Owner’s Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Number 005030-0 (15kW)
005028-0 (20kW)
005031-0 (25kW)
This manual should remain with the unit.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!
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Table of Contents
Liquid-cooled 15, 20 and 25 kW Generators
INTRODUCTION................................................IFC
Read this Manual Thoroughly......................................IFC
Operation and Maintenance ........................................IFC
How to Obtain Service ................................................IFC
Authorized Service Dealer Location ............................IFC
SAFETY RULES....................................................2
Standards Index..............................................................3
Section 1 — GENERAL INFORMATION ............4
1.1 Generator..............................................................4
1.2 Transfer Switch ....................................................4
1.3 ATS Mode (Automatic Operation)..........................4
Section 3 — OPERATION ................................15
3.1 Control Console Components..............................15
3.2 Manual Transfer and Startup..............................15
3.3 Engine Governor Gain Adjustments....................16
3.4 Manual Retransfer and Shutdown ......................17
3.5 Automatic Operation ..........................................17
3.6 Weekly Exercise Cycle..........................................17
3.7 Control Board DIP Switch Settings ....................18
3.8 Voltage Regulator Adjustment..............................18
Section 4 — MAINTENANCE ..........................19
4.1 Maintenance Performed by Authorized
Service Facilities..................................................19
1.4 Engineered Transfer Switch (2-wire Start
GTS Mode)............................................................4
4.2 Exhaust Manifold Procedure ..............................19
4.3 Intake Manifold Procedure ..................................19
4.4 Cylinder Head Procedure ....................................20
4.5 Cooling System....................................................20
1.5 Generator AC Connection Systems........................4
1.6 Main Circuit Breaker ............................................5
1.7 Generator Fuel System..........................................5
1.8 Engine Protective Devices......................................5
1.9 Unpacking ............................................................6
1.10 Lifting the Generator ............................................6
1.11 Specifications ........................................................7
1.12 Fuel Consumption ................................................7
1.13 Reconfiguring the Fuel System for LP Vapor..........7
1.14 Engine Oil Recommendations ..............................8
1.15 Coolant Recommendations....................................8
1.16 Before Installation ................................................8
Section 2 — INSTALLATION ............................9
2.1 Standby Generator Installation ............................9
2.2 Generator Location................................................9
2.3 Generator Mounting and Support ........................9
2.4 Basic Standby Electric System............................10
2.5 Emergency Circuit Isolation Method....................10
2.6 Total Circuit Isolation Method ............................10
2.7 Grounding the Generator ....................................10
2.8 Generator AC Neutral Connections......................11
2.9 Automatic Transfer Switch (ATS Mode) ..............11
4.6 Overload Protection for Engine DC
Electrical System ................................................20
4.7 Checking Fluid Levels ........................................20
4.8 Maintenance Owner/Operator
Can Perform........................................................21
4.9 Miscellaneous Maintenance ................................22
4.10 Scheduled Maintenance ......................................24
Section 5 — TROUBLESHOOTING ..................27
Section 6 — NOTES ........................................28
Section 7 — ELECTRICAL DATA ....................30
Section 8 — EXPLODED VIEWS AND
PARTS LISTS ..............................38
Section 9 — INSTALLATION DIAGRAM ..........55
Section 10 — WARRANTY...............................56
2.10 Engineered Transfer Switch (2-wire Start
GTS Mode)..........................................................12
2.11 Battery Installation..............................................13
2.12 Preparation Before Start-Up................................14
1
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Important Safety Instructions
Liquid-cooled 15, 20 and 25 kW Generators
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe
operation be copied and posted in potential hazard areas. Safety should be stressed to all
operators, potential operators, and service and repair technicians for this equipment.
!
!
!
SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be
followed during installation and maintenance of the generator and batteries.
!
!
!
GENERAL HAZARDS
!
!
WARNING:
• For safety reasons, the manufacturer recommends that this
equipment be installed, serviced and repaired by an
Authorized Service Dealer or other competent, qualified
electrician or installation technician who is familiar with
applicable codes, standards and regulations. The operator
also must comply with all such codes, standards and regu-
lations.
• Installation, operation, servicing and repair of this (and
related) equipment must always 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, operated and serv-
iced in accordance with the manufacturer’s instructions
and recommendations. Following installation, do nothing
that might render the unit unsafe or in noncompliance with
the aforementioned codes, standards, laws and regula-
tions.
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 installing,
operating or servicing this equipment. Become familiar
with this Owner’s Manual and with the unit. The gen-
erator 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 fun-
damental rules or precautions.
The manufacturer cannot anticipate every possible cir-
cumstance that might involve a hazard. The warnings in
this manual, and on tags and decals affixed to the unit
are, therefore, not all-inclusive. If using a procedure,
work method or operating technique that the manufac-
turer does not specifically recommend, ensure that it is
safe for others. Also make sure the procedure, work
method or operating technique chosen does not render
the generator unsafe.
• The engine exhaust fumes contain carbon monoxide gas,
which can be DEADLY. This dangerous gas, if breathed in
sufficient concentrations, can cause unconsciousness or
even death. For that reason, adequate ventilation must be
provided.
• Keep hands, feet, clothing, etc., away from drive belts, fans,
and other moving or hot parts. Never remove any drive belt
or fan guard while the unit is operating.
• Adequate, unobstructed flow of cooling and ventilating air
is critical to prevent buildup of explosive gases and to
ensure correct generator operation. Do not alter the instal-
lation or permit even partial blockage of ventilation provi-
sions, as this can seriously affect safe operation of the gen-
erator.
• Keep the area around the generator clean and uncluttered.
Remove any materials that could become hazardous.
• 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 promptly repair or
replace all worn, damaged or defective parts using only fac-
tory-approved parts.
DANGER
Despite the safe design of this generator,
operating this equipment imprudently, neglecting
!
its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to install, operate or main-
tain this equipment.
Potentially lethal voltages are generated by these
machines. Ensure all steps are taken to render the
machine safe before attempting to work on the
generator.
• Before performing any maintenance on the generator, dis-
connect 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.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running gen-
erators.
!
• Never use the generator or any of its parts as a step.
Stepping on the unit can stress and break parts, and may
result in dangerous operating conditions from leaking
exhaust gases, fuel leakage, oil leakage, etc.
2
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Important Safety Instructions
Liquid-cooled 15, 20 and 25 kW Generators
ELECTRICAL HAZARDS
FIRE HAZARDS
• All generators covered by this manual produce dangerous
electrical voltages and can cause fatal electrical shock.
Utility power delivers extremely high and dangerous volt-
ages to the transfer switch as well as the standby generator.
Avoid contact with bare wires, terminals, connections, etc.,
on the generator as well as the transfer switch, if applicable.
Ensure all appropriate covers, guards and barriers are in
place before operating the generator. If work must be done
around an operating unit, stand on an insulated, dry surface
to reduce shock hazard.
• Do not handle any kind of electrical device while standing
in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
• If personnel must stand on metal or concrete while
installing, operating, servicing, adjusting or repairing this
equipment, place insulative mats over a dry wooden plat-
form. Work on the equipment only while standing on such
insulative mats.
• The National Electrical Code (NEC), Article 250 requires
the frame and external electrically conductive parts of the
generator to be connected to an approved earth ground
and/or grounding rods. This grounding will help prevent
dangerous electrical shock that might be caused by a
ground fault condition in the generator set or by static elec-
tricity. Never disconnect the ground wire.
• Wire gauge sizes of electrical wiring, cables and cord sets
must be adequate to handle the maximum electrical current
(ampacity) to which they will be subjected.
• Keep a fire extinguisher near the generator at all times. Do
NOT use any carbon tetra-chloride type extinguisher. Its
fumes are toxic, and the liquid can deteriorate wiring insu-
lation. Keep the extinguisher properly charged and be
familiar with its use. If there are any questions pertaining
to fire extinguishers, consult the local fire department.
EXPLOSION HAZARDS
• Do not smoke around the generator. Wipe up any fuel or oil
spills immediately. Ensure that no combustible materials
are left in the generator compartment, or on or near the
generator, as FIRE or EXPLOSION may result. Keep the
area surrounding the generator clean and free from debris.
• These generator sets may operate using one of several types
of fuels. All fuel types are potentially FLAMMABLE and/or
EXPLOSIVE and should be handled with care. Comply with
all laws regulating the storage and handling of fuels. Inspect
the unit’s fuel system frequently and correct any leaks
immediately. Fuel supply lines must be properly installed,
purged and leak tested according to applicable fuel-gas
codes before placing this equipment into service.
• Gaseous fluids such as natural gas and liquid propane (LP)
gas are extremely EXPLOSIVE. Natural gas is lighter than
air, and LP gas is heavier than air; install leak detectors
accordingly.
• Before installing or servicing this (and related) equipment,
make sure that all power voltage supplies are positively
turned off at their source. Failure to do so will result in haz-
ardous and possibly fatal electrical shock.
• Connecting this unit to an electrical system normally sup-
plied by an electric utility shall be by means of a transfer
switch so as to isolate the generator electric system from
the electric utility distribution system when the generator is
operating. Failure to isolate the two electric system power
sources from each other by such means will result in dam-
age to the generator and may also result in injury or death
to utility power workers due to backfeed of electrical ener-
gy.
• Generators installed with an automatic transfer switch will
crank and start automatically when NORMAL (UTILITY)
source voltage is removed or is below an acceptable preset
level. To prevent such automatic start-up and possible
injury to personnel, disable the generator’s automatic start
circuit (battery cables, etc.) before working on or around
the unit. Then, place a “Do Not Operate” tag on the genera-
tor control panel and on the transfer switch.
• In case of accident caused by electric shock, immediately
shut down the source of electrical power. If this is not pos-
sible, attempt to free the victim from the live conductor.
AVOID DIRECT CONTACT WITH THE VICTIM. Use a
nonconducting implement, such as a dry rope or board, to
free the victim from the live conductor. If the victim is
unconscious, apply first aid and get immediate medical
help.
STANDARDS INDEX
In the absence of pertinent standards, codes, regulations and
laws, the published information listed below may be used as
installation guide for this equipment.
‹
1. NFPA No. 37, STATIONARY COMBUSTION ENGINES
AND GAS TURBINES, available from the National Fire
Protection Association, 470 Atlantic Avenue, Boston, MA
02210.
2. NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS FOR
HEALTH CARE FACILITIES, available same as Item 1.
3. NFPA No. 54, NATIONAL FUEL GAS CODE, available
same as Item 1.
4. NFPA No. 58, AMERICAN NATIONAL STANDARD FOR
STORAGE AND HANDLING OF LIQUEFIED PETROLE-
UM GAS, available same as Item 1.
5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL ELEC-
TRIC CODE, available same as Item 1.
6. Article X, NATIONAL BUILDING CODE, available from
the American Insurance Association, 85 John Street, New
York, N.Y. 10038.
7. AGRICULTURAL WIRING HANDBOOK, available from the
Food and Energy Council, 909 University Avenue,
Columbia, MO 65201.
8. ASAE EP-3634, INSTALLATION AND MAINTENANCE OF
FARM STANDBY ELECTRICAL SYSTEMS, available from
the American Society of Agricultural Engineers, 2950
Niles Road, St. Joseph, MI 49085.
• Never wear jewelry when working on this equipment.
Jewelry can conduct electricity resulting in electric shock, 9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQ-
or may get caught in moving components causing injury.
UIDS CODE, available same as Item 1.
3
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Section 1 - General Information
Liquid-cooled 15, 20 and 25 kW Generators
If a transfer switch is not included, one may be pur-
chased separately from an Authorized Dealer.
1.1 GENERATOR
This equipment is a liquid-cooled, engine-driven gen-
erator set. The generator is designed to supply elec-
trical power that operates critical electrical loads
during utility power failure. The unit has been facto-
ry-installed in a weather resistant, all metal enclosure
and is intended for outdoor installation only. Use this
generator as a source of electrical power for the oper-
ation of 120 and/or 240VAC, single-phase loads.
1.3 AUTOMATIC TRANSFER SWITCH
(ATS MODE)
When this generator, along with an HS Type automat-
ic transfer switch has been installed and connected,
a circuit board in the generator control panel con-
stantly monitors the utility voltage and controls the
operation of the transfer switch.
These models are available. They are rated as follows:
In ATS Mode utility voltage sensing, weekly exercis-
ing, and load transferring is under the control of the
generator.
Model 005031-0: Provides 25,000 watts (25 kW) of single-
phase power.
Model 005028-0: Provides 20,000 watts (20 kW) of single-
phase power.
Should the utility voltage drop below a preset value,
and remain at this low voltage for a preset amount of
time, the generator cranks and starts. After the gen-
erator starts, the transfer switch transfers the load
circuits to the generator so the generator can power
them. When the utility source voltage has been
restored, the transfer switch re-transfers the load cir-
cuits back to the utility source voltage and the gener-
ator shuts down.
Model 005030-0: Provides 15,000 watts (15 kW) of single-
phase power.
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 electric system from the utility distri-
bution system when the generator is operating
(NEC 701). Failure to isolate an electrical system
by such means results in damage to the genera-
tor and may also result in injury or even death
to utility power workers due to backfeed of
electrical energy.
1.4 ENGINEERED TRANSFER SWITCH
(2-WIRE START GTS MODE)
When required, the pre-packaged standby generator
can be installed with an engineered W-type transfer
switch which controls utility voltage sensing, weekly
exercising and load transferring.
UTILITY voltage sensing, weekly exercising and load
transferring is then under the control of the
Engineered W-type transfer switch (GTS Mode).
1.2 TRANSFER SWITCH
This generator system is intended to be used with a
matched automatic transfer switch. It may be supplied
in either a NEMA 1 enclosure or a NEMA 3R enclo-
sure. The NEMA 1 enclosure is intended for indoor
use only. The NEMA 3R enclosure is weather proof and
can be used indoors or outdoors. Follow these rules:
1.5 GENERATOR AC CONNECTION
SYSTEMS
The generator was shipped from the factory with its
stator AC output leads connected in a single-phase,
3-wire generator AC connection system (Figure 1.1).
The stator assembly in this system consists of a pair
of stationary windings, with two leads brought out of
each winding. Each single winding can supply 120
VAC, 60 Hertz. When the two windings are connected
in series, a 240 VAC, 60 Hertz AC output results.
Typically the two “hot” leads in the circuit are Wires
No. 11 and 44. The “Neutral” leads are the junction
of Wires 22 and 33.
• Install the transfer switch on a firm, sturdy sup-
porting structure.
• To prevent switch distortion, level the switch if nec-
essary. This can be done by placing washers
between the switch enclosure and the mounting
surface.
• Never install the switch where water or any corro-
sive substance might drip onto the enclosure.
• Protect the switch at all times against excessive
moisture, dust, dirt, lint, construction grit and cor-
rosive vapors.
Figure 1.2 - Main Circuit Breaker
Model
005031-0
005028-0
005030-0
Rating
25,000 W
20,000 W
15,000 W
Phase
Actual Current
C/B Rating*
% over rating
120%
Circuit Breaker
125A BQ2
1
1
1
104.2 A
125 A
83.3 A
62.5
100 A
70 A
120%
112%
100A BQ2
70A BQ2
* Amp Rating of C/B structured under model.
4
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Section 1 - General Information
Liquid-cooled 15, 20 and 25 kW Generators
Figure 1.1 - Generator AC Connection System
Figure 1.3 - Engine Protective Devices
(BLACK)
0
(WHITE)
(BLACK)
NEUTRAL
1.6 MAIN CIRCUIT BREAKER
The generator’s main circuit breaker is included with
the unit as shipped from the factory. The breaker for
each unit is described in Figure 1.2.
1.7 GENERATOR FUEL SYSTEM
This unit has been factory tested and adjusted using
a natural gas fuel system. If propane (LP) gas is pre-
ferred, refer to Section 1.13, Reconfiguring the Fuel
System for LP Vapor.
Fuel pressure for a natural gas set up should be five
inches to 14 inches of water column (0.18 to 0.5
psi) at all load ranges.
1.8.1 LOW OIL PRESSURE SWITCH
‹
This switch is normally-closed (N.C.) but is held open
by engine oil pressure during engine running. Should
operating oil pressure drop below about 8-10 psi
(55-68 kPa), the switch contacts close and the engine
shuts down automatically (Figure 1.4).
Fuel pressure for an LP vapor set up should be 11
inches to 14 inches of water column (0.4 to 0.5
psi) at all load ranges.
NOTE:
Figure 1.4 - Low Oil Pressure Switch
A seperate gas line and regulator may be needed
to assure proper gas pressure to the generator.
Improper gas pressure can cause hard starting and
affect engine durability.
Gaseous fuels such as natural and LP (propane)
!
gas are highly explosive. Even the slightest
spark can ignite such fuels and cause an explo-
sion. No leakage of fuel is permitted. Natural
gas, which is lighter than air, tends to collect in
high areas. LP gas is heavier than air and tends
to settle in low areas.
1.8.2 HIGH COOLANT TEMPERATURE
SWITCH
Normally open (N.O.) thermostatic switch has sens-
ing tip which is immersed in captive coolant. Should
coolant temperature exceed about 230°F (110°C), the
switch contacts close, which causes the engine to
shut down automatically (Figure 1.5).
‹
1.8 ENGINE PROTECTIVE DEVICES
The engine has several safety switches which cause
the engine to automatically shut down under the fol-
lowing conditions: low oil pressure, high coolant tem-
perature, engine overspeed, low coolant level or over-
crank (Figure 1.3).
5
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Section 1 — General Information
Liquid-cooled 15, 20 and 25 kW Generators
Figure 1.5- High Coolant Temperature Switch
‹
1.8.6 LOW BATTERY
The engine control board continually monitors the
battery voltage and turns on the low battery LED if
the battery voltage falls below 12 VDC for one minute.
Low battery voltage is a non-latching alarm, which
will automatically clear if the battery voltage rises
above 12 VDC. If battery voltage goes below 6 VDC
during cranking, the low battery voltage alarm is
latched, cranking is terminated, and the low battery
LED stays on.
1.8.7 15A DC FUSE
‹
This fuse is located inside the control panel. It pro-
tects the panel wiring and components from damag-
ing overload. The unit will not start or crank if the
fuse is blown. Replace the fuse with one of the same
size, type, and rating.
1.8.3 LOW COOLANT LEVEL SWITCH
‹
Should engine coolant level drop below the level of
the high coolant temperature switch, it is possible for
the engine to overheat without automatic shutdown.
To prevent such overheating without automatic shut
down, the engine has a low coolant level sensor. If the
engine coolant drops too low, the engine automatical-
ly shuts down (Figure 1.6).
1.9 UNPACKING
1.9.1 UNPACKING PRECAUTIONS
‹
Handle shipping cartons and crates with care. Use
care to avoid damage from dropping, bumping, colli-
sion, etc. Store and unpack cartons with the proper
side up, as noted on the shipping carton.
Figure 1.6 - Low Coolant Level Sensor
1.9.2 INSPECTION
‹
Upon delivery, carefully inspect the generator for any
damage that may have occurred during shipment. If
loss or damage is noted at the time of delivery, have
the person(s) making delivery note all damage on the
freight bill or affix their signature under the consign-
or’s memo of loss or damage.
1.10 LIFTING THE GENERATOR
1.8.4 OVERSPEED SHUTDOWN
‹
Should AC frequency exceed about 72 Hz, circuit
board action will automatically shutdown the engine.
When lifting or hoisting equipment is used, be
!
careful not to touch overhead power lines. The
generators weight of more than 900 pounds
requires proper tools, equipment, and qualified
personnel to be used in all phases of handling
and unpacking.
‹
1.8.5 OVERCRANK SHUTDOWN
The engine control board uses a cyclic cranking
process when attempting to start the engine. The first
crank cycle is a 15-second crank followed by a seven-
second rest. This is followed by five more crank
cycles each with a seven second crank followed by a
seven-second rest.
If the engine fails to start after all six attempts, the start
attempt is stopped and the overcrank LED turns on.
6
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Section 1 — General Information
Liquid-cooled 15, 20 and 25 kW Generators
1.11 SPECIFICATIONS
1.12 FUEL CONSUMPTION
15 kW Models
Using Natural Gas ........................................236 cu. ft. per hour
Using LP Gas ..................................................92 cu. ft. per hour
20 kW Models
1.11.1 ENGINE
‹
Make ......................................................................................Ford
Displacement ............................................153 inches3 (2.5 liters)
Cylinder Arrangement......................................................4, in-line
Valve Arrangement................................................Overhead Cam
Firing Order........................................................................1-3-4-2
Number of Main Bearings............................................................5
Compression Ratio..........................................................9.37 to 1
No. of Teeth on Crank ............................................................36-1
Ignition Timing (Waste Spark System)
Using Natural Gas ........................................307 cu. ft. per hour
Using LP Gas ................................................122 cu. ft. per hour
25 kW Models
Using Natural Gas ........................................441 cu. ft. per hour
Using LP Gas ................................................175 cu. ft. per hour
NOTE:
Fuel consumption is given at rated maximum con-
tinuous power output when using natural gas
rated at 1000 Btu per cubic foot; or LP gas rated
2520 Btu per cubic foot. Actual fuel consumption
obtained may vary depending on such variables as
applied load, ambient temperature, engine condi-
tions and other environmental factors.
at 1800 rpm (NG) ..........................................36 degrees BTDC
at 1800 rpm (LP vapor)................................28` degrees BTDC
Spark Plug Gap ............................................................0.044 inch
Recommended Spark Plugs
Motorcraft ................................................................AWSF-52-C
Oil Pressure....................................................................30-50 psi
Crankcase Oil Capacity......................4.5 U.S. quarts (4.26 liters)
Recommended Engine Oil........................................SAE 15W-40
Type of Cooling System ..................Pressurized, closed recovery
Cooling Fan ..............................................................Pusher Type
Cooling System Capacity ......................2 U.S. gallons (7.6 liters)
Fuel pressure for a natural gas set up should be five
inches to 14 inches of water column (0.18 to 0.5
psi) at all load ranges.
Fuel pressure for an LP vapor set up should be 11
inches to 14 inches of water column (0.4 to 0.5
psi) at all load ranges.
Recommended Coolant ............Use a 50-50 mixture of ethylene
glycol base and deionized water.
1.13 RECONFIGURING THE FUEL
SYSTEM FOR LP VAPOR
NOTE:
Home standby control board assembly part
number 0E9704 must be used on 1800 rpm gen-
!
All models are configured for natural gas (NG)
from the factory.
erators.
To reconfigure the fuel system from NG to LP vapor,
follow these steps:
1. Turn the main gas supply off.
1.11.2 GENERATOR
‹
Single-phase
Single-phase
Single-phase
Model
005031-0
25
005028-0
20
005030-0
15
Rated Max. Cont.
AC Power Output (kW)*
Rated Voltage (volts)
No. of Rotor Poles
Driven Speed of Rotor (rpm)
Rotor Excitation System
Type of Stator
120/240
4
1800
120/240
4
1800
120/240
4
1800
Direct excited brush type
Direct excited brush type
Direct excited brush type
4 Wire
4 Wire
4 Wire
Rotor Insulation
Stator Insulation
Class F
Class H
Class F
Class H
Class F
Class H
* Rated power of generator is subject to and limited by such factors as ambient temperature, altitude, engine condition, and other fac-
tors. Engine power will decrease about 3.5% for each 1000 feet above sea level and will decrease an additional 1% for each 10°F
above 60°F. Maximum output power of the generator is limited by maximum engine power.
7
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Section 1 — General Information
Liquid-cooled 15, 20 and 25 kW Generators
2. Remove the carburetor fuel hose from the outlet
port (Port 1) of the demand regulator (Figure
1.8).
NOTE:
Synthetic oil is highly recommended when the
generator will be operating in ambient tempera-
tures which regularly exceed 90° F and/or fall
below 30° F.
3. Remove the brass hose fitting from the outlet port
(Port 1) of the demand regulator.
4. Remove pipe plug from Port 2.
5. Install brass hose fitting into Port 2.
6. Install pipe plug into Port 1.
7. Connect carburetor gas hose to brass fitting.
8. Tighten all clamps and plugs.
9. Make sure fuel supply is of the proper pressure
and type for configuration (not to exceed 14 inch-
es water column).
10. Move DIP switch position 4 on the control board
to the off position (LP vapor, see Figure 3.2 and
Section 3.7).
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.
!
1.15 COOLANT RECOMMENDATIONS
Use a mixture of half low silicate ethylene glycol base
anti-freeze and half deionized water. Cooling system
capacity is about 8 U.S. quarts (7.6 liters). Use only
deionized water and only low silicate anti-freeze. If
desired, add a high quality rust inhibitor to the rec-
ommended coolant mixture. When adding coolant,
always add the recommended 50-50 mixture.
11. Reverse the procedure to convert back to natural
gas.
Figure 1.8 — Reconfigure the Fuel System
Port 1
Port 2
FUEL HOSE
FUEL HOSE
BRASS HOSE
FITTING
BRASS HOSE
FITTING
Do not use any chromate base rust inhibitor
with ethylene glycol base anti-freeze or chromi-
PLUG
PLUG
!
OUT
PORT 1
OUT
PORT 2
umhydroxide (“green slime”) forms and will
cause overheating. Engines that have been
operated with a chromate base rust inhibitor
must be chemically cleaned before adding eth-
ylene glycol base anti-freeze. Using any high
silicate anti-freeze boosters or additives will
also cause overheating. DO NOT use any solu-
ble oil inhibitor for this equipment.
FUEL INLET
NG FUEL SYSTEM
LP FUEL SYSTEM
NOTE:
1.16 BEFORE INSTALLATION
Before installing this equipment, check the ratings of
both the generator and the transfer switch. Read
“Emergency Isolation Method” and “Total Circuit
Isolation Method” in the installation manual (Part No.
079699).
Port 1 is for NG only and Port 2 is for LP vapor
only. No provision for dual fuel has been made.
DANGER
Serious injury or damage may occur if not con-
figured properly. Please consult an Authorized
Service Dealer with any questions.
The generator’s rated wattage/amperage capacity
must be adequate to handle all electrical loads that
the unit will power. It may be necessary to group the
critical (essential) loads together and wire them into
a separate “emergency” distribution panel.
!
1.14 ENGINE OIL RECOMMENDATIONS
The unit has been filled with 15W-40 engine oil at the
factory. Use a high-quality detergent oil classified “For
Service CC, SD, SE, SF.” Detergent oils keep the
engine cleaner and reduce carbon deposits. Use oil
having the following SAE viscosity rating, based on
the ambient temperature range anticipated before the
next oil change:
This generator can be installed in conjunction with
an engineered transfer switch, if necessary (see
Section 2.10).
The standard prepackaged transfer switch (ATS
mode) does not have sensing or controlling circuit
boards. Instead, the generator control console hous-
es a “Printed Circuit Board Assembly”, which con-
trols all phases of operation, including engine start
up and load transfer.
Temperature
Above 80° F (27° C)
32° to 80° F (-1° to 27° C)
Below 32° F (0° C)
Oil Grade (Recommended)
SAE 30W or 15W-40
SAE 20W-20 or 15W-40
SAE 10W or 15W-40
8
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Section 2 — Installation
Liquid-cooled 15, 20 and 25 kW Generators
2.1.2 OTHER PUBLISHED STANDARDS
In addition to NFPA standards, the following infor-
mation pertaining to the installation and use of
standby electric systems is available:
‹
2.1 STANDBY GENERATOR
INSTALLATION
DANGER
• Article X, NATIONAL BUILDING CODE, available
from the American Insurance Association, 85 John
Street, New York, N.Y. 10038.
• AGRICULTURAL WIRING HANDBOOK, obtainable
from the Food and Energy Council, 909 University
Avenue, Columbia, MO, 65201.
• ASAE EP-364.2, INSTALLATION AND MAINTE-
NANCE OF FARM STANDBY ELECTRIC POWER,
available from the American Society of Agricultural
Engineers, 2950 Niles Road, St. Joseph, MI 49085.
• A52.1, AMERICAN NATIONAL STANDARD FOR
CHIMNEYS, FIREPLACES AND VENTING SYS-
TEMS, available from the American National
Standard Institute, 1430 Broadway, New York, N.Y.
10018.
Connecting this generator to an electrical sys-
tem normally supplied by an electric utility
shall be by means of a transfer switch, so as to
isolate the electric system from the utility distri-
bution system when the generator is operating.
Failure to isolate the electric system by these
means will result in damage to the generator
and may also result in injury or death to utility
workers due to backfeed of electrical energy.
If an open bottom is used, the engine-genera-
tor must be installed over non-combustible
materials and should be located such that com-
bustible materials are not capable of accumu-
lating under the generator set.
Only qualified, competent installation contractors or
electricians thoroughly familiar with applicable
codes, standards and regulations should install this
standby electric power system. The installation must
comply strictly with all codes, standards and regula-
tions pertaining to the installation.
2.2 GENERATOR LOCATION
Install the generator set, in its protective enclosure
outdoors, where adequate cooling and ventilating air
always is 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, consider using a windbreak to protect the unit.
• Install the generator on high ground where water
levels will not rise and endanger it.
• Allow sufficient room on all sides of the generator
for maintenance and servicing. A required mini-
mum allowance of space to any solid structure is
three feet. Five feet allowance of space is recom-
mended.
• Where strong prevailing winds blow from one
direction, face the generator air inlet openings into
the prevailing winds.
• Install the generator as close as possible to the
transfer switch. This reduces the length of wiring
and conduit.
After the system has been installed, do nothing
that might render the installation in noncompli-
ance with such codes, standards and regula-
tions.
!
NOTE:
For more information about the installation of a
standby system contact an Authorized Service
Dealer.
2.1.1 NFPA STANDARDS
‹
The following published standards booklets pertain-
ing to standby electric systems are available form the
National Fire Protection Association (NFPA),
Batterymarch Park, Quincy, MA 02269:
• Install the generator as close as possible to the fuel
supply, to reduce the length of piping. HOWEVER,
REMEMBER THAT LAWS OR CODES MAY REG-
ULATE THE DISTANCE.
• NFPA No. 37, STATIONARY COMBUSTION
ENGINES AND GAS TURBINES.
• NFPA No. 76A, ESSENTIAL ELECTRICAL SYS-
TEMS FOR HEALTH CARE FACILITIES.
• NFPA No. 220, STANDARD TYPES OF BUILDING
CONSTRUCTION
• NFPA No. 68, GUIDE FOR EXPLOSION VENTING
• NFPA No. 70, NATIONAL ELECTRICAL CODE.
• NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE.
2.3 GENERATOR MOUNTING AND
SUPPORT
Retain the generator compartment to a concrete slab
with 1/4-inch masonry type anchor bolts. Be sure the
bolts are long enough to retain the compartment. The
slab should be at least six inches thick and should
extend beyond the enclosure to a distance of at least
three inches on all sides.
• NFPA No. 10, INSTALLATION, MAINTENANCE AND
USE OF PORTABLE FIRE EXTINGUISHERS.
9
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Section 2 — Installation
Liquid-cooled 15, 20 and 25 kW Generators
• It must have an ampere rating equal to the total
amperage rating of the emergency distribution
panel circuit.
• It must be installed between the building’s main
distribution panel and the emergency distribution
panel.
2.4 BASIC STANDBY ELECTRIC
SYSTEM
Figure 2.1 shows a schematic diagram of a basic
standby electric system. Both the UTILITY power
supply and the STANDBY GENERATOR output are
connected to an approved transfer switch. The trans-
fer switch is required by electrical code and serves
the following functions:
2.6 TOTAL CIRCUIT ISOLATION
METHOD
• Permits the LOAD circuits to be connected to only
one power supply at a time.
When a generator capable of powering all electrical
loads in the circuit is to be installed, the “Total
Circuit Isolation Method” may be used. The following
apply to the transfer switch in this type of system.
• Prevents electrical backfeed between the generator
and the UTILITY power circuits.
Notice that both the STANDBY and the UTILITY
power supplies to the transfer switch are protected
against overload by a main line circuit breaker.
• Ampere rating of the transfer switch must equal
the ampere rating of the normal incoming utility
service.
• The transfer switch is installed between the utility
service entrance and the building distribution
panel.
Figure 2.1 – Basic Standby Electric System
2.7 GROUNDING THE GENERATOR
A GROUNDING LUG (Figure 2.2) is provided on the
generator mounting base for the purpose of ground-
ing the frame and the external electrically conductive
parts of the equipment to an approved earth ground
and/or grounding rods where required by the
National Electrical Code. Consult a qualified electri-
cian for grounding requirements in the area.
Grounding procedures must meet local regulations.
DANGER
Do not connect the ground wire to any pipe
that carries a flammable or explosive substance
– FIRE or an EXPLOSION may result.
NOTE:
Proper grounding helps protect personnel against
electrical shock in the event of a ground fault condi-
tion in the generator or in connected electrical
devices. In addition, grounding helps dissipate static
electricity that often builds up in ungrounded
devices.
The manufacturer recommends the use of a
Generac Power Systems transfer switch in con-
junction with this generator.
2.5 EMERGENCY CIRCUIT ISOLATION
METHOD
Figure 2.2 – Generator Grounding Lug (typical)
This prevents overloading the generator by keeping
electrical loads below the wattage/amperage capacity
of the generator. If the generator is powering only crit-
ical loads, within its wattage/amperage capacity, dur-
ing utility power outages, consider using the emer-
gency circuit isolation method.
Critical electrical loads are grouped together and
wired into a separate “Emergency Distribution
Panel.” The generator only supplies electrical circuits
connected to the emergency distribution panel during
utility power outages. Load circuits powered by that
panel must be within the wattage/amperage capacity
of the generator set. The transfer switch must meet
the following requirements:
10
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Section 2 — Installation
Liquid-cooled 15, 20 and 25 kW Generators
The HS Type transfer switch is controlled by the gen-
erator circuit board via control wires 23 and 194.
Wire 23 connects the relay driver output (collector of
an NPN transistor) on the generator circuit board to
the "low side" (Terminal 23) of the transfer relay coil
in the transfer switch. Wire 194 connects positive
battery voltage from the generator circuit board to the
"high side" (Terminal 194) of the transfer relay coil in
the transfer switch.
2.8 GENERATOR AC NEUTRAL
CONNECTIONS
The manufacturer uses an UNGROUNDED AC neu-
tral. Grounding is recommended only at the main
service entrance. If the neutral wire is grounded and
one of the phase loads becomes grounded, the exces-
sive current opens the load circuit breaker or col-
lapses the generator field. The actual result depends
on the electrical characteristics of the particular
installed generator.
If generator wires 23 and 194 are not wired to
2.9 AUTOMATIC TRANSFER SWITCH
!
the correct terminals in the transfer switch, the
circuit board in the generator control panel will
be damaged.
(ATS MODE)
When this generator, along with an HS Type automat-
ic transfer switch has been installed and connected,
a circuit board in the generator control panel con-
stantly monitors the utility voltage and controls the
operation of the transfer switch.
In order for the generator utility voltage sensing and
battery charging functions to work, it is necessary to
provide a 5 amp fused 240Vac utility source connec-
tion from the transfer switch main N1 and N2 termi-
nals to the generator control panel N1 and N2 termi-
nals (See Figure 2.3).
To implement this mode of operation, Position 2 of
the eight-position DIP switch, which is located on the
generator circuit board (see Figure 3.2), must be in
the OFF position. In ATS Mode utility voltage sensing,
weekly exercising, and load transferring is under the
control of the generator.
Transfer Switch terminals N1 and N2 (also called
Utility 1 and Utility 2) are the input utility AC power
connections to the Transfer Switch. Transfer Switch
terminals T1 and T2 (also called Load 1 and Load 2)
are the transfer switch AC output power terminals
that go to the load circuit distribution panel. Transfer
Switch terminals E1 and E2 are the AC power termi-
nals that come from the generator's main alternator.
Should the utility voltage drop below a preset value,
and remain at this low voltage for a preset amount of
time, the generator cranks and starts. After the gen-
erator starts, the transfer switch transfers the load
circuits to the generator so the generator can power
them. When the utility source voltage has been
restored, the transfer switch re-transfers the load cir-
cuits back to the utility source voltage and the gener-
ator shuts down.
Figure 2.3 - Connection Diagram (ATS Mode)
FROM UTILITY
TO LOAD
FEEDER CIRCUITS
MAIN LINE
CIRCUIT
BREAKER
OR FUSE
LOAD
DISTRIBUTION
PANEL
N1 N2
FUSE
FUSE
N1
N2
T1
T2
GENERATOR
194
23
194
23
HS TYPE
TRANSFER
SWITCH
178
183
N2 N1
E1 E2
E1 E2
11
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Section 2 — Installation
Liquid-cooled 15, 20 and 25 kW Generators
Start terminals. Recommended wire gauge sizes for
the 2-Wire Start wiring depend on the length of the
wire (see wiring length chart).
2.10 ENGINEERED TRANSFER SWITCH
(2-WIRE START GTS MODE)
When required, the pre-packaged standby generator
can be installed with an engineered W Type transfer
switch which controls utility voltage sensing, weekly
exercising and load transferring.
MAXIMUM WIRE LENGTH RECOMMENDED WIRE
SIZE
460 feet (140m)
No. 18 AWG.
No. 16 AWG.
No. 14 AWG.
No. 12 AWG.
461 to 730 feet (223m)
731 to 1,160 feet (354m)
1,161 to 1,850 feet (565m)
When Position 2 of the eight-position DIP switch,
which is located on the generator circuit board (See
Figure 3.2), is in the ON position then utility voltage
sensing, weekly exercising and load transferring is
under the control of the Engineered W Type transfer
switch (GTS Mode).
Route the 2-Wire Start control wires through suitable,
approved conduit which is separate from the AC
power leads. Connection of wire 178 to wire 183 by
relay contact closure action (volt free switch contacts)
in the transfer switch must result in generator engine
cranking and startup (See Figure 2.4).
Generator DIP Switch Position 2 ON = 2-Wire Start
GTS Mode
• The generator control board will NOT monitor the
utility.
• The generator control board will NOT perform a
weekly exercise. (The five red LEDs will flash one
at a time in GTS mode.)
Do NOT connect battery voltage, utility voltage
!
(N1/N2) or load voltage (T1/T2) to either the
178 or the 183 2-Wire start terminals as this will
damage the generator control board.
• The generator control board will NOT activate the
transfer output.
The generator control board WILL monitor all engine
conditions and shut down on all the faults listed in
this document.
In order for the generator battery charging function to
work, it is necessary to provide a 5 amp fused 240Vac
utility source connection from the transfer switch
main N1 and N2 terminals to the generator control
panel N1 and N2 terminals (See Figure 2.4).
For the W Type transfer switch to control utility volt-
age sensing, weekly exercising and load transferring,
suitable wiring must also be connected from the
transfer switch 178 and 183, 2-Wire Start terminals
to the corresponding generator 178 and 183 2-Wire
Figure 2.4 - Connection Diagram (GTS Mode)
FROM UTILITY
TO LOAD
FEEDER CIRCUITS
MAIN LINE
CIRCUIT
BREAKER
OR FUSE
LOAD
DISTRIBUTION
PANEL
N1 N2
FUSE
FUSE
N1
N2
T1
T2
GENERATOR
W-TYPE
TRANSFER
SWITCH
194
23
178
183
178
183
N2 N1
E1 E2
E1 E2
12
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Section 2 — Installation
Liquid-cooled 15, 20 and 25 kW Generators
Transfer Switch terminals N1 and N2 (also called
Utility 1 and Utility 2) are the input utility AC power
connections to the Transfer Switch. Transfer Switch
terminals T1 and T2 (also called Load 1 and Load 2)
are the transfer switch AC output power terminals
that go to the load circuit distribution panel. Transfer
Switch terminals E1 and E2 are the AC power termi-
nals that come from the generator's main alternator.
Battery electrolyte fluid is an extremely corro-
!
sive sulfuric acid solution that can cause severe
burns. Do not permit fluid to contact eyes, skin,
clothing, painted surfaces, etc. Wear protective
goggles, protective clothing and gloves when
handling a battery. If fluid is spilled, flush the
affected area immediately with clear water.
When in GTS mode, the control board will respond
as follows based on the generator AUTO/OFF/MANU-
AL switch position.
Do not dispose of the battery in a fire. The bat-
tery is capable of exploding.
OFF — The generator will not start and run in this
Do not open or mutilate the battery. Released
electrolyte can be toxic and harmful to the skin
and eyes.
position
!
MANUAL — The generator control board will start
and run the generator whenever the switch is in the
manual position.
The battery represents a risk of high short cir-
cuit current. When working on the battery,
always remove watches, rings or other metal
objects, and only use tools that have insulated
handles.
AUTO — The generator control board will monitor
the 2-Wire start circuit (terminals 178 and 183 in the
generator control panel). When a 2-Wire start signal
is issued by the W type engineered transfer switch,
via a relay contact closure that connects wire 178 to
wire 183, the generator control board will immedi-
ately start and run the generator. When the 2-Wire
start signal is removed the control board will imme-
diately stop the generator.
2.11.1 VENTED BATTERIES
‹
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
conductive and corrosive. The following proce-
dures are to be observed:
!
2.11 BATTERY INSTALLATION
DANGER
• Wear full eye protection and protective clothing,
• Where electrolyte contacts the skin, wash it off
immediately with water,
• Where electrolyte contacts the eyes, flush thor-
oughly and immediately with water and seek med-
ical attention, and
• Spilled electrolyte is to be washed down with an
acid-neutralizing agent. A common practice is to
use a solution of one pound (500 grams) bicarbon-
ate of soda to one gallon (4 liters) of water. The
bicarbonate of soda solution is to be added until
the evidence of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water and the
area dried.
Standby generators installed with automatic
transfer switches will crank and start automati-
!
cally when NORMAL (UTILITY) source voltage is
removed or is below an acceptable preset level.
To prevent such automatic start-up and possible
injury to personnel, do not connect battery
cables until certain that normal source voltage at
the transfer switch is correct; the generator main
line circuit breaker is switched to OFF; the
AUTO/OFF/MANUAL switch on the control con-
sole is switched to OFF; the 15A and 5A fuses
have been removed from the control console;
utility fed supply to battery charger (terminals
N1 and N2) is removed; and the system is ready
to be placed into operation. Ensure that the 5A
and 15A fuses in the control panel are removed
when connecting or disconnecting battery cables.
Lead acid batteries present a risk of fire
because they generate hydrogen gas. The fol-
lowing procedure are to be followed:
• DO NOT SMOKE when near batteries,
Storage batteries give off explosive hydrogen
gas. This gas can form an explosive mixture
around the battery for several hours after
charging. The slightest spark can ignite the gas
and cause an explosion. Such an explosion can
shatter the battery and cause blindness or
other injury. Any area that houses a storage
battery must be properly ventilated. Do not
allow smoking, open flame, sparks or any spark
producing tools or equipment near the battery.
• DO NOT cause flame or spark in battery area, and
• Discharge static electricity from body before touch-
ing batteries by first touching a grounded metal
surface.
Servicing of batteries is to be performed or super-
vised by personnel knowledgeable of batteries and
the required precautions. Keep unauthorized person-
nel away from batteries.
13
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Section 2 — Installation
Liquid-cooled 15, 20 and 25 kW Generators
The recommended battery is Group 26, 12VDC, 550
‹
2.12.3 FUEL SYSTEM
CCA/75 AH minimum. All batteries must be at 100
percent state-of-charge before they are installed on
the generator.
Make sure the fuel supply system to the generator (a)
delivers the correct fuel at the correct pressure and
volume and, (b) is properly purged and leak tested
according to code. No fuel leakage is permitted.
When using maintenance-free batteries, it is not nec-
essary to check the specific gravity or electrolyte level.
Have these procedures performed at the intervals
specified in Section 4, “Maintenance.” A negative
ground system is used. Battery connections are
shown on the wiring diagrams. Make sure all batter-
ies are correctly connected and terminals are tight.
Observe battery polarity when connecting batteries to
the generator set.
‹
2.12.4 GENERATOR SET LUBRICATION
Check the engine crankcase oil level before operating
and add oil to the proper level – the dipstick “FULL”
mark. Never operate the engine with the oil level
below the dipstick “ADD” mark. See “Specifications”
and “Engine Oil Recommendations”.
NOTE:
NOTE:
Damage will result if the battery connections are
This engine is shipped from the manufacturer
with 15W-40 oil. This oil should be changed after
30 hours of operation.
made in reverse.
2.12 PREPARATION BEFORE START-UP
The instructions in this section assume that the
standby generator has been properly installed, serv-
iced, tested, adjusted and otherwise prepared for use
by a competent, qualified installation contractor. Be
sure to read the “Safety Rules” on pages 2 and 3, as
well as all other safety information in this manual,
before attempting to operate this (and related) equip-
ment.
‹
2.12.5 ENGINE COOLANT
Have the engine cooling system properly filled with
the recommended coolant mixture. Check the system
for leaks and other problems. See “Specifications”
and “Coolant”.
‹
2.12.6 BELT TENSION
Check the engine fan belt tension and condition prior
to placing the unit into service and at recommended
intervals. Belt tension is correct when a force of
approximately 22 pounds (10 kg), applied midway
between pulleys, deflects the belt about 3/8- to 5/8-
inches (10 to 16 mm).
2.12.1 PRIOR TO INITIAL START-UP
‹
Prior to initially starting the generator, it must
be properly prepared for use. Any attempt to
crank or start the engine before it has been
properly serviced with the recommended types
and quantities of engine fluids (oil, coolant,
fuel, etc.) may result in an engine failure.
!
‹
2.12.7 ELECTRICAL SYSTEM
Make sure the generator is properly connected to an
approved earth ground and/or ground rod.
Before starting the generator for the first time, the
installer must complete the following procedures. For
follow-up maintenance information and/or service
intervals, please refer to Section 4, “Maintenance.”
Make sure the generator battery is fully charged,
properly installed and interconnected, and ready for
use.
Check to ensure that there are no loose electrical con-
nections. Restrain any loose wires to keep them clear
of any moving generator set components.
‹
2.12.2 TRANSFER SWITCH
If this generator is used to supply power to any elec-
trical system normally powered by an electric utility,
the National Electrical Code requires that a transfer
switch be installed. The transfer switch prevents elec-
trical backfeed between two different electrical sys-
tems, (for additional information, see the applicable
transfer switch manual for this unit). The transfer
switch, as well as the generator and other standby
components, must be properly located and mounted
in strict compliance with applicable codes, standards
and regulations.
14
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Section 3 - Operation
Liquid-cooled 15, 20 and 25 kW Generators
See Section 1.7 for further explanation of engine pro-
tection functions.
3.1 CONTROL CONSOLE
COMPONENTS
The components of a home standby generator control
console (Figure 3.1) are as follows:
3.1.3 15 AMP FUSE
‹
This fuse protects the control console’s DC control
circuit against electrical overload and is located
inside the control panel. If the fuse has melted open
because of an overload, engine cranking and startup
cannot occur. If the fuse needs to be replaced, use
only an identical 15-amp replacement fuse (type
ATO).
Figure 3.1 - Generator Control Console
OVER CRANK
CAUTION
OVER SPEED
LOW COOL. LEVEL
HI COOL. TEMP.
LOW OIL PRESS.
RISK OF ELECTRICAL SHOCK. DO NOT REMOVE COVER. NO USER SERVICEABLE
PARTS INSIDE. REFER SERVICING TO QUALIFIED SERVICE PERSONNEL.
LOW BATTERY
SYSTEM READY
LED INDICATORS:
FLASHING GREEN LED
CAUTION
=
NO UTILITY SENSE
5
FLASHING RED LED'S
(IN AUTO MODE ONLY)
SOLID GREEN LED SYSTEM READY, UTILITY POWER ON
RED LED'S INDIVIDUAL FAULT
=
EXERCISER NOT SET
FOR STAND-BY SERVICE CONNECT OUTPUT OF GENERATOR TO SUITABLY RATED
TRANSFER SWITCH IN ACCORDANCE WITH CANADIAN ELECTRICAL CODE, PART I.
=
3.1.4 5 AMP FUSE
=
‹
(SEE OWNER'S MANUAL FOR COMPLETE LED DETAILS)
TENTION: POUR L'ALIMENTATION DE RESERVE, CONNECTER LA SORTIE DE
ATRICE A UN COMMUTATEUR DE CALIBRE APPROPRIE, CONFORMENENT AU
CANADIEN DE L'ECTRICITE, PREMIERE PARTIE.
This fuse protects the battery charger against electri-
cal overload and is located inside the control panel. If
the fuse needs to be replaced, use only an identical 5-
amp replacement fuse (type ATO).
AUTO
OFF
OFF
ON
WARNING
CAN AUTOMATICALLY START AT ANYTIME WITHOUT NOTICE.
Y REMOVE FUSE ON CONTROL PANEL AND NEGATIVE BATTE
SERVICING.
SET
EXERCISE
TIME
MANUAL
WARNING
TO SET EXERCISER TIME
1) PLACE AUTO/OFF/MANUAL SWITCH TO AUTO POSITION.
NOTE:
THIS EMERGENCY POWER SYSTEM IS DESIGNED EXCLUSIVELY FOR
OUTDOOR INSTALLATION ONLY!
2) HOLD "SET EXERCISE TIME" SWITCH IN "ON" POSITION FOR THREE SECONDS
AND RELEASE. (SEE OWNER'S MANUAL FOR COMPLETE DETAILS)
THE EXERCISER IS NOW SET. ALL FIVE RED LED'S WILL FLASH FOR 10 SECONDS
THEN THE UNIT WILL START, RUN THROUGH THE EXERCISE CYCLE AND SHUTDOWN.
This fuse will not remove the + battery input
power from the PCB when it opens. This means
the exercise timer will not be reset.
USE OF SYNTHETIC OIL IS RECOMMENDED
0F2629
0E7193
3.1.1 AUTO/OFF/MANUAL SWITCH
Use this three-position switch as follows:
‹
3.1.5 SET EXERCISE TIME SWITCH
‹
This switch allows programming the generator to
start and exercise automatically. “See Weekly
Exercise Cycle” (see Figure 3.3 and Section 3.6).
• Set the switch to AUTO for fully automatic opera-
tion. See “Automatic Operation” (Section 3.6).
• Set switch to MANUAL position to crank and start
the generator engine.
• Set switch to OFF position to shut down an oper-
ating engine. With OFF selected, operation will not
be possible.
3.1.6 SYSTEM READY LED
‹
The System Ready LED (green) has two main pur-
poses. First, the LED will be ON when the
AUTO/OFF/MANUAL switch is in the AUTO position,
utility is present, and there are no system alarms.
This ON state indicates the system is fully ready for
automatic operation.
DANGER
With switch set to AUTO, engine can crank and
!
start suddenly without warning. Such automat-
ic start up normally occurs when utility source
voltage drops below a pre-set level. To prevent
possible injury that might be caused by such
sudden starts, set AUTO/OFF/ MANUAL switch
to OFF before working on or around the unit.
Then, place a “DO NOT OPERATE” tag on con-
trol console.
The system ready LED will be OFF when the switch
is in the MANUAL or OFF positions.
The system ready LED is also used to indicate the
presence of utility sensing at the PCB when the switch
is either in the AUTO or MANUAL modes. The LED
will flash at the rate of 1/2 second on, 1/2 second off
if the utility sensing level is below the transfer back
threshold.
3.1.2 FAULT INDICATOR LEDS
‹
This secondary function is only available with DIP
switch two in the OFF position (ATS - automatic
transfer switch application).
(SEE CHART ON PAGE 16)
These red LEDs turn ON when one or more of the fol-
lowing engine faults occurs and the engine shuts
down.
3.2 MANUAL TRANSFER AND
• Low Oil Pressure
• Overcrank
• Low Battery
• Overspeed/Engine Speed Signal Fault
• High Coolant Temperature/Low Coolant Level
START-UP
To transfer electrical loads to the Standby (EMER-
GENCY) power source side and start the engine man-
ually, refer to the Owner’s Manual of the particular
transfer switch.
15
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Section 3 - Operation
Liquid-cooled 15, 20 and 25 kW Generators
Condition
System
Ready (Green)
Low
Bat (Red)
Low
Oil (Red)
High
Temp (Red)
Over
Speed (Red)
Over
Crank (Red)
Switch Position
Manual
Auto
Off
Generator Switch is
in the OFF Mode.
OFF
ON
OFF
X
X
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
O
System Ready for
Automatic Start
X
X
O
Generator Switch is
in the MANUAL Mode
OFF
OFF
OFF
OFF
O
O
O
Weekly Exerciser
is not set
Flashing
Flashing
Flashing
Flashing
Flashing
O
O
O
O
(-----------------------------------1 sec rate---------------------------------------)
Battery Voltage <12.2V
for >1 minute
X
ON
(Non-latching)
Battery Voltage <6V
OFF
OFF
ON
X
O
O
O
O
Unit Shutdown due
to Low Oil Pressure
ON
Unit Shutdown due to
High Coolant Temperature
or Low Coolant Level
OFF
OFF
OFF
X
X
X
X
ON
O
O
O
O
O
O
O
O
Unit Shutdown due
to Engine Overspeed
ON
Unit Failed to Start
during it’s Crank Cycle
ON
Utility Voltage is
<45% of Nominal
Flashing
1 sec rate
Engine Speed Signal Fault
OFF
OFF
X
X
Flashing
O
O
O
O
Control Board is
in GTS Mode
The five RED LED’s will turn on one at a time
O
X = indicates that the LED can be ON or OFF depending on the operating conditions.
Figure 3.2 — Control Board Dip Switch Location
3.3 ENGINE GOVERNOR GAIN
ADJUSTMENTS
Engine speed governing is also controlled by the
engine control board. The engine governor has been
set by the factory during final testing of the generator
and should not be adjusted.
If, however, adjustments are necessary, the following
procedure should be followed (Figure 3.2 and Section
3.7):
1. Move DIP switch 8 to the TEST mode (OFF posi-
tion).
2. Set all three potentiometers (pots) fully counter-
clockwise.
3. Under no load condition, increase the GAIN pot
as much as possible without causing instability.
4. Apply 1/4, 1/2, 3/4 and full load to the unit.
Decrease the GAIN pot if there is instability at any
load point.
5. Under full load condition, increase the stability
pot until the unit returns to 60 Hertz (or 50 Hertz
in 50 Hertz applications).
16
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Section 3 - Operation
Liquid-cooled 15, 20 and 25 kW Generators
6. Reduce load to 3/4, 1/2, 1/4 and no load.
Decrease the stability pot if there is instability at
any load point.
7. Adjust differential pot to make the recovery to
load changes even faster and minimize load
change undershoot and overshoot. If it is set too
high, it may introduce oscillations at some load.
It can be set to zero (full CCW) if a small amount
causes oscillations at some load.
1. Place the AUTO/OFF/MANUAL switch in the
AUTO position (Figure 3.3).
2. Press and hold the “Set Exercise Time” switch for
five seconds, then release.
At this time all five red LEDs will flash for approxi-
mately 10 seconds, then the engine will start and run
for it’s 12 minute exercise period, then shut down.
The generator will now start and run each week at the
same time.
8. Leave DIP switch 8 in TEST mode.
Figure 3.3 - “Set Exercise Time” Switch
3.4 MANUAL RETRANSFER AND
RED LED'S = INDIVIDUAL FAULT
SHUTDOWN
(SEE OWNER'S MANUAL FOR COMPLETE LED DETAILS)
When utility power source voltage has been restored,
electrical loads may be transferred back to that
source and the generator can be shut down as fol-
lows:
AUTO
OFF
OFF
ON
• Verify that utility power supply voltage to the trans-
fer switch has been positively turned Off, using
whatever means provided (such as utility main line
circuit breaker).
SET
EXERCISE
TIME
MANUAL
• Set the generator’s main circuit breaker to its Off
or Open position.
TO SET EXERCISER TIME
• Let the generator engine run at no-load for a few
minutes, to stabilize internal unit temperatures.
• On the generator console, set the Auto/Off/ Manual
switch to Off. Wait for engine to come to a complete
stop.
1) PLACE AUTO/OFF/MANUAL SWITCH TO AUTO POSITION.
2) HOLD "SET EXERCISE TIME" SWITCH IN "ON" POSITION FOR THREE SECONDS
AND RELEASE. (SEE OWNER'S MANUAL FOR COMPLETE DETAILS)
THE EXERCISER IS NOW SET. ALL FIVE RED LED'S WILL FLASH FOR 10 SECONDS
THEN THE UNIT WILL START, RUN THROUGH THE EXERCISE CYCLE AND SHUTDOWN.
0
• For transfer to utility position, refer to the Owner’s
Manual of the particular transfer switch.
• Turn on the utility power supply to the transfer
switch, using whatever means provided (such as a
utility main line circuit breaker). The utility power
source now powers the loads.
If DC power to the control board is lost, the weekly
exercise setting will be lost. This is indicated by all
five red LEDs continually flashing. In this state the
generator will still start and run in MANUAL mode,
or automatically start and run if utility is lost while in
AUTO mode, but it will not perform a weekly exercise
cycle.
3.5 AUTOMATIC OPERATION
To set the system for fully automatic operation, pro-
ceed as follows:
If a failure occurs while running in this mode, the five
red LEDs will stop flashing, the individual fault LED
will turn on and the engine will shut down. Once the
AUTO/OFF/MANUAL switch has been switched to
OFF, the individual fault LED will turn OFF and the
five red LEDs will begin flashing to show exercise has
still not been set.
• Check that load circuits are connected to the
utility power supply.
• Set the AUTO/OFF/MANUAL switch to its AUTO
position.
• Set the generator main circuit breaker to its ON or
CLOSED position.
3.6 WEEKLY EXERCISE CYCLE
The engine control board will start and run the gen-
erator once every seven days for approximately 12
minutes. If utility should fail during this exercise
period, the engine control board will transfer the load
to the generator output and continue to run until util-
ity returns.
On the day, and at the time of day chosen for the gen-
erator to exercise, set the weekly exercise cycle as fol-
lows:
17
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Section 3 - Operation
Liquid-cooled 15, 20 and 25 kW Generators
3.7 CONTROL BOARD DIP SWITCH
3.8 VOLTAGE REGULATOR
SETTINGS
ADJUSTMENT
Located on the control board is an eight position DIP
switch (see Figure 3.2). The eight different switches,
are used to configure the control board for the spe-
cific engine and governor being used and are pre-set
at the factory.
Four adjustment potentiometers are provided on the
voltage regulator installed in the control panel (Figure
3.4). These are (a) voltage adjust, (b) gain, (c) stabili-
ty and (d) underfrequency adjust. The voltage regula-
tor potentiometers have been factory set and
SHOULD NOT be adjusted. If however, adjustments
are necessary, contact the local Dealer to implement
the following procedure.
If the DIP switch settings are not set correctly,
the generator may not start or operate correct-
!
ly.
High voltage is present inside the control panel
during this procedure.
1. Disconnect all electrical loads from the generator
(initial adjustments are done under no-load con-
ditions).
240 VAC can be present within the control
panel.
If it is necessary to select an alternate switch position,
move the AUTO/OFF/MANUAL switch to the OFF
position. Remove the 15 amp fuse in the generator
control panel. Move the DIP switch position that
needs to be changed to its new position. Wait five sec-
onds, then re-install the 15 amp fuse.
Figure 3.4 — Voltage Regulator
The ON position is marked on the switch and is
shown in Figure 3.2.
Switch Position 1 — Selects the generator alternator
output frequency and is factory pre-set for 60 Hz.
Switch Position 2 — Selects the type of transfer
switch and is factory pre-set for an automatic trans-
fer switch (ATS).
Switch Position 3 — Selects the type of governor
control used, and is factory pre-set for stepper motor
operation.
Switch Position 4 — Selects the type of fuel being
used and is factory pre-set for natural gas (NG).
Switch Position 5 — Selects the engine displacement
and is factory pre-set for a 2.5 liter (2.5L) engine.
2. Connect an accurate AC voltmeter and AC fre-
quency meter to the generator’s AC output leads.
3. On the voltage regulator, set the potentiometers
as follows:
Switch Position 6 — Selects the number of engine
cylinders and is factory pre-set for four cylinders.
Switch Position 7 — Selects the direction of rotation
of the governor stepper motor and is factory pre-set
for CCW rotation (rotation is observed looking at the
stepper shaft as it moves from closed throttle to open
throttle).
A. Turn the Voltage Adjust pot fully counterclock-
wise (CCW).
B. Set the GAIN pot to its centered (mid) position.
C. Set the STABILITY pot to its centered (mid)
position.
Switch Position 8 — Selects whether the control is
in the Normal Mode of operation or Test Mode. In the
Normal Mode of operation, pre-determined governor
gains are used and the gain trimpots on the control
board (Gain, Stability, and Differential) are not active
and have no effect on the gains. In Test Mode the gain
trimpots are active and can be adjusted. See Section
3.3.
D. DO NOT adjust the UNDERFREQUENCY
ADJUST pot.
4. Start the engine. Let it stabilize and warm up at
no-load.
5. Verify that the three voltage regulator’s LED’s are
ON.
6. Check the reading on the AC frequency meter.
18
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Section 4 — Maintenance
Liquid-cooled 15, 20 and 25 kW Generators
7. Turn the voltage regulator’s VOLTAGE ADJUST
pot to obtain a line-to-line voltage of:
A. 240 VAC if the generator has been configured for
60 Hertz operation.
D. FIRST 100 OPERATING HOURS
1. Change engine oil and oil filter. After initial
change, service engine oil and filter at 150 oper-
ating hours or six months, whichever comes first.
2. Retorque cylinder head (see torque specs).
3. Retorque intake and exhaust manifold (see
torque specs).
B. 200 VAC if the generator has been configured for
50 Hertz operation.
8. If the RED REGULATOR LED is flashing, adjust
the STABILITY pot in either direction until the
flashing stops.
E. EVERY 500 OPERATING HOURS
1. Service air cleaner.
2. Check starter.
9. Apply an electrical load and check the engine
speed recovery.
A. Adjust the UNDERFEQUENCY ADJUST pot
CCW to reduce load during engine recovery.
B. For flat regulation (no voltage decrease as fre-
quency drops) set the UNDERFREQUENCY
ADJUST pot fully CW.
C. To obtain a constant voltage regulation as fre-
quency decreases, set the UNDERFREQUENCY
ADJUST pot fully CCW.
10. With the electrical load still applied, check the
REGULATOR LED for flashing. If the LED is
flashing, adjust the STABILITY pot until the flash-
ing stops.
11. If better response is needed, adjust the GAIN pot
clockwise (CW) as needed. Then (if needed) cor-
rect for stability by adjusting the STABILITY pot.
12. Turn OFF the electrical loads.
3. Check engine DC alternator.
F. EVERY 800 OPERATING HOURS
1. Retorque cylinder head (see torque specs).
2. Retorque intake and exhaust manifold (see
torque specs).
3. Check engine compression.
4. Check valve clearance.
4.2 EXHAUST MANIFOLD PROCEDURE
1. If necessary, clean gasket surfaces on exhaust
manifold and cylinder head.
2. Install exhaust manifold and exhaust manifold
gasket.
3. Install fasteners.
13. Verify that all the voltage regulator’s LED’s are
NOTE:
ON.
Exhaust manifold fasteners must be tightened in
two stages.
14. Turn OFF the generator.
4.1 MAINTENANCE PERFORMED BY
AUTHORIZED SERVICE FACILITIES
4. Tighten fasteners to 20-30 N-m (15-22 lb-ft) dur-
ing the first stage.
5. Retighten fasteners to 60-80 N-m (44-59 lb-ft)
during the second stage.
A. EVERY THREE MONTHS
1. Check battery condition.
2. Inspect and test fuel system.
3. Check transfer switch.
4. Inspect exhaust system.
5. Check engine ignition system.
6. Check fan belts.
4.3 INTAKE MANIFOLD PROCEDURE
1. Clean and inspect the mounting surfaces of the
intake manifold and the cylinder head. Both sur-
faces must be clean and flat (Figure 4.1).
2. Clean and lightly oil the manifold bolt/stud
threads.
Figure 4.1 — Intake Manifold Installation
B. ONCE EVERY SIX MONTHS
1. Test Engine Safety Devices (low oil pressure, low
coolant level, high coolant temperature).
C. ONCE ANNUALLY
1. Test engine governor; adjust or repair, if needed.
2. Clean, inspect generator.
3. Flush cooling system.
19
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Section 4 — Maintenance
Liquid-cooled 15, 20 and 25 kW Generators
3. Install a new lower intake manifold gasket.
4. Position the lower intake manifold to the cylinder
head.
The exhaust system parts from this product get
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.
5. Install retaining bolts/studs finger tight.
6. Tighten all bolts/studs to specifications in the
tightening sequence shown:
• First pass = 7=10 N-m (5-7 lb-ft).
• Final pass = 26-38 N-m (19-28 lb-ft).
4.6 OVERLOAD PROTECTION FOR
4.4 CYLINDER HEAD PROCEDURE
1. Position head gasket on the block (Figure 4.2).
2. Position cylinder head to cylinder block.
3. Install 10 cylinder head bolts in numerical
sequence. Tighten to 70 N-m (52 lb-ft) in
sequence. Retighten to 70 N-m (52 lb-ft) in
sequence. Then turn all head bolts an additional
90 - 100 degrees in sequence.
ENGINE DC ELECTRICAL SYSTEM
Engine cranking, start up and running are controlled
by a solid state Engine Controller circuit board.
Battery voltage is delivered to that circuit board via a
15 amp fuse. These overcurrent protection devices
will open if the circuit is overloaded.
Figure 4.2 — Cylinder Head Installation
If a circuit breaker opens or a fuse element
!
melts, find the cause of the overload before
resetting the circuit breaker or replacing the
fuse.
4.7 CHECKING FLUID LEVELS
4.7.1 CHECK ENGINE OIL
‹
Check engine crankcase oil level (Figure 4.3) at least
every 20 hours of operation, or prior to use.
• Remove oil dipstick and wipe dry with a clean,
lint-free cloth.
• Install oil dipstick, then remove again.
• Oil should be between FULL and ADD marks.
• If oil level is below the dipstick ADD mark, remove
oil fill cap. Add the recommended oil to bring oil
level up to the FULL mark. DO NOT FILL ABOVE
THE “FULL” MARK. See “Engine Oil Recommen-
dations” for recommended oils.
Figure 4.3 - Oil Dipstick and Oil Fill Cap
Engine
Air Cleaner
Oil Fill Cap
Oil Dipstick
4.5 COOLING SYSTEM
Air intake and outlet openings in the generator com-
partment must be open and unobstructed for contin-
ued proper operation. This includes such obstruc-
tions as high grass, weeds, brush, leaves and snow.
Oil
Filter
Without sufficient cooling and ventilating air flow, the
engine/generator quickly overheats, which causes it
to shut down. (See the installation diagram.)
20
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Section 4 — Maintenance
Liquid-cooled 15, 20 and 25 kW Generators
4.7.2 BATTERY FLUID
4.8.6 PERFORM VISUAL INSPECTION
‹
‹
Check battery electrolyte fluid based on the
Maintenance Schedule. Fluid should cover separa-
tors in all battery cells. If fluid level is low, add dis-
tilled water to cover tops of separators. DO NOT USE
TAP WATER IN BATTERY.
Complete a thorough visual inspection of the entire
engine-generator monthly. Look for obvious damage,
loose, missing or corroded nuts, bolts and other fas-
teners. Look for fuel, oil or coolant leaks.
4.8.7 INSPECT EXHAUST SYSTEM
‹
4.7.3 ENGINE COOLANT
Check coolant level in coolant recovery bottle. See
Specifications.
‹
Inspect the exhaust system at least once every three
months. Check all exhaust system pipes, mufflers,
clamps, etc. for condition, tightness, leaks, security,
damage.
• Add recommended coolant mixture as necessary.
• Periodically remove radiator pressure cap (only
when engine has cooled down) to make sure the
coolant recovery system is functioning properly.
Coolant should be at bottom of radiator filler neck.
If coolant level is low, inspect gasket in radiator
pressure cap. Replace cap, if necessary. To have
pressure cap tested, contact an Authorized Service
Dealer. Inspect cooling system and coolant recov-
ery system for leaks.
4.8.8 CHECK FAN BELT
• Inspect fan belts every three months. Replace any
damaged, deteriorated, worn or otherwise defec-
tive belt.
• Check fan belt tension. Thumb pressure, exerted
midway between pulleys, should deflect about 3/8
to 5/8 of an inch. Adjust belt tension as required.
‹
4.8.9 INSPECT ENGINE GOVERNOR
Visually inspect electronic governor.
‹
4.8 MAINTENANCE OWNER/
OPERATOR CAN PERFORM
DANGER
4.8.1 CHECK ENGINE OIL LEVEL
‹
Do not attempt to adjust the governor. Only
qualified service facilities should adjust the
Refer to “Checking Fluid Levels”.
!
governor. Excessively high operating speeds are
dangerous and increase the risk of personal
injury. Low speeds impose a heavy load on the
engine when adequate engine power is not
available and may shorten engine life. Correct
rated frequency and voltage are supplied only
at the proper governed speed. Some connected
electrical load devices may be damaged by
incorrect frequency and/or voltage. Only quali-
fied service technicians should adjust the gov-
erned speed.
4.8.2 CHECK BATTERY
• See “Checking Fluid Levels”.
• Check battery cables for condition, tightness, cor-
rosion or damage. Clean, tighten or replace as
necessary.
‹
4.8.3 EXERCISE SYSTEM
Start the generator engine at least once every seven
days and let it run at least 12 minutes. See “Weekly
Exercise Cycle”.
‹
4.8.10 CHANGING ENGINE OIL
Refer to maintenance performed by authorized service
facilities for engine oil and filter change frequencies.
‹
4.8.4 INSPECT COOLING SYSTEM
• Inspect engine cooling system. See “Maintenance
Schedule”.
‹
Drain the oil while the engine is still warm from run-
ning. This means warm up the engine, shut it down
and drain immediately as follows:
• Check hoses for damage, deterioration, leaks, etc.
Correct any discrepancies found.
• Check hose clamps for tightness.
1. Remove OIL DRAIN HOSE from its retaining clip.
2. Loosen and remove OIL DRAIN HOSE CAP. Drain
oil completely into suitable container.
3. When all oil has drained, install and tighten OIL
DRAIN HOSE CAP, and re-install into its retaining
clip.
4.8.5 CHECK ENGINE COOLANT LEVEL
See “Checking Fluid Levels”.
‹
4. Turn OIL FILTER (Figure 4.1) counterclockwise
and remove. Properly dispose of old filter.
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Section 4 — Maintenance
Liquid-cooled 15, 20 and 25 kW Generators
5. Apply light coating of new engine oil to seal of new
4.8.13 COOLANT CHANGE
‹
oil filter. Install FILTER and tighten by hand only.
Every year, have an Authorized Service Facility drain,
flush and refill the cooling system. See
“Specifications” for cooling system recommenda-
tions.
DO NOT OVER TIGHTEN.
6. Remove OIL FILL CAP. Add recommended oil (see
SPECIFICATIONS). DO NOT FILL ABOVE THE
DIPSTICK “FULL” MARK. Crankcase oil capacity
is 4.0 U.S. quarts (3.8 liters).
4.9 MISCELLANEOUS MAINTENANCE
4.9.1 CLEANING THE GENERATOR
‹
After refilling the crankcase with oil, always
check oil level on dipstick. NEVER OPERATE
ENGINE WITH OIL BELOW THE DIPSTICK “ADD”
MARK.
Keep the generator as clean and as dry as possible.
Dirt and moisture that accumulates on internal gen-
erator windings have an adverse effect on insulation
resistance.
!
7. Start engine and check for oil leaks.
Periodically clean generator exterior surfaces. A soft
brush may be used to loosen caked on dirt. Use a
vacuum system or dry, low pressure air to remove
any accumulations of dirt. The generator is housed
inside an all-weather enclosure, clean the enclosure
with a soft, damp cloth or sponge and water.
4.8.11 CHANGING THE ENGINE AIR CLEANER
‹
To replace the engine air cleaner, (part number
059402), simply remove the air cleaner cover and
replace the air filter making sure it is positioned
properly before reattaching the cover (Figure 4.1).
Once each year have the generator cleaned and
inspected by an Authorized Service Dealer. That deal-
er will use dry, low pressure air to clean internal
windings. Parts inside the control console should be
cleaned and inspected at this time as well.
See the “Service Schedule,” for air cleaner mainte-
nance.
4.8.12 SPARK PLUGS
‹
Reset the spark plug gap or replace the spark plugs
as necessary (Figure 4.4). See Section 6.
Finally, have the insulation resistance of stator and
rotor windings checked. If insulation resistances are
excessively low, the generator may require drying.
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 com-
mercial 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
6, for recommended inspection.
3. Check the spark plug gap using a wire feeler
gauge. Adjust the gap to 1.07-1.17 mm (0.042-
0.046 inch) by carefully bending the ground elec-
trode (Figure 4.2).
4.9.2 BATTERY
‹
All lead-acid storage batteries discharge when not in
use. Refer to specific instructions and warnings that
accompany the battery. If such information is not
available, observe the following precautions when
handling a battery:
• DO NOT use jumper cables and a booster battery
to crank or start the generator engine.
• DO NOT recharge a weak battery while it is
installed in the generator. Remove battery from
generator and recharge in a well-ventilated area,
away from fuel vapors, sparks, heat or flames.
• Battery electrolyte fluid is an extremely caustic
sulfuric solution that can cause severe burns. DO
NOT permit fluid to contact eyes, skin, clothing,
painted surfaces, wiring insulation, etc. If any bat-
tery fluid is spilled, flush the affected area with
clear water immediately.
Figure 4.4 – Setting the Spark Plug Gap
SET PLUG GAP AT 1.07 - 1.17 mm
(0.042 - 0.046 inch)
• Always wear safety glasses, rubber apron and
gloves when handling a battery.
• Batteries give off explosive hydrogen gas while
charging. The gas can form an explosive mixture
around the battery for several hours after charging.
Any spark, heat or flames can ignite the gas and
cause an explosion which can shatter the battery,
causing blindness or other serious injury.
22
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Section 4 — Maintenance
Liquid-cooled 15, 20 and 25 kW Generators
4.9.3 BATTERY MAINTENANCE
‹
The battery should be inspected per Section 4.7,
Scheduled Maintenance. The following procedure
should be followed for inspection:
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.
1. Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.
2. Check the battery fluid level of unsealed batteries
and, if necessary, fill with DISTILLED WATER
ONLY. Do not use tap water in batteries.
3. Have the state of charge and condition checked.
This should be done with an automotive-type bat-
tery hydrometer.
Be sure the utility power supply to the battery
charger is turned off, or sparking may occur at
the battery posts as the cables are attached
and cause an explosion.
4.9.4 BATTERY REPLACEMENT
‹
DANGER
When replacing batteries, use the same number and
the type of battery that follows:
Storage batteries give off explosive hydrogen
gas. This gas can form an explosive mixture
around the battery for several hours after
charging. The slightest spark can ignite the gas
and cause an explosion. Such an explosion can
shatter the battery and cause blindness or
other injury. Any area that houses a storage
battery must be properly ventilated. Do not
allow smoking, open flame, sparks or any spark
producing tools or equipment near the battery.
BCI Group No.
CCA
525 @ 0 deg. F
26-60R
NOTE:
The BCI number should be located directly
on the battery.
PERIODIC REPLACEMENT PARTS
Battery electrolyte fluid is an extremely corro-
sive sulfuric acid solution that can cause severe
burns. Do not permit fluid to contact eyes, skin,
clothing, painted surfaces, etc. Wear protective
goggles, protective clothing and gloves when
handling a battery. If fluid is spilled, flush the
affected area immediately with clear water.
Part Name
Part Number
!
Oil Filter
Motorcraft FL-400-S (supplied with engine)
Radiator Cap
Air Cleaner
Spark Plug
Battery
# 046627
# 059402
Motorcraft AWSF-52-C (supplied with engine)
# 077483
Do not use any jumper cables or booster bat-
tery to crank and start the generator engine. If
!
the battery has completely discharged, remove
it from the generator for recharging.
23
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Section 4 — Maintenance
Liquid-cooled 15, 20 and 25 kW Generators
4.10 SCHEDULED MAINTENANCE
The following is a recommended maintenance schedule for small standby and residential generator sets. The
established intervals in the schedule are the maximum recommended when the unit is used in an average service
application. They will need to be decreased (performed more frequently) if the unit is used in a severe application.
Use calendar time from the previous maintenance interval to determine the next required maintenance interval.
Service Maintenance Interval Information:
The various service maintenance intervals are designated by interval numbers as follows:
1 An early inspection of the generator set to insure it is ready to operate when required and to identify any poten-
tial problem areas.
Performed monthly this 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 5 amp and 15 amp control panel fuses.
Turn off the battery charger (turn OFF utility supply to ATS).
Remove the negative battery cable.
The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condi-
tion from burning out sensitive control panel components and circuits.
Following all maintenance, reverse these steps to assure the unit is returned to standby setup for normal
operation when required.
2 A break-in service inspection of the generator set to insure it is ready to operate and carry the load when
required, and to identify any potential problem areas.
Performed ONLY ONCE following the first three months 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 this 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 this 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.
24
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Section 4 — Maintenance
Liquid-cooled 15, 20 and 25 kW Generators
Maintenance
Tasks
Level 1
Recom-
mended
Level 2
Required
Level 3
Required
Level 4
Task
Task
Task
Task
Comp.
Comp. to be done Comp. to be done Comp.
Required
to be done (Date-
monthly Initials)
3 months/
Break-in
(Date-
Initials)
Semi-
annually
(Date-
Initials)
to be done (Date-
Annually
Initials)
1. Disable the unit from
operating per the first page
warning.
2. Check the engine oil level.
Adjust as necessary.
3. Check the engine coolant
level. Adjust as necessary.
4. Check the engine coolant
thermal protection level.
Correct as necessary.
5. Check the natural gas
delivery system on gas
engine driven units.
Tighten connections as
necessary.
6. Check the air inlets and
outlets for debris. Clean as
necessary.
7. Check the battery
electrolyte level if
accessible. Adjust as
necessary.
8. Check the battery posts,
cables, and charger for
loose connections,
corrosion, and proper
operation. Correct as
necessary.
9. Check the unit wiring for
loose connections,
corrosion, and damage.
Correct as necessary.
10. Check the engine
accessory drive belts for
wear, weather cracking,
and damage. Replace as
necessary.
11. Visually inspect the unit
looking for leaks, wear or
damage, loose connections
or components, and
corrosion. Correct as
necessary.
12. Test the engine and
transfer switch safety
devices. Correct and/or
adjust as necessary.
25
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Section 4 — Maintenance
Liquid-cooled 15, 20 and 25 kW Generators
Maintenance
Tasks
Level 1
Recom-
mended
Level 2
Required
Level 3
Required
Level 4
Task
Task
Task
Task
Comp.
Comp. to be done Comp. to be done Comp.
Required
to be done (Date-
monthly Initials)
3 months/
Break-in
(Date-
Initials)
Semi-
annually
(Date-
Initials)
to be done (Date-
Annually Initials)
13. 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.
14. 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.
15. Change the engine oil.
16. Replace the engine oil
filter(s).
17. Replace the engine air
filter(s).
18. Replace the engine fuel
filter(s) on diesel engine
driven units and re-prime
the fuel system.
19. Check the engine spark
plugs on gas engine driven
units. Clean and re-gap or
replace as necessary.
20. Perform a 5 minute no-load
operational run of the unit
looking for any post service
problems.
21. Return the unit to standby
setup for operation when
required.
26
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Section 5 — Troubleshooting
Liquid-cooled 15, 20 and 25 kW Generators
TROUBLESHOOTING POINTS
PROBLEM
CAUSE
CORRECTION
Engine won’t crank.
1. 15 amp fuse blown.
1. Replace fuse.
2. Loose or corroded or defective
battery cables.
2. Tighten, clean or replace
battery cables as necessary.
3. Defective starter contactor.
4. Defective starter motor.
5. Dead or Defective Battery.
6. 5 amp fuse blown.
3. Replace contactor.
4. Replace starter motor.
5. Remove, change or replace battery.
6. Replace fuse.
Engine cranks but won't start
1. Out of fuel.
2. Fuel solenoid (FS) is defective
3. Open Wire #14A from Engine Control
circuit board.
1. Replenish fuel.
2. Replace solenoid.
3. Reconnect wire.
4. Spark plugs defective.
4. Clean, regap or replace plugs.
1. Clean or replace as needed.
Engine starts hard, runs rough.
Engine starts then shuts down.
1. Flame arrestor (air cleaner) plugged or
damaged.
2. Plugged fuel line.
3. Defective spark plugs.
2. Unclog fuel line.
3. Clean, regap or replace plugs.
1. Engine oil level is low.
2. Engine is overheated.
3. Defective Low Oil Pressure Switch
4. Defective Coolant Temperature Switch
5. Defective Control Module circuit board.
6. Coolant Level is Low.
1. Check oil and add oil as needed.
2. Check cooling system for leaks.
3. Replace switch.
4. Replace switch.
5. Replace board.
6. Repair leak - Add coolant.
7. Replace Switch.
7. Defective Low Coolant Level Switch
AUTO/OFF/MANUAL Switch at OFF, 1. Defective AUTO/OFF/MANUAL switch
1. Replace switch.
engine continues to run
2. Open/disconnected wire #15A between
AUTO/OFF/MANUAL switch and Control
Module circuit board.
2. Reconnect/close wire.
3. Defective Control Module circuit board
3. Replace board.
No AC output from generator.
1. Main line circuit breaker open.
2. Circuit breakers & fuses open.
3. Transfer switch set to NORMAL position
4. Generator internal failure.
1. Reset to ON or CLOSED.
2. Reset and replace, if necessary.
3. Set to GENERATOR position.
4. Contact an Authorized Service Dealer.
5. Auto-reset - Wait 5 min. and attempt restart.
5. Thermal circuit breaker open.
27
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Section 6 — Notes
Liquid-cooled 15, 20 and 25 kW Generators
28
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Section 6 — Notes
Liquid-cooled 15, 20 and 25 kW Generators
29
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Section 7 - Electrical Data
Liquid-cooled 15, 20 and 25 kW Generators
Wiring Diagram — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F2183-B
30
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Section 7 - Electrical Data
Liquid-cooled 15, 20 and 25 kW Generators
Wiring Diagram — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F2183-B
31
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Section 7 - Electrical Data
Liquid-cooled 15, 20 and 25 kW Generators
Electrical Schematic — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F2184-B
32
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Section 7 - Electrical Data
Liquid-cooled 15, 20 and 25 kW Generators
Electrical Schematic — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F2184-B
33
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Section 7 - Electrical Data
Liquid-cooled 15, 20 and 25 kW Generators
Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No. 0F1286-B
34
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Section 7 - Electrical Data
Liquid-cooled 15, 20 and 25 kW Generators
Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No. 0F1286-B
35
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Section 7 - Electrical Data
Liquid-cooled 15, 20 and 25 kW Generators
Electrical Schematic — 2.5L (25kW unit) — Drawing No. 0F1287-B
36
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Section 7 - Electrical Data
Liquid-cooled 15, 20 and 25 kW Generators
Electrical Schematic — 2.5L (25kW unit) — Drawing No. 0F1287-B
37
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Section 8 - Exploded Views and Parts Lists
Liquid-cooled 15, 20 and 25 kW Generators
Mounting Base — Drawing No. 0F0104-B
38
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Section 8 - Exploded Views and Parts Lists
Liquid-cooled 15, 20 and 25 kW Generators
Mounting Base — Drawing No. 0F0104-B
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
0F1705
0E8834
0E9911
049813
022097
026850
055414
022473
047411
052860
052251
052257
052252
052259
052891
0536210261
074906
077483
0F0796
025507
060619
046526
022131
021991
038805G
050331
050331A
038804J
045771
022129
027482
075763
0E9748A
0F0795
0C2454
065852
045764
1
1
1
1
4
2
1
4
4
4
4
4
4
4
4
1
1
REF
3
3
1
1
1
1
1
REF
REF
1
REF
REF
1
1
1
3
33
1
SUPPORT BATTERY TRAY
HOLD DOWN BATTERY
ASSEMBLY BATTERY TRAY
NUT HEX M6 X 1.0 G8 YEL CHR
WASHER LOCK M6-1/4
WASHER SHAKEPROOF EXT 1/4 STL
LUG SLDLSS #2-#8 X 17/64 CU
WASHER FLAT 1/4-M6 ZINC
SCREW HHC M6-1.0 X 16 G8.8
NUT FLANGED HEX M12-1.75
DAMPENER VIBRATION 40 BLUE
SPACER .49 X .62 X 1.87 PWDR/ZNC
DAMPENER VIBRATION
WASHER FLAT M12
SCREW HHC M12-1.75 X 80 G8.8
ASSY WIRE #0 12.00"
SCREW HHTT M6-1.0 X 20 BP
BATT 12VDC 75-AH 26 (NOT SHOWN)
BRACKET CONTROL PANEL SUPPORT
WASHER SHAKEPROOF EXT 7/16 STL
SCREW SHC M10-1.50 X 40 G12.9
WASHER LOCK M10
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
WASHER FLAT 3/8-M10 ZINC
EARTH STRAP
CABLE BATT BLK #1 X 41.50
BATTERY POST COVER (BLACK)
BATTERY POST COVER (RED)
CABLE BATT RED #1 X 40.50
NUT HEX M8-1.25 G8 YEL CHR
WASHER LOCK M8-5/16
WASHER SHAKEPROOF EXT 5/16 STL
BOOT BATTERY CABLE
ASSY MTG BASE 2.5L AL ENCL
SUPPORT CONTROL PANEL 2.5L
SCREW THF M6-1 X 16 N WA Z/JS
SPRING CLIP HOLDER .37-.62
SCREW HHTT M4-0.7 X 8 BP
1
39
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Section 8 - Exploded Views and Parts Lists
Liquid-cooled 15, 20 and 25 kW Generators
Enclosure — Drawing No. 0F1645-H
40
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Section 8 - Exploded Views and Parts Lists
Liquid-cooled 15, 20 and 25 kW Generators
Enclosure — Drawing No. 0F1645-H
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
0F0783
0F0781
0F0780
0C2454
0F0779
0E0072AB
0E0072AC
0E0072AD
0E5912
0F0787
1
1
1
34
1
1
1
1
2
1
2
4
1
1
1
13
13
2
4
4
4
1
1
3
8
1
1
2
1
2
1
2
1
1
1
1
1
4
2
2
10
1
1
1
1
1
1
DUCT INTAKE MID AL 2.5L
DUCT DISCHARGE RH AL 2.5L
DUCT DISCHARGE LH AL 2.5L
SCREW TH-FRM M6-1 X 16 N WA Z/JS
SUPPORT RADIATOR 2.5L AL
AI INSULATION SIDE REAR CORNER POST RH
AI INSULATION INTAKE DUCT TOP PANEL
AI INSULATION LH SIDE REAR CORNER POST PANEL (BOTTOM)
DOOR SIDE HSB AL
SUPPORT RH SIDE AL 2.5L
FOAM STRIP 3/4" WIDE X 3/16" THK (40" LG)
WASHER NYLON .257
AI NSULATION LH SIDE REAR CORNER POST PANEL (TOP)
HINGE TYPE B W/STUDS, SOCKET
HINGE TYPE B W/STUDS, PIN
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
GAS SPRING
BALL STUD GAS SPRING MOUNT
NUT HEX 5/16-18 LOCK
SCREW WING M6-1.00 X 25
HINGE TYPE A W/STUDS, SOCKET
HINGE TYPE A W/STUDS, PIN
GASKET CLIP-ON SELF GRIPPING (84" LG)
WASHER SELF LOCKING DOME
KIT SAE FOAM 2.5L QUIET SOURCE
ROOF 2.5L FORD AL
AI DOOR PANEL
LATCH 1/4 TURN NONLOCKING
PAWL DOOR HSB
10
11
12
13
14
15
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
089961
0A2115
0E0072AE
0F0165A
0F0165
022097
022473
0E7570
0E7571
070015
0E7662
0F0164A
0F0164
0D2023
078115
0F2179
0F0788
0E7829B
0D3037A
0C7781
0F0786
0E0072Q
0D3037
0E0072Y
0E0072AF
0E0072AA
0F0782
SUPPORT LH SIDE AL 2.5L
AI INSULATION RAD SUPPORT PANEL
LATCH QUARTER TURN LOCKING
AI INSULATION SIDE BRACE PANEL RH
AI INSULATION SIDE BRACE PANEL LH
AI INSULATION ROOF PANEL
DUCT DISCHARGE MID AL 2.5L
WASHER SHAKEPROOF EXT 1/4 STL
ASSY WIRE 14AWG 7.5 #0 GRN/YEL
ASSY WIRE 14AWG 7.5 #0 GRN/YEL
NUT HEX M6 X 1.0 G8 YEL CHR
CORNER POST REAR LH SIDE AL
CORNER POST REAR RH SIDE AL
BRACKET STIFFENER LH FRONT
DOOR BATTERY COMPARTMENT
SCREW BHSC M6-1.0 X 16 SS
BRACKET STIFFENER RH FRONT
026850
0912970064
0912970063
049813
0F0784
0F0785
0E8665
0E8837
0A3359
0E8404
* ALL ITEMS NOTATED WITH "AI" ARE COMPONENTS OF 0F2179
41
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Section 8 - Exploded Views and Parts Lists
Liquid-cooled 15, 20 and 25 kW Generators
Control Panel (15kW and 20kW) — Drawing No. 0F2267-D
42
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Section 8 - Exploded Views and Parts Lists
Liquid-cooled 15, 20 and 25 kW Generators
Control Panel (15kW and 20kW) — Drawing No. 0F2267-D
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
0F0790
0F0789
0F0791
0E9704
067680
0E6875A
0C3910
048468
0D5070A
057073
040213
0C2265
029673
0F0793
0E7890
0D5541*
0D5544**
0F1264
0F1263
0F1262
0E7403A
0E7403C
0E2514
020911
023897
022152
051716
082573
0E4494
0C4167
0C2699
0C2212
047411
022097
022473
0E7358
064733
0F0798A
0E6881
048352
0C1127
0C1229
0F2632
0F2629
0E7193
0F6146
1
1
1
1
1
2
1
1
1
1
2
18
1
1
1
1
1
1
1
2
1
1
1
2
4
2
2
1
1
REF.
4
1
4
4
4
TOP, CONTROL PANEL
BACK & BOTTOM, CONTROL PANEL
PANEL, FRONT 2.5L CONTROL PNL
ASSY PCB HSB CONTROLLER 2.5L
ASSY VOLTAGE REGULATOR 60HZ
RELAY, 12VDC C FORM W/DIODE
XFMR 240/16V 1VA&56VA
CIRCT BRK 8 X 1 ETA 46-500-P
ASSY PCB 2A 12V UL BATT CHRGR
JUNCTION BLOCK 3/8-16
PCB SUPPORT SNAP-IN 1/4"
SCREW PHTT M4-0.7 X 12 ZYC
DIO BRIDGE 25A 600V
BRACKET, CB SIEMENS BQ
BRKT CB MTG BACK
CB 0070A 2P 240V S BQ2 LL
CB 0100A 2P 240V S BQ2 LL
ADPTR,LH SIDE WICKMAN 178.6192
ADPTR,RH SIDE WICKMAN 178.6191
HOLDER, FUSE WICKMANN 178.6150
FUSE ATO TYPE 5 AMP (TAN)
FUSE, ATO TYPE 15 AMP (BLUE)
FITTING CONDUIT STR 1-1/2"
SCREW PPHM M5-0.8 X 30 ZINC
WASHER FLAT #10 ZINC
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
WASHER LOCK #10
NUT HEX M5-0.8 G8 YEL CHR
SWITCH ROC DPST 125V SPD
SWITCH ROC DPDT ON-OFF-ON
BLOCK TERM 20A 14 X 6 X 1100V
SCREW PHTT #6-32 X 3/8 ZYC
SCREW PHTT M4-0.7 X 16 ZYC
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
SCREW PPPH HI-LO #4-24 X 3/8
RES MTG BRACKET
HARNESS, C-PNL 2.5L QS 15&20KW (NOT SHOWN)
SOCKET, RELAY
4
2
1
REF
1
1
1
1
1
RES 5R 5% 25W
DECAL AVR COVER
DECAL WARNING ELECTRICAL SHOCK
DECAL TERMINAL BLOCK
DECAL CONTROL HSB
1
1
DECAL, WARNINGS HSB
HANG TAG 2 WIRE START (NOT SHOWN)
* 15KW
** 20KW
43
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Section 8 - Exploded Views and Parts Lists
Liquid-cooled 15, 20 and 25 kW Generators
Control Panel (25kW) — Drawing No. 0E7615-C
28
27
32
33
34
42
43
1
4
21
11
6
20
17
18
35
30
5
12
12
38
7
23
24
12
41
2
12
3
2
9
24
13
25
31
26
8
39
12
14
40
12
16
34
15
33
32
12
44
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Section 8 - Exploded Views and Parts Lists
Liquid-cooled 15, 20 and 25 kW Generators
Control Panel (25kW) — Drawing No. 0E7615-C
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
0F0790
0F0789
0F0791
0E9704
067680
0E6875A
0C3910
054450
0D5070A
057073
040213
0C2265
029673
0F0793
0E7890
0A2077
0F1264
0F1263
0F1262
0E7403A
0E7403C
0E2514
020911
023897
022152
051716
082573
0E4494
0C4167
0C2699
0C2212
047411
022097
022473
0E7358
0F0798
0E6881
0C1127
0C1229
0F2632
0F2629
0E7193
0F6146
1
1
1
1
1
2
1
1
1
1
2
16
1
1
1
1
1
1
2
1
1
1
2
4
2
2
1
1
REF.
4
1
4
4
4
4
TOP, CONTROL PANEL
BACK & BOTTOM, CONTROL PANEL
PANEL, FRONT 2.5L CONTROL PNL
ASSY PCB HSB CONTROLLER 2.5L
ASSY VOLTAGE REGULATOR 60HZ
RELAY, 12VDC C FORM W/DIODE
XFMR 240/16V 1VA&56VA
CIRCT BRK 5.5 X 1 ETA 46-500-P
ASSY PCB 2A 12V UL BATT CHRGR
JUNCTION BLOCK 3/8-16
PCB SUPPORT SNAP-IN 1/4"
SCREW PHTT M4-0.7 X 12 ZYC
DIO BRIDGE 25A 600V
BRACKET, CB SIEMENS BQ
BRKT CB MTG BACK
CB 0125A 2P 240V S BQ2 LL
ADPTR,LH SIDE WICKMAN 178.6192
ADPTR,RH SIDE WICKMAN 178.6191
HOLDER, FUSE WICKMANN 178.6150
FUSE ATO TYPE 5 AMP (TAN)
FUSE, ATO TYPE 15 AMP (BLUE)
FITTING CONDUIT STR 1-1/2"
SCREW PPHM M5-0.8 X 30 ZINC
WASHER FLAT #10 ZINC
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
37
38
39
40
41
42
43
44
WASHER LOCK #10
NUT HEX M5-0.8 G8 YEL CHR
SWITCH ROC DPST 125V SPD
SWITCH ROC DPDT ON-OFF-ON
BLOCK TERM 20A 14 X 6 X 1100V
SCREW PHTT #6-32 X 3/8 ZYC
SCREW PHTT M4-0.7 X 16 ZYC
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
SCREW PPPH HI-LO #4-24 X 3/8
HARNESS CTRL PNL 2.5L FORD AL (NOT SHOWN)
SOCKET, RELAY
DECAL AVR COVER
DECAL WARNING ELECTRICAL SHOCK
DECAL TERMINAL BLOCK
DECAL CONTROL HSB
DECAL, WARNINGS HSB
1
REF
1
1
1
1
1
1
HANG TAG 2 WIRE START (NOT SHOWN)
45
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Section 8 - Exploded Views and Parts Lists
Liquid-cooled 15, 20 and 25 kW Generators
Engine — Drawing No. 0E9918-F
46
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Section 8 - Exploded Views and Parts Lists
Liquid-cooled 15, 20 and 25 kW Generators
Engine — Drawing No. 0E9918-F
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
7
0E9909
0E9739
049814
0F0001
0D3488B
0A8584
0E0561
REF
ENGINE 2.5L FORD
35
36
37
38
39
40
41
42
43
44
45
46
47
0E9930
049821
0E9747
043116
022473
045772
064416
0F0252
0E9868
0F0035
026082
0E9928
0F0383
1
3
1
5
6
2
2
1
1
1
1
1
1
HEAT SHIELD, EXHAUST MANIFOLD
SCREW SHC M8-1.25 X 30 G12.9
STARTER, 12 VOLT
SCREW HHC M6-1.0 X 12 G8.8
WASHER FLAT 1/4-M6 ZINC
NUT HEX M10-1.5 G8 YEL CHR
SCREW HHC M10-1.5 X 45 G8.8
SPRING BUSHING
1
8
1
1
1
1
PULLEY, 2.5L FORD WATER PUMP
SCREW HHC M10-1.5 X 25 G8.8
CLUTCH, COOLING FAN 2.5L FORD
SERPENTINE BELT - 40.85" LENGTH
SWITCH,OIL PRESSURE,10PSI,2POL
ASSY WATER LEVEL SENSOR C/E
PL
8
9
10
11
0A6751
035579
026925
0E9611
1
1
1
1
SW-TMP 245DEG 3/8NPT
ALTERNATOR, D.C
BUSHING REDUCER 1/4 TO 1/8
PLUG STD PIPE 3/8 STEEL SQ HD
MANIFOLD, INTAKE (MACHINED)
(STEPPER MOTOR)
MANIFOLD INTAKE MACH BOSCH32
(BOSCH GOV.) (NOT SHOWN)
GASKET, 2.5L FORD INTAKE MAN.
SCREW HHC M8-1.25 X 20 G8.8
SCREW SHC M6-1.0 X 25 G12.9 ZP
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M6-1/4
BRKT,D.C. ALTERNATOR(MACHINED)
SCREW HHC 3/8-16 X 2-1/4 G5
TENSIONER, D.C. ALTERNATOR
HOSE,2.5L FORD COOLANT BY-
PASS
0E9611A
1
48
49
50
51
52
53
54
55
56
57
58
59
057823
0E9737
0F0393
045757
069860C
048031J
055596
077456
052677
049813
0E9738A
0F1132
2
1
1
2
1
REF
1
1
1
1
CLAMP HOSE #10 .56-1.06
LOWER HOSE ADAPTER,2.5L FORD
O-RING 1-3/16 X 1-7/16 X 1/8
SCREW HHC M6-1.0 X 25 G8.8
HOSE OIL DRAIN ASSY 21"
HOSE CLAMP BAND 5/8"
BARBED STR 3/8NPT X 3/8
ADAPTER M12-1.75 3/8NPT
WASHER NYLON .50 X .87 X .06
NUT HEX M6 X 1.0 G8 YEL CHR
DIPSTICK TUBE, 2.5L FORD
COVER, R/H SIDE ENGINE
ADAPTOR
COVER, L/H SIDE ENGINE ADAPTOR
SCREW SHC M10-1.50 X 50 G12.9
TANK COOLANT RECOVERY
HOSE 9/32 ID (39"LG)
BRACKET,2.5L FORD WATER
BOTTLE
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
0E9681
039253
097962
022145
022097
022129
043107
022131
046526
052625
0E9708
0E9738
0E9929
0F0230
0E9834
1
4
4
8
11
16
11
19
22
2
2
1
1
1
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 25 G8.8
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
SCREW SHC M10-1.5 X 35 G12.9
ENGINE FOOT, 2.5L FORD
DIPSTICK, 2.5L FORD
BRACKET, DIPSTICK TUBE
FAN 16" COOLING
HARNESS, 2.5L FORD ENGINE (NOT
SHOWN)
1
1
60
61*
62
63
64
0F1133
059355
076749
029032
0F1433
1
8
1
1
1
1
0E9834A
1
HARNESS,2.5L FORD (BOSCH GOV.)
(NOT SHOWN)
27
28
29
30
31
32
33
34
0D5417
0E5048B
0E9655
057192
060619
0E8940
0E9680
0E9609
6
1
1
4
2
1
1
1
SCREW HHC M10-1.0 X 25 G10.9
FLEXPLATE 2.5L FORD
ADAPT CASTING MACH 2.5L FORD
SCREW SHC M10-1.5 X 30 G12.9
SCREW SHC M10-1.50 X 40 G12.9
SPACER FLEXPLATE HSB
65
66
67
68
69
070007
070005
080826
045771
048031C
3
3
3
1
2
WASHER FLAT M6 SS
WASHER LOCK M6 SS
SCREW HHC M6-1.0 X 12 SS
NUT HEX M8-1.25 G8 YEL CHR
CLAMP HOSE BAND 1/4
GASKET, 2.5L FORD EXHAUST MAN.
MANIFOLD, EXHAUST ( MACHINED)
* NOTE: TORQUE TO 44 FT/LBS.
47
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Section 8 - Exploded Views and Parts Lists
Liquid-cooled 15, 20 and 25 kW Generators
Fuel System — Drawing No. 0E9980-D
48
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Section 8 - Exploded Views and Parts Lists
Liquid-cooled 15, 20 and 25 kW Generators
Fuel System — Drawing No. 0E9980-D
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8 *
9
0E8456
075580
0E9967
039253
022145
022129
045771
0F1570
0A6344
0F3994
0E1056
0F0397
0A5547
048031C
0D1509
0E0591
059402
037561
0E1028A
059401
091526
049226
026307
062522
022127
022259
050279
0A6125
0C2454
0E1104
0E0668
0E0590A
0C5133
0E0665
0E1108
033138
022152
0E0645
034339
059194
057823
0F0382
1
1
1
4
2
6
2
1
1
REF.
1
1
1
2
1
1
1
1
1
1
4
4
1
1
1
2
1
2
3
1
1
1
1
1
BRACKET FUEL REGULATOR
FLANGE FUEL INLET
ASSY FUEL REG 2.5L FRD N/G-L/P
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
BODY CARBURETOR ASSEMBLY
BARBED EL 90 1/8 NPT X 3/8
PCV VALVE 2.5L FORD
FUEL HOSE ASSM. NAT. GAS/L.P.V.
HOSE CRANKCASE BREATHER
COVER AIR CLEANER
10
11
12
13
14
15
16 *
17
18
19
20
21 *
22 *
23
24
25
26
27
28
29
30*
31*
32*
33*
34*
35*
36*
37*
38*
39*
40
41
42
CLAMP HOSE BAND 1/4
DECAL INLET PRESSURE
ADAPTER CARB. TO AIR CLNR
FILTER ELEMENT
NUT WING 1/4-20 NYLK
CARBURETOR ASSY. 2.5L FORD
CARBURETOR GASKET
SCREW PPHM M5-0.8 X 12 ZNC
WASHER LOCK M5
ELBOW 90D STREET 3/4
STUD TH 1/4-20 X 3 G2 ZNC FULL
NUT HEX 1/4-20 STEEL
NUT HEX 5/16-18 STEEL
DECAL FUEL INLET NG
STUD 5/16-18 X 1.25 F THR
SCREW TH-FRM M6-1 X 16 N WA Z/JS
GASKET, AIR CLEANER ADAPTER
O-RING 2-028 1.38 X 1.50 X .06
VENTURI 20MM
0-RING 29.82 X 2.62
SCREW THROTTLE PIN STOP
THROTTLE ARM REWORK
SCREW HHM #10-32 X 5/8
WASHER LOCK #10
LEVER,THROTTLE STOP
BARBED EL 90 3/8 NPT X 5/8
HOSE 5/8 ID LPG & NG (24" LG)
CLAMP HOSE #10 .56 - 1.06
HOSE 3/8" 90 DEG 2.5L PVC
1
1
1
1
1
1
2
1
* INCLUDED IN ITEM 19 (CARBURETOR ASSY )
49
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Section 8 - Exploded Views and Parts Lists
Liquid-cooled 15, 20 and 25 kW Generators
Alternator — Drawing No. 0E8660-C
50
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Section 8 - Exploded Views and Parts Lists
Liquid-cooled 15, 20 and 25 kW Generators
Alternator — Drawing No. 0E8660-C
ITEM
PART NO.
QTY.
DESCRIPTION
1
0F1659A
0F1657A
0F1655A
0E5093A
0E7413A
0F1660A
0F1658A
0F1656A
0E5094A
0E7412A
0E5706
1
1
1
1
1
1
1
1
1
1
1
REF
REF
REF
1
1
8
4
4
ROTOR 390 15KW 1P DIRECT HSB (2.5L FORD)
ROTOR 390 20KW 1P DIRECT HSB (2.5L FORD)
ROTOR 390 25KW 1P DIRECT HSB (2.5L FORD)
ROTOR 390 30KW 1P DIRECT HSB (3.0L FORD & 2.5L FORD)
ROTOR 390 40KW 1P DIRECT HSB (3.9L CHRYSLER)
STR 390 15AD HSB (382MM LONG)(2.5L FORD)
STR 390 20AD HSB (382MM LONG)(2.5L FORD)
STR 390 25AD HSB (382MM LONG)(2.5L FORD)
STR 390 35AD1 HSB (382MM LONG)(3.0L FORD & 2.5L FORD)
STR 390 40AD HSB (433MM LONG)(3.9L CHRYSLER)
REAR BEARING CARRIER 390/DRCT
FLEXPLATE 3.0L FORD
FLEXPLATE 3.9L HSB
FLEXPLATE 2.5L FORD
FLYWHEEL ASSY 3.0L HSB LG GEAR
REVCOR FAN 10.75 X 2 W/PRESS DIS
WASHER LOCK M10
2
3
4
0E5048
0E5048A
0E5048B
0E6668
0E6076
046526
5
6
7
8
9
051755
SCREW HHC M10-1.5 X 16 G8.8
04576100BK
04576100BF
043123
STUD M14-2.0 X 490 G5 ZINC (3.0L FORD & 2.5L FORD)
STUD M14-2.0 X 540 G5 ZINC (3.9L CHRYSLER)
WASHER LOCK M14
4
4
10
11
12
13
14
15
16
17
18
19
20
21
051779
0E7587
023365
0C3993
057192
0A2602
042558
0A2601
022264
4
1
1
4
4
1
1
1
4
4
1
1
NUT HEX M14-2.0 G8 YEL CHR
ASSY BRUSH HOLDER 390/HSB
WASHER SHAKEPROOF INT #8
SCREW HHTT M4-0.7 X 25 BP
SCREW SHC M10-1.5 X 30 G12.9
WASHER FLAT .688 ID X 3.25 OD
KEY SQ 3/8 X 1 STEEL
SCREW HHC M16-2.0 X 45 G8.8
WASHER LOCK #8-M4
WASHER FLAT #8 ZINC
CONDUIT FLEX 1-1/4" (30" LG - 3.0L FORD & 3.9L CHRYSLER)
CONDUIT FLEX 1-1/4" (18" LG - 2.5L FORD)
038150
077043F
077043F
ROTOR REPLACEMENT PARTS
30
31
047248
070892
1
1
BALL BEARING-45 MM
SLIP RING -MACHINED-
51
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Section 8 - Exploded Views and Parts Lists
Liquid-cooled 15, 20 and 25 kW Generators
Muffler — Drawing No. 0F2930-C
1
4
24
5
6
7
11
13
3
15
17
20
20
12
19
11
20
6
18
4
5
6
7
15
14
16
9
8
10
2
21
22
23
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
7
8
9
0F2912
0F2869
0F2823
036434
036449
022129
022259
0E0170A
044149
0E8816
0F2925
0F2926
1
1
1
2
2
6
4
1
1
1
2
1
PIPE MUFFLER OUT
13
14
15
16
17
18
19
20
21
22
23
24
042568
022097
022473
049813
039253
045771
0A4010
022145
022131
085917
0D2611
052858
4
4
8
4
2
2
1
5
2
2
2
1
SCREW HHC M6-1.0 X 20 G8.8
WASHER LOCK M6-1/4
PIPE EXHAUST 2.5L FORD
MUFFLER 2.5L FORD
BOLT U 5/16-18 X 2.09
SADDLE 2 INCH
WASHER LOCK M8-5/16
NUT HEX 5/16-18 STEEL
EXHAUST BLANKET 800MM
GASKET EXHAUST RING
EXHAUST FLANGE 2" PIPE
STRAP MUFFLER
WASHER FLAT 1/4-M6 ZINC
NUT HEX M6 X 1.0 G8 YEL CHR
SCREW HHC M8-1.25 X 20 G8.8
NUT HEX M8-1.25 G8 YEL CHR
SCREW HHC M8-1.25 X 60 G8.8 FT
WASHER FLAT 5/16-M8 ZINC
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK 3/8 SS
10
11
12
SCREW HHC 3/8-16 X 1-3/4 SS
NUT TOP LOCK FL M8-1.25
BRACKET, MUFFLER
52
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Section 8 - Exploded Views and Parts Lists
Liquid-cooled 15, 20 and 25 kW Generators
Stepper Motor — Drawing No. 0E9979-C
5
4
3
ITEM (13) NEOPRENE
COATING
2
1
14
6
7
10
WIRE HARNESS
15
SECURE WIRE HARNESS
WITH TIE WRAP AS SHOWN.
12
7
9
"A"
16
17
INTAKE MANIFOLD
(REF.)
10
7
6
CARBURETOR ARM
(REF.)
11
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
098290
098941A
0F0454
098942A
098225
043146
022097
0E7358
098783
037398
0E1326
0A7106
074031
029333A
022507
022473
064526
0E1694
1
1
REF
1
2
3
5
REF
1
2
1
1
AR
1
2
2
ASM MOTOR STEPPER
HOUSING GOVERNOR CONNECTOR
HARN GOV 2.5L FORD
COVER CONNECTOR HOUSING
SCREW PFHST #2 X 5/8
SCREW HHC M6-1.0 X 10 G8.8
WASHER LOCK M6-1/4
SCREW PPPH HI-LO #4-24 X 3/8
LEVER STEPPER MOTOR
NUT LOCK HEX #10-32 NYL INS
ASSY. CARBURETOR LINKAGE ROD
BRACKET STEPPER MOTOR
LIQUID NEOPRENE
TIE WRAP 7.4"X.19" BLK UL
SCREW HHC 1/4-20 X 1/2 G5
WASHER FLAT 1/4 ZINC
1
1
SCREW TAP HWH #6-25 X 3/8 ZINC
SPRING,ANTI LASH
53
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Section 8 - Exploded Views and Parts Lists
Liquid-cooled 15, 20 and 25 kW Generators
Radiator — Drawing No. 0E9965-F
1
19
18
5
11
12
2
14
26
TO THERMOSTAT
ADAPTER
5
9
18
8
10
TO BASE OF
WATER INLET
TUBE (ON BLOCK)
7
5
25
5
9
7
24
15
3
27
4
16
20
21
17
6
27
9
8
10
24
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
0E9769
0F0779
0E9769A
REF
REF
REF
SUPPORT RADIATOR 2.5L FORD
SUPPORT RADIATOR 2.5L AL
SUPPORT RADIATOR 2.5L FORD
ALM
15
0E9833
1
HOSE, 2.5L FORD LOWER
RADIATOR
BARBED STR 1/4 NPT X 3/8
HOSE OIL DRAIN ASSY 21"
FOAM 1.5 X 1 ADHESIVE BACKING
(21.5" LG)
BOLT CARR 1/4-20 X 1-3/4 JS500
SPRING CLIP HOLDER .37-.62
SCREW SWAGE 10-32 X 5/16 Z/YC
SCREW TH-FRM M6-1 X 16 N WA
Z/JS
SCREW HHC 1/4-20 X 3/4 G5
NUT HEX LOCK M6-1.0 SS NY INS
DECAL WARNING-FAN
16
17
18
035461
069860C
0A7275
1
1
4
2
3
4
5
6
7
8
9
10
11
12
14
0E9837
0F0123
0F0118
099502
0C2454
052250
022097
022473
022127
046627
060035
0F0127
1
1
1
4
REF.
2
8
12
8
1
4
RADIATOR 2.5L FORD
VENTURI 16" FAN 2.5L FORD
GUARD FAN 2.5L FORD
CLAMP HOSE #24 B1.06-2.00
SCREW THF M6-1 X 16 N WA Z/JS
TAPE FOAM 1 X 1(21" LG)
WASHER LOCK M6-1/4
WASHER FLAT 1/4 ZINC
NUT HEX 1/4-20 STEEL
CAP RADIATOR
19
20
21
24
031669
065852
0A2111
0C2454
4
1
1
6
25
26
27
022287
077992
050275
4
REF
2
SPACER .41 X .75 X .87 ST/ZNC
HOSE, UPPER RADIATOR 174MM
TAL
1
54
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Section 9 — Installation Diagram
Liquid-cooled 15, 20 and 25 kW Generators
Installation Diagram — Drawing No. 0F1022-A
55
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Section 10 – Warranty
Liquid-cooled 15, 20 and 25 kW Generators
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission
Control System Warranty on your new engine.* In California, new utility, and lawn and garden equipment engines must be
designed, built and equipped to meet the state’s stringent anti-smog standards. Generac will warrant the emission control
system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modifi-
cation 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 Dealer.
PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:
As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory
supplied Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance
on your engine. However, Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the
completion of all scheduled maintenance.
As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or
responsibility if your engine, or a part/component thereof, has failed due to abuse, neglect , improper maintenance or unap-
proved modifications, or the use of counterfeit and/or “grey market” parts not made, supplied or approved by Generac.
You are responsible for presenting your engine to a Generac Authorized Warranty Service Dealer as soon as a prob-
lem 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 Dealer.
To locate the Generac Authorized Warranty Service Dealer 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 Power
Systems, Inc., Two Year Limited Warranty” which is enclosed herewith on a separate sheet, also provided to you by Generac.
The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in terms between
the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where the Generac
Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe important rights
and obligations with respect to your new engine.
Warranty service can be performed only by a Generac Authorized Warranty Service Dealer. When requesting warranty serv-
ice, evidence must be presented showing the date of the sale to the original purchaser/owner.
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the fol-
lowing address:
ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297
WHITEWATER, WI 53190
Part 1
56
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Section 10 – Warranty
Liquid-cooled 15, 20 and 25 kW Generators
EMISSION CONTROL SYSTEM WARRANTY
Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines:
(a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on
the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall con-
tinue 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 war-
ranted emissions-related part to fail to be identical in all material respects to the part as described in the engine man-
ufacturer’s application for certification.
(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:
(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall
be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the
ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.
(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual
shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or
replace as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS
Warranty shall be warranted for the remainder of the ECS Warranty Period.
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part
fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection
(4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the
remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no
charge to the owner at a Generac Authorized Warranty Service Dealer.
(5) When the engine is inspected by a Generac Authorized Warranty Service Dealer, the owner shall not be held responsi-
ble for diagnostic costs if the repair is deemed warrantable.
(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused
by a failure under warranty of any emission-related part covered by the ECS Warranty.
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient
to meet the expected demand for such emission-related parts.
(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS
Warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce Generac
ECS Warranty obligations.
(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac
engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim.
Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of
such an unapproved, add-on, modified, counterfeit and/or “grey market” part.
EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
1) Fuel Metering System:
3) Ignition System including:
a) Spark plug
b) Ignition module
1.2) LPG/Natural Gas carburetion assembly and its internal
components.
a) Fuel controller (if so equipped)
4) Catalytic Muffler Assembly (if so equipped) including:
a) Muffler gasket
b) Exhaust manifold
b) Mixer and its gaskets (if so equipped)
c) Carburetor and its gaskets (if so equipped)
d) Primary gas regulator (if so equipped)
e) LP liquid vaporizer (if so equipped)
5) Crankcase Breather Assembly including:
a) Breather connection tube
2) Air Induction System including:
a) Intake pipe/manifold
b) Air cleaner
*Generac engine types covered by this warranty statement include the following:
1) Prepackaged Standby Generator
2) Auxiliary Power Unit (APU) Generator
3) Standby Generator
Part 2
57
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Section 10 – Warranty
Liquid-cooled 15, 20 and 25 kW Generators
GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR QUIETSOURCE™
"PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"
For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Quietsource
generator will be free from defects in material and workmanship for the items and period set forth below. Generac will, at its
option, repair or replace any part which, upon examination, inspection and testing by Generac or an Authorized Warranty
Service Dealer, is found to be defective. Any equipment that the purchaser/owner claims to be defective must be examined by
the nearest Authorized Warranty Service Dealer. All transportation costs under the warranty, including return to the factory, are
to be borne and prepaid by the purchaser/owner. This warranty applies only to Generac Quietsource prepackaged emergency
automatic standby generators sold and rated for use in "Standby" applications.
WARRANTY SCHEDULE
YEARS ONE and TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed (proof of purchase
and maintenance is required):
Engine - All Components
Alternator - All Components
Transfer System - All Components
All warranty expense allowances are subject to the conditions defined in Generac's Warranty Policies, Procedures and Flat
Rate Manual.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
• Quietsource generators that utilize non-Generac replacement parts.
• Quietsource generators utilizing non-Generac automatic transfer switches.
• Repairs or diagnostics performed by individuals other than Guardian/Generac authorized dealers not authorized in writing by
Generac Power Systems.
• Any Quietsource generators used as rental or trailer mounted applications.
• Units used for prime power in place of existing utility power where utility power is present or in place of utility power where
utility power service does not normally exist.
• Costs of normal maintenance, adjustments, installation and start-up.
• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.
• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with
all mechanical devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty
will not cover repair when normal use has exhausted the life of a part(s) or engine.
• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire,
freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.
• Damage related to rodent and/or insect infestation.
• Products that are modified or altered in a manner not authorized by Generac in writing.
• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or
replacement of the defective part(s).
• Failure due to misapplication.
• Telephone, cellular phone, facsimile, internet access or other communication expenses.
• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit
warranty period.
• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.
• Rental equipment used while warranty repairs are being performed.
• Costs incurred for equipment used for removal and/or reinstallation of generator, (i.e.; cranes, hoists, lifts, etc.)
• Overnight freight costs for replacement part(s).
• Overtime labor.
• Starting batteries, fuses, light bulbs and engine fluids.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC
MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some
states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO
EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH
DAMAGES ARE A DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of
incidental or consequential damages, so the above limitation may not apply to you.
This warranty gives you specific legal rights. You also have other rights from state to state.
P.O. BOX 297 • WHITEWATER, WI 53190
Revision (2.05)
Part No. 0F1007
Revision F (07/25/05)
Printed in U.S.A.
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