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Generac Power Systems 05176-0 Portable Generator User Manual

1. TRANSFER SWITCH N2A N1A 126 15A 1 COIL H 15A 1 A ooo 5 _ oo ooo GTS NA 126 NA 2 XB1 B E1 COIL T 2 E1 E2 E2 205 nA 126 15A 147 Tp 126 205 7 1 6 3 194 NA NA 23 205 E2 23 194 N2A N2A 15 NIA 3 15A 147 E2 RELAY BOARD F3 F4 H 14 147 RY2 E NEUTRAL is i 29 229 RY4 TS RY5 A2 RY6 15A COM O Ni REMOTE Lj SIGNALS RELAY KEY NEU RY1 ENGINE RUN E1 RY2 SWITCH IN EMERGENCY E2 0 RY3 SWITCH IN AUTO GRD J 15 RY4 COMMON ALARM N2 A2 RY6 DOOR OPEN Ni 14 194 23 15 0 158 A2 14 229 31 ELECTRICAL DATA gt Section 8 Electrical Data Air cooled 15 kW Generators Electrical Schematic Drawing No 0F5844 B 11 11 22 22 BATTERY CHARGER 225B TX 225A 224A 224B 22 0 13A BATTERY CHARGE WINDING 77 TO ALA ALAS 66 o
2. 205 224A CONTROL PANEL BOX 224 225A L 224A 225A 10 9 7 6 CLOSEST TO BEARING i BCR CB2 46 O 13 0 66 zl w 224B 2248 14 0 225B 2258 4 e 9 lt 14 2 8 lt 0 6 7 EE 22 22 22 5 4 4 0 E 0 ae 6 6 25 0 13A 2 1 162 224 1 VOLTAGE 66A 55 C2 REGULATOR 5 1 66A 0 66A N2 0 0 14 13 TB o b Ole 15 r 15 0 0 0 0 A2 225 n 4 2 24 ii 351 a 1 N AUTO 24 351 14 13 13 15 15 15 2 SW1 MANUAL 66A 13 K B 15 29 1 L_ FA F2 15 ib ct 6 Sw i 15 158 66A 239 15A NEU 15 Et 0 0 GRD 25 23 0 GRD 224 194 m i Ni 3 bs 194 2 194 23 23 1 23 4 15A 6 lt 15A 0 5 lt 0 158 4 158 ne 3 lt 4 2 14 29 1 lt 29 c3 30 Section 8 Electrical Data Air cooled 15 kW Generators ER 5 ELECTRICAL Wiring Diagram Drawing No 0F5643 B Part 3 lt DATA
3. CO QO OO CO QO CO O1 CO n9 0E7886G 0 1801 083049 0C2174 075210A 0D3062 0D8615 032300 022676 0E4494 0E7890 023484E 075476 0F4793 0 6480 023897 0C1085 0D8443 054502 0F5747 075235 0D5240 0D9784 0D8502 031879 0 5679 074908 049813 082025 003910 022507 099727 046689 063617 075475 043180 0D8439 092036 045770 0E7866 0D3700 0912970069 0E2874 0A1658 022473 038750 022097 027770 027771 043182 084464 042632 ci BO RO CO ho s SoS cx oL Oo y Ng SR ee cs Section 9 Exploded Views and Parts Lists LISTS Air cooled 15 kW Generators Control Panel Drawing No 0F5846 0 CIRCUIT BREAKER 70A X 2P 240V 15KW ASSEMBLY BATTERY CHARGER ENGINE ASSEMBLY POTTED REGULATOR RELAY 12V 25A SPST BLOCK 1 POSITION HEX STAND OFF 6 32 x 3 8 ASSEMBLY HOME STANDBY CONTROLLER HOLDER FUSE FUSE 15AMP X AGC15 SWITCH ROCKER DPDT ON OFF ON CIRCUIT BREAKER MOUNTING BRACKET SNAP BUSHING SCREW PPHM 4 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 CONTRO
4. PARTS qea 00 HINGE TYPE B WITH STUDS PIN LATCH QUARTER TURN NON LOCKING WASHER NYLON 250 WASHER FLAT 5 16 SCREW 8 1 25 X 16 G8 8 RIVET POP 0 125 X 0 337 SCREW HHC M6 1 0 X 16 G8 8 SCREW HHC M6 1 0 X 12 G8 8 NUT LOCKING FLANGE M6 1 0 SCREW HHTT M8 1 2 X 20 BP SCREW TAPTITE M6 1 0 X 12 BP NUT LOCK TRIC M6 X 1 0 Y ZNC ASSEMBLY TRANSFER SWITCH GASKET BATTERY SUPPORT BRACKET PLUG PLASTIC 0 593 LUG SLDLSS 2 8 17 64 CU SCREW TAPTITE M6 1 0X25 BP L WASH SPECIAL 4 SCREW 8 1 25 X 16mm BRACKET REGULATOR MOUNTING GROMMET 38 1 CROSS SLIT WITH HOLE PANEL EXHAUST ALIGNMENT WASHER LOCK 5 16 SCREW TAPTITE 5 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 GASKET EXTRUDED TRIM PLATE HOT GROMMET 2 75 X 1 16 SCREW HHTR 1 4 20 X 3 4 SCREW 8 1 25 X 25 HARNESS HINGE TYPE A WITH STUDS SOCKET HINGE TYPE B WITH STUDS SOCKET NUT HEX M8 1 25 FUEL LINE 3 4 OUTDOOR NOT SHOWN 35 Section 9 Exploded Views and Parts Lists Air cooled 15 kW Generators Control Panel Drawing No 0F5846 36 WP O10101 00
5. 1 16 85 14 SCR 18 14 18 56 86 351 J2 1 351 86 23 23 194 CONTROL 56 PRINTED CIRCUIT BOARD 18 194 66A 229 O 12V BATTERY CUSTOMER SUPPLIED RED 98 8 7 6 5 4 3 2 66 239 239 5 15 15 15A ON INDICATES 225 225 1 20 Va Sense Transformer 2 Remote Not Auto 3 50 Hz Operation 17 16 15 14 13 12 11 10 4 SPARE 5 L E D ALARM INDICATORS 224 224 ELECTRICAL DATA Section 8 Electrical Data Air cooled 15 kW Generators Wiring Diagram Drawing No 0 5645 Part 2
6. NOTE The voltage regulator is housed above the generator s control panel The regulator maintains a voltage in direct proportion to frequency For example at 62 Hertz line to neutral voltage will be 124 volts OPERATION Section 4 Operation ix Air cooled 15 kW Generators 4 1 USING THE AUTO OFF MANUAL SWITCH FIGURE 4 1 4 1 1 AUTO POSITION Selecting this switch position activates fully automatic system operation It also permits starting and exercising of the engine every seven days with the exercise timer see Generator Test Under Load This position also is used for remote starting when it is set up 4 1 2 OFF POSITION This switch position shuts down the engine This position also prevents automatic operation 4 1 55 MANUAL POSITION Set the switch to MANUAL to crank and start the engine Transfer to standby power will not occur unless there is a utility failure Figure 4 1 Generator Control Panel FUSE Locate your nearest GENERAC dealer at www generac com GENER AC power systems 5A SYSTEM SET LOW OIL FUSE HIGH TEMP OVER SPEED 1 OVER CRANK L 15A SET FLASHING GREEN LED NO UTILITY SENSE EXERCISE Q 4 FLASHING RED LEDS TIME XERCISER NOT SET AUTO OFF MAN waRNING AN With the switch set to AUTO the engine may cran
7. 46 45 PER LOCATION X X X x lt x 28 10 32 31 19 Bnet ENCLOSURE 46 A A GROUND LUG ASSEMBLY DETAIL Section 9 Exploded Views and Parts Lists i urs Air cooled 15 kW Generators Transfer Switch Drawing No 0F5633 A 0 1 009618 1 SW HSB 200A 2 250V 2 0E3375 6 LUG SLDLSS 250 46 AL CU 3 0F1252 6 SCREW BHSC 1 4 20 X 3 8 4 022097 6 WASHER LOCK M6 1 4 5 074908 5 SCREW HHTT M5 0 8 X 16 BP 6 045771 1 NUT HEX 8 1 25 G8 YEL CHR 7 057329 1 SLDLSS 350 16 X 13 32 AL CU 8 027482 1 WASHER SHAKEPROOF EXT 5 16 STL 9 022129 1 WASHER LOCK M8 5 16 10 073590A 2 FUSE 5A X BUSS wee 073591 2 FUSE HOLDER 12 090388 2 SCREW HHTT M6 1 0 X 12 ZINC 13 041495 4 SCREW HHTT 4 0 7 X 10 BP 149 063617 1 RELAY PNL 12VDC DPDT 10A 240VA 15 0C2454 2 SCREW TH FRM M6 1 X 16 N WA Z JS 16 0 1661 2 RIVET 156 X 675 AL 17 0C4449A 1 ASS Y NTRL BL150 200A 18 0 5634 1 WELDMENT XFER SW BOX HSB 19 0 6056 1 COVER TRANSFER SWITCH BOX HSB 20 0 0668 1 DECAL TRANSFER SWITCH 21 0C2262 1 DECAL TERMINAL STRIP 22 095282 1 DECAL LIVE CIRCUIT 23 027770 2 SCREW RHM 44 40 x 5 8 24 064101 4 NUT LOCK FL 3 8 16 25 0 5694 1 SUBPLT TRANSFER SWITCH HSB gon 063378 3 HOLDER CABLE TIE ars 028739 5 TIE WRAP UL 3 9 X 10 NATL 28 0 5893 1 DECAL TRANSFER SWITCH DATA 200 29 067210A 1 DECAL GROUND LUG 30 0A9457 1 DECAL NEUTRA
8. 194 66 56 18 14 66 239 15 15 225 224 Section 8 Electrical Data Air cooled 15 kW Generators Electrical Schematic Drawing No 0F5844 B ELECTRICAL DATA 11 lt C2 6 22 c25 c43 18 F3 m NI gt NIA poh 126 C44 E 126 147 15 id 59 ea N2A B AUTO MAN F4 d s 158 C O C42 no M 1 1 4 1 I 15 NB 1 P P SW1 ps xu xd 9 X f 2 Fe cow TOM 15A 15 239 15B a T sl GTS 15 N2A va B 147 POWER WINDING 15 STATOR 0 18 y y Y 57 A B 1 5 LE2 E2 11 205 b TR 0 194 23 N2A 15 15 ii 147 3m 194 RELAY BOARD 13 15 239 4 0 55 147 RY2 PEI lt C3 5 15B RS RY1 ENGINE RUN 129 I lt 0 RY2 SWITCH IN EME
9. 225A 56VA N2 224A 225 1VA 224 Ni 15 ELECTRONIC VOLTAGE REGULATOR 11 22 aas 4 BA 0 gt 4 C2 9 FIELD C24 ENGINE RUN WINDING STATOR AAA C2 3 13 0 162 2 C2 7 MEI DPE WINDING STATOR C2 8 A DIAGRAM KEY BA BRUSH ASSEMBLY BCR BATTERY CHARGE RELAY C1 8 POSITION CONNECTOR C2 12 POSITION CONNECTOR C3 4 POSITION CONNECTOR C4 6 POSITION CONNECTIR MAIN OUTPUT BREAKER CB2 CIRCUIT BREAKER ALTERNATOR EXCITATION D DIODE FS FUEL SOLENOID F1 FUSE 5A BATTERY CHARGER F2 FUSE 15 AMP SYSTEM F4 FUSE SENSING GTS TRANSFER SWITCH CONTACTOR HTO HIGH OIL TEMPERATURE SWITCH IGNITION MODULE CYLINDER 1 IM2 IGNITION MODULE CYLINDER 2 LOP LOW OIL PRESSURE SWITCH NB NEUTRAL BLOCK SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SP1 SP2 SPARK PLUGS SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH SWS DOOR ALARM SWITCH SM STARTER MOTOR TR RELAY TRANSFER TS TERMINAL STRIP TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC VR1 VR2 VARISTORS XM XB1 XC1 LIMIT SWITCHES 66A 14 23 194 225 224 66A 229 CONTROL PRINTED CIRCUIT BOARD 86 23
10. CS3HONIJ 5 31 5 11 WAWANIW MJM 3GIS 1431 MIA 3GIS LHOIH LNOUH Vid 10061 29 npg x50N 553099 31492 LG S 901 I Gs vel iw e mur WEG TEIL lt 2 01 092 u a 9 9 1 HOLIMS N34SNVSI OLLYWOLNY l137NI 1304 LAN 1 471 LS2te 262 L 82 9 SHL 1411 LON SATOH 1 6110 0 0 3 LINN 11 o N3dU 09E Wupl6 b h Section 7 Mounting Dimensions Air cooled 15 kW Generators Drawing No 0F5927 gt ELECTRICAL DATA SP1 SP2 BLACK DIAGRAM KEY BA BRUSH ASSEMBLY BCR BATTERY CHARGE RELAY C1 8 POSITION CO
11. GASKET SOLENOID 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 ADJUSTER SCREW TWIN REGULATOR LEVER REGULATOR SUPPORT INLET SEAL SEAL INLET PIN PIVOT ARM SPRING REGULATOR SPRING REGULATOR 7KW SCREW PFHMS M3 0 5 x 5 GASKET DIAPHRAGM COVER TWIN REGULATOR SCREW TAPTITE M4X8 BP RIVET POP 118 X 125 SUPPORT DIAPHRAGM 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 WASHER FLAT 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 45 Section 9 Exploded Views and Parts Lists Air cooled 15 kW Generators Transfer Switch Drawing No 0F5633 A 23147148 34135136 3 eeo Q eeo 3 STANDBY C2 amp VR2 B 5 UTILITY amp 1 RELAY KEY RELAY ENGINE RUN BELAY Z ERGY RELAYS IN AUTO RELAY 4 COMMON ALARM RELAYS Low FUEL RELAY DOOR OPEN 40 7 4
12. AN 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 AN Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators waRNING A AN Please read all hazards carefully N GENERAL HAZARDS N 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 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 D
13. ASSEMBLY BRUSH HOLDER TAPE ELEC UL FOAM 1 8 X 1 2 WASHER FLAT 4060 X 1 6200 WASHER LOCK 3 8 SCREW HHC 3 8 16 X 1 1 4 G5 WASHER FLAT 3 8 ZINC 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 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 HOSE CLAMP 3 4 I D 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 45 5 0 62 0 62 HOSE 1M ID LPG 350PSI UL21 SCREW HHTT M5 0 8 X 16 Q umm Section 9 Exploded Views and Parts Lists Air cooled 15 kW Generators 0 Gas Regulator Drawing No 0D8720 H 415555 44 Section 9 Exploded Views and Parts Lists Air cooled 15 kW Generators Gas Regulator Drawing 008720 PARTS dab 00 1 005694 1 2 0 5022 1 3 0C4647 1 4 0D4166 1 5 0C6070 1 8 0F4795 4 9 0C5760J 1 10 0C6606 2 11 097934 2 12 0 4645 2 18 0C5761 2 14 0 5968 2 15 0C6066 2 16 005759 2 17 005764 2 0C5764A 2 18 070728 4 19 0C6069 2 20 0 5762 2 21 045764 16 22 066731 2 23 0C6067 2 24 0C4706 2 25 0C6068 2 26 0C4643A 2 27 026073 1 026073 2 28 044032 2 29 0D3308 4 30 024310 1 31 028414A 1 32 0D5698A 1 37 003973 1 QUANTITY OF 1 15 BE USED ON 7KW HOME STANDBY CASTING TWIN REGULATOR HOUSING SOLENOID COIL 12VDC
14. After this heading read instructions that if not strictly complied with will result in serious person al injury including death in addition to property damage wanNING amp After this heading read instructions that if not strictly complied with may result in serious person al injury or property damage caution After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety informa tion that if not followed could endanger personal safety and or property of others A This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment The manufacturer strongly recom mends that the operator read this Owner s Manual and thoroughly understand all instructions before using this equipment The manufacturer al
15. LIQUIDS CODE available same as Item 1 3 Section 1 General Information Air cooled 15 kW Generators A DIE Only qualified electricians or contractors should attempt such installations which must comply strictly with applicable codes standards and regulations 11 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 A WARNING amp AN If this generator is used to power electrical load circuits normally powered by a utility power source it is required by code to install a 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 If any loss or damage is noted at time of delivery have the person s making the delivery note all damage on the freight bill or affix his or her signature under the consignor s memo of loss or damage If there is loss or damage after delivery separate the damaged materials and contact the carrier for claim procedures Concealed damage is understood to mean damage to the contents of a
16. 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 se
17. 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 Section 5 Maintenance Air cooled 15 kW Generators MAINTENANCE Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom Task Task mended Comp Comp Required Task Task Required Task to be done Comp Required Comp to be done Comp Semi Date to be done Date Bi Date monthly Initials to be done Initials annually Initials Annually Initials annually Initials 10 hrs 6 months 50 hrs 100 hrs 250 hrs 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
18. 13 Let the engine run at no load for a few minutes 14 Set the AUTO OFF MANUAL switch to OFE The engine should shut down 11 2 POST Section 5 Post Installation Start up and Adjustments INSTALLATION START UP ADJUSTMENTS Air cooled 15 kW Generators 3 5 CHECKING AUTOMATIC OPERATION To check the system for proper automatic operation proceed as follows 1 Set the generator s main circuit breaker to it s OFF or open position 2 Check that the AUTO OFF MANUAL switch is set to OFF 3 Manually set the transfer switch to the UTILITY position i e load terminals connected to the 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 6 Turn OFF the utility power supply to the transfer switch With the AUTO OFF MANUAL switch at AUTO the engine should crank and start when the utility source power is turned OFF After starting the transfer switch should connect load circuits to the standby side Let the system go through its entire automatic sequence of operation With the generator running and loads powered by generator AC output turn ON the utility power supply to the transfer switch The following should occur After
19. 8152 063011 0C3009 0C3010 093873 0 5458 0 5998 001667 0C2991 0C2988 i l caca RH Section 9 Exploded Views and Parts Lists PARTS 5 LISTS Air cooled 15 kW Generators Ve GT 990 Engine Drawing No 0E8774 Q Part 1 0 ASSEMBLY CRANKCASE HOUSING WITH SLEEVE SEAL 38 1 0 CRANKSHAFT SCREW TAPTITE M6 1 0 X 12 YC ASSEMBLY BREATHER GASKET BREATHER COVER SEPARATOR OIL BREATHER ASSEMBLY HEAD 1 G amp S RETAINER PISTON PIN 20 ROCKER COVER NO OIL FILL STUD M8 1 25 10MM X 30 G5 ZINC PISTON HC SET PISTON RING 90MM PIN PISTON ASSEMBLY CAMSHAFT amp GEAR SHAFT GOVERNOR ROLLER BEARING GOVERNOR PLATE ROLLER BEARING GOVERNOR ASSEMBLY GOVERNOR GEAR SPOOL GOVERNOR MACHINED GASKET CRANK CASE SEAL OIL PASSAGE ASSEMBLY CRANKSHAFT HORIZONTAL DIRECT DRIVE ASSEMBLY CONNECTING ROD SCREW SHC M6 1 0 X 50 G8 8 SCREEN OIL PICKUP ASSEMBLY OIL PUMP O RING 49 ID X 07 THICK COVER OIL RELIEF SPRING OIL RELIEF BALL 1 2D OIL RELIEF WASHER LOCK RIB M6 SCREW PLASTITE HI LOW 10 CLAMP OIL TUBE ARM GOVERNOR E RING GOVERNOR ARM THRUST WASHER GOVERNOR 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 0803
20. Exhaust Enclosure Fuel Regulator Fuel Inlet Battery Composite Base Oil Filter Compartment Figure 1 2 15 kW V twin GT 990 Engine Rear View AANAAAN AAA AA 1 VVVVVV VVVVVV AUTOMATIC TRANSFER SWITCH GENERAL Air cooled 15 kW Generators INFORMATION 1 5 SPECIFICATIONS 1 5 1 GENERATOR Rated Max Continuous Power Capacity 5 13 000 NG 15 000 LP Rated Voltage oco ae v er eu SE Reed 120 240 Rated Max Continuous Load Current Amps 120 16 lt 5 tore one porcis 108 3 NG 125 0 LP 240 VollS uu 54 2 NG 62 5 LP Main Line Circuit Bre ker eterne 70 Amp PHASE 1 Number of Rotor Poles a ene 2 Rated AC Frequency eee reset pebou qun teda 60 Hz Power 1 Recommended Air Filter Part 0C8127 Battery Requirement Group 26 26R at 17 8 C O F 12 Volts and 525 Cold cranking Amperes Minimum M 640 Pounds Output Sound Level 23 ft 7m at full load 71 5 db A Normal Operating 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 amb
21. 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 OF5631 Revision C 12 07 06 Printed in U S A
22. 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 to done Date Required Date 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 E Section 5 Maintenance MAINTENANCE Air cooled 15 kW Generators 2 09 Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom Task Task Required Task Task Required Task mended Comp Comp to be done Comp Required Comp to be done Comp to be done Date Required Date Semi Date to be done Date Bi Date monthly Initials to be done Initials annually Initials Annually Initials annually Initials 10 hrs 6 months 50 hrs 100 hrs 250 hrs 16 Replace the engine air filter s 17 Perform a 5 minute no load operational run of the unit looking for any post service problems 18 Return the unit to standby setup for operation when required Section 6 Troubleshooting TROUBLESHOOTING Air cooled 15 kW Generators 6 1 TROUBLESHOOTING GUIDE Problem The engine will not crank The engine cranks but will not start The engine starts hard
23. about 15 seconds the switch should transfer loads back to the utility power source About one minute after retransfer the engine should shut down 3 6 ADJUSTING THE REGULATOR NATURAL GAS ONLY Although the generator has been factory set to 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 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 12 3 Turn on electrical loads Be cautious not to over load the generator Use the following chart as a guide Model 120 Volts 240 Volts 005176 108 3 amps 54 1 amps 4 When full load has been achieved Connect a fre quency meter to the output lugs of generator s main line circuit breaker 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
24. and runs rough The AUTO OFF MANUAL switch is set to but the engine continues to run There is no AC output from the generator There is no transfer to standby after utility source failure Cause 1 Fuse blown 2 Loose corroded or defective battery cables Defective starter motor Dead Battery Out of fuel Defective fuel solenoid FS Open 14 wire from engine control board Defective spark plug s Valve lash out of adjustment Air cleaner plugged or damaged Defective spark plug s Fuel regulator not set Fuel pressure incorrect Defective switch 2 AUTO OFF MANUAL switch wired incorrectly Defective control board Main line circuit breaker open Generator internal failure Defective transfer switch coil Defective transfer relay Transfer relay circuit open Defective control logic board Correction l 2 Replace 15A fuse on generator control panel Tighten clean or replace as necessary Charge or replace battery Replenish fuel Clean re gap or replace plug s Reset valve lash Check replace air cleaner Clean re gap or replace plug s Set fuel regulator 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 Reset circuit breaker to ON or closed Contact the nearest Authorized Dealer for assistance 7
25. 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 NOTE Hold the rocker arm jam nut in place as the pivot ball stud is turned When valve clearance is correct hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut Tighten the jam nut to 174 in lbs torque After tightening the jam nut recheck valve clearance to make sure it did not change Figure 5 6 Valve Clearance Adjustment Rocker Pivot Ball Arm Jam Nut Install new valve cover gasket Re attach the valve cover 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 Re attach the spark plug wire to the spark plug Repeat the process for the other cylinder 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 we
26. not rise and endanger it Allow sufficient room on all sides of the generator for maintenance and servicing A good rule is to allow three feet of space on all sides Where strong prevailing winds blow from one direction face the generator air inlet openings to the prevailing winds Install the generator as close as possible to the fuel supply to reduce the length of piping 2 1 1 REMOTE MONITORING CONNECTIONS Mounted in the transfer switch is relay contact board Figure 2 1 that can be used to remotely monitor various functions of the generator system The contacts are rated as shown below Failure to 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 Wire Range 26 14Awg Terminal tightening torque 5 in Ib Figure 2 1 Remote Monitoring Connections RELAY KEY O 1 O RELAY 1 NC ENGINE T No RUN n SI RELAY 2 G NC SWITCH IN S T S No EMERGENCY d Sc RELAY 3 S NC SWITCH IN T No AUTO d Gc RELAY 4 S NC COMMON S ALARM 1 S RELAY 5 NC LOW T S No FUEL n S RELAY 6 S Ne DOOR T o LS INSTALLATION Section 2 Installation Air cooled 15 kW Generators Remote mon
27. package that is not in evidence at the time of delivery but is discovered later 1 2 PROTECTION SYSTEMS Unlike an automobile engine the generator may have to run for long periods of time with no operator pres ent to monitor engine conditions For that reason the engine is equipped with the following systems that protect it against potentially damaging conditions 1 Low Oil Pressure Sensor 3 Overcrank 2 High Temperature Sensor 4 Overspeed There are LED readouts on the control panel to notify personnel that one of these faults has occurred There is also a System Set LED that is described below 1 3 SYSTEM SET LED The System Set LED is lit when all of the following conditions are true 1 The AUTO OFF MANUAL switch is set to the AUTO position 2 The utility voltage being supplied to the unit is being sensed by the Control PCB If the utility sense voltage is not connected to the unit or if it is below 168 volts AC then the system set light will flash rapidly This indicates that if the AUTO OFF MANUAL switch is placed in the Auto posi tion the generator will start 3 Not In Auto dip switch is set to the OFF position on the control board 4 No alarms are present for example low oil pres sure high temperature etc Section 1 General Information Air cooled 15 kW Generators INFORMATION GENERAL 1 4 THE GENERATOR Figure 1 1 15 kW V twin GT 990 Engine Control Panel Oil Dipstick
28. 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 generators 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 1 2 terminals The transfer switch operating lever should be down 5 Set the generator s AUTO OFF MANUAL switch to MANUAL The engine should crank and start immediately 6 Let the engine stabilize and warm up for a few minutes 7 Setthe 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 1 and E2 Voltage should be greater than 230 volts frequency should be greater than 58 Hertz 10 Let the generator run at full rated load for 20 30 minutes Listen for unusual noises vibration or other indications of abnormal operation Check for oil leaks evidence of overheating etc 11 When testing under load is complete turn OFF electrical loads 12 Set the generator s main circuit breakers to their OFF or open positions
29. 18 093064 001839 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 N qe 49 4 OMA L EL IE lE dm ak AS Tuy BUSHING GOVERNOR LOWER ASSEMBLY DIPSTICK WITH HANDLE TUBE DIPSTICK O RING OIL CLR 3 8 X 1 2 SEAL 42 1 0 CRANKSHAFT ASSY HS COVER W SLV SCREW 10 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 SEAL VALVE STEM D7 WASHER VALVE SPRING STUD ROCKER ARM PIVOT NUT HEX 8 1 0 G8 YEL CHR O RING 3 8 X 1 2 ROCKER ARM PLATE PUSH ROD GUIDE SCREW HHFC M8 1 25 X 65 VALVE EXHAUST VALVE INTAKE TAPPET SOLID ASSEMBLY HEAD 42 G amp S PUSHROD 147 GASKET HEAD BARBED ELBOW 90 3 8NPT X 3 8 KIT GASKET KIT PISTON amp RINGS KIT BREATHER ASSEMBLY KIT GOVERNOR ASSEMBLY KIT HEAD ASSEMBLY CYLINDER 1 KIT HEAD ASSEMBLY CYLINDER 2 KIT OIL RELIEF KIT GEAR COVER 39 Section 9 Exploded Views and Parts Lists Air cooled 15 kW Generators GT 990 Engine Drawing No 0E8774 Q Part 2 PARTS 40 ITEM PART QTY DESCRIPTION 74 75 76 77 78 79 80 81 8
30. 2 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 0C5136A 0C3024 0C3040 0C8127 0D8564A 0D8564B 0D2595 0D4417 0C3025 0D3083 0C7292 070185B 075281 0 2094 035461 0 6301 090286 0C3026 0C9764 0C3043 0C7694 0C7693 0C3041A 070008 070006 040976 0C3016A 0E4997 0C3725B 0C3031 0C3032 045992 051754 0C3033 0C3034 0C8549A i laca KR Section 9 Exploded Views and Parts Lists Air cooled 15 kW Generators PARTS 5 LISTS GT 990 Engine Drawing No 0E8774 Q Part 2 0 KNOB AIR CLEANER COVER AIRBOX NG LP PRE CLEANER 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 ASSEMBLY OIL DRAIN HOSE NIPPLE 3 4 16 UNF OIL FILTER SWITCH THERMAL 284F SCREW M3 0 5 X 6 SEMS BARBED STR 1 4 X 3 8 CLAMP HOSE OETIKER 16 5mm HOSE 3 8 1 0 X 6 LG SAE J30R9 COOLER OIL PLASTITE 1 4 15 X 3 4 GASKET MANIFOLD PORT MANIFOLD CYLINDER 2 MANIFOLD CYLINDER 1 SLEEVE RUBBER WASHER FLAT M8 SS WASHER LOCK M8 SSTL SCREW 8 1 25 X 20 G12 9 PLATE BACKING WITH OIL COOLER GROUND WIRE CONNECTOR FLYWHEEL ASSEMBLY FAN NYLON PLATE FAN WASHER SHAKEPROOF INT M8 SS SCREW HHC 8 1 25 X 12 08 8 WASHER 25mm NUT HEX M
31. 24 SNORKEL AIR INTAKE 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 142 143 144 145 0C3022A 001131 045756 0C9763 0C3036A 022145 022129 0C3018 0C3019 0D1142A 0D1143 0 6043 0 1177 003052 022097 092079 0 4271 004529 022129 061906 082774 0 5343 0C8468 0C3048 0D3754 0D3742 0C8482 0E0486 0D3743 0D3705 0C2993 045771 0D6147 0E8152 0 7743 1 25 EL A NX qd b 4 W o L 4 lx JM 6 jo x HOUSING BLOWER NG COOLER GUARD FAN SCREW TAPTITE M6 1X10 YELLOW CHROME NUT GROMMET 1 4 PLUG HOSE BREATHER WASHER FLAT 5 16 M8 ZINC WASHER LOCK 8 5 16 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 6 1 4 SCREW TAPTITE M6 1 0 X 25 BP STARTER SPARKPLUG WASHER LOCK M8 5 16 SCREW HHC 8 1 25 X 85 G8 8 KEY WOODRFF 4 X 19D NUT HEX LOCK M10 1 50 SPRING ANTI LASH ROD GOVERNOR CONTROL ASSEMBLY GOVERNOR LEVER SPRING GOVERNOR ASSEMBLY GOVERNOR ADJUSTER SCREW SHC M10 1 5 X 75 G10 9 SPRING GOVERNOR IDLE ASSEMBLY GOVERNOR ADJUSTER BRACKET SEAL GOVERNOR SHAFT NUT HEX M8 1 25 G8 SCREW HHFC M6 1 0 X 10mm O RING 0 49 1 0 X 0 07 THICK ASSY IGNITI
32. 849 F initiating an engine shutdown The generator will automatically restart and the LED will reset once the temperature has returned to a safe operating level Figure 4 3 Low Oil Pressure and High Temperature Switches Low Oil Switch High Temp Switch e T am Loos Oil Drain 9 Hose Oil Filter 4 8 5 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 MAINTENANCE 2 09 Section 5 Maintenance Air cooled 15 kW Generators 4 8 5 1 Approximate Crank Cycle Times 15 seconds ON 7 seconds OFF 7 seconds ON 7 seconds OFF Repeat for 45 seconds Approximately 90 seconds total 4 8 4 OVERSPEED This feature protects the generator from damage by shutting it down if it happens to run faster than the preset limit This protection also prevents the gen erator from supplying an output that could poten tially damage appliances connected to the generator circuit Contact the nearest A
33. AL 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 A DEH A AN 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 2 Section 5 Post Installation Start up and Adjustments POST CE Check utility power source voltage across termi nals N1 and the transfer switch neutral lug then across terminal N2 and neutral Nominal line to neutral voltage should be 120 volts AC 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 Set the generator s main circuit breaker to its OFF or OPEN position Initial tests will be con ducted at no load condition On the generator panel set the AUTO OFF MANUAL switch to MANUAL The engine should crank and start 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 A Di Proceed with caution Generator power voltage 10 11 is now supplied to th
34. Clockwise Governor Clamp Bolt No Load Idle Adjustment Screw 2 Completely remove the idle spring 3 With governor arm at wide open throttle position rotate governor shaft fully clockwise Tighten clamp bolt to 84 inch pounds 4 Start unit and apply full load Use full load speed adjust screw Figure 3 4 to adjust frequency to 58 Hz 5 Remove load stop engine loosen the idle adjust screw and reconnect the idle spring 6 Using a hand push the governor arm to the closed throttle position Make sure the idle spring does not stretch at all 7 Restart the unit 8 Slowly turn the idle adjust screw to adjust the no load idle frequency to 63 63 5 Hz 9 The governor is now set INSTALLATION START UP ADJUSTMENTS Air cooled 15 kW Generators Figure 3 4 V twin Full Load Speed Adjust Screw Full Load Speed Adjust Screw 3 7 1 ADDITIONAL CORROSION PROTECTION Periodically spray all engine linkage parts and brack ets with corrosion inhibiting spray such as WD 40 or a comparable product 3 8 VOLTAGE REGULATOR ADJUSTMENT With the frequency between 62 63 5 Hertz slowly turn the slotted potentiometer Figure 3 5 until line voltage reads 244 252 volts NOTE Remove the access panel on top of the control panel to adjust the voltage regulator Figure 3 5 Voltage Adjustment Potentiometer ppp p Turn to adjust voltage
35. GENERAG POW ER SYSTEMS INC Installation and Owner s Manual Air cooled Automatic Standby Generators Model 05176 0 13 kW NG 15 kW LP N JULY SYSTEMS This manual should remain with the unit Not intended for use as Primary Power in place of utility N or in life support applications DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY INTRODUCTION Thank you for purchasing this model by Generac Power Systems Inc This model is a compact high performance air cooled engine driven generator designed to automatically supply electrical power to operate critical loads during a utility power failure This unit is factory installed in an all weather metal enclosure that is intended exclusively for outdoor instal lation This generator will operate using either vapor withdrawn liquid propane LP or natural gas NG READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood contact the nearest Authorized Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert person nel to special instructions about a particular opera tion that may be hazardous if performed incorrectly or carelessly Observe them carefully Their defini tions are as follows
36. ITCH 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 Figure 2 3 Typical 2 Pole Transfer Mechanism 200 Amp Shown UTILITY LUGS D 0 U S UTILITY CLOSING H COIL H H eee jH H GENERATOR 999 127 LUGS E1 amp E2 GENERATOR CLOSING COIL ciem uH LOAD LUGS T1 amp T2 Solderless screw type terminal 1195 are standard Conductor Tightening Conductor sizes must be adequate to handle the maximum current to which they will be subjected to based on the 75 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 t
37. L 31 0A9517 1 DECAL MANUAL 5A FUSE 32 0E6190 1 DECAL TEST SEQUENCE 2P TS 3R 33 081221 1 DECAL UL LIST HSB 34 0E6193 1 BRACKET ARM EXTENDER 35 064526 2 SCREW HWHS 46 25 X 3 8 ZNC 36 0E6155 1 ARM EXTENDER PIN 37 0F5748 1 HARN 100 200A 2P HS 38 0E6033 2 90 DEGREE DN SPADE CONNECTOR 39 0E6303B 1 WIRE E1 40 0E6303 1 WIRE A 41 0E6303A 1 WIRE B 42 0F5770 1 DECAL TERMINAL STRIP 43 020757 1 ALARM PCB 44 0D3062 4 HEX PCB SUPPORT SCREW IN 45 092036 8 46 32 x 0 25 PPH W LOCK 46 048850 1 ASSY TERM BLOCK 20A 5 x 1100VAC 47 084464 1 LIMIT SW SW OPERATION 48 043182 2 WASHER LOCK M3 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 99 SUPPLIED WITH HARNESS P N 0F5748 47 Section 10 Warranty 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 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
38. L 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 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 4 0 7 x 10mm WASHER FLAT M4 COVER CONTROL PANEL COMPONENT SCREW PPHMS LW 46 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 44 40 X 5 8 NUT HEX 44 40 WASHER LOCK M3 LIMIT SWITCH OPERATION GROMMET 1 2 X 1 16 X 3 8 37 PART 5 D Section 9 Exploded Views and Parts Lists Q 2 Air cooled 15 kW Generators Q GT 990 Engine Drawing No 0E8774 Q Part 1 42 58 ge B 54 zn g 28 m ag lt M ms 8 8 2 20 E FFR g S si O ri FS FS BE IS 38 ITEM PART NO QTY DESCRIPTION 1 1 0C5729 0 9843 090388 0 5372 0C3005 0E3372B 0D8067A 071983 0C2981C 045761A 0E2985 021533 0E1466 0D4041 0C2983 0C2985A 0C2985B 0D4042 0A7811 0C2977 0 5943 0G0140E 0E3223 0D2157 0E6098 001536 0
39. NNECTOR C2 12 POSITION CONNECTOR C3 4 POSITION CONNECTOR C4 6 POSITION CONNECTIR CB1 MAIN OUTPUT BREAKER CB2 CIRCUIT BREAKER ALTERNATOR EXCITATION D DIODE DSW PCB MOUNTED DIP SWITCH FS FUEL SOLENOID F1 FUSE BATTERY CHARGER F2 FUSE 15 SYSTEM FUSE SENSING GRD CONTROL PANEL GROUND GTS TRANSFER SWITCH CONTACTOR HTO HIGH OIL TEMPERATURE SWITCH IC INLINE CONNECTOR IM1 IGNITION MODULE CYLINDER 1 IM2 IGNITION MODULE CYLINDER 2 LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SP1 SP2 SPARK PLUGS SW1 AUTO OFF MANUAL SWITCH SW SET EXERCISE SWITCH SW3 DOOR ALARM SWITCH SM STARTER MOTOR TB INSULATED TERMINAL BLOCK TR RELAY TRANSFER TS TERMINAL STRIP TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC VR1 VR2 VARISTORS XA1 XB1 XC1 LIMIT SWITCHES E D IM1 Section 8 Electrical Data Air cooled 15 kW Generators Wiring Diagram Drawing No 0 5645 Part 1 ENGINE WIRING BATTERY C 1 CHARGER D 225B 224B ELECTRICAL DATA 13A 224B 225B 14 A2 85 gt 4 14 14 86 3 B
40. ON COIL 270mm CYLINDER 1 ae Section 9 Exploded Views and Parts Lists Air cooled 15 kW Generators 15 kW Generator Drawing No 0D3417 L 35 36 X N 7 21 43 ZR 2 Y j 3 NS NAA c 8 amp 31 32 0 6934 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 004662 0F7065 048031 0 0462 0C2824 025145 0C4138 040173 074995 066849 ums OR lt a wa 2 6 FT yA HARRAH A T mo Rn m ro Section 9 Exploded Views and Parts Lists et LISTS Air cooled 15 kW Generators 15 kW Generator Drawing No 0D3417 L 0 ADAPTOR ENGINE STATOR 12KW STATOR 13KW 15KW ROTOR 12KW ROTOR 13KW 15KW CARRIER REAR BEARING FAN 12 CURVED BLADE MUFFLER TAIL PIPE MUFFLER PANEL MUFFLER BASE BEARING 1 1811 2 8346 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 CABLE 6 48 BLACK BATTERY EARTH STRAP 3 8X 3 8 CLIP J VYNL COAT 0 625 ID
41. RGENCY T 28 e RY3 SWITCH IN AUTO 0 5 RY4 COMMON ALARM C36 2 RYG RY6 DOOR OPEN 15A lt 15A COM 14 SIGNALS D NO 9 239 F 15A 93 gt 56 C1 5 NC 18 18 Di gt 14 14 D q s 15 0 5 1 2 S NZ ps D gt D SP2 gc 15 e M 15 e 16 16 re TUE 0 0 0 0 4 BLACK CUSTOMER SUPPLIED 33 Section 9 Exploded Views and Parts Lists Air cooled 15 kW Generators Enclosure Drawing No 0F5845 3a ITEM PART QTY DESCRIPTION 1 37 38 39 40 0 6140 0 6735 0 0063 0C7062 0 5629 0 9873 0C7065 0C8101A 0C8101B 0C8283 0C8284A 0C8284B 0C8284C 0C8285 0C8899A 0 5630 0 4244 001606 001839 001840 002425 002588 002676 002677 0029798 002979 0029790 0 4245 0 4245 0 4245 0030570 003059 0030598 0D3059C 0D7176 0D3059D 003059 0 7781 003037 0 0164 lx qw c TAS My i lx 2E CAS NN cx 24 Section 9 Exploded Views and Parts Lists Air cooled 15 kW Generators Enclosure Drawing No 0F5845 ASSEMBLY ENCLOSURE BASE SUPPORT ROOF FOLDING ENCLOSURE FRONT ENCLOSURE EXHAUST SIDE ENCLOSURE SIDE amp BACK ENCLOSURE ROOF PANEL ALTERNA
42. TOR DIVIDER PANEL MUFFLER BOX SIDE COVER MUFFLER BOX GASKET DOOR SEAL FOAM BACK ENCLOSURE FOAM ROOF ENCLOSURE FOAM FRONT ENCLOSURE BRACKET BATTERY SUPPORT PAD 24 X48 WITH MOUNTING HOLES PANEL ENGINE DIVIDER BAFFLE INTAKE HOUSING FAN BRACKET TOP SUPPORT 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 FOAM EXHAUST FAN HOUSING WASHER SELF LOCKING FOAM FRONT EXHAUST ENCLOSURE COVER FOAM BACK EXHAUST ENCLOSURE COVER DOOR PAWL LATCH QUARTER TURN LOCKING HINGE TYPE A WITH STUDS PIN 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 7 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 0 0164 0 0165 045771 003031 1
43. TY RULES 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 The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm 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 Dd A
44. 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 Aut
45. amage could be done to the manual handle 4 4 1 CLOSE TO NORMAL SOURCE SIDE Before proceeding verify the position of the switch by observing the position of manual operation handle in Figure 4 2 If the handle is UB the contacts are closed in the NORMAL position no further action is required If the handle is DOWN proceed with Step 1 Step 1 With the handle inserted into the actuating shaft move handle UP Be sure to hold on to the handle as it will move quickly after the center of travel Figure 4 2 Actuating Transfer Switch Attach handle to actuating shaft Move handle UP for the NORMAL UTILITY position NOTE Return handle to storage position in enclosure when finished with manual transfer Move handle 2 DOWN for the EMERGENCY STANDBY position 15 OPERATION Section 4 Operation ix Air cooled 15 kW Generators 442 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 UB proceed with Step 1 Step 1 With the handle inserted into the actuating shaft move the handle DOWN Be sure to hold on to the handle as it will move quickly after the center of travel 4 4 5 RETURN TO NORMAL SOURCE SIDE Manually actuate switch to return manual operati
46. and tighten as necessary 11 Replace the engine air in baffle using the four M6 Screws 12 Identify both brass adjustment screws on the regulator NOTE One adjustment screw can be accessed from the front of the unit and the second can be accessed from the back of the unit enclosure by removing the plastic hole plug The screw can be turned with a long flat blade screwdriver 13 To adjust the system to run on LP fuel turn BOTH adjuster screws 1 2 TURN CLOCKWISE The system should now be set for maximum power and best perfomance DO NOT UNDER ANY CIRCUMSTANCES REMOVE THE SET PINS FROM THE REGULATOR HOUSING THIS WILL VOID THE WARRANTY INSTALLATION Section 2 Installation Air cooled 15 kW Generators 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 21 INSTALLATION Install the generator set in its protective enclosure outdoors where adequate cooling and ventilating air is always available Consider these factors Install the unit where air inlet and outlet openings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or drift ing snow consider using a windbreak to protect the unit Install the generator on high ground where water levels will
47. and refill with the proper oil 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 Clean and wipe the entire generator Remove the 5A fuse from the generator control panel Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incorrectly Replace the 5A fuse in the generator control panel Open the fuel shutoff valve Start the unit by moving the AUTO OFF MANUAL switch to MANUAL Allow the unit to warm up thoroughly 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 Turn on the utility power to the transfer switch The generator is now ready for service NOTE If the battery was dead or disconnected the exer cise timer must be reset Section 5 Maintenance Air cooled 15 kW Generators MAINTENANCE 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 the schedule are the maximum recommended when the unit is used in an average service application They will need to be decreased
48. anel 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 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 NOTE The exerciser will only work in the AUTO mode and will not work unless this procedure is per formed The exerciser will need to be reset every time the 12 volt battery is disconnected and then reconnected The exerciser WILL NOT work if dip switch 2 Remote Not Auto on the controller printed circuit board is ON Section 4 Operation OPERATION Air cooled 15 kW Generators ix 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 4 8 2 HIGH TEMPERATURE SWITCH This switch s contacts Figure 4 3 close if the tem perature should exceed approximately 140 C 2
49. ard action de energizes the transfer relay in the transfer switch Retransfer to utility power source then occurs Engine Cool down Timer When the load is transferred back to utility power source the engine cool down timer starts tim ing The timer will run for about one minute and the generator will then shut down 44 MANUAL OPERATION A A Do NOT manually transfer under load Disconnect transfer switch from all power sourc es by approved means such as a main circuit breaker s A manual HANDLE is shipped with the transfer switch Manual operation must be checked BEFORE the transfer switch is operated electrically To check manual operation proceed as follows 1 Turn the generators 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 Section 4 Operation OPERATION Air cooled 15 kW Generators a 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 1 E2 caution Do not use excessive force when operating the transfer switch manually or d
50. e The 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 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 WARNING Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes immediately flush thoroughly with water and seek medical attention and Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters or water The 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 eo Lead acid batteries present a risk of fire because they gen
51. e transfer switch Contact with live transfer switch parts will result in dan gerous and possibly fatal electrical shock Connect an accurate AC voltmeter and fre quency meter across transfer switch terminal Iugs 1 and E2 Voltage should be 242 252 volts frequency should read about 61 63 Hertz Connect the AC voltmeter test leads across ter minal lug 1 and neutral then across E2 neutral In both cases voltage reading should be 121 126 volts AC 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 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 INSTALLATION START UP ADJUSTMENTS Air cooled 15 kW Generators 3 4 GENERATOR TESTS UNDER LOAD warninc 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 To test
52. eds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to quickly shut down See Figure 5 7 for vent loca tions warninc 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 caution A The maximum ambient temperature for the generator is 48 9 C 104 F MAINTENANCE Section 5 Maintenance Air cooled 15 kW Generators Figure 5 7 Cooling Vent Locations AIR OUTLET j j 1 i m i I ttt t AIR INTAKE 5 10 ATTENTION AFTER SUBMERSION If the generator has been submerged in water it MUST NOT be started and operated Following any submersion in water have an Authorized Dealer thoroughly clean and dry the generator 5 11 CORROSION PROTECTION Periodically wash and wax the enclosure using 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 5 12 OUT OF SERVICE PROCEDURE 5 12 1 REMOVAL FROM SERVICE If the generator cannot be exercised every seven days and it is to be out of service longer
53. enerator 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 E Section 5 Maintenance MAINTENANCE Air cooled 15 kW Generators 2 9 Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom Task Task Required Task Task Required Task mended Comp Comp to be done Comp Required Comp to be done Comp to be done Date Required Date Semi Date to be done Date Bi Date monthly Initials to be done Initials annually Initials Annually Initials annually Initials 10 hrs 6 months 50 hrs 100 hrs 250 hrs 1 Disable the unit from operating per the first page warning 2 Check the engine oil level Adjust as necessary 3 Check the natural gas delivery system for leaks and correct pressure on gas engine driven units Tighten connections as necessary 4 Check the air inlets and outlets for debris Clean as necessary 5 Check the battery electrolyte level and specific gravity if accessible Adjust as necessary 6 Check the battery
54. erate hydrogen gas The following pro cedures are to be followed DO NOT SMOKE when near the battery DO NOT cause flame or spark in battery area and Discharge static electricity from body before touch ing the battery by first touching a grounded metal surface 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 A Be sure the utility power supply is turned off and the 5A fuse is removed from the generator control panel or sparking may occur at the bat tery posts as the cables are attached causing an explosion 5 8 ADJUSTING VALVE CLEARANCE After the first 50 hours of operation adjust the valve clearance in the engine Important If feeling uncomfortable about doing this procedure or the proper tools are not available 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 Remove the four screws attaching the valve cover with a 2 or 3 phillips screwdriver Make sure the piston is at Top Dead Center TDC of its compression stroke both valves closed To get the piston at TDC remove the intake screen
55. erminal lugs carefully wipe away any excess corrosion inhibitor All power cables should enter the switch next to the transfer mechanism terminals caution Use a torque wrench to tighten the conductors being sure not to over tighten or damage to the switch base could occur If not tightened enough a loose connection would result caus ing excess heat which could damage the switch base Connect power source load conductors to clearly marked transfer mechanism terminal lugs as fol lows 1 Connect UTILITY NORMAL power source cables to switch terminals N1 N2 2 Connect customer LOAD leads to switch termi nals T1 T2 Conductors must be properly supported of approved insulative qualities protected by approved conduit and of the correct wire gauge size in accordance with applicable codes Be sure to maintain proper electrical clearance between live metal parts and grounded metal Allow at least 1 2 inch for 100 400 amp circuits 2 2 BATTERY INSTALLATION Dd Do not dispose of the battery fire The 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 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 cha
56. etain the hose in the clip 4 Refil with the proper recommended oil see Changing the Engine Oil See the Specifications section for oil capacities 5 4 CHANGING THE OIL FILTER Change the engine oil filter as follows 1 With the oil drained remove the old oil filter by turning it counterclockwise 2 Apply a light coating of clean engine oil to the gasket of the new filter See the Specifications section for recommended filter 3 Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter Then tighten the filter an additional 3 4 to one turn Figure 5 3 4 with the proper recommended oil see Changing the Engine Oil See the Specifications section for oil capacities 5 Start the engine and check for leaks 5 5 CHANGING THE ENGINE AIR CLEANER See Figures 1 1 and 1 2 for the location of the air cleaner Use the following procedure Figure 5 4 1 Turn the two screws counterclockwise to loosen 2 Remove the cover and air filter 3 Wipe away dust or debris from inside of the air box and around edges 4 Install the new air cleaner into the air box 5 Install the cover Turn the two cover screws clock wise to tighten See the Service Schedule section for air cleaner maintenance See the Specifications section for air filter replacement part number MAINTENANCE Section 5 Maintenance Air cooled 15 kW Generators Figure 5 4 Engine Air C
57. fter 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 Upon restoration of utility source voltage above a preset level generator circuit board action signals the transfer switch to transfer loads back to that power supply After retransfer the engine is signalled to shut down The actual sequence of operation is controlled by sensors and timers on a control logic circuit board as follows A Utility Voltage Dropout Sensor This sensor monitors utility source voltage If utility source voltage drops below about 70 percent of the nominal supply voltage the sensor energizes a 15 second timer Once the timer has expired the engine will crank and start B Engine Warm up Time Delay This mechanism lets the engine warm up for about 10 seconds before the load is transferred to a standby source C Standby Voltage Sensor This sensor monitors generator AC output volt age When the voltage has reached 50 percent of the nominal rated voltage transfer to standby can occur D Utility Voltage Pickup Sensor This sensor monitors utility power supply volt age When that voltage is restored to above 70 percent of the nominal source voltage a retrans fer time delay starts timing E Retransfer Time Delay This timer runs for about 15 seconds At end of a 15 second delay circuit bo
58. he 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 counte
59. horized 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 Section 10 Warranty Air cooled 15 kW Generators WARRANTY 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 cert
60. ient 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 Total current in two separate curcuits Current in each curcuit must not exceed the value stated for 240V 1 5 2 ENGINE oret rri erga eerie GT 990 N rmb r of Cylind6rs eese 2 Rated 30 3 600 rpm Displacement eset ette 992cc Cylinder BIOCK 4 rro een Aluminum w Cast Iron Sleeve Valve Arrangement Overhead Valves Ignition System Solid state w Magneto Recommended Spark RC12YC Spark Plug enn 0 508 mm 0 020 inch Compression Ratio poete vene reed Sn eos 9 5 1 21 lA 12Vdc Oil Capacity Including Filter Approx 1 7 Qts Recommended Oil Filter Part 070185B Recommended Air Filter Part 0C8127 Operating RPM 3 600 Section 1 General Information 1 6 FUEL REQUIREMENTS AND RECOMMENDATIONS 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 ta
61. ification 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 t
62. 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 SAFETY RULES 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 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 sys
63. itoring functions are only available with the AUTO OFF MANUAL switch in the Auto or Manual position Since the contacts are SPDT it is possible to monitor either state of each alarm function Relay 1 Engine running normally closed Engine not running normally open Relay 2 Transfer Switch in Emergency normally closed Transfer Switch in Utility normally open Relay 3 Control panel switch in Auto normally open Control panel switch in Manual or Off nor mally closed Relay 4 The common alarm is activated by any of the following shutdown faults Low Oil Pressure High Engine Temperature Overspeed Overcrank Common alarm active normally open No Common alarm normally closed Relay 5 Spare not used on this model Relay 6 Enclosure door open normally closed Enclosure door closed normally open 2 1 2 ROOF OPEN ALARM This generator is equipped with an alarm to detect when the roof of the enclosure is open A limit switch that is installed in the generator enclosure controls this alarm During shipping the generator s enclosure panels may have shifted and this limit switch may require adjustment Simply loosen the two screws and adjust the placement of the limit switch The arm of the limit switch should be in the depressed posi tion when the enclosure roof is closed and the door latch is secure see Figure 2 2 Figure 2 2 Limit Switch Up Down Slots 2 1 5 TRANSFER SW
64. k and start at any time without warning Such automatic starting normally occurs when 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 4 2 AUTOMATIC TRANSFER OPERATION To select automatic operation do the following 1 Make sure the transfer switch main contacts are set to their Utility position i e loads connected to the utility power source Figure 4 2 2 Be sure that normal utility power source voltage is available to transfer switch terminal lugs 1 and N2 Set the generator s AUTO OFF MANUAL switch to AUTO 4 Setthe generator s main circuit breaker to its ON or closed position With the preceding steps complete the generator will start automatically when utility source voltage drops below a preset level After the unit starts loads are transferred to the standby power source Refer to Sequence of Automatic Operation 4 3 SEQUENCE OF AUTOMATIC OPERATION The generator s control panel houses a control logic circuit board This board constantly monitors util ity power source voltage Should that voltage drop below a preset level circuit board action will signal the engine to crank and start A
65. leaner 5 6 SPARK PLUG S Reset the spark plugs gap or replace the spark plugs as necessary See the Service Schedule section for maintenance requirements 1 Clean the area around the base of the spark plugs to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and commercial solvent Do not blast the spark plugs to clean 2 Remove the spark plugs and check the condition Replace the spark plugs if worn or if reuse is questionable See the Service Schedule section for recommended inspection 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 50 mm 0 020 inch for by carefully bending the ground electrode Figure 5 5 Figure 5 5 Setting the Spark Plug Gap SET PLUG GAP AT 0 50 mm 0 020 inch 19 MAINTENANCE 2 09 Section 5 Maintenance Air cooled 15 kW Generators 5 7 BATTERY MAINTENANCE The battery should be inspected per the Service Schedule The following procedure should be fol lowed for inspection l 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 Do not dispose of the battery a fir
66. 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 V twin Engine Adjustment Screw Both Sides f Set Pin Both Sides When the highest frequency is reached maximum power has been set Then turn both adjustment screws 1 4 turn counterclockwise Regulator is now set Figure 3 2 Placement of Regulator Adjustment Screw Section 5 Post Installation Start up and Adjustments POST 7 Turn utility power to the main distribution panel 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 warninc 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 1 Loosen governor clamp bolt See Figure 3 3 Figure 3 3 V twin Engine Governor Adjustment Shaft Rotate
67. n 8 2 2 Battery Installation 9 2 8 Battery aeree rere nre dcr 10 Section 5 Post Installation Start up and Adjustments 10 3 1 Before Initial Start up peret 10 3 2 Check Transfer Switch Operation 10 3 3 Electrical Checks trcs 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 POSIlOn crier 14 4 1 2 Off POSIDOn Q 14 4 1 3 Manual Position 14 Table of Contents E Air cooled 15 kW Generators CONTENTS 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 comme 16 4 6 Generator Tests Under 16 4 7 Setting the Exercise Timer 17 4 8 Pr
68. ng handle to the UP position 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 A DIE A PROCEED WITH CAUTION THE TRANSFER SWITCH IS NOW ELECTRICALLY HOT CONTACT WITH LIVE TERMINALS RESULTS IN EXTREMELY HAZARDOUS AND POSSIBLY FATAL ELECTRICAL SHOCK 2 With an accurate AC voltmeter check for correct voltage Single phase utility supply Measure across ATS terminal lugs N1 and N2 Also check N1 to NEUTRAL and N2 to NEUTRAL 3 When certain that UTILITY supply voltage is 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 5 Let the generator stabilize and warm up at no load for at least five minutes 6 Set the generator s main circuit breaker 1 to its ON or CLOSED position A 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 7 With an accurate AC voltmeter and frequency meter check the no load voltage and frequency Single phase generator supply Measure across ATS terminal lugs 1 to E2 Also check E1 to NEUTRAL E2 to NEUTRAL a FREQUENCY ie
69. nk The engine has been fitted with a fuel carburetion system that meets the specifications of the 1997 California Air Resources Board for tamper proof dual fuel systems The unit will run on natural gas or LP gas but it has been factory set to run on natural gas Should the primary fuel need to be changed to LP gas the fuel system needs to be reconfigured See Reconfiguring the Fuel System for instructions on reconfiguration of the fuel system Recommended fuels should have a Btu content of at least 1 000 Btus per cubic foot for natural gas or at least 2 520 Btus per cubic foot for LP gas Ask the fuel supplier for the Btu content of the fuel Required fuel pressure for natural gas is five inches to seven inches water column 0 18 to 0 25 psi and for liquid propane 11 inches to 14 inches of water column 0 4 to O 5 psi NOTE Any piping used to connect the generator to the fuel supply should be of adequate size to ensure the fuel pressure NEVER drops below 4 inches water colum for natural gas or 10 inches water column for liquid propane for all load ranges 1 7 FUEL CONSUMPTION Model Nat Gas LP Vapor 1 2 Load Full Load 1 2 Load Full Load 05176 1 58 58 2 40 88 Natural gas is in cubic feet per hour LP is in gallons per hour cubic feet per hour 1 8 RECONFIGURING THE FUEL SYSTEM To reconfigure the fuel system from NG to LP follow these steps NOTE The primary regulator for the propane
70. 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 expe
71. nse 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 Any unit built manufactured prior to January 1 2005 Costs of normal maintenance i e tune ups associated part s adjustments loose leaking clamps installation and start up Any failure caused by contaminated fuels oils coolants antifreeze or lack of proper fuels oils or coolants antifreeze 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 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 Failures caused by any external cause or act of G
72. o 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 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 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 A ELECTRICAL HAZARDS N 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 n
73. od 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 Products that are modified or altered in a manner not authorized by Generac Power Systems in writing Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation or sizing 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
74. ot handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT The National Electrical Code NEC requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground Local electrical codes also may require proper grounding of the generator electrical 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 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 FIRE HAZARDS For fire safety the generator must be
75. otection Systems eee 17 4 8 1 Low Oil Pressure Switch 17 4 8 2 High Temperature Switch 17 4 8 3 Overcrank acce terrx ei 17 4 8 4 oie nn 18 Section 5 Maintenance 18 EDU E 18 5 2 Checking the Engine Oil Level 18 5 3 Changing the Engine 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 Plugs eere er vie vere YU RIT 19 5 7 Battery Maintenance eene 20 5 8 Adjusting Valve Clearance 20 5 9 Cooling System ion cas itid e etd dera 21 5 10 Attention After Submersion 21 5 11 Corrosion Protection eerte tn ety 21 5 12 Out of Service 21 5 12 1 Removal From Service 21 5 122 Return t Service eere 22 Section 6 Troubleshooting 27 6 1 Troubleshooting 27 Section 7 Mounting Dimensions 28 Section 8 Electrical Data 29 Section 9 Exploded Views and Parts Lists 34 Section 10 Warranty 48 SAFE
76. ove the dipstick and wipe it dry with a clean cloth Figure 5 2 Oil Dipstick and Fill Oil Dipstick 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 FILL ABOVE THE FULL MARK cauroN Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 4 Install the dipstick 5 Reset the AUTO OFF MANUAL switch to its origi nal position 5 5 CHANGING THE ENGINE OIL 5 3 1 ENGINE OIL RECOMMENDATIONS Use all season SAE 5W 30 synthetic oil or use SAE 30 oil of American Petroleum Institute API Service Class SG SH SJ or SL caution Any attempt to crank or start the engine before it has been properly serviced with the recom mended oil may result in an engine failure 5 5 2 OIL CHANGE PROCEDURE To change the oil proceed as follows 1 Run the engine until it is thoroughly warmed up then shut OFF the engine 2 Immediately after the engine shuts OFE 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 Figure 5 3 Oil Drain Hose and Filter LNW I Loos 17 Filter 3 After the oil has drained replace the cap onto the end of the oil drain hose R
77. r than 230 volts and frequency should be greater than 59 Hertz Letthe generator run under rated load for at least 30 minutes With unit running listen for unusual noises vibration overheating etc that might indicate a problem 5 When checkout under load is complete set main circuit breaker of the generator to its OFF or OPEN position 6 Let the generator run at no load for several min utes Then shut down by setting the AUTO OFF MANUAL switch to its OFF position 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 9 Set the generator s AUTO OFF MANUAL switch to its AUTO position The system is now set for fully automatic operation 4 7 SETTING THE EXERCISE TIMER The generator is equipped with an exercise timer Once it is set the generator will start and exercise once every seven days on the day of the week and at the time of day the following sequence is completed During this exercise period the unit runs for approx imately 12 minutes and then shuts down Transfer of loads to the generator output does not occur during the exercise cycle A switch on the control p
78. rectly connected and terminals are tight Observe battery polarity when connecting the battery to the generator set 10 Section 5 Post Installation Start up and Adjustments 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 Setthe 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 fuel shutoff valves in the fuel supply lines must be open caution Ak Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 5 2 CHECK TRANSFER SWITCH OPERATION Refer to the Manual Operation section of the owner s manual for manual operation procedures DIG A 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 5 ELECTRIC
79. rfeit and or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 3 Ignition System including 1 2 LPG Natural Gas carburetion assembly and its internal a Spark plug components b Ignition module a Fuel controller if so equipped 4 Catalytic Muffler Assembly if so equipped including b Mixer and its gaskets if so equipped a Muffler gasket c Carburetor and its gaskets if so equipped b Exhaust manifold d Primary gas regulator if so equipped 5 Crankcase Breather Assembly including LP liquid vaporizer if so equipped a Breather connection tube 2 Air Induction System including a Intake pipe manifold b Air cleaner Gcuci au TUUT typos DLALTILITCLIL LIC LULU WY 1 Prepackaged Standby Generator 2 Auxiliary Power Unit APU Generator 3 Standby Generator Part 2 49 Section 10 Warranty 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
80. rging source prior to connecting or disconnecting battery terminals WARNING amp Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes immediately flush thoroughly with water and seek medical attention and Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters or water The 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 INSTALLATION Section 2 Installation Air cooled 15 kW Generators Lead acid batteries present a risk of fire because they generate hydrogen gas The following procedures are to be followed DO NOT SMOKE when near the battery DO NOT cause flame or spark in battery area and Discharge static electricity from body before touch ing the battery by first touching a grounded metal surface Be sure the AUTO OFF MANUAL switch is se
81. s 60 62 Hertz b Terminals 1 to E2 240 246 VAC c Terminals El to NEUTRAL 120 123 VAC d Terminals E2 to NEUTRAL 120 123 VAC 8 Set the generator s main circuit breaker 1 to its OFF or OPEN position 9 Set the AUTO OFF MANUAL switch to the OFF position to shut down the generator NOTE Do NOT proceed until generator AC output 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 6 GENERATOR TESTS UNDER LOAD Set the generator s main circuit breaker to its OFF or OPEN position 2 Manually actuate the transfer switch main con tacts to their EMERGENCY STANDBY position Refer to Manual Operation 3 Tostartthe generator set the AUTO OFF MANUAL switch to MANUAL When engine starts let it sta bilize for a few minutes 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 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 1 and E2 Voltage should be greate
82. s data decal which is located on the generator See The Generator section for decal location Model No Serial No AUTHORIZED DEALER LOCATION locate the nearest AUTHORIZED DEALER please call this number 1 800 333 1322 or locate us on the web at www generac com Introduction Inside Front Cover Read This Manual Thoroughly IFC CONTEN EET IFC Operation and Maintenance IFC How 10 Obtain Service esee IFC Authorized Dealer Locator Number IFC Safety Rules 2 Standards Index uuu err er ER 3 Section 1 General Information 4 11 2 4 1 2 Protection Systemi S seniii erie nirna 4 1 3 System Set LED 4 1 4 The G neratOr ooi c pr 5 1 5 Specifications co t rr re 6 1 5 L Generator rie eren ee caes 6 1 9 2 ENGINE iod er toi nd verd saunders 6 1 6 Fuel Requirements and Recommendations 6 1 7 Consumpltion erri tret cna 6 1 8 Reconfiguring the Fuel System 6 Section 2 Installation 7 2 1 Installation n retro 7 2 1 1 Remote Monitoring Connections 7 2 1 2 Roof Open Alarm bre mens 8 2 1 3 Transfer Switch Connectio
83. se POST INSTALLATION START UP ADJUSTMENTS Air cooled 15 kW Generators Figure 2 4 Battery Cable Connections BLACK LEAD FROM FRAME 0 REDIEND FROM STARTER CONTACTOR NICE PER 2 BATTERY BLACK 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 2 5 THE BATTERY Servicing of the battery is to be performed or super vised by personnel knowledgeable of batteries and the required precautions Keep unauthorized person nel away from batteries When replacing the battery use the following type of battery Group 26 26R 12 volt battery with a rating of 525 cold cranking amps minimum at 17 8 C 0 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 negative ground system is used Battery connections are shown on the wiring diagrams Make sure the battery is cor
84. so strong ly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded views and lists of repair parts for model 05176 0 13 kW NG 15 kW LP V twin GT 990 Engine OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by an Authorized Dealer Normal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expenses at a minimum See the Authorized Dealer for service aids and accessories HOW TO OBTAIN SERVICE When the generator requires servicing or repairs simply contact an Authorized Dealer for assistance Service technicians are factory trained and are capa ble of handling all service needs When contacting an Authorized Dealer about parts and service always supply the complete model num ber and serial number of the unit as given on it
85. 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
86. 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 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 lift up the hose edge 6 Remove the small brass hose fitting from the regulator casting 7 Place the small fuel jet thread side first into the threaded hole originally occupied by the brass hose fitting Figure 1 3 Figure 1 3 Demand Regulator OUTLET PORTS FUEL HOSE F BRASS HOSE FITTING IDLE CIRCUIT BRASS HOSE PORT FITTING SMALL FUEL REGULATOR HOUSING PORT I 2 5 ADJUSTER SCREWS 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
87. t to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the utility power supply is turned off or sparking may occur at the battery posts as the cables are attached and cause an explosion Fill the battery with the proper electrolyte fluid if necessary and have the battery fully charged before installing it Before installing and connecting the battery complete the following steps 1 Setthe generator s AUTO OFF MANUAL switch to OFF 2 Turn off utility power supply to the transfer switch 3 Remove the 5 amp fuse from the generator con trol panel warninc amp 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 Battery cables were factory connected at the genera tor Figure 2 4 Connect cables to battery posts as follows 4 Connect the red battery cable from starter con tactor to the battery post indicated by a positive POS or 5 Connect the black battery cable from frame ground to the battery post indicated by a nega tive NEG or 6 Replace the 5 amp fuse in the generator control panel NOTE Damage will result if battery connections are made in rever
88. t 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 Acomprehensive inspection of the g
89. tem 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 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 NFPA No 76A ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES available same as Item 1 NFPA No 54 NATIONAL FUEL GAS CODE available same as Item 1 NFPA No 58 AMERICAN NATIONAL STANDARD FOR STORAGE AND HANDLING OF LIQUEFIED PETROLEUM GAS available same as Item 1 NFPA No 70 NFPA HANDBOOK OF NATIONAL ELECTRIC CODE available same as Item 1 Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 AGRICULTURAL WIRING HANDBOOR avail able from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 3634 INSTALLATION AND MAINTENANCEOFFARM STANDBYELECTRICAL SYSTEMS available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 NFPA No 30 FLAMMABLE AND COMBUSTIBLE
90. than 90 days pre pare the generator for storage as follows 1 Start the engine and let it warm up 2 Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down 3 Once the unit has shut down it will signal a low oil fault 4 Set the AUTO OFF MANUAL switch to OFF and turn off the utility power to the transfer switch 5 While the engine is still warm from running drain the oil completely Refill the crankcase with oil See Engine Oil Recommendations 6 Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase 7 Remove the spark plugs and spray fogging agent into the spark plugs threaded openings Reinstall and tighten the spark plugs 8 Remove the battery and store it in a cool dry room on a wooden board Never store the battery on any concrete or earthen floor 9 Clean and wipe the entire generator E Section 5 Maintenance MAINTENANCE Air cooled 15 kW Generators 2 09 5 12 2 RETURN TO SERVICE To return the unit to service after storage proceed as follows 1 2 10 11 12 Set the generator s main circuit breaker to its OFF or OPEN position Verify that utility power is turned off and that the AUTO OFF MANUAL switch is set to OFF 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
91. uthorized Dealer if this failure occurs 5 FUSE 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 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 Figure 5 1 Generator Control Panel FUSE Locate your t GENERAC dealer at ww w generac com GENER power systems INC 5A SYSTEM SET OVER SPEED OVER CRANK FLASHNG GREEN LED NO SENSE FLASHNG RED LESE exe RCISER NOT SET AUTO OFF MAN FUSE 15A SET EXERCISE TIME 5 2 CHECKING THE ENGINE OIL LEVEL For oil capacities see Specifications For engine oil recommendations see Changing the Engine Oil To check the engine oil level proceed as follows Figure 5 2 1 Start the generator by moving the ATUO OFF MANUAL switch to the MANUAL position Allow it to run for a short while and then shut it down by moving the switch to the OFF position 2 Rem

Generac Power Systems 05176-0 Portable Generator User Manual

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