A
U
G
T
IL IT
E D L E D
IS E R
Y
S
E N
S
S
=
E
A.Utility Voltage Dropout Sensor
4
F L A
S
R
E X E R
C
N
O
T
S
E T
• 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
With the switch set to AUTO, the engine may
crank and start at any time without warning.
and start.
B.Engine Warm-up Time Delay
Such automatic starting normally occurs when
• This mechanism lets the engine warm up for
about 10 seconds before the load is transferred
to a standby source.
utility power source voltage drops below 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.
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
can occur.
D.Utility Voltage Pickup Sensor
4.2 AUTOMATIC TRANSFER
• This sensor monitors utility power supply volt-
age. When that voltage is restored to above 70
percent of the nominal source voltage, a retrans-
fer time delay starts timing.
OPERATION
To select automatic operation, do the following:
1. Make sure the transfer switch main contacts are
set to their “Utility” position, i.e., loads connected
to the utility power source (Figure 4.2).
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.
2. Be sure that normal utility power source voltage
is available to transfer switch terminal lugs N1
14
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Section 4 — Operation
Air-cooled 15 kW Generators
• Retransfer to utility power source then occurs.
F. Engine Cool-down Timer
• When the load is transferred back to utility power
source, the engine cool-down timer starts tim-
ing.
3. Note position of transfer mechanism main con-
tacts by observing the moveable contact carrier
arm.
• Manual operation handle towards the top of
switch mechanism - LOAD terminals (T1, T2) are
connected to UTILITY terminals (N1, N2).
• Manual operation handle towards the bottom of
switch mechanism - LOAD terminals (T1, T2) are
connected to EMERGENCY terminals (E1, E2).
• The timer will run for about one minute, and the
generator will then shut down.
4.4 MANUAL OPERATION
DANGER
Do not use excessive force when operating the
Do NOT manually transfer under load.
Disconnect transfer switch from all power sourc-
es by approved means, such as a main circuit
breaker(s).
transfer switch manually or damage could be
done to the manual handle.
‹
4.4.1 CLOSE TO NORMAL SOURCE SIDE
A manual HANDLE is shipped with the transfer
switch. Manual operation must be checked BEFORE
the transfer switch is operated electrically. To check
manual operation, proceed as follows:
Before proceeding, verify the position of the switch
by observing the position of manual operation handle
in Figure 4.2. If the handle is UP, the contacts are
closed in the NORMAL position, no further action is
required. If the handle is DOWN, proceed with Step
1.
1. Turn the generator’s AUTO/OFF/MANUAL switch
to OFF.
2. Turn OFF both UTILITY and EMERGENCY power
supplies to the transfer switch, with whatever
means provided (such as the main line circuit
breakers).
Step 1: With the handle inserted into the actuating
shaft, move handle UP. Be sure to hold on to
the handle as it will move quickly after the
center of travel.
Figure 4.2 — Actuating Transfer Switch
Attach handle to actuating shaft.
NOTE: Return handle to
storage position in enclosure
when finished with manual transfer.
Move handle
Move handle
DOWN for the
EMERGENCY
(STANDBY)
position.
UP for the
NORMAL
(UTILITY)
position.
15
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Section 4 — Operation
Air-cooled 15 kW Generators
7. With an accurate AC voltmeter and frequency
meter, check the no-load, voltage and frequency.
Single-phase generator supply:
‹
4.4.2 CLOSE TO EMERGENCY SOURCE SIDE
Before proceeding, verify the position of the switch
by observing the position of the manual operation
handle in Figure 4.2. If the handle is DOWN, the
contacts are closed in the EMERGENCY (STANDBY)
position. No further action is required. If the handle
is UP, proceed with Step 1.
Measure across ATS terminal lugs E1 to E2. Also
check E1 to NEUTRAL and E2 to NEUTRAL.
a. Frequency.......................................60-62 Hertz
b. Terminals E1 to E2 ........................240-246 VAC
c. Terminals E1 to NEUTRAL.............120-123 VAC
d. Terminals E2 to NEUTRAL.............120-123 VAC
8. Set the generator’s main circuit breaker (CB1) to
its OFF or OPEN position.
Step 1: With the handle inserted into the actuating
shaft, move the handle DOWN. Be sure to
hold on to the handle as it will move quickly
after the center of travel.
9. Set the AUTO/OFF/MANUAL switch to the OFF
position to shut down the generator.
‹
4.4.3 RETURN TO NORMAL SOURCE SIDE
NOTE:
Manually actuate switch to return manual operating
handle to the UP position.
Do NOT proceed until generator AC output volt-
age and frequency are correct and within stated
limits. If the no-load voltage is correct but no-
load frequency is incorrect, the engine governed
speed probably requires adjustment. If no-load
frequency is correct but voltage is not, the voltage
regulator may require adjustment.
4.5 VOLTAGE CHECKS
1. Turn ON the UTILITY power supply to the trans-
fer switch with whatever means provided (such as
the UTILITY main line circuit breaker).
DANGER
4.6 GENERATOR TESTS UNDER LOAD
1. Set the generator's main circuit breaker to its
OFF or OPEN position.
PROCEED WITH CAUTION. THE TRANSFER
SWITCH IS NOW ELECTRICALLY HOT. CONTACT
WITH LIVE TERMINALS RESULTS IN EXTREMELY
HAZARDOUS AND POSSIBLY FATAL ELECTRICAL
SHOCK.
2. Manually actuate the transfer switch main con-
tacts to their EMERGENCY (STANDBY) position.
Refer to "Manual Operation".
2. With an accurate AC voltmeter, check for correct
voltage.
3. To start the generator, set the AUTO/OFF/MANUAL
switch to MANUAL. When engine starts, let it sta-
bilize for a few minutes.
Single-phase utility supply:
4. Turn the generator's main circuit breaker to its
ON or CLOSED position. The generator now pow-
ers all LOAD circuits. Check generator operation
under load as follows:
Measure across ATS terminal lugs N1 and N2. Also
check N1 to NEUTRAL and N2 to NEUTRAL.
3. When certain that UTILITY supply voltage is cor-
rect and compatible with transfer switch ratings,
turn OFF the UTILITY supply to the transfer
switch.
4. On the generator panel, set the AUTO/OFF/
MANUAL switch to MANUAL position. The gen-
erator should crank and start.
•
Turn ON electrical loads to the full rated watt-
age/amperage capacity of the generator. DO
NOT OVERLOAD.
•
With maximum rated load applied, check
voltage and frequency across transfer switch
terminals E1 and E2. Voltage should be
greater than 230 volts and frequency should
be greater than 59 Hertz.
5. Let the generator stabilize and warm up at no-
load for at least five minutes.
6. Set the generator's main circuit breaker (CB1) to
its ON or CLOSED position.
•
Let the generator run under rated load for at
least 30 minutes. With unit running, listen for
unusual noises, vibration, overheating, etc.,
that might indicate a problem.
DANGER
5. When checkout under load is complete, set main
circuit breaker of the generator to its OFF or
OPEN position.
6. Let the generator run at no-load for several min-
utes. Then, shut down by setting the AUTO/OFF/
MANUAL switch to its OFF position.
PROCEED WITH CAUTION. GENERATOR
OUTPUT VOLTAGE IS NOW BEING DELIVERED
TO TRANSFER SWITCH TERMINALS. CONTACT
WITH LIVE TERMINALS RESULTS IN EXTREMELY
DANGEROUS AND POSSIBLY FATAL ELECTRICAL
SHOCK.
16
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Section 4 — Operation
Air-cooled 15 kW Generators
7. Move the switch's main contacts back to their
UTILITY position. For example, load connected
to UTILITY power supply. Refer to "Manual
Operation". Handle and operating lever of trans-
fer switch should be in UP position.
8. Turn on the UTILITY power supply to transfer
switch, using whatever means provided (such as
a UTILITY main line circuit breaker). The UTIL-
ITY power source now powers the loads.
4.8 PROTECTION SYSTEMS
‹
4.8.1 LOW OIL PRESSURE SWITCH
This switch (Figure 4.3) has normally closed con-
tacts that are held open by engine oil pressure during
cranking and operating. Should oil pressure drop
below the 8 psi range, switch contacts close, and the
engine shuts down. The unit should not be restarted
until oil is added, and the AUTO/OFF/MANUAL switch
must be turned to OFF and then back to AUTO.
9. Set the generator's AUTO/OFF/MANUAL switch to
its AUTO position. The system is now set for fully
automatic operation.
‹
4.8.2 HIGH TEMPERATURE SWITCH
This switch’s contacts (Figure 4.3) close if the tem-
perature should exceed approximately 140º C (284º
F), initiating an engine shutdown. The generator will
automatically restart and the LED will reset once the
temperature has returned to a safe operating level.
4.7 SETTING THE EXERCISE TIMER
The generator is equipped with an exercise timer.
Once it is set, the generator will start and exercise
once every seven days, on the day of the week and at
the time of day the following sequence is completed.
During this exercise period, the unit runs for approx-
imately 12 minutes and then shuts down. Transfer of
loads to the generator output does not occur during
the exercise cycle.
Figure 4.3 – Low Oil Pressure and
High Temperature Switches
A switch on the control panel (see Figure 4.1) allows
for selection of the day and time for system exercise.
To select the desired day and time of day, the follow-
ing sequence must be done at that time.
Low Oil Switch
High Temp Switch
1. Verify that the AUTO/OFF/MANUAL switch is set
to AUTO.
2. Hold down the set timer switch until the genera-
tor starts (approximately 10 seconds) and then
release.
3. The generator will start and run for approximately
12 minutes and then shut down on its own. The
exerciser will then be set to run at that time of day
every week.
Oil
Drain
Hose
NOTE:
Oil Filter
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 board is ON.
‹
4.8.3 OVERCRANK
This feature prevents the generator from damaging
itself when it continually attempts to start and anoth-
er problem, such as no fuel supply, prevents it from
starting. The unit will crank and rest for a preset time
limit. Then, it will stop cranking, and the LED will
light indicating an overcrank failure. The AUTO/OFF/
MANUAL switch will need to be set to OFF and then
back to AUTO to reset the generator control board.
NOTE:
If the fault is not repaired, the overcrank feature
will continue to activate.
17
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Section 5 — Maintenance
Air-cooled 15 kW Generators
2. Remove the dipstick and wipe it dry with a clean
cloth.
4.8.3.1 Approximate Crank Cycle Times
• 15 seconds ON
• 7 seconds OFF
• 7 seconds ON
• 7 seconds OFF
Figure 5.2 — Oil Dipstick and Fill
Oil Dipstick
• Repeat for 45 seconds
Approximately 90 seconds total
‹
4.8.4 OVERSPEED
Oil Fill
This feature protects the generator from damage by
shutting it down if it happens to run faster than the
preset limit. This protection also prevents the gen-
erator from supplying an output that could poten-
tially damage appliances connected to the generator
circuit. Contact the nearest Authorized Dealer if this
failure occurs.
5.1 FUSE
3. Install the dipstick; then, remove it again. The oil
level should be at the dipstick “Full” mark. If nec-
essary, add oil to the “Full” mark only. DO NOT
FILL ABOVE THE “FULL” MARK.
The generator panel’s 15 amp fuse (Figure 5.1) pro-
tects the DC control circuit against overload. The fuse
is wired in series with the battery output lead to the
panel. If the fuse element has melted open, the engine
cannot crank or start. Replace the fuse using only an
identical 15-amp replacement.
Never operate the engine with the oil level
The generator panel’s 5 amp fuse protects the battery
charge circuit against overload. If the fuse element
has melted open, battery charging will not be pos-
sible. Replace the fuse using only an identical 5 amp
replacement. To remove fuse, push cap down and
rotate counterclockwise.
below the “Add” mark on the dipstick. Doing
this could damage the engine.
4. Install the dipstick.
5. Reset the AUTO/OFF/MANUAL switch to its origi-
nal position.
Figure 5.1 – Generator Control Panel
5.3 CHANGING THE ENGINE OIL
‹
5.3.1 ENGINE OIL RECOMMENDATIONS
FUSE
R
L o c a t
e
y o u r n e a r e s t
d e a le r a t
:
Use all season SAE 5W-30 synthetic oil or use SAE
30 oil of American Petroleum Institute (API) Service
Class SG, SH, SJ or SL.
R
POWER SYSTEMS, INC.
5A
AUTO OFF MAN.
SYSTEM SET
LOW OIL
HIGH TEMP.
OVER SPEED
OVER CRANK
FUSE
F L
4
A
S
H
IN
N
H
G
O
IN
G R E E N
L
S
L
E D
E N
E D
=
SET
EXERCISE
TIME
15A
U
G
T
IL IT
E D
IS E R
Y
S
=
E
F L
A
S
R
S
Any attempt to crank or start the engine before
E X E R
C
N
O
T
S
E T
it has been properly serviced with the recom-
mended oil may result in an engine failure.
5.2 CHECKING THE ENGINE
OIL LEVEL
‹
5.3.2 OIL CHANGE PROCEDURE
To change the oil, proceed as follows:
For oil capacities, see “Specifications”. For engine oil
recommendations, see "Changing the Engine Oil". To
check the engine oil level, proceed as follows (Figure
5.2):
1. Run the engine until it is thoroughly warmed up
then shut OFF the engine.
2. Immediately after the engine shuts OFF, pull the
oil drain hose (Figure 5.3) free of its retaining
clip. Remove the cap from the hose and drain the
oil into a suitable container.
1. Start the generator by moving the ATUO/OFF/
MANUAL switch to the MANUAL position. Allow
it to run for a short while and then shut it down
by moving the switch to the OFF position.
18
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Section 5 — Maintenance
Air-cooled 15 kW Generators
Figure 5.3 – Oil Drain Hose and Filter
Figure 5.4 — Engine Air Cleaner
Screw
Oil
Drain
Hose
Cover
Filter
Oil Filter
3. After the oil has drained, replace the cap onto the
end of the oil drain hose. Retain the hose in the
clip.
4. Refill with the proper recommended oil (see
"Changing the Engine Oil"). See the "Specifications"
section for oil capacities.
5.4 CHANGING THE OIL FILTER
Change the engine oil filter as follows:
5.6 SPARK PLUG(S)
1. With the oil drained, remove the old oil filter by
turning it counterclockwise.
2. Apply a light coating of clean engine oil to the
gasket of the new filter. See the "Specifications"
section for recommended filter.
3. Screw the new filter on by hand until its gasket
lightly contacts the oil filter adapter. Then, tighten
the filter an additional 3/4 to one turn (Figure
5.3).
4. Refill with the proper recommended oil (see
"Changing the Engine Oil"). See the "Specifications"
section for oil capacities.
Reset the spark plugs gap or replace the spark plugs
as necessary. See the “Service Schedule” section for
maintenance requirements.
1. Clean the area around the base of the spark plugs
to keep dirt and debris out of the engine. Clean
by scraping or washing using a wire brush and
commercial solvent. Do not blast the spark plugs
to clean.
2. Remove the spark plugs and check the condition.
Replace the spark plugs if worn or if reuse is
questionable. See the “Service Schedule” section
for recommended inspection.
3. Check the spark plug gap using a wire feeler
gauge. Adjust the gap to 0.50 mm (0.020 inch) for
by carefully bending the ground electrode (Figure
5.5).
5. Start the engine and check for leaks.
5.5 CHANGING THE ENGINE
AIR CLEANER
See Figures 1.1 and 1.2, for the location of the air
cleaner. Use the following procedure (Figure 5.4):
Figure 5.5 – Setting the Spark Plug Gap
1. Turn the two screws counterclockwise to loosen.
2. Remove the cover and air filter.
SET PLUG GAP AT 0.50 mm (0.020 inch)
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 "Specifications" section for air
filter replacement part number.
19
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Section 5 — Maintenance
Air-cooled 15 kW Generators
5.7 BATTERY MAINTENANCE
Lead-acid batteries present a risk of fire because
they generate hydrogen gas. The following pro-
cedures are to be followed:
The battery should be inspected per the “Service
Schedule”. The following procedure should be fol-
lowed for inspection:
• 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.
1. Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.
2. Check the battery fluid level of unsealed batteries
and, if necessary, fill with DISTILLED WATER
ONLY. DO NOT USE TAP WATER IN BATTER-
IES.
3. Have the state of charge and condition checked.
This should be done with an automotive-type bat-
tery hydrometer.
Be sure the AUTO/OFF/MANUAL switch is set to
the OFF position before connecting the battery
cables. If the switch is set to AUTO or MANUAL,
the generator can crank and start as soon as the
battery cables are connected.
Be sure the utility power supply is turned off,
DANGER
Do not dispose of the battery in a fire. The
and the 5A fuse is removed from the generator
control panel, or sparking may occur at the bat-
tery posts as the cables are attached, causing an
explosion.
battery is capable of exploding.
A battery presents a risk of electrical shock
and high short circuit current. The following pre-
cautions are to be observed when working on
batteries:
5.8 ADJUSTING VALVE CLEARANCE
After the first 50 hours of operation, adjust the
valve clearance in the engine.
• Remove watches, rings or other metal objects;
• Use tools with insulated handles;
• Wear rubber gloves and boots;
• Do not lay tools or metal parts on top of the
battery; and
• Disconnect charging source prior to connecting or
disconnecting battery terminals.
Important: If feeling uncomfortable about doing this
procedure or the proper tools are not available, con-
tact the nearest Authorized Dealer for service assis-
tance. This is a very important step to insure longest
life for the engine.
To adjust valve clearance:
• Make sure the engine is at room temperature.
• Make sure that the spark plug wire is removed
from the spark plug and out of the way.
Do not open or mutilate the battery. Released
• Remove the four screws attaching the valve cover
electrolyte has been known to be harmful to the
with a #2 or #3 phillips screwdriver.
skin and eyes, and to be toxic.
• Make sure the piston is at Top Dead Center (TDC)
of its compression stroke (both valves closed). To
get the piston at TDC, remove the intake screen
at the front of the engine to gain access to the fly-
wheel nut. Use a large socket and socket wrench
to rotate the nut and hence the engine. While
watching the piston through the spark plug hole.
The piston should move up and down. The piston
is at TDC when it is up as high as it can go.
• Loosen the rocker jam nut. Use an 10mm allen
wrench to turn the pivot ball stud while checking
clearance between the rocker arm and the valve
stem with a feeler gauge. Correct clearance is
0.002-0.004 inch (0.05-0.1 mm). See Figure 5.6.
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
conductive and corrosive. The following
procedures are to be observed:
• Wear full eye protection and protective clothing;
• Where electrolyte contacts the skin, wash it off
immediately with water;
• Where electrolyte contacts the eyes, immediately
flush thoroughly with water and seek medical
attention; and
• Spilled electrolyte is to be washed down with an
acid neutralizing agent. A common practice is to
use a solution of 1 pound (500 grams) bicarbonate
of soda to 1 gallon (4 liters) or water. The bicar-
bonate of soda solution is to be added until the
evidence of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water and the
area dried.
NOTE:
Hold the rocker arm jam nut in place as the pivot
ball stud is turned.
20
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Section 5 — Maintenance
Air-cooled 15 kW Generators
When valve clearance is correct, hold the pivot ball
stud in place with the allen wrench and tighten the
rocker arm jam nut. Tighten the jam nut to 174
in/lbs. torque. After tightening the jam nut, recheck
valve clearance to make sure it did not change.
Figure 5.7 – Cooling Vent Locations
Figure 5.6 - Valve Clearance Adjustment
Rocker
Arm
Pivot Ball
Stud
Jam Nut
Valve
Stem
5.10 ATTENTION AFTER SUBMERSION
If the generator has been submerged in water,
it MUST NOT be started and operated. Following
any submersion in water, have an Authorized Dealer
thoroughly clean and dry the generator.
5.11 CORROSION PROTECTION
• Install new valve cover gasket.
• Re-attach the valve cover.
Periodically wash and wax the enclosure using auto-
motive type products. Frequent washing is recom-
mended in salt water/coastal areas. Spray engine
linkages with a light oil such as WD-40®.
NOTE:
Start all four screws before tightening or it will not
be possible to get all the screws in place. Make
sure the valve cover gasket is in place.
5.12 OUT OF SERVICE PROCEDURE
• Re-attach the spark plug wire to the spark plug.
• Repeat the process for the other cylinder.
‹
5.12.1 REMOVAL FROM SERVICE
If the generator cannot be exercised every seven days,
and it is to be out of service longer than 90 days, pre-
pare the generator for storage as follows:
5.9 COOLING SYSTEM
Air inlet and outlet openings in the generator com-
partment must be open and unobstructed for con-
tinued proper operation. This includes such obstruc-
tions as high grass, weeds, brush, leaves and snow.
1. Start the engine and let it warm up.
2. Close the fuel shutoff valve in the fuel supply line
and allow the unit to shut down.
3. Once the unit has shut down, it will signal a low
oil fault.
Without sufficient cooling and ventilating air flow, the
engine/generator quickly overheats, which causes it
to quickly shut down. (See Figure 5.7 for vent loca-
tions.)
4. Set the AUTO/OFF/MANUAL switch to OFF and
turn off the utility power to the transfer switch.
5. While the engine is still warm from running,
drain the oil completely. Refill the crankcase with
oil. See ”Engine Oil Recommendations”.
6. Attach a tag to the engine indicating the viscosity
and classification of the oil in the crankcase.
7. Remove the spark plugs and spray fogging agent
into the spark plugs threaded openings. Reinstall
and tighten the spark plugs.
The exhaust from this product gets extremely
hot and remains hot after shutdown. High grass,
weeds, brush, leaves, etc. must remain clear of
the exhaust. Such materials may ignite and burn
from the heat of the exhaust system.
8. Remove the battery and store it in a cool, dry
room on a wooden board. Never store the battery
on any concrete or earthen floor.
The maximum ambient temperature for the
generator is 48.9° C (104° F).
9. Clean and wipe the entire generator.
21
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Section 5 — Maintenance
Air-cooled 15 kW Generators
‹
5.12.2 RETURN TO SERVICE
To return the unit to service after storage, proceed
as follows:
1. Set the generator’s main circuit breaker to its
OFF (or OPEN) position.
2. Verify that utility power is turned off and that the
AUTO/OFF/MANUAL switch is set to OFF.
3. Check the tag on the engine for oil viscosity and
classification. Verify that the correct recom-
mended oil is used in the engine (see "Enging Oil
Requirements"). If necessary, drain and refill with
the proper oil.
4. Check the state of the battery. Fill all cells of
unsealed batteries to the proper level with dis-
tilled water. DO NOT USE TAP WATER IN THE
BATTERY. Recharge the battery to 100 percent
state of charge, or, if defective, replace the bat-
tery. See the “Specifications” section for type and
size.
5. Clean and wipe the entire generator.
6. Remove the 5A fuse from the generator control
panel.
7. Reconnect the battery. Observe battery polarity.
Damage may occur if the battery is connected
incorrectly. Replace the 5A fuse in the generator
control panel.
8. Open the fuel shutoff valve.
9. Start the unit by moving the AUTO/OFF/MANUAL
switch to MANUAL. Allow the unit to warm up
thoroughly.
10. Stop the unit and set the AUTO/OFF/MANUAL
switch to AUTO. Set the generator’s main circuit
breaker to its ON (or CLOSED) position.
11. Turn on the utility power to the transfer switch.
12. The generator is now ready for service.
NOTE:
If the battery was dead or disconnected, the exer-
cise timer must be reset.
22
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Section 5 — Maintenance
Air-cooled 15 kW Generators
‹
7 KW - 40 KW SMALL STANDBY GENERATOR SETS
Following is a recommended maintenance schedule for small standby and residential generator sets from 7 kW to
40 kW in size, and applies to gas engine driven units. The established intervals in the schedule are the maximum
recommended when the unit is used in an average service application. They will need to be decreased (performed
more frequently) if the unit is used in a severe application. Use calendar time from the previous maintenance
interval to determine the next required maintenance interval.
Service Maintenance Interval Information:
The various service maintenance intervals are designated by interval numbers as follows:
1 An early inspection of the generator set to insure it is ready to operate when required and to identify any poten-
tial problem areas.
Performed monthly or following each 10 hours of operation of the unit and requires approximately .5 man-
hours per unit to complete.
This inspection may be performed by the end user providing the following safety steps are taken to prevent
the engine from starting automatically without warning:
To prevent injury, perform the following steps in the order indicated before starting any maintenance:
• Disable the generator set from starting and/or connecting to the load by setting the control panel Auto/Off/
Manual switch to the “OFF” position.
• Remove the control panel fuse.
• Turn off the battery charger.
• Remove the negative battery cable.
The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition
from burning out sensitive control panel components and circuits.
Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal
operation when required.
2 A wear-in service inspection of the generator set to insure it is ready to operate and carry the load when
required, and to identify any potential problem areas.
Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of
the unit and requires approximately 2.5 man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by an Authorized Service Dealer.
3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required,
and to identify any potential problem areas.
Performed semi-annually or following each 50 hours of operation of the unit and requires approximately 1.5
man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by an Authorized Service Dealer.
4 A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required,
and to identify any potential problem areas.
Performed annually or following each 100 hours of operation of the unit and requires approximately 4.0
man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by an Authorized Service Dealer.
5 A comprehensive inspection of the generator set to insure it is properly serviced and ready to operate and carry
the load when required, and to identify any potential problem areas.
Performed annually or following each 250 hours of operation of the unit and requires approximately 6.0
man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by an Authorized Service Dealer.
23
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Section 5 — Maintenance
Air-cooled 15 kW Generators
Maintenance Level 1
Level 2
Level 3
Level 4
Level5
Tasks
Recom-
mended
Task
Task
Required
Task
Task
Required
Task
Comp.
Comp. to be done Comp.
Semi-
Initials) to be done Initials) annually/
6 months 50 hrs.
Required
Comp. to be done Comp.
Bi- (Date-
Annually/ Initials) annually/ Initials)
100 hrs. 250 hrs.
to be done (Date- Required (Date-
monthly/
10 hrs.
(Date- to be done (Date-
Initials)
1. Disable the unit
from operating
per the first page
warning.
2. Check the engine
oil level. Adjust
as necessary.
3. Check the natural
gas delivery
system for leaks
and correct
pressure on gas
engine driven
units. Tighten
connections as
necessary.
4. Check the air
inlets and outlets
for debris. Clean
as necessary.
5. Check the battery
electrolyte level
and specific
gravity if
accessible. Adjust
as necessary.
6. Check the battery
posts, cables,
and charger for
loose
connections,
corrosion, and
proper operation.
Correct as
necessary.
7. Check the unit
wiring for loose
connections,
corrosion, and
damage. Correct
as necessary.
8. Check the engine
valve clearance.
Adjust as
necessary.
9. Visually inspect
the unit looking
for leaks, wear or
damage, loose
connections or
components, and
corrosion. Correct
as necessary.
24
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Section 5 — Maintenance
Air-cooled 15 kW Generators
Maintenance Level 1
Level 2
Level 3
Level 4
Level5
Tasks
Recom-
mended
Task
Comp.
Task
Comp. to be done Comp.
Semi-
Initials) to be done Initials) annually/
6 months 50 hrs.
Required
Task
Task
Required
Task
Required
Comp. to be done Comp.
Bi- (Date-
Annually/ Initials) annually/ Initials)
to be done (Date- Required (Date-
monthly/
10 hrs.
(Date- to be done (Date-
Initials)
100 hrs.
250 hrs.
10. Test the engine
and transfer
switch safety
devices. Correct
and/or adjust as
necessary.
11. Initiate an
automatic start
and transfer of
the unit to site
load and exercise
it for at least 1
hour looking for
leaks, loose
connections or
components, and
abnormal
operating
conditions.
Correct as
necessary.
12. Start and
exercise the unit
at full rated load
(use a load bank
if the site load is
not enough) for
at least 2 hours
looking for leaks,
loose
connections or
components, and
abnormal
operating
conditions.
Correct as
necessary.
13. Perform an
engine oil
analysis (send a
sample to a lab
for results).
Change the
engine oil and
filters if the
analysis results
indicate this is
required.
14. Change the
engine oil.
15. Replace the
engine oil filter(s).
*
*
* Change oil and filter after first eight (8) hours of operation and then every 100 hours thereafter. Change sooner when operating under a heavy load or in
a dusty or dirty environment or in high ambient temperatures.
25
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Section 5 — Maintenance
Air-cooled 15 kW Generators
Maintenance Level 1
Level 2
Level 3
Level 4
Level5
Tasks
Recom-
mended
Task
Task
Required
Task
Task
Required
Task
Comp.
Comp. to be done Comp.
Semi-
Initials) to be done Initials) annually/
6 months 50 hrs.
Required
Comp. to be done Comp.
Bi- (Date-
Annually/ Initials) annually/ Initials)
100 hrs. 250 hrs.
to be done (Date- Required (Date-
monthly/
10 hrs.
(Date- to be done (Date-
Initials)
16. Replace the
engine air
filter(s).
17. Perform a 5
minute no-load
operational run
of the unit
looking for any
post service
problems.
18. Return the unit
to standby setup
for operation
when required.
26
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Section 6 — Troubleshooting
Air-cooled 15 kW Generators
6.1 TROUBLESHOOTING GUIDE
Problem
Cause
Correction
The engine will not crank.
1. Fuse blown
1. Replace 15A fuse on generator
control panel.
2. Tighten, clean or replace
as necessary.
2. Loose, corroded or defective
battery cables
3. Defective starter motor
4. Dead Battery
3. *
4. Charge or replace battery.
The engine cranks but
will not start.
1. Out of fuel
1. Replenish fuel.
2. *
3. *
2. Defective fuel solenoid (FS)
3. Open #14 wire from
engine control board
4. Defective spark plug(s)
5. Valve lash out of adjustment.
4. Clean, re-gap or replace plug(s).
5. Reset valve lash.
The engine starts hard
and runs rough.
1. Air cleaner
1. Check, replace air cleaner.
plugged or damaged
2. Defective spark plug(s)
3. Fuel regulator not set.
4. Fuel pressure incorrect.
2. Clean, re-gap or replace plug(s).
3. Set fuel regulator.
4. Confirm fuel pressure is at 11-14”
water column (0.4-0.5 psi) for LP,
and 5-7” water column (0.18-0.25
psi) for natural gas.
The AUTO/OFF/MANUAL switch 1. Defective switch
1. *
2. *
is set to OFF, but the engine
2. AUTO/OFF/MANUAL switch
continues to run.
wired incorrectly
3. Defective control board
3. *
There is no AC output from
the generator.
1. Main line circuit breaker open
2. Generator internal failure
1. Reset circuit breaker
to ON (or closed).
2. *
There is no transfer to
standby after utility
source failure.
1. Defective transfer switch coil
2. Defective transfer relay
3. Transfer relay circuit open
4. Defective control logic board
1. *
2. *
3. *
4. *
*Contact the nearest Authorized Dealer for assistance.
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Section 7 — Mounting Dimensions
Air-cooled 15 kW Generators
Drawing No. 0F5927
28
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Section 8 — Electrical Data
Air-cooled 15 kW Generators
Wiring Diagram – Drawing No. 0F5643-B Part 1
DIAGRAM KEY
BA - BRUSH ASSEMBLY
ENGINE WIRING
BCR - BATTERY CHARGE RELAY
C1 - 8 POSITION CONNECTOR
C2 - 12 POSITION CONNECTOR
C3 - 4 POSITION CONNECTOR
C4 - 6 POSITION CONNECTIR
CB1 - MAIN OUTPUT BREAKER
CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION
D - DIODE
3
1
BATTERY
CHARGER
2
1
DSW - PCB MOUNTED DIP SWITCH
FS - FUEL SOLENOID
0
14
13A
F1 - FUSE 5A BATTERY CHARGER
F2 - FUSE 15 AMP SYSTEM
F3, F4 - FUSE 5A SENSING
225B
224B
GRD - CONTROL PANEL GROUND
GTS - TRANSFER SWITCH CONTACTOR
FS
13A
0
13A
0
HTO - HIGH OIL TEMPERATURE SWITCH
IC - INLINE CONNECTOR
IM1 - IGNITION MODULE, CYLINDER #1
14
224B
225B
IM2 - IGNITION MODULE, CYLINDER #2
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
0
SCR - STARTER CONTACTOR RELAY
SP1, SP2 - SPARK PLUGS
14
0
0
SW1 - AUTO / OFF / MANUAL SWITCH
SW2 - SET EXERCISE SWITCH
SW3 - DOOR ALARM SWITCH
SM - STARTER MOTOR
14
A2
0
TB - INSULATED TERMINAL BLOCK
TR - RELAY, TRANSFER
TS - TERMINAL STRIP
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)
VR1, VR2 - VARISTORS
XA1, XB1, XC1 - LIMIT SWITCHES
14
14
IC
SW3
SP1
D
6
0
0
IM1
18
18
85
86
4
3
14
14
A2
0
SP2
D
2
1
13
13
0
16
0
0
14
13
IC
IC
13
85
C1
IM2
86
85
SCR
15
15
16
A
B
0
0
85
56
0
A2
86
HTO
0
14
56
85
86
351
351
86
229
86
1
2
3
4
5
56
14
4
86
23
4
LOP
0
J1
23
194
56
CONTROL
PRINTED CIRCUIT BOARD
14
66A
239
15A
229
66A
239
15A
RED
BLACK
DSW
ON
15
0
15
0
13
225
224
225
224
1 - 20 Vac Sense Transformer
2 - Remote Not Auto
3 - 50 Hz Operation
4 - SPARE
SM
16
+
12V
BATTERY
SC
CUSTOMER SUPPLIED
L.E.D - ALARM INDICATORS
29
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Section 8 — Electrical Data
Air-cooled 15 kW Generators
Wiring Diagram – Drawing No. 0F5643-B Part 2
CONTROL PANEL BOX
225
224A
224
225A
224A
225A
10
1
9
7
6
5
CLOSEST TO BEARING
TX
BCR
BA
CB2
162
1
3
4
0
4
N1
N2
7
13A
0
STATOR
66
A
77
2
224B
225B
224B
225B
2
14
0
4
10
9
11
66
11
6
14
0
55
2
6
8
22
4
66
66A
11
6
5
11
22
11
22
4
22
4
77
77 66
0
22
44
0
6
0
6
3
2
33
225
0
0
13A
162
162
0
1
224
N1
N2
VOLTAGE
REGULATOR
0
66A
55
C2
0
66A
0
0
66A
4
N2
N1
55
0
0
0
0
0
0
14
0
GRD
13
0
15
15
15
15
0
0
0
0
0
0
0
0
0
A2
22
33
11
44
225
CB1
224
N2
N1
351
4
AUTO
351
0
0
0
N2
239
0
N1
15
13A
13
14
15
15
15
A2
SW1
MANUAL
15A
23
13
1a
66A
194
1
239
F1
F2
1b
SW2
15
229
66A
239
15A
15
15A
15
15B
NEU
E1
15
0
GRD
0
E2
225
224
23
0
GRD
194
4
3
2
1
N2
N1
N2
N1
194
23
194
23
194
23
C4
6
15A
0
15A
0
5
4
3
15B
A2
15B
A2
2
1
14
14
229
229
C3
30
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Section 8 — Electrical Data
Air-cooled 15 kW Generators
Wiring Diagram – Drawing No. 0F5643-B Part 3
TRANSFER SWITCH
N2A
N1A
126
15A
15A
15A
147
COIL
1
A
XA1
GTS
N1A
N2A
126
N2A
B
COIL
2
E1 E2
E2
205
126
15A
15A
147
N1A
N1A
126 205
TR
1
194
23
N1A
N2A
N1A
N2A
205
E2
23
194
N2A
N2A
N1A
N1A
15A
15A
147
E1 E2
RELAY
BOARD
F3 F4
14
147
15B
0
RY1+
RY3+
COM-
RY4-
RY5-
NEUTRAL
N1
N2
229
194
TS
A2
15A
COM+
GRD
REMOTE
SIGNALS
N1
N2
194
RELAY KEY
NEU
E1
RY1 - ENGINE RUN
RY2 - SWITCH IN EMERGENCY
RY3 - SWITCH IN AUTO
RY4 - COMMON ALARM
RY6 - DOOR OPEN
0
E2
GRD
15B
GRD
A2
N2
N1
14
229
194
23
15A
0
15B
A2
14
229
31
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Section 8 — Electrical Data
Air-cooled 15 kW Generators
Electrical Schematic – Drawing No. 0F5844-B
11
22
11
22
TX
225A
56VA
N2
3
225A
224A
2
1
224A
225
BATTERY
CHARGER
225B
F1
13A
13
224B
1VA
224
13A
2
F2
N1
1
7
7
9
9
BCR
1
3
4
11 22
0
13A
13 15
77
C2-1
0
77
14
BATTERY CHARGE
WINDING
66
66
15
0
C2-2
0
HTO
13
55
LOP
11
22
ENGINE RUN
WINDING
(STATOR)
BA
FIELD
SW2
C1-4
0
14
85
C1-3
0
351
C2-3
4
0
ELECTRONIC
VOLTAGE
REGULATOR
C2-9
4
4
66A
0
23
6
86
194
162
C1-6
4
6
CB2
0
225
14
224
C2-7
C2-8
66A
2
DPE WINDING
(STATOR)
229
DIAGRAM KEY
85
229
BA - BRUSH ASSEMBLY
351
BCR - BATTERY CHARGE RELAY
1
3
4
5
C1 - 8 POSITION CONNECTOR
C2 - 12 POSITION CONNECTOR
J2
23
C3 - 4 POSITION CONNECTOR
C4 - 6 POSITION CONNECTIR
CB1 - MAIN OUTPUT BREAKER
1
2
4
66A
J1
194
86
3
5
7
23
194
CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION
D - DIODE
FS - FUEL SOLENOID
F1 - FUSE 5A BATTERY CHARGER
F2 - FUSE 15 AMP SYSTEM
56
18
14
66A
239
15A
F3, F4 - FUSE 5A SENSING
GTS - TRANSFER SWITCH CONTACTOR
HTO - HIGH OIL TEMPERATURE SWITCH
IM1 - IGNITION MODULE, CYLINDER #1
CONTROL
PRINTED CIRCUIT
BOARD
9
10
IM2 - IGNITION MODULE, CYLINDER #2
LOP - LOW OIL PRESSURE SWITCH
11
12
13
14
15
16
17
15
NB - NEUTRAL BLOCK
SC - STARTER CONTACTOR
0
SCR - STARTER CONTACTOR RELAY
SP1, SP2 - SPARK PLUGS
225
224
SW1 - AUTO / OFF / MANUAL SWITCH
SW2 - SET EXERCISE SWITCH
SW3 - DOOR ALARM SWITCH
SM - STARTER MOTOR
TR - RELAY, TRANSFER
TS - TERMINAL STRIP
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)
VR1, VR2 - VARISTORS
XA1, XB1, XC1 - LIMIT SWITCHES
32
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Section 8 — Electrical Data
Air-cooled 15 kW Generators
Electrical Schematic – Drawing No. 0F5844-B
11
22
C2-6
TR
TS
C2-5
C4-3
F3
1
N1
N1A
126
E1
7
126
147
15
N2
N2A
B
A
N1A
F4
B
AUTO
MAN
E1
15B
C4-2
A
NO
NC
NC
NO
NC
NO
N1
15
NB
XB1
XA1
XC1
SW1
E2
194
COM
COM
COM
23 11 22
15A
15
239 15B
33
GTS
E1
A
15
VR2
B
147
N2A
POWER
WINDING
(STATOR)
COIL
2
COIL
1
15
0
44
13
CB1
11
A
B
9
6
11
E2
E2
205
15
TR
N2A
194
0
23
15
15
23
147
147
194
RELAY
BOARD
13 15A
239
15B
C3-2
C3-5
14
RY1+
RY2+
RY3+
COM-
RY4-
RY5-
RY6-
COM+
147
15B
0
0
0
RELAY KEY
RY1 - ENGINE RUN
C3-4
0
RY2 - SWITCH IN EMERGENCY
RY3 - SWITCH IN AUTO
RY4 - COMMON ALARM
RY6 - DOOR OPEN
229
229
C3-1
A2
C3-6
15A
15A
0
14
REMOTE
SIGNALS
C3-3
A2
0
NO
COM
SW3
239
15A
56
NC
C1-5
13
18
18
14
IM1
D
D
14
SP1
C1-2
56
15
0
13
RED
IM2
SP2
SC
15
0
15
SCR
14
16
16
C1-1
BATTERY
12V
0
SC
0
FS
0
SM
0
0
BLACK
CUSTOMER
SUPPLIED
33
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Section 9 — Exploded Views and Parts Lists
Air-cooled 15 kW Generators
Enclosure – Drawing No. 0F5845
71
40
68
69
41
30
17
78
72
1
79
72
5
73
52
80
29
12
49
53
19
28
55
75
65
47
54
0
35
46
11
49
51
25
14
8
74
57
9
35
27
56
50
22
49
49
5
1
67
44
35
26
3
51
39
37
42
43
36
51
21
49
43
34
2
32
10
18
52
20
4
15
44
71
69
35
63
81
25
68
34
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Section 9 — Exploded Views and Parts Lists
Air-cooled 15 kW Generators
Enclosure – Drawing No. 0F5845
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
0C6140
0C6735
0F0063
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
2
1
1
1
1
1
1
1
1
ASSEMBLY, ENCLOSURE BASE
SUPPORT, ROOF FOLDING
ENCLOSURE, FRONT
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
0F0165
0D3037A
0A2115
022145
042907
0F0710
047411
043116
0D3700
0D4662
090388
092120
0F5633
0D3167
0A3328
055414
092079
0A1658
042907
0E9692
0E1330A
0E4321
022129
074908
0D2346
023484F
0C3906
0A7836
0A8475
0912970069
0912970070
055450
0E5968
0D3701
0D3472
0E2874
043107
0F5681
0F0164A
0F0165A
045771
0D3031
1
1
4
8
4
HINGE TYPE B WITH STUDS, PIN
LATCH, QUARTER TURN NON-LOCKING
WASHER NYLON .250"
3
4
0C7062
0F5629
ENCLOSURE, EXHAUST SIDE
ENCLOSURE, SIDE & BACK
ENCLOSURE, ROOF
WASHER FLAT 5/16
SCREW HHC M8-1.25 X 16 G8.8
5
6
0E9873
0C7065
0C8101A
0C8101B
0C8283
0C8284A
0C8284B
0C8284C
0C8285
0C8899A
0F5630
14 RIVET POP 0.125 X 0.337
7
PANEL, ALTERNATOR DIVIDER
PANEL, MUFFLER BOX SIDE
COVER, MUFFLER BOX
6
4
SCREW HHC M6-1.0 X 16 G8.8
SCREW HHC M6-1.0 X 12 G8.8
8
9
26 NUT, LOCKING FLANGE M6-1.0
11 SCREW HHTT M8-1.2 X 20 BP
36 SCREW TAPTITE M6-1.0 X 12 BP
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
GASKET, DOOR SEAL
FOAM, BACK ENCLOSURE
FOAM, ROOF ENCLOSURE
FOAM, FRONT ENCLOSURE
BRACKET, BATTERY SUPPORT
PAD, 24"X48" WITH MOUNTING HOLES
PANEL, ENGINE DIVIDER
2
1
1
1
1
1
2
2
1
1
1
NUT LOCK TRIC M6 X 1.0 Y/ZNC
ASSEMBLY, TRANSFER SWITCH
GASKET, BATTERY SUPPORT BRACKET
PLUG, PLASTIC 0.593
LUG SLDLSS #2-#8X17/64 CU
SCREW TAPTITE M6-1.0X25 BP
L/WASH SPECIAL ¼
0E4244
0D1606
0D1839
0D1840
0D2425
0D2588
0D2676
0D2677
0D2979B
0D2979C
0D2979D
0E4245
0E4245A
0E4245B
0D3057D
0D3059A
0D3059B
BAFFLE, INTAKE
HOUSING, FAN
BRACKET, TOP SUPPORT
SCREW HHC M8-1.25 X 16mm
BRACKET, REGULATOR MOUNTING
GROMMET, 38.1 CROSS SLIT WITH HOLE
PANEL, EXHAUST ALIGNMENT
BRACKET, BOTTOM SUPPORT
DUCT, BASE AIR
GASKET, FRONT DIVIDER
COVER, FRONT EXHAUST ENCLOSURE
COVER, BACK EXHAUST ENCLOSURE
CLOTH, HARDWARE 266.7mm x 146mm
CLOTH, HARDWARE 543mm x 146mm
CLOTH, HARDWARE 266.7mm x 387.4mm
FOAM, FRONT INTAKE BAFFLE
FOAM, TOP INTAKE BAFFLE
FOAM, BACK INTAKE BAFFLE
FOAM, BACK ENCL. STRIP
FOAM, EXHAUST SIDE ENCLOSURE END
FOAM, EXHAUST SIDE ENCLOSURE
FRONT
10 WASHER LOCK 5/16
8
1
1
2
2
2
1
2
1
SCREW TAPTITE M5-0.8 X 10 BP
HARNESS, ENGINE
BUSHING, SNAP SB-1000-12
SELF-ALIGN SCREW M6 HH
RIVET,1/8" X 0.126" - 0.375" LSH POP
L/WASH SPECIAL #10
ASSEMBLY, ROOF / DOOR GROUND WIRE
ASSEMBLY, ROOF / DOOR GROUND WIRE
PLUG PLASTIC 1.375
11 GASKET, EXTRUDED TRIM
1
1
1
4
1
1
1
4
1
PLATE, "HOT"
GROMMET 2.75 X 1/16
34
35
36
0D3059C
0D7176
0D3059D
1
24 WASHER, SELF LOCKING
FOAM, EXHAUST FAN HOUSING
SCREW HHTR 1/4-20 X 3/4
SCREW HHC M8-1.25 X 25
HARNESS
1
1
FOAM, FRONT EXHAUST ENCLOSURE
COVER
37
0D3059E
FOAM, BACK EXHAUST ENCLOSURE
COVER
DOOR, PAWL
HINGE TYPE A WITH STUDS, SOCKET
HINGE TYPE B WITH STUDS, SOCKET
NUT HEX M8-1.25
38
39
40
0C7781A
0D3037
0F0164
2
1
1
LATCH, QUARTER TURN LOCKING
HINGE TYPE A WITH STUDS, PIN
FUEL LINE, 3/4"OUTDOOR (NOT SHOWN)
35
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Section 9 — Exploded Views and Parts Lists
Air-cooled 15 kW Generators
Control Panel – Drawing No. 0F5846
36
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Section 9 — Exploded Views and Parts Lists
Air-cooled 15 kW Generators
Control Panel – Drawing No. 0F5846
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
0E7886G
0A1801
083049
0C2174
075210A
0D3062
0D8615
032300
022676
0E4494
0E7890
023484E
075476
0F4793
0E6480
023897
0C1085
0D8443
054502
0F5747
075235
0D5240
0D9784
0D8502
031879
0F5679
074908
049813
082025
0C3910
022507
099727
046689
063617
075475
043180
0D8439
092036
045770
0E7866
0D3700
0912970069
0E2874
0A1658
022473
038750
022097
027770
027771
043182
084464
042632
1
1
1
1
2
4
1
2
1
1
1
1
4
2
6
2
4
1
1
1
4
1
6
1
6
1
4
1
6
1
2
1
1
1
2
2
1
8
2
1
8
1
1
2
3
1
3
2
2
2
1
1
CIRCUIT BREAKER 70A X 2P 240V (15KW)
ASSEMBLY, BATTERY CHARGER ENGINE
ASSEMBLY, POTTED REGULATOR
RELAY, 12V 25A SPST
3
4
5
BLOCK 1 POSITION
6
HEX STAND-OFF #6-32 x 3/8"
ASSEMBLY, HOME STANDBY CONTROLLER
HOLDER, FUSE
7
8
9
FUSE, 15AMP X AGC15
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
SWITCH, ROCKER DPDT ON-OFF-ON
CIRCUIT BREAKER MOUNTING BRACKET
SNAP BUSHING
SCREW PPHM M4-0.7 x 16mm
SCREW PPHM M3-0.5 x 10mm
NUT HEX LOCK M4-0.7 NYLON INSERT
WASHER FLAT #10
SCREW PPHM M3-0.5 X 8mm
DECAL, CONTROL PANEL (NOT SHOWN)
CIRCUIT BREAKER 3 X 1 ETA 46-500-P
CONTROL, PANEL BOTTOM
SCREW HHC M5-0.8 x 30mm
SWITCH, SPST (ON)-ON N/O
NUT HEX LOCK M3-0.5 NYLON INSERT
NEUTRAL CONNECTOR
WASHER FLAT #4
HARNESS, CONTROL PANEL (NOT SHOWN)
SCREW TAPTITE, M5-0.8 x 10 BP
NUT HEX M6-1.0
NUT HEX LOCK M5-0.8 NYLON INSERT
TRANSFORMER
SCREW HHC 1/4"-20 x 1/2"
FUSE 5A X AGC5
BLOCK TERMINAL STRIP 20A 4 X 6 X 1100V
RELAY PANEL 12VDC DPDT 10A 240VAC
SCREW PPHM M4-0.7 x 10mm
WASHER FLAT M4
COVER, CONTROL PANEL COMPONENT
SCREW PPHMS/LW #6-32 x 1/4"
SCREW HHC M5-0.8 x10mm
COVER, CONTROL PANEL
NUT FLANGE M6-1.0 NYLOK
ASSEMBLY, ROOF/DOOR GROUND WIRE
SCREW HHTR 1/4"-20 X 3/4"
WASHER LOCK SPECIAL 1/4"
WASHER FLAT 1/4"-M6
SCREW HHC M6-1.0 x 30mm
WASHER LOCK M6-1/4"
SCREW RHM #4-40 X 5/8"
NUT HEX #4-40
WASHER LOCK M3
LIMIT SWITCH OPERATION
GROMMET 1/2 X 1/16 X 3/8
37
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Section 9 — Exploded Views and Parts Lists
Air-cooled 15 kW Generators
GT-990 Engine – Drawing No. 0E8774-Q Part 1
38
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Section 9 — Exploded Views and Parts Lists
Air-cooled 15 kW Generators
GT-990 Engine – Drawing No. 0E8774-Q Part 1
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
0C5729
1
ASSEMBLY, CRANKCASE HOUSING WITH
SLEEVE
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
0C2992
0C3971C
0C5305
0C3027
0E9842
0C5731
0C3006
080318
093064
0G1839
0D2723B
0C2979
086515
0D2274
0D3867
078672
0C5371
072694
0D3998
0C3027
0D5313
0D6024
0C2976
086516
0C2229
083897
0D8067B
0D9853D
0C2978
043790
0D4010
0D4011
0D4012
0D4013
0D8675A
0D8675B
0D4015
0D4016
1
1
1
1
1
1
9
8
1
2
1
2
8
4
4
2
4
4
4
2
4
2
12
2
2
4
1
4
2
1
1
1
1
1
1
1
1
1
BUSHING, GOVERNOR LOWER
ASSEMBLY, DIPSTICK WITH HANDLE
TUBE, DIPSTICK
2
3
0E9843
090388
1
3
1
1
1
1
4
1
4
2
2
2
1
1
2
1
1
1
1
1
1
SEAL, 38 I.D. CRANKSHAFT
SCREW, TAPTITE M6-1.0 X 12 YC
ASSEMBLY, BREATHER
O-RING, OIL CLR 3/8 X 1/2
SEAL, 42 I.D. CRANKSHAFT
ASSY, HS COVER W/SLV
SCREW, HHFC M10-1.5 X 55
SCREW HHFC M6-1.0 X 25
ASSEMBLY, OIL FILL CAP
LIFT HOOK, GT990/760
ROCKER, COVER WITH OIL FILL
GASKET, VALVE COVER
KEEPER, VALVE SPRING
RETAINER, VALVE SPRING
SPRING, VALVE
4
0C5372
0C3005
0E3372B
0D8067A
071983
5
GASKET, BREATHER COVER
SEPARATOR, OIL BREATHER
ASSEMBLY, HEAD #1 G&S
RETAINER, PISTON PIN 20
ROCKER, COVER NO OIL FILL
STUD M8-1.25/10MM X 30 G5 ZINC
PISTON, HC
6
7
8
9
0C2981C
045761A
0E2985
021533
10
11
12
13
14
15
16A
16B
17
18
19
20
21
SET, PISTON RING 90MM
PIN PISTON
0E1466
0D4041
0C2983
0C2985A
0C2985B
0D4042
0A7811
0C2977
0C5943
0G0140E
ASSEMBLY, CAMSHAFT & GEAR
SHAFT, GOVERNOR
SEAL, VALVE STEM D7
WASHER, VALVE SPRING
STUD, ROCKER ARM PIVOT
NUT HEX M8-1.0 G8 YEL CHR
O-RING, 3/8” X 1/2”
ROLLER BEARING, GOVERNOR PLATE
ROLLER BEARING, GOVERNOR
ASSEMBLY,GOVERNOR GEAR
SPOOL, GOVERNOR MACHINED
GASKET, CRANK CASE
ROCKER ARM
SEAL, OIL PASSAGE
ASSEMBLY, CRANKSHAFT HORIZONTAL
DIRECT DRIVE
PLATE, PUSH ROD GUIDE
SCREW HHFC M8-1.25 X 65
VALVE, EXHAUST
22
23
24
25
26
27
28
29
30
31
32
33
34
35
0E3223
0D2157
0E6098
0G1536
0E8152
0C3011
0C3009
0C3010
093873
0F5458
0C5998
0D1667
0C2991
0C2988
2
2
1
1
1
2
2
2
2
1
1
1
2
1
ASSEMBLY, CONNECTING ROD
SCREW SHC M6-1.0 X 50 G8.8
SCREEN, OIL PICKUP
VALVE, INTAKE
TAPPET, SOLID
ASSEMBLY, HEAD #2 G&S
PUSHROD, 147
GASKET, HEAD
ASSEMBLY, OIL PUMP
O-RING .49 ID X .07 THICK
COVER, OIL RELIEF
SPRING, OIL RELIEF
BARBED ELBOW 90 3/8NPT X 3/8
KIT GASKET
KIT PISTON & RINGS
BALL, 1/2D OIL RELIEF
WASHER, LOCK RIB M6
SCREW, PLASTITE HI-LOW #10
CLAMP, OIL TUBE
KIT BREATHER ASSEMBLY
KIT GOVERNOR ASSEMBLY
KIT HEAD ASSEMBLY CYLINDER 1
KIT HEAD ASSEMBLY CYLINDER 2
KIT OIL RELIEF
ARM, GOVERNOR
E-RING, GOVERNOR ARM
THRUST WASHER, GOVERNOR
KIT GEAR COVER
39
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Section 9 — Exploded Views and Parts Lists
Air-cooled 15 kW Generators
GT-990 Engine – Drawing No. 0E8774-Q Part 2
40
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Section 9 — Exploded Views and Parts Lists
Air-cooled 15 kW Generators
GT-990 Engine – Drawing No. 0E8774-Q Part 2
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
74
75
76
77
78
0C5136A
0C3024
0C3040
0C8127
0D8564A
0D8564B
0D2595
0D4417
0C3025
0D3083
0C7292
070185B
075281
0F2094
2
1
1
1
1
1
4
4
1
1
1
1
1
2
KNOB, AIR CLEANER
COVER, AIRBOX NG/LP
PRE-CLEANER,
110
111
112
0C3022A
0D1131
045756
1
1
HOUSING, BLOWER NG COOLER
GUARD, FAN
25
SCREW TAPTITE M6-1X10 YELLOW
CHROME
ELEMENT, AIR CLEANER
ASSEMBLY, MIXER/AIRBOX 990
ASSEMBLY, MIXER/AIRBOX 760
SCREW SHOULDER (8MM) M6-1.0 X 18
WASHER,RUBBER 1/4" X 1/8" THICK
SWITCH, OIL PRESS
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
1 30
1 31
1 32
1 33
1 34
1 35
1 36
1 37
1 38
1 39
0C9763
0C3036A
022145
022129
0C3018
0C3019
0D1142A
0D1143
0E6043
0F1177
0C3052
022097
092079
0E4271
0D4529
022129
061906
082774
0E5343
0C8468
0C3048
0D3754
0D3742
0C8482
0E0486
0D3743
0D3705
4
1
1
1
1
1
1
1
2
1
1
4
4
1
2
2
2
1
1
1
1
1
1
1
1
1
1
NUT, GROMMET 1/4 PLUG
HOSE, BREATHER
79
80
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
81
82
WRAPPER, UPPER CYLINDER 1
WRAPPER, LOWER CYLINDER 1
WRAPPER, LOWER CYLINDER 2
WRAPPER, UPPER CYLINDER 2
SCREW TAPTITE M5-0.8 X 8 ZP
ASSEMBLY, GROUND WIRE
ASSY, IGNITION COIL GV-990 CYLINDER 2
WASHER LOCK M6-1/4
ASSEMBLY, OIL DRAIN HOSE
NIPPLE, 3/4"-16 UNF
OIL FILTER
83
84
85
86
SWITCH, THERMAL 284F
SCREW, M3-0.5 X 6 SEMS
87
88
035461
0F6301
0G0286
0C3026
0C9764
0C3043
0C7694
0C7693
0C3041A
070008
070006
040976
0C3016A
0E4997
0C3725B
0C3031
0C3032
0A5992
051754
0C3033
0C3034
0C8549A
2
4
2
1
4
2
1
1
2
4
4
4
1
1
1
1
1
2
2
1
1
1
BARBED STR 1/4NPT X 3/8
CLAMP, HOSE OETIKER 16.5mm
HOSE, 3/8" I.D. X 6" LG SAE J30R9
COOLER, OIL
89
90
SCREW TAPTITE M6-1.0 X 25 BP
STARTER
SPARKPLUG
91
92
PLASTITE,1/4-15 X 3/4
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 85 G8.8
KEY, WOODRFF 4 X 19D
93
94
GASKET, MANIFOLD / PORT
MANIFOLD CYLINDER 2
MANIFOLD CYLINDER 1
SLEEVE, RUBBER
95
96
NUT HEX LOCK M10-1.50
SPRING, ANTI-LASH
97
98
WASHER FLAT M8 SS
ROD, GOVERNOR CONTROL
ASSEMBLY, GOVERNOR LEVER
SPRING, GOVERNOR
WASHER LOCK M8 SSTL
SCREW SHC M8-1.25 X 20 G12.9
PLATE, BACKING WITH OIL COOLER
GROUND WIRE CONNECTOR
FLYWHEEL ASSEMBLY
FAN, NYLON
99
100
101
102
103
104
105
106
107
108
109
ASSEMBLY, GOVERNOR ADJUSTER
SCREW SHC M10-1.5 X 75 G10.9
SPRING, GOVERNOR IDLE
ASSEMBLY, GOVERNOR ADJUSTER
BRACKET
PLATE, FAN
WASHER SHAKEPROOF INT M8 SS
SCREW HHC M8-1.25 X 12 G8.8
WASHER, 25mm I.D.
140
142
143
144
145
0C2993
045771
0D6147
0E8152
0E7743
1
1
7
1
1
SEAL, GOVERNOR SHAFT
NUT HEX M8-1.25 G8
SCREW HHFC M6-1.0 X 10mm
O-RING 0.49” I.D. X 0.07” THICK
ASSY, IGNITION COIL 270mm CYLINDER 1
NUT,HEX M24
SNORKEL, AIR INTAKE
41
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Section 9 — Exploded Views and Parts Lists
Air-cooled 15 kW Generators
15 kW Generator – Drawing No. 0D3417-L
42
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Section 9 — Exploded Views and Parts Lists
Air-cooled 15 kW Generators
15 kW Generator – Drawing No. 0D3417-L
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
0C6934
0C7930
0D2359
0C7944
0D2356
0C6043
0D2336
0D6634
0D3220
0C8101
056482
0C3168
0D1838
0D1846
0C7038
0D1609
0D2559
0C7038A
0C7758
0388050AD0
0C2417A
082121C
066386
029451
049451
022237
022511
022131
051731
022145
049820
045756
022129
022259
059637
0D4662
0F7065
048031M
0F0462
0C2824
025145
0C4138
040173
074995
066849
1
1
ADAPTOR, ENGINE
STATOR 12KW
STATOR 13KW / 15KW
ROTOR 12KW
ROTOR 13KW / 15KW
3
1
4
5
1
CARRIER, REAR BEARING
FAN, 12” CURVED BLADE
MUFFLER
1
6
1
7
1
TAIL PIPE, MUFFLER
PANEL, MUFFLER BASE
BEARING 1.1811-2.8346
8
1
9
1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
3
5/16 SPECIAL LOCK WASHER
BOLT, HHCS 3/8”-24 x 15.50”
BOLT, HHCS M8-1.25 x 345mm
BRACKET, ALTERNATOR MOUNTING
DUCT, ALTERNATOR AIR
GASKET, ALTERNATOR AIR DUCT
BRACKET, ENGINE MOUNTING
RUBBER MOUNT
1
4
1
1
1
1
4
1
CABLE, #6 48” BLACK BATTERY
EARTH STRAP 3/8X 3/8
1
1
CLIP-J, VYNL COAT 0.625” ID
ASSEMBLY BRUSH HOLDER
TAPE ELEC UL FOAM 1/8 X 1/2
WASHER FLAT .406ID X 1.62OD
WASHER LOCK 3/8
1
2.6 FT
1
5
4
SCREW HHC 3/8-16 X 1-1/4 G5
WASHER FLAT 3/8 ZINC
4
4
12
SCREW HHC M8-1.25 X 50 G8.8
WASHER FLAT 5/16 ZINC
NUT LOCK HEX M8-1.25 NYL INSERT
SCREW TAPTITE M6-1.0X10 BP
WASHER LOCK M8-5/16
4
2
10
8
NUT HEX 5/16-18 STEEL
SCREW TAPTITE 3/8-16 X 3/4 BP
SCREW 5/16-18X3/4” HH THD ROLL
HOSE RES 1/2 LP GAS
2
4
3 FT
4
HOSE CLAMP 3/4” I.D.
4
NUT HEX W/TOOTH WSHR M8-1.25
SCREW TAP-R #10-32 x 9/16
U-BOLT 5/16”-18 X 1.25” WITH SADDLE
GASKET, EXHAUST PORT
CLAMP HOSE #5.5 0.62”-0.62”
HOSE 1\4 ID LPG 350PSI UL21
SCREW HHTT M5-0.8 X 16
1
1
2
2
1.44 FT
2
43
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Section 9 — Exploded Views and Parts Lists
Air-cooled 15 kW Generators
Gas Regulator – Drawing No. 0D8720-H
44
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Section 9 — Exploded Views and Parts Lists
Air-cooled 15 kW Generators
Gas Regulator – Drawing No. 0D8720-H
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
0D5694
0F5022
0C4647
0D4166
0C6070
0F4795
0C5760J
0C6606
097934
0C4645
0C5761
0C5968
0C6066
0C5759
0C5764
0C5764A
070728
0C6069
0C5762
045764
0C6731
0C6067
0C4706
0C6068
0C4643A
026073
026073
0A4032
0D3308
024310
028414A
0D5698A
0D3973
1
1
CASTING, TWIN REGULATOR HOUSING
SOLENOID COIL, 12VDC
GASKET , SOLENOID
3
1
4
1
PLUNGER, LP REGULATOR ASSEMBLY
SPRING-SOLENOID, PLUNGER
SCREW PPHM SEMS M4-0.7 X 10
JET, GN 410 ENGINE LP (7KW)
BARBED STRAIGHT 1/2NPT x 1/2
O-RING, CHECK VALVE
5
1
8
4
9
1
10
11
12
13
14
15
16
17
2*
2*
2*
2
ADJUSTER SCREW, TWIN REGULATOR
LEVER, REGULATOR
SUPPORT, INLET SEAL
2
2
SEAL, INLET
PIN, PIVOT ARM
SPRING, REGULATOR
2
2
2
SPRING, REGULATOR (7KW)
SCREW, PFHMS M3-0.5 x 5
GASKET, DIAPHRAGM
18
19
20
21
22
23
24
25
26
27
4
2
2
COVER, TWIN REGULATOR
SCREW, TAPTITE M4X8 BP
16
2
RIVET, POP .118 X .125
SUPPORT, DIAPHRAGM
2
2
DIAPHRAGM, TWIN REGULATOR
CAP, DIAPHRAGM SUPPORT
INLET, TWIN REGULATOR 11.11 DIA.
PLUG, STANDARD PIPE 1/8” STEEL SQUARE HEAD
PLUG, STANDARD PIPE 1/8” STEEL SQUARE HEAD (7KW)
PIN, LIMITED ADJUSTMENT
2
2
1
2
28
29
30
31
32
37
2*
4
WASHER, FLAT M3 X 10mm O.D.
PLUG, STANDARD PIPE 1/2” STEEL SQUARE HEAD (7KW)
BARBED STRAIGHT 1/8”NPT X 1/4”
JET IDLE PRIMER PHILLIPS HD (V-TWIN ONLY)
PLUG, EXPANSION 16mm
1
1
1
1
* A QUANTITY OF 1 IS TO BE USED ON 7KW HOME STANDBY
45
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Section 9 — Exploded Views and Parts Lists
Air-cooled 15 kW Generators
Transfer Switch – Drawing No. 0F5633$-A
46
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Section 9 — Exploded Views and Parts Lists
Air-cooled 15 kW Generators
Transfer Switch – Drawing No. 0F5633$-A
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
0D9618
0E3375
0F1252
022097
074908
045771
057329
027482
022129
073590A
073591
090388
0A1495
063617
0C2454
0A1661
0C4449A
0F5634
0E6056
0F0668
0C2262
095282
027770
064101
0F5694
063378
028739
0F5893
067210A
0A9457
0A9517
0E6190
081221
0E6193
064526
0E6155
0F5748
0E6033
0E6303B
0E6303
0E6303A
0F5770
020757
0D3062
092036
048850
084464
043182
1
6
6
6
5
1
1
1
1
2
2
2
4
1
2
2
1
1
1
1
1
1
2
4
1
3
5
1
1
1
1
1
1
1
2
1
1
2
1
1
1
1
1
4
8
1
1
2
TR SW-HSB 200A 2P 250V
LUG SLDLSS 250-#6 AL/CU
SCREW BHSC 1/4-20 X 3/8
WASHER LOCK M6-1/4
3
4
5
SCREW HHTT M5-0.8 X 16 BP
NUT HEX M8-1.25 G8 YEL CHR
LUG SLDLSS 350-#6 X 13/32 AL/CU
WASHER SHAKEPROOF EXT 5/16 STL
WASHER LOCK M8-5/16
FUSE 5A X BUSS
6
7
8
9
10
11*****
12
13
FUSE HOLDER
SCREW HHTT M6-1.0 X 12 ZINC
SCREW HHTT M4-0.7 X 10 BP
RELAY PNL 12VDC DPDT 10A@240VA
SCREW TH-FRM M6-1 X 16 N WA Z/JS
RIVET POP .156 X .675 AL
ASS’Y-NTRL BL150-200A
WELDMENT XFER SW BOX HSB
COVER TRANSFER SWITCH BOX HSB
DECAL TRANSFER SWITCH
DECAL TERMINAL STRIP
DECAL-LIVE CIRCUIT
14*****
15
16
17
18
19
20****
21
22***
23
SCREW RHM #4-40 x 5/8
NUT LOCK FL 3/8-16
24
25
SUBPLT TRANSFER SWITCH HSB
HOLDER CABLE TIE
26*****
27*****
28
TIE WRAP UL 3.9” X .10” NATL
DECAL TRANSFER SWITCH DATA 200
DECAL GROUND LUG
29
30
DECAL NEUTRAL
31
DECAL MANUAL 5A FUSE
DECAL TEST SEQUENCE 2P TS 3R
DECAL-UL LIST HSB
32 *
33
34
35
BRACKET ARM EXTENDER
SCREW HWHS #6-25 X 3/8 ZNC
ARM EXTENDER PIN
36 **
37
HARN 100/200A 2P HS
38 **
39
90 DEGREE DN SPADE CONNECTOR
WIRE E1
WIRE A
40
41
WIRE B
DECAL TERMINAL STRIP
ALARM PCB
42
43
44
45
HEX PCB SUPPORT, SCREW-IN
#6-32 x 0.25” PPH W/ LOCK
ASSY. TERM. BLOCK 20A 5 x 1100VAC
LIMIT SW-SW OPERATION
WASHER LOCK M3
46
47
48
* CENTER DECAL ON INSIDE OF THE COVER (ITEM #19)
** SUPPLIED WITH TRANSFER SWITCH (ITEM #1).
*** PLACE DECAL ON OUTSIDE OF COVER, LOWER RIGHT CORNER.
**** NOT SHOWN ON THIS ASSEMBLY, CENTER DECAL ON FRONT OF COVER, 7” FROM TOP OF ENCLOSURE.
***** SUPPLIED WITH HARNESS (P/N 0F5748)
47
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Section 10 – Warranty
Air-cooled 15 kW Generators
NOTE: This Emission Control Warranty Statement pertains to this product only IF the generator size is 15 kW or below.
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission
Control System Warranty on your new engine.* In California, new utility, and lawn and garden equipment engines must be
designed, built and equipped to meet the state’s stringent anti-smog standards. Generac will warrant the emission control
system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modifica-
tion or improper maintenance of your engine.
Your emission control system may include parts such as the carburetor, ignition system and exhaust system. Generac will
repair your engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.
MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:
Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted. If, dur-
ing such warranty period, any emission-related component or system on your engine is found to be defective in materials or
workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Facility.
PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:
As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory
supplied Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance
on your engine. However, Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the
completion of all scheduled maintenance.
As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or
responsibility if your engine, or a part/component thereof, has failed due to abuse, neglect , improper maintenance or unap-
proved modifications, or the use of counterfeit and/or “grey market” parts not made, supplied or approved by Generac.
You are responsible for contacting a Generac Authorized Warranty Service Facility as soon as a problem occurs. The
warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility.
To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number:
1-800-333-1322
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System
Warranty (ECS Warranty), which is provided to you by Generac pursuant to California law. See also the “Generac Limited
Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you by
Generac. The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in
terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where
the Generac Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe
important rights and obligations with respect to your new engine.
Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty ser-
vice, evidence must be presented showing the date of the sale to the original purchaser/owner.
If there are any questions regarding the warranty rights and responsibilities, contact Generac at the following
address:
ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 340
EAGLE, WI 53119
Part 1
48
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Section 10 – Warranty
Air-cooled 15 kW Generators
EMISSION CONTROL SYSTEM WARRANTY
Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines:
(a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on the
date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue
for 24 consecutive months thereafter.
(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or
equipment and to each subsequent purchaser/owner that each of its engines is ...
(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its
authority, and
(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a
warranted emissions-related part to fail to be identical in all material respects to the part as described in the engine
manufacturer’s application for certification.
(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:
(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall
be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the
ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.
(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual
shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or
replace as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS
Warranty shall be warranted for the remainder of the ECS Warranty Period.
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part
fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection
(4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the
remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no
charge to the owner at a Generac Authorized Warranty Service Facility.
(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsible
for diagnostic costs if the repair is deemed warrantable.
(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused
by a failure under warranty of any emission-related part covered by the ECS Warranty.
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient
to meet the expected demand for such emission-related parts.
(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS
Warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce Generac
ECS Warranty obligations.
(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac
engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim.
Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of
such an unapproved, add-on, modified, counterfeit and/or “grey market” part.
EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
1) Fuel Metering System:
3) Ignition System including:
a) Spark plug
1.2) LPG/Natural Gas carburetion assembly and its internal
components.
b) Ignition module
a) Fuel controller (if so equipped)
4) Catalytic Muffler Assembly (if so equipped) including:
a) Muffler gasket
b) Exhaust manifold
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)
5) Crankcase Breather Assembly including:
a) Breather connection tube
2) Air Induction System including:
a) Intake pipe/manifold
b) Air cleaner
*Generac engine types covered by this warranty statement include the following:
1) Prepackaged Standby Generator
2) Auxiliary Power Unit (APU) Generator
3) Standby Generator
Part 2
49
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Section 10 – Warranty
Air-cooled 15 kW Generators
GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR
HOME STANDBY/LIGHT COMMERCIAL PRODUCT 45kW AND BELOW
For a period of two (2) years from the date of sale, or start-up by Authorized/Certified Generac Power Systems Dealer, or branch thereof, Generac
Power Systems, Inc. will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or
an Authorized/Certified Generac Power Systems Dealer, or branch thereof, is found to be defective under normal use and service, in accordance with
the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Authorized/
Certified Generac Power Systems Dealer, or branch thereof. This warranty applies only to Generac Power Systems Generators used in "Standby"
applications, as Generac Power Systems, Inc. has defined Standby, provided said generator has been properly installed and inspected on-site by
appropriate personnel. Scheduled maintenance, as outlined by the generator owner's manual, is highly recommended. This should be performed by
an Authorized/Certified Generac Power Systems Dealer, or branch thereof. This will verify service has been performed on the unit throughout the
warranty period.
WARRANTY SCHEDULE
YEARS ONE and TWO — Limited comprehensive coverage on mileage, labor, and parts listed.
• - ALL COMPONENTS
*Start-up and/or On-line Registration, or Registration Card, along with Proof of Purchase, must be performed and/or sent in.
Guidelines:
• Any and all warranty repairs and/or concerns, must be performed and/or addressed by an Authorized/Certified Generac Power Systems Dealer, or
branch thereof.
• A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a Non - Generac Power
Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the genset, no warranty coverage shall apply.
• All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty, Policies, and Procedures Flat Rate Manual.
• Units that have been resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable.
• Unit enclosure is only covered against rust or corrosion the first year of the warranty provision.
• Use of Non-Generac replacement part(s) will void the warranty in its entirety.
• Engine coolant heaters (block-heaters), heater controls and circulating pumps are only covered during the first year of the warranty provision (If
applicable).
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
1. Any unit built/manufactured prior to January 1, 2005.
2. Costs of normal maintenance (i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up).
3. Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze.
4. Units sold, rated or used for "Prime Power", "Trailer Mounted" or "Rental Unit" applications as Generac Power Systems have defined Prime Power,
Trailer Mounted or Rental Unit. Contact a Generac Power Systems Distributor for Prime Power, Trailer Mounted or Rental Unit definition and warranty.
5. Units used for prime power in place of existing utility power where utility is present or in place of utility power where utility power service does not
normally exist.
6. Failures caused by any external cause or act of God such as, but not limited to, collision, fire, theft, freezing, vandalism, riot or wars, lightning,
earthquake, windstorm, hail, volcanic eruption, water or flood, tornado, hurricane, terrorist acts or nuclear holocaust.
7. Products that are modified or altered in a manner not authorized by Generac Power Systems in writing.
8. Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing.
9. Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the
defective part(s).
10. Failure due to misapplication, misrepresentation, or bi-fuel conversion.
11. Telephone, facsimile, cell phone, satellite, internet, or any other communication expenses.
12. Rental equipment used while warranty repairs are being performed (i.e. rental generators, cranes, etc.).
13. Overtime, holiday, or emergency labor.
14. Planes, ferries, railroad, busses, helicopters, snowmobiles, snow-cats, off-road vehicle or any other mode of transportation deemed abnormal.
15. Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct
cause of the problem.
16. Starting batteries, fuses, light bulbs, engine fluids, and overnight freight cost for replacement part(s).
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC POWER SYSTEMS
MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow
limitations on how long an implied warranty lasts, so the above limitation may not apply to purchaser/owner.
GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT
SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A
DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/
owner. Purchaser/owner agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gives purchaser/owner
specific legal rights. Purchaser/owner also may have other rights that vary from state to state.
Generac Power Systems, Inc. • P.O. Box 8 • Waukesha, WI 53187
Ph: (262) 544-4811 • Fax: (262) 544-4851
Bulletin 0171360SVE / Printed in U.S.A. 7.05
Part No. 0F5631
Revision C (12/07/06)
Printed in U.S.A.
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