Page 2 - INTRODUCTION; READ THIS MANUAL THOROUGHLY; tions are as follows:; DANGER; After this heading, read explanatory statements; CONTENTS; Engine; OPERATION AND MAINTENANCE; AUTHORIZED
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...
Page 3 - Table of Contents; Air-cooled 15 kW Generators; Section 3 – Post Installation Start-up
Table of Contents Air-cooled 15 kW Generators 1 Introduction ........................Inside Front Cover Read This Manual Thoroughly ........................ IFC Contents .......................................................... IFC Operation and Maintenance ............................ IFC How to O...
Page 4 - Owner’s Manual; Despite the safe design of this generator, operat-; GENERAL HAZARDS
2 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 ...
Page 5 - STANDARDS INDEX; IMPORTANT SAFETY INSTRUCTIONS
3 ELECTRICAL HAZARDS • All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous voltages to the transfer switch as does the standby generator when it is in opera-tion. Avoid contact with ...
Page 6 - Only qualified electricians or contractors should; outdoor installation only; If this generator is used to power electrical load; SYSTEMS; Section 1 — General Information
DANGER Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and regulations. 1.1 UNPACKING/INSPECTION After unpacking, carefully inspect the contents for damage. • This standby generator set has been factory sup- ...
Page 8 - This type of system uses the vapors formed; CONSUMPTION; Load Full Load
6 Section 1 — General Information Air-cooled 15 kW Generators 1.5 SPECIFICATIONS 1.5.1 GENERATOR Rated Max. Continuous Power Capacity (Watts*) .......................... 13,000 NG/15,000 LPRated Voltage........................................................ 120/240Rated Max. Continuous Load Current...
Page 9 - MONITORING; Figure 2.1 — Remote Monitoring Connections; Section 2 — Installation
7 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 necess...
Page 10 - Use a torque wrench to tighten the conductors,; witch Wire Conductor
Remote monitoring functions are only available with the AUTO/OFF/MANUAL switch in the Auto or Manual position. Since the contacts are SPDT, it is possible to monitor either state of each alarm function.Relay 1: Engine running, normally closed. Engine not running, normally open Relay 2: Transfer Swit...
Page 11 - Connect customer LOAD leads to switch termi-; INSTALLATION; Turn off utility power supply to the transfer
9 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...
Page 12 - Figure 2.4 – Battery Cable Connections; BATTERY; Never operate the engine with the oil level; Do not attempt manual transfer switch opera-; CHECKS; The transfer switch is now electrically “hot.”
10 Figure 2.4 – Battery Cable Connections NOTE: The generator is equipped with a battery trickle charger that is active when the unit is set up for automatic operation. With the battery installed and utility power source voltage available to the transfer switch, the battery receives a trickle charge...
Page 13 - Proceed with caution! Generator power voltage; GENERATOR TESTS UNDER LOAD
11 3. 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. 4. When certain that utility supply voltage is compat- ible with transfer switch and load circuit ratings, ...
Page 14 - Figure 3.1 — Dual Fuel Regulators; Figure 3.2 — Placement of Regulator; Adju; Section 3 — Post Installation Start-up and Adjustments; Model
12 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,...
Page 15 - Do not make any unnecessary adjustments.; A service fee may be charged for this adjustment.; ENGINE GOVERNOR ADJUSTMENT; Adjustment; Figure 3.5 – Voltage Adjustment Potentiometer
13 Section 3 — Post Installation Start-up and Adjustments Air-cooled 15 kW Generators 7. Turn utility power to the main distribution panel back on. This can be done by switching the ser-vice main breaker to the on or closed position. Allow the generator to shut down. Do not make any unnecessary ad...
Page 16 - Section 4 — Operation; POSITION; Figure 4.1 – Generator Control Panel; With the switch set to AUTO, the engine may
14 Section 4 — Operation Air-cooled 15 kW Generators 4.1 USING THE AUTO/OFF/MANUAL SWITCH (FIGURE 4.1) 4.1.1 “AUTO” POSITION Selecting this switch position activates fully automatic system operation. It also permits starting and exercising of the engine every seven days with the exercise timer (see ...
Page 17 - OPERATION; Do NOT manually transfer under load.; Figure 4.2 — Actuating Transfer Switch
15 • Retransfer to utility power source then occurs. F. Engine Cool-down Timer • When the load is transferred back to utility power source, the engine cool-down timer starts tim-ing. • The timer will run for about one minute, and the generator will then shut down. 4.4 MANUAL OPERATION DANGER Do NO...
Page 18 - PROCEED WITH CAUTION. THE TRANSFER; PROCEED WITH CAUTION. GENERATOR; GENERATOR TESTS UNDER LOAD
16 4.4.2 CLOSE TO EMERGENCY SOURCE SIDE Before proceeding, verify the position of the switch by observing the position of the manual operation handle in Figure 4.2. If the handle is DOWN, the contacts are closed in the EMERGENCY (STANDBY) position. No further action is required. If the handle is UP,...
Page 19 - SETTING THE EXERCISE TIMER; Hold down the set timer switch until the genera-; Figure 4.3 – Low Oil Pressure and; Oil Filter
17 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 whate...
Page 20 - Figure 5.1 – Generator Control Panel; Remove the dipstick and wipe it dry with a clean; Figure 5.2 — Oil Dipstick and Fill; the; CHANGING THE ENGINE OIL; Any attempt to crank or start the engine before; Run the engine until it is thoroughly warmed up; Section 5 — Maintenance
18 4.8.3.1 Approximate Crank Cycle Times • 15 seconds ON• 7 seconds OFF• 7 seconds ON• 7 seconds OFF• Repeat for 45 seconds Approximately 90 seconds total 4.8.4 OVERSPEED This feature protects the generator from damage by shutting it down if it happens to run faster than the preset limit. This prote...
Page 21 - Figure 5.3 – Oil Drain Hose and Filter; CHANGING THE OIL FILTER; Figure 5.4 — Engine Air Cleaner; Cover; Figure 5.5 – Setting the Spark Plug Gap
19 Figure 5.3 – Oil Drain Hose and Filter Oil Filter OilDrainHo s e Loose n 3. After the oil has drained, replace the cap onto the end of the oil drain hose. Retain the hose in the clip. 4. Refill with the proper recommended oil (see "Changing the Engine Oil"). See the "Specifications...
Page 22 - MAINTENANCE; ADJUSTING VALVE CLEARANCE; To adjust valve clearance:
20 5.7 BATTERY MAINTENANCE The battery should be inspected per the “Service Schedule”. The following procedure should be fol-lowed for inspection: 1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary. 2. Check the battery fluid level of unsealed batteri...
Page 23 - SYSTEM; The exhaust from this product gets extremely; Figure 5.7 – Cooling Vent Locations; ATTENTION AFTER SUBMERSION; MUST NOT; CORROSION PROTECTION
21 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 Jam...
Page 25 - KW - 40 KW SMALL STANDBY GENERATOR SETS; hours; Manual switch to the “OFF” position.; required, and to identify any potential problem areas.
23 Section 5 — Maintenance Air-cooled 15 kW Generators 7 KW - 40 KW SMALL STANDBY GENERATOR SETS Following is a recommended maintenance schedule for small standby and residential generator sets from 7 kW to 40 kW in size, and applies to gas engine driven units. The established intervals in the sched...
Page 29 - Section 6 — Troubleshooting; GUIDE; Problem Cause; *Contact the nearest Authorized Dealer for assistance.
27 Section 6 — Troubleshooting Air-cooled 15 kW Generators 6.1 TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank. 1. Fuse blown 1. Replace 15A fuse on generator control panel. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables as necessary. 3. Defectiv...
Page 30 - Section 7 — Mounting Dimensions
28 Section 7 — Mounting Dimensions Air-cooled 15 kW GeneratorsDrawing No. 0F5927
Page 31 - Section 8 — Electrical Data
29 Section 8 — Electrical Data Air-cooled 15 kW Generators Wiring Diagram – Drawing No. 0F5643-B Part 1 TR - RELAY, TRANSFER CUSTOMER SUPPLIED BLACK BATTERY 12V 0 HTO SP2 SP1 LOP 0 86 85 IM2 85 IM1 D D BA - BRUSH ASSEMBLY DIAGRAM KEY CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION CB1 - MAIN OUTPUT BRE...
Page 36 - Section 9 — Exploded Views and Parts Lists
34 47 54 72 2 20 49 49 43 43 36 4 37 25 35 32 34 35 26 53 74 46 51 8 78 80 39 81 18 52 44 63 15 51 21 71 69 42 10 41 73 49 9 51 49 11 0 72 79 5 27 35 49 44 5 56 1 57 19 52 47 40 69 50 22 65 12 68 14 75 49 71 55 17 30 68 67 3 35 25 28 1 29 Section 9 — Exploded Views and Parts Lists Air-cooled 15 kW G...
Page 39 - ITEM PART
37 ITEM PART NO. QTY. DESCRIPTION 1 0E7 88 6G 1 CIRCUIT BREAKER 70A X 2P 240V (15KW) 2 0A1 8 01 1 A SS EMBLY, BATTERY CHARGER ENGINE 3 0 83 04 9 1 A SS EMBLY, POTTED REGULATOR 4 0C2174 1 RELAY, 12V 25A S P S T 5 075210A 2 BLOCK 1 PO S ITION 6 0D 3 062 4 HEX S TAND-OFF #6- 3 2 x 3 / 8 " 7 0D 8 61...
Page 50 - CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT; YOUR WARRANTY RIGHTS AND OBLIGATIONS; Section 10 – Warranty
48 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new engine. * In California, new utility, and lawn and garden...
Page 51 - EMISSION CONTROL SYSTEM WARRANTY; EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
49 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/de...
Page 52 - GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR; WARRANTY SCHEDULE; THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
Part No. 0F5631 Revision C (12/07/06) Printed in U.S.A. Section 10 – Warranty Air-cooled 15 kW Generators GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR HOME STANDBY/LIGHT COMMERCIAL PRODUCT 45kW AND BELOW For a period of two (2) years from the date of sale, or start-up by Authorized/Certified ...