Generac Power Systems Portable Generator 05176 0 User Manual

®
POWER SYSTEMS, INC.  
Installation and  
Owner’s Manual  
Air-cooled Automatic  
Standby Generators  
Model:  
05176-0 (13 kW NG, 15 kW LP)  
*This manual should remain with the unit.*  
Not intended for use as Primary Power in place of utility   
or in life-support applications.  
DANGER  
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!  
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Table of Contents  
Air-cooled 15 kW Generators  
4.2 Automatic Transfer Operation.....................14  
4.3 Sequence of Automatic Operation ...............14  
4.4 Manual Operation .......................................15  
4.4.1 Close to Normal Source Side.............15  
4.4.2 Close to Emergency Source Side .......16  
4.4.3 Return to Normal Source Side...........16  
4.5 Voltage Checks ............................................16  
4.6 Generator Tests Under Load.......................16  
4.7 Setting the Exercise Timer ..........................17  
4.8 Protection Systems......................................17  
4.8.1 Low Oil Pressure Switch ..................17  
4.8.2 High Temperature Switch.................17  
4.8.3 Overcrank ........................................17  
4.8.4 Overspeed ........................................18  
Introduction ........................Inside Front Cover  
Read This Manual Thoroughly........................ IFC  
Contents.......................................................... IFC  
Operation and Maintenance ............................ IFC  
How to Obtain Service..................................... IFC  
Authorized Dealer Locator Number................... IFC  
Safety Rules ........................................................2  
Standards Index..................................................3  
Section 1 – General Information...................4  
1.1 Unpacking/Inspection....................................4  
1.2 Protection Systems........................................4  
1.3 System Set LED ............................................4  
1.4 The Generator...............................................5  
1.5 Specifications................................................6  
1.5.1 Generator...........................................6  
1.5.2 Engine................................................6  
1.6 Fuel Requirements and Recommendations ...6  
1.7 Fuel Consumption.........................................6  
1.8 Reconfiguring the Fuel System ......................6  
Section 2 – Installation....................................7  
2.1 Installation....................................................7  
2.1.1 Remote Monitoring Connections ........7  
2.1.2 Roof Open Alarm ...............................8  
2.1.3 Transfer Switch Connection...............8  
2.2 Battery Installation........................................9  
2.3 The Battery .................................................10  
Section 5 – Maintenance...............................18  
5.1 Fuse.............................................................18  
5.2 Checking the Engine Oil Level.....................18  
5.3 Changing the Engine Oil..............................18  
5.3.1 Engine Oil Recommendations ..........18  
5.3.2 Oil Change Procedure.......................18  
5.4 Changing the Oil Filter ................................19  
5.5 Changing the Engine Air Cleaner.................19  
5.6 Spark Plug(s) ..............................................19  
5.7 Battery Maintenance....................................20  
5.8 Adjusting Valve Clearance ...........................20  
5.9 Cooling System ...........................................21  
5.10 Attention After Submersion.........................21  
5.11 Corrosion Protection...................................21  
5.12 Out of Service Procedure.............................21  
5.12.1 Removal From Service......................21  
5.12.2 Return to Service .............................22  
Section 3 – Post Installation Start-up  
and Adjustments .......................10  
3.1 Before Initial Start-up..................................10  
3.2 Check Transfer Switch Operation ...............10  
3.3 Electrical Checks ........................................10  
3.4 Generator Tests Under Load.......................11  
3.5 Checking Automatic Operation....................12  
3.6 Adjusting the Regulator (Natural Gas Only)..12  
3.7 Engine Governor Adjustment......................13  
3.7.1 Additional Corrosion Protection.......13  
3.8 Voltage Regulator Adjustment......................13  
Section 4 – Operation ....................................14  
4.1 Using the Auto/Off/Manual Switch...............14  
4.1.1 Auto” Position..................................14  
4.1.2 “Off Position....................................14  
4.1.3 “Manual” Position.............................14  
Section 6 – Troubleshooting.........................27  
6.1 Troubleshooting Guide................................27  
Section 7 – Mounting Dimensions............. 28  
Section 8 – Electrical Data........................... 29  
Section 9 – Exploded Views and  
Parts Lists................................... 34  
Section 10 – Warranty................................... 48  
1
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IMPORTANT SAFETY INSTRUCTIONS  
Air-cooled 15 kW Generators  
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe  
operation be copied and posted near the unit’s installation site. Safety should be stressed to  
all operators and potential operators of this equipment.  
WARNING:  
contains chemicals known to the state  
of California to cause cancer, birth  
defects or other reproductive harm.  
The engine exhaust from this product  
Please read all hazards carefully!  
GENERAL HAZARDS  
WARNING:  
For safety reasons, the manufacturer recommends  
that the installation, initial start-up and main-  
tenance of this equipment is carried out by an  
Authorized Dealer.  
This product contains or emits chemicals  
known to the state of California to cause  
cancer, birth defects or other reproductive harm.  
• The engine exhaust fumes contain carbon monox-  
ide, which can be DEADLY. This dangerous gas, if  
breathed in sufficient concentrations, can cause  
unconsciousness or even death. This exhaust  
system must be installed properly, in strict com-  
pliance with applicable codes and standards.  
Following installation, do nothing that might ren-  
der the system unsafe or in noncompliance with  
such codes and standards.  
• Keep hands, feet, clothing, etc., away from drive  
belts, fans, and other moving or hot parts. Never  
remove any drive belt or fan guard while the unit  
is operating.  
• Adequate, unobstructed flow of cooling and venti-  
lating air is critical to correct generator operation.  
Do not alter the installation or permit even partial  
blockage of ventilation provisions, as this can seri-  
ously affect safe operation of the generator. The  
generator MUST be installed outdoors.  
• When working on this equipment, remain alert  
at all times. Never work on the equipment when  
physically or mentally fatigued.  
Study these SAFETY RULES carefully before install-  
ing, operating or servicing this equipment. Become  
familiar with this Owner’s Manual and with the  
unit. The generator can operate safely, efficiently and  
reliably only if it is properly installed, operated and  
maintained. Many accidents are caused by failing to  
follow simple and fundamental rules or precautions.  
The manufacturer cannot anticipate every possible  
circumstance that might involve a hazard. The warn-  
ings in this manual, and on tags and decals affixed  
to the unit are, therefore, not all-inclusive. If using  
a procedure, work method or operating technique  
the manufacturer does not specifically recommend,  
ensure that it is safe for others. Also make sure the  
procedure, work method or operating technique uti-  
lized does not render the generator unsafe.  
DANGER  
Despite the safe design of this generator, operat-  
ing this equipment imprudently, neglecting its  
maintenance or being careless can cause possible  
injury or death. Permit only responsible and capa-  
ble persons to operate or maintain this equip-  
ment.  
• Inspect the generator regularly, and contact the  
nearest Authorized Dealer for parts needing repair  
or replacement.  
• Before performing any maintenance on the gen-  
erator, disconnect its battery cables to prevent  
accidental start up. Disconnect the cable from the  
battery post indicated by a NEGATIVE, NEG or (–)  
first. Reconnect that cable last.  
Potentially lethal voltages are generated by  
these machines. Ensure all steps are taken to  
render the machine safe before attempting to  
work on the generator.  
• Never use the generator or any of its parts as a  
step. Stepping on the unit can stress and break  
parts, and may result in dangerous operating con-  
ditions from leaking exhaust gases, fuel leakage,  
oil leakage, etc.  
Parts of the generator are rotating and/or hot  
during operation. Exercise care near running  
generators.  
2
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IMPORTANT SAFETY INSTRUCTIONS  
Air-cooled 15 kW Generators  
• Keep a fire extinguisher near the generator at all  
times. Extinguishers rated ABC” by the National  
Fire Protection Association are appropriate for  
use on the standby electric system. Keep the extin-  
guisher properly charged and be familiar with its  
use. If there are any questions pertaining to fire  
extinguishers, consult the local fire department.  
ELECTRICAL HAZARDS  
• All generators covered by this manual produce  
dangerous electrical voltages and can cause fatal  
electrical shock. Utility power delivers extremely  
high and dangerous voltages to the transfer switch  
as does the standby generator when it is in opera-  
tion. Avoid contact with bare wires, terminals,  
connections, etc., while the unit is running. Ensure  
all appropriate covers, guards and barriers are in  
place before operating the generator. If work must  
be done around an operating unit, stand on an  
insulated, dry surface to reduce shock hazard.  
• Do not handle any kind of electrical device while  
standing in water, while barefoot, or while hands or  
feet are wet. DANGEROUS ELECTRICAL SHOCK  
MAY RESULT.  
EXPLOSION HAZARDS  
• Do not smoke around the generator. Wipe up any  
fuel or oil spills immediately. Ensure that no com-  
bustible materials are left in the generator com-  
partment, or on or near the generator, as FIRE or  
EXPLOSION may result. Keep the area surround-  
ing the generator clean and free from debris.  
• Gaseous fluids such as natural gas and liquid pro-  
pane (LP) gas are extremely EXPLOSIVE. Install  
the fuel supply system according to applicable  
fuel-gas codes. Before placing the home standby  
electric system into service, fuel system lines must  
be properly purged and leak tested according to  
applicable code. After installation, inspect the fuel  
system periodically for leaks. No leakage is permit-  
ted.  
• The National Electrical Code (NEC) requires the  
frame and external electrically conductive parts of  
the generator to be connected to an approved earth  
ground. Local electrical codes also may require  
proper grounding of the generator electrical sys-  
tem.  
• After installing this home standby electrical sys-  
tem, the generator may crank and start at any  
time without warning. When this occurs, load cir-  
cuits are transferred to the STANDBY (generator)  
power source. To prevent possible injury if such a  
start and transfer occur, always set the generator’s  
AUTO/OFF/MANUAL switch to its OFF position  
before working on equipment and remove the 5A  
and 15A fuses from the generator control panel.  
• In case of accident caused by electric shock, imme-  
diately shut down the source of electrical power. If  
this is not possible, attempt to free the victim from  
the live conductor. AVOID DIRECT CONTACT WITH  
THE VICTIM. Use a nonconducting implement,  
such as a rope or board, to free the victim from the  
live conductor. If the victim is unconscious, apply  
first aid and get immediate medical help.  
STANDARDS INDEX  
In the absence of pertinent standards, codes, regu-  
lations and laws, the published information listed  
below may be used as installation guide for this  
equipment.  
1. NFPA No. 37, STATIONARY COMBUSTION  
ENGINES AND GAS TURBINES, available from  
the National Fire Protection Association, 470  
Atlantic Avenue, Boston, MA 02210.  
2. NFPA No. 76A, ESSENTIAL ELECTRICAL  
SYSTEMS FOR HEALTH CARE FACILITIES,  
available same as Item 1.  
3. NFPA No. 54, NATIONAL FUEL GAS CODE,  
• Never wear jewelry when working on this equip-  
ment. Jewelry can conduct electricity resulting in  
electric shock, or may get caught in moving com-  
ponents causing injury.  
available same as Item 1.  
4. NFPA No. 58, AMERICAN NATIONAL STANDARD  
FOR STORAGE AND HANDLING OF LIQUEFIED  
PETROLEUM GAS, available same as Item 1.  
5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL  
ELECTRIC CODE, available same as Item 1.  
6. Article X, NATIONAL BUILDING CODE, available  
from the American Insurance Association, 85  
John Street, New York, N.Y. 10038.  
FIRE HAZARDS  
For fire safety, the generator must be installed  
and maintained properly. Installation always must  
comply with applicable codes, standards, laws  
and regulations. Adhere strictly to local, state and  
national electrical and building codes. Comply  
with regulations the Occupational Safety and  
Health Administration (OSHA) has established.  
Also, ensure that the generator is installed in  
accordance with the manufacturer’s instructions  
and recommendations. Following proper installa-  
tion, do nothing that might alter a safe installation  
and render the unit in noncompliance with the  
aforementioned codes, standards, laws and regula-  
tions.  
7. AGRICULTURAL WIRING HANDBOOK, avail-  
able from the Food and Energy Council, 909  
University Avenue, Columbia, MO 65201.  
8. ASAE  
EP-3634,  
INSTALLATION  
AND  
MAINTENANCEOFFARMSTANDBYELECTRICAL  
SYSTEMS, available from the American Society  
of Agricultural Engineers, 2950 Niles Road, St.  
Joseph, MI 49085.  
9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE  
LIQUIDS CODE, available same as Item 1.  
3
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Section 1 — General Information  
Air-cooled 15 kW Generators  
1.2 PROTECTION SYSTEMS  
DANGER  
Unlike an automobile engine, the generator may have  
to run for long periods of time with no operator pres-  
ent to monitor engine conditions. For that reason, the  
engine is equipped with the following systems that  
protect it against potentially damaging conditions:  
Only qualified electricians or contractors should  
attempt such installations, which must comply  
strictly with applicable codes, standards and  
regulations.  
1. Low Oil Pressure Sensor  
2. High Temperature Sensor  
There are LED readouts on the control panel to notify  
personnel that one of these faults has occurred. There  
is also a “System Set” LED that is described below.  
3. Overcrank  
4. Overspeed  
1.1 UNPACKING/INSPECTION  
After unpacking, carefully inspect the contents for  
damage.  
• This standby generator set has been factory sup-  
plied with a weather protective enclosure that is  
intended for outdoor installation only.  
1.3 SYSTEM SET LED  
The “System Set” LED is lit when all of the following  
conditions are true:  
If this generator is used to power electrical load  
1. The AUTO/OFF/MANUAL switch is set to the  
AUTO position.  
circuits normally powered by a utility power  
source, it is required by code to install a trans-  
fer switch. The transfer switch must effectively  
isolate the electrical system from the utility  
distribution system when the generator is oper-  
ating (NEC 700, 701 and 702). Failure to isolate  
an electrical system by such means will result in  
damage to the generator and also may result in  
injury or death to utility power workers due to  
backfeed of electrical energy.  
2. The utility voltage being supplied to the unit is  
being sensed by the Control PCB. If the utility  
sense voltage is not connected to the unit or if it  
is below 168 volts AC, then the system set light  
will flash rapidly. This indicates that if the AUTO/  
OFF/MANUAL switch is placed in the Auto posi-  
tion , the generator will start.  
3. The “Not In Auto” dip switch is set to the OFF  
position on the control board.  
If any loss or damage is noted at time of delivery, have  
the person(s) making the delivery note all damage on  
the freight bill or affix his or her signature under the  
consignor's memo of loss or damage.  
4. No alarms are present, for example, low oil pres-  
sure, high temperature, etc.  
If there is loss or damage after delivery, separate the  
damaged materials and contact the carrier for claim  
procedures.  
“Concealed damage” is understood to mean damage  
to the contents of a package that is not in evidence at  
the time of delivery, but is discovered later.  
4
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Section 1 — General Information  
Air-cooled 15 kW Generators  
1.4 THE GENERATOR  
Figure 1.1 – 15 kW, V-twin GT-990 Engine  
Control  
Panel  
Oil  
Dipstick  
Data  
Decal  
Exhaust  
Enclosure  
Fuel  
Regulator  
Fuel  
Inlet  
Composite Base  
Battery  
Compartment  
Oil Filter  
Figure 1.2 – 15 kW, V-twin GT-990 Engine Rear View  
AUTOMATIC TRANSFER  
SWITCH  
5
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Section 1 — General Information  
Air-cooled 15 kW Generators  
1.5 SPECIFICATIONS  
1.6 FUEL REQUIREMENTS  
AND RECOMMENDATIONS  
1.5.1 GENERATOR  
With LP gas, use only the vapor withdrawal sys-  
tem. This type of system uses the vapors formed  
above the liquid fuel in the storage tank.  
Rated Max. Continuous Power  
Capacity (Watts*).......................... 13,000 NG/15,000 LP  
Rated Voltage........................................................120/240  
Rated Max. Continuous Load Current (Amps)  
The engine has been fitted with a fuel carburetion  
system that meets the specifications of the 1997  
California Air Resources Board for tamper-proof  
dual fuel systems. The unit will run on natural gas or  
LP gas, but it has been factory set to run on natural  
gas. Should the primary fuel need to be changed to  
LP gas, the fuel system needs to be reconfigured. See  
"Reconfiguring the Fuel System" for instructions on  
reconfiguration of the fuel system.  
120 Volts +...................................... 108.3 NG/125.0 LP  
240 Volts.............................................. 54.2 NG/62.5 LP  
Main Line Circuit Breaker.................................... 70 Amp  
Phase ..............................................................................1  
Number of Rotor Poles....................................................2  
Rated AC Frequency................................................ 60 Hz  
Power Factor ...................................................................1  
Recommended Air Filter ........................... Part # 0C8127  
Battery Requirement......Group 26/26R at -17.8° C ( 0° F)  
12 Volts and 525 Cold-cranking Amperes Minimum  
Weight ............................................................640 Pounds  
Recommended fuels should have a Btu content of at  
least 1,000 Btus per cubic foot for natural gas; or at  
least 2,520 Btus per cubic foot for LP gas. Ask the  
fuel supplier for the Btu content of the fuel.  
Output Sound Level  
@ 23 ft (7m) at full load ...............................71.5 db (A)  
Required fuel pressure for natural gas is five inches  
to seven inches water column (0.18 to 0.25 psi);  
and for liquid propane, 11 inches to 14 inches of  
water column (0.4 to 0.5 psi).  
Normal Operating Range............................-20°F (-28.8°C)  
to 104°F (40°C)  
* Maximum wattage and current are subject to and limited by such  
factors as fuel Btu content, ambient temperature, altitude, engine  
power and condition, etc. Maximum power decreases about 3.5 per-  
cent for each 1,000 feet above sea level; and also will decrease about  
1 percent for each 6° C (42° F) above 16° C (60° F).  
NOTE:  
Any piping used to connect the generator to the  
fuel supply should be of adequate size to ensure  
the fuel pressure NEVER drops below 4 inches  
water colum for natural gas or 10 inches water  
column for liquid propane for all load ranges.  
+ Total current in two separate curcuits. Current in each curcuit must  
not exceed the value stated for 240V.  
1.5.2 ENGINE  
Type of Engine ...................................................... GT-990  
Number of Cylinders.......................................................2  
Rated Horsepower...................................30 @ 3,600 rpm  
Displacement .......................................................... 992cc  
Cylinder Block ......................................Aluminum w/Cast  
Iron Sleeve  
1.7 FUEL CONSUMPTION  
Model #  
Nat. Gas (*)  
LP Vapor (**)  
1/2 Load Full Load 1/2 Load  
Full Load  
2.40/88  
05176  
156  
220  
1.58/58  
Valve Arrangement .................................. Overhead Valves  
Ignition System ...............................Solid-state w/Magneto  
Recommended Spark Plug...................................RC12YC  
Spark Plug Gap............................ 0.508 mm (0.020 inch)  
Compression Ratio....................................................9.5:1  
Starter.....................................................................12Vdc  
Oil Capacity Including Filter.....................Approx. 1.7 Qts  
Recommended Oil Filter ......................... Part # 070185B  
Recommended Air Filter ........................... Part # 0C8127  
Operating RPM.........................................................3,600  
*Natural gas is in cubic feet per hour.  
**LP is in gallons per hour/cubic feet per hour.  
1.8 RECONFIGURING THE  
FUEL SYSTEM  
To reconfigure the fuel system from NG to LP, follow  
these steps:  
NOTE:  
The primary regulator for the propane supply is  
NOT INCLUDED with the generator. A fuel pres-  
sure of 11 to 14 inches of water column (0.4 to  
0.5 psi) to the fuel inlet of the generator MUST  
BE SUPPLIED.  
1. Turn off the gas supply. (if connected)  
2. Open the roof and remove the door.  
3. Remove the battery. (if installed)  
6
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Section 2 — Installation  
Air-cooled 15 kW Generators  
4. Remove the engine air in baffle located on the left-  
hand side of the battery compartment. Two M6  
screws are located on top of the baffle and two  
M6 screws are located on the inside of the baffle  
towards the back.  
5. Remove the small hose clamp and hose from the  
fuel regulator. It may be necessary to pry the hose  
off of the brass fitting using a screwdriver to gen-  
tly lift up the hose edge.  
14. It may be necessary to make minor adjustments  
to the preset adjustment screw settings to achieve  
maximum power, particularly at higher altitudes.  
If experiencing problems with the unit produc-  
ing maximum power, follow the procedure in  
"Adjusting the Fuel Regulator".  
2.1 INSTALLATION  
Install the generator set, in its protective enclosure,  
outdoors, where adequate cooling and ventilating air  
is always available. Consider these factors:  
6. Remove the small brass hose fitting from the  
regulator casting.  
• Install the unit where air inlet and outlet openings  
will not become obstructed by leaves, grass, snow,  
etc. If prevailing winds will cause blowing or drift-  
ing snow, consider using a windbreak to protect  
the unit.  
7. Place the small fuel jet, thread side first, into the  
threaded hole originally occupied by the brass  
hose fitting (Figure 1.3).  
Figure 1.3 - Demand Regulator  
• Install the generator on high ground where water  
OUTLET PORTS  
FUEL HOSE  
levels will not rise and endanger it.  
• Allow sufficient room on all sides of the generator  
for maintenance and servicing. A good rule is to  
allow three feet of space on all sides.  
BRASS HOSE  
FITTING  
IDLE CIRCUIT  
PORT  
BRASS HOSE  
FITTING  
SMALL  
FUEL JET  
1
NP  
• Where strong prevailing winds blow from one  
direction, face the generator air inlet openings to  
the prevailing winds.  
REGULATOR  
HOUSING PORT  
ADJUSTER  
SCREWS  
• Install the generator as close as possible to the fuel  
supply, to reduce the length of piping.  
2.1.1 REMOTE MONITORING CONNECTIONS  
Mounted in the transfer switch is relay contact board  
(Figure 2.1) that can be used to remotely monitor  
various functions of the generator system.  
8. Using a short No. 2 Phillips screw driver, thread  
the small fuel jet into the regulator casting. Do  
not over tighten.  
9. Apply thread sealant to the threads of the hose  
fitting and replace it into the regulator body.  
10. Re-attach the small hose and hose clamp and  
tighten as necessary.  
The contacts are rated as shown below. Failure to fol-  
low these ratings will cause unit failure.  
• Arrangement: SPCT (Form C)  
• Ratings: Resistive Load, 4Amp max switching  
current at 30VDC; 2Amp max switching  
current at 125VAC  
11. Replace the engine air in baffle using the four M6  
screws.  
12. Identify both brass adjustment screws on the  
regulator.  
• Wire Range: 26-14Awg  
Terminal tightening torque: 5 in/lb.  
NOTE:  
Figure 2.1 — Remote Monitoring Connections  
One adjustment screw can be accessed from the  
front of the unit and the second can be accessed  
from the back of the unit enclosure by removing  
the plastic hole plug. The screw can be turned  
with a long flat blade screwdriver.  
RELAY KEY  
RELAY 1  
C
NC  
NO  
C
ENGINE  
RUN  
RELAY 2  
NC  
NO  
C
SWITCH IN  
EMERGENCY  
13. To adjust the system to run on LP fuel, turn  
BOTH adjuster screws 1/2 TURN CLOCKWISE.  
The system should now be set for maximum  
power and best perfomance. DO NOT, UNDER  
ANY CIRCUMSTANCES, REMOVE THE SET  
PINS FROM THE REGULATOR HOUSING.  
THIS WILL VOID THE WARRANTY.  
RELAY 3  
NC  
NO  
C
SWITCH IN  
AUTO  
RELAY 4  
NC  
NO  
C
COMMON  
ALARM  
RELAY 5  
NC  
NO  
C
LOW  
FUEL  
RELAY 6  
NC  
NO  
DOOR  
OPEN  
7
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Section 2 — Installation  
Air-cooled 15 kW Generators  
Remote monitoring functions are only available with  
the AUTO/OFF/MANUAL switch in the Auto or Manual  
position. Since the contacts are SPDT, it is possible  
to monitor either state of each alarm function.  
2.1.3 TRANSFER SWITCH CONNECTION  
These switches (Figure 2.3) are used with a single-  
phase system, when the single-phase NEUTRAL line  
is to be connected to a Neutral Lug and is not to be  
switched.  
Relay 1: Engine running, normally closed.  
Engine not running, normally open  
Figure 2.3 — Typical 2-Pole Transfer Mechanism  
(200 Amp Shown)  
Relay 2: Transfer Switch in Emergency, normally  
closed  
Transfer Switch in Utility, normally open  
UTILITY LUGS  
Relay 3: Control panel switch in Auto, normally  
open  
UTILITY  
CLOSING  
COIL  
Control panel switch in Manual or Off, nor-  
mally closed  
Relay 4: The common alarm is activated by any of  
the following shutdown faults  
Low Oil Pressure  
High Engine Temperature  
GENERATOR  
LUGS (E1 & E2)  
GENERATOR  
CLOSING  
COIL  
Overspeed  
Overcrank  
Common alarm active, normally open  
No Common alarm, normally closed  
Relay 5: Spare, not used on this model  
Relay 6: Enclosure door open, normally closed  
Enclosure door closed, normally open  
LOAD LUGS (T1 & T2)  
Solderless, screw-type terminal lugs are standard.  
Switch  
Rating  
200A  
Wire  
Range  
#6-250 MCM  
Conductor Tightening  
Torque  
275 in-lbs.  
2.1.2 ROOF OPEN ALARM  
This generator is equipped with an alarm to detect  
when the roof of the enclosure is open. A limit switch  
that is installed in the generator enclosure controls  
this alarm. During shipping, the generator's enclosure  
panels may have shifted and this limit switch may  
require adjustment. Simply loosen the two screws  
and adjust the placement of the limit switch. The arm  
of the limit switch should be in the depressed posi-  
tion when the enclosure roof is closed and the door  
latch is secure (see Figure 2.2).  
Conductor sizes must be adequate to handle the  
maximum current to which they will be subjected to,  
based on the 75°C column of tables, charts, etc. used  
to size conductors. The installation must comply fully  
with all applicable codes, standards and regulations.  
Before connecting wiring cables to terminals, remove  
any surface oxides from the cable ends with a wire  
brush. All power cables should enter the switch next  
to transfer mechanism terminals. If ALUMINUM con-  
ductors are used, apply corrosion inhibitor to con-  
ductors. Tighten terminal lugs to the torque values as  
noted on the decal located on the inside of the door.  
After tightening terminal lugs, carefully wipe away  
any excess corrosion inhibitor.  
Figure 2.2 — Limit Switch  
All power cables should enter the switch next to the  
transfer mechanism terminals.  
Up  
Use a torque wrench to tighten the conductors,  
Down  
being sure not to over tighten, or damage to  
the switch base could occur. If not tightened  
enough, a loose connection would result, caus-  
ing excess heat which could damage the switch  
base.  
Slots  
8
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Section 2 — Installation  
Air-cooled 15 kW Generators  
Connect power source load conductors to clearly  
marked transfer mechanism terminal lugs as fol-  
lows  
Lead-acid batteries present a risk of fire because  
they generate hydrogen gas. The  
following procedures are to be followed:  
1. Connect UTILITY (NORMAL) power source cables  
to switch terminals N1, N2.  
• DO NOT SMOKE when near the battery;  
• DO NOT cause flame or spark in battery area; and  
• Discharge static electricity from body before touch-  
ing the battery by first touching a grounded metal  
surface.  
2. Connect customer LOAD leads to switch termi-  
nals T1, T2.  
Conductors must be properly supported, of approved  
insulative qualities, protected by approved conduit,  
and of the correct wire gauge size in accordance with  
applicable codes.  
Be sure the AUTO/OFF/MANUAL switch is set to  
the OFF position before connecting the battery  
cables. If the switch is set to AUTO or MANUAL,  
the generator can crank and start as soon as the  
battery cables are connected.  
Be sure to maintain proper electrical clearance  
between live metal parts and grounded metal. Allow  
at least 1/2 inch for 100-400 amp circuits.  
Be sure the utility power supply is turned off, or  
sparking may occur at the battery posts as the  
2.2 BATTERY INSTALLATION  
DANGER  
cables are attached and cause an explosion.  
Fill the battery with the proper electrolyte fluid if  
necessary and have the battery fully charged before  
installing it.  
Do not dispose of the battery in a fire. The  
battery is capable of exploding.  
Before installing and connecting the battery, complete  
the following steps:  
A battery presents a risk of electrical shock  
and high short circuit current. The following pre-  
1. Set the generator's AUTO/OFF/MANUAL switch to  
cautions are to be observed when working on  
batteries:  
OFF.  
2. Turn off utility power supply to the transfer  
• Remove watches, rings or other metal objects;  
• Use tools with insulated handles;  
• Wear rubber gloves and boots;  
• Do not lay tools or metal parts on top of the  
battery; and  
switch.  
3. Remove the 5 amp fuse from the generator con-  
trol panel.  
• Disconnect charging source prior to connecting or  
disconnecting battery terminals.  
If the AUTO/OFF/MANUAL switch is not set to its  
OFF position, the generator can crank and start  
as soon as the battery cables are connected. If  
the utility power supply is not turned off, spark-  
ing can occur at the battery posts and cause an  
explosion.  
Do not open or mutilate the battery. Released  
electrolyte has been known to be harmful to the  
skin and eyes, and to be toxic.  
Battery cables were factory connected at the genera-  
tor (Figure 2.4). Connect cables to battery posts as  
follows:  
The electrolyte is a dilute sulfuric acid that is  
harmful to the skin and eyes. It is electrically  
conductive and corrosive.  
4. Connect the red battery cable (from starter con-  
tactor) to the battery post indicated by a positive,  
POS or (+).  
5. Connect the black battery cable (from frame  
ground) to the battery post indicated by a nega-  
tive, NEG or (—).  
The following procedures are to be observed:  
• Wear full eye protection and protective clothing;  
• Where electrolyte contacts the skin, wash it off  
immediately with water;  
• Where electrolyte contacts the eyes, immediately  
flush thoroughly with water and seek medical  
attention; and  
6. Replace the 5 amp fuse in the generator control  
panel.  
• Spilled electrolyte is to be washed down with an  
acid neutralizing agent. A common practice is to  
use a solution of 1 pound (500 grams) bicarbonate  
of soda to 1 gallon (4 liters) or water. The bicar-  
bonate of soda solution is to be added until the  
evidence of reaction (foaming) has ceased. The  
resulting liquid is to be flushed with water and the  
area dried.  
NOTE:  
Damage will result if battery connections are made  
in reverse.  
9
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Section 3 — Post Installation Start-up and Adjustments  
Air-cooled 15 kW Generators  
Figure 2.4 – Battery Cable Connections  
3.1 BEFORE INITIAL START-UP  
Before starting, complete the following:  
1. Set the generator’s main circuit breaker to its  
OFF (or open) position.  
2. Set the generator's AUTO/OFF/MANUAL switch to  
the OFF position.  
3. Turn OFF the utility power supply to the transfer  
switch using the means provided (such as the  
utility main line circuit breaker).  
4. Check the engine crankcase oil level and, if neces-  
sary, fill to the dipstick FULL mark with the rec-  
ommended oil. Do not fill above the FULL mark.  
5. Check the fuel supply. Gaseous fuel lines must  
have been properly purged and leak tested in  
accordance with applicable fuel-gas codes. All  
fuel shutoff valves in the fuel supply lines must  
be open.  
NOTE:  
The generator is equipped with a battery trickle  
charger that is active when the unit is set up for  
automatic operation. With the battery installed  
and utility power source voltage available to the  
transfer switch, the battery receives a trickle  
charge while the engine is not running, to prevent  
self-discharge. The trickle charger is designed to  
help extend the life of the battery by maintain-  
ing the battery when the unit is not running. The  
trickle charge feature cannot be used to recharge  
a discharged battery.  
Never operate the engine with the oil level  
below the “Add” mark on the dipstick. Doing  
this could damage the engine.  
3.2 CHECK TRANSFER SWITCH  
OPERATION  
Refer to the "Manual Operation" section of the owner’s  
manual for manual operation procedures.  
2.3 THE BATTERY  
DANGER  
Servicing of the battery is to be performed or super-  
vised by personnel knowledgeable of batteries and  
the required precautions. Keep unauthorized person-  
nel away from batteries.  
Do not attempt manual transfer switch opera-  
tion until all power voltage supplies to the  
transfer switch have been positively turned off.  
Failure to turn off all power voltage supplies  
will result in extremely hazardous and possibly  
fatal electrical shock.  
When replacing the battery, use the following type of  
battery: Group 26/26R 12-volt battery with a rating  
of 525 cold-cranking amps minimum at -17.8º C (0º  
F) minimum. When using a maintenance-free battery,  
it is not necessary to check the specific gravity or  
electrolyte level. Have these procedures performed  
at the intervals specified in the “Service Schedule.” A  
negative ground system is used. Battery connections  
are shown on the wiring diagrams. Make sure the  
battery is correctly connected and terminals are tight.  
Observe battery polarity when connecting the battery  
to the generator set.  
3.3 ELECTRICAL CHECKS  
Complete electrical checks as follows:  
1. Turn on the utility power supply to the transfer  
switch using the means provided (such as a utility  
main line circuit breaker).  
DANGER  
The transfer switch is now electrically “hot.”  
Contact with “hot” parts will result in extremely  
hazardous and possibly fatal electrical shock.  
Proceed with caution.  
2. Use an accurate AC voltmeter to check utility  
power source voltage across terminals N1 and  
N2. Nominal line-to-line voltage should be 240  
volts AC.  
10  
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Section 3 — Post Installation Start-up and Adjustments  
Air-cooled 15 kW Generators  
3. Check utility power source voltage across termi-  
3.4 GENERATOR TESTS UNDER LOAD  
nals N1 and the transfer switch neutral lug; then  
across terminal N2 and neutral. Nominal line-to-  
neutral voltage should be 120 volts AC.  
4. When certain that utility supply voltage is compat-  
ible with transfer switch and load circuit ratings,  
turn OFF the utility power supply to the transfer  
switch.  
Do not attempt manual transfer switch opera-  
tion until all power voltage supplies to the  
transfer switch have been positively turned off.  
Failure to turn off all power voltage supplies  
will result in extremely hazardous and possibly  
fatal electrical shock.  
5. Set the generator's main circuit breaker to its  
OFF (or OPEN) position. Initial tests will be con-  
ducted at no-load condition.  
6. On the generator panel, set the AUTO/OFF/  
MANUAL switch to MANUAL. The engine should  
crank and start.  
7. Let the engine warm up for about five minutes to  
allow internal temperatures to stabilize. Then, set  
the generator’s main circuit breaker to its ON (or  
closed) position.  
To test the generator set with electrical loads applied,  
proceed as follows:  
1. Set generator’s main circuit breaker to its OFF  
(or OPEN) position.  
2. Set the generator's AUTO/OFF/MANUAL  
switch to OFF.  
3. Turn OFF the utility power supply to the transfer  
switch, using the means provided (such as a util-  
ity main line circuit breaker).  
4. Manually set the transfer switch to the STANDBY  
position, i.e., load terminals connected to the  
generator's E1/E2 terminals. The transfer switch  
operating lever should be down.  
5. Set the generator's AUTO/OFF/MANUAL switch  
to MANUAL. The engine should crank and start  
immediately.  
DANGER  
Proceed with caution! Generator power voltage  
is now supplied to the transfer switch. Contact  
with live transfer switch parts will result in dan-  
gerous and possibly fatal electrical shock.  
8. Connect an accurate AC voltmeter and a fre-  
quency meter across transfer switch terminal  
lugs E1 and E2. Voltage should be 242-252 volts;  
frequency should read about 61-63 Hertz.  
9. Connect the AC voltmeter test leads across ter-  
minal lug E1 and neutral; then across E2 and  
neutral. In both cases, voltage reading should be  
121-126 volts AC.  
10. Set the generator’s main circuit breaker to its  
OFF (or open) position. Let the engine run at no-  
load for a few minutes to stabilize internal engine  
generator temperatures.  
6. Let the engine stabilize and warm up for a few  
minutes.  
7. Set the generator’s main circuit breaker to its ON  
(or closed) position. Loads are now powered by  
the standby generator.  
8. Turn ON electrical loads. Apply an electrical load  
equal to the full rated wattage/amperage capacity  
of the installed generator.  
9. Connect an accurate AC voltmeter and a frequen-  
cy meter across terminal lugs E1 and E2. Voltage  
should be greater than 230 volts; frequency  
should be greater than 58 Hertz.  
10. Let the generator run at full rated load for 20-30  
minutes. Listen for unusual noises, vibration or  
other indications of abnormal operation. Check  
for oil leaks, evidence of overheating, etc.  
11. When testing under load is complete, turn OFF  
electrical loads.  
11. Set the generator's AUTO/OFF/MANUAL switch to  
OFF. The engine should shut down.  
NOTE:  
It is important not to proceed until certain that  
generator AC voltage and frequency are correct  
and within the stated limits. Generally, if both AC  
frequency and voltage are high or low, the engine  
governor requires adjustment. If frequency is cor-  
rect, but voltage is high or low, the generator’s  
voltage regulator requires adjustment.  
12. Set the generator's main circuit breakers to their  
OFF (or open) positions.  
13. Let the engine run at no-load for a few minutes.  
14. Set the AUTO/OFF/MANUAL switch to OFF. The  
engine should shut down.  
11  
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Section 3 — Post Installation Start-up and Adjustments  
Air-cooled 15 kW Generators  
3. Turn on electrical loads. Be cautious not to over-  
3.5 CHECKING AUTOMATIC  
load the generator. Use the following chart as a  
guide:  
OPERATION  
To check the system for proper automatic operation,  
proceed as follows:  
Model  
005176  
120 Volts  
108.3 amps  
240 Volts  
54.1 amps  
1. Set the generator’s main circuit breaker to it’s  
OFF (or open) position.  
4. When full load has been achieved. Connect a fre-  
quency meter to the output lugs of the generator’s  
main line circuit breaker.  
2. Check that the AUTO/OFF/MANUAL switch is set  
to OFF.  
3. Manually set the transfer switch to the UTILITY  
position, i.e., load terminals connected to the util-  
ity power source side.  
4. Turn ON the utility power supply to the transfer  
switch, using the means provided (such as a util-  
ity main line circuit breaker).  
5. Set the AUTO/OFF/MANUAL switch to AUTO.  
Then set the generator’s main circuit breaker to  
its ON (or closed) position. The system is now  
ready for automatic operation.  
5. The fuel regulator is fitted with two adjustment  
screws. While watching the frequency meter,  
slowly turn the adjustment screw clockwise or  
counterclockwise one at a time until highest fre-  
quency is read on the meter. Only limited adjust-  
ment is available between the set pins. Under no  
circumstances should any of the pins be removed  
(Figures 3.1 and 3.2).  
Figure 3.1 — Dual Fuel Regulators  
6. Turn OFF the utility power supply to the transfer  
switch.  
V-twin Engine  
With the AUTO/OFF/MANUAL switch at AUTO, the  
engine should crank and start when the utility source  
power is turned OFF. After starting, the transfer  
switch should connect load circuits to the standby  
side. Let the system go through its entire automatic  
sequence of operation.  
Adjustment  
Screw  
(Both Sides)  
With the generator running and loads powered by  
generator AC output, turn ON the utility power supply  
to the transfer switch. The following should occur:  
Set Pin  
(Both Sides)  
• After about 15 seconds, the switch should transfer  
loads back to the utility power source.  
• About one minute after retransfer, the engine  
should shut down.  
6. When the highest frequency is reached maximum  
power has been set. Then turn both adjustment  
screws 1/4 turn counterclockwise. Regulator is  
now set.  
3.6 ADJUSTING THE REGULATOR  
(NATURAL GAS ONLY)  
Although the generator has been factory set to pro-  
vide maximum power, it may be necessary in some  
areas to adjust this setting. Because natural gas has  
different BTU or power content across the country  
the engine may not perform as designed.  
Figure 3.2 — Placement of Regulator  
If experiencing engine problems at high or full load  
conditions follow these steps. It will require a fre-  
quency meter to perform this procedure.  
1. Turn off utility power to the main distribution  
panel in the house. This can be done by switching  
the service main breaker to the off or open posi-  
tion.  
2. Allow the generator to start before loading the  
generator. Confirm the no-load frequency with  
the roof open and door off is set at 63-63.5 Hz.  
Transfer load to emergency circuits.  
Adjustment Screw  
12  
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Section 3 — Post Installation Start-up and Adjustments  
Air-cooled 15 kW Generators  
7. Turn utility power to the main distribution panel  
Figure 3.4 — V-twin Full Load Speed Adjust  
Screw  
back on. This can be done by switching the ser-  
vice main breaker to the on or closed position.  
Allow the generator to shut down.  
Full Load Speed Adjust Screw  
Do not make any unnecessary adjustments.  
Factory settings are correct for most applica-  
tions. However, when making adjustments, be  
careful to avoid overspeeding the engine.  
If this procedure or equipment are not available,  
locate the nearest Service Dealer and they can per-  
form the adjustments.  
NOTE:  
A service fee may be charged for this adjustment.  
3.7 ENGINE GOVERNOR ADJUSTMENT  
If both AC frequency and voltage are correspondingly  
high or low, adjust the engine governor as follows:  
3.7.1 ADDITIONAL CORROSION  
PROTECTION  
Periodically spray all engine linkage parts and brack-  
ets with corrosion inhibiting spray such as WD-40®  
or a comparable product.  
1. Loosen governor clamp bolt (See Figure 3.3).  
Figure 3.3 — V-twin Engine Governor  
Adjustment  
3.8 VOLTAGE REGULATOR  
ADJUSTMENT  
Idle Spring  
With the frequency between 62-63.5 Hertz, slowly  
turn the slotted potentiometer (Figure 3.5) until line  
voltage reads 244-252 volts.  
Governor  
Shaft  
(Rotate  
Clockwise)  
NOTE:  
Remove the access panel on top of the control  
panel to adjust the voltage regulator.  
Figure 3.5 – Voltage Adjustment Potentiometer  
No Load Idle  
Adjustment Screw  
Governor Clamp Bolt  
2. Completely remove the idle spring.  
3. With governor arm at wide open throttle position,  
rotate governor shaft fully clockwise. Tighten  
clamp bolt to 84 inch-pounds.  
4. Start unit and apply full load. Use full load speed  
adjust screw (Figure 3.4) to adjust frequency to  
58 Hz.  
Turn to  
adjust voltage.  
5. Remove load, stop engine, loosen the idle adjust  
screw and reconnect the idle spring.  
6. Using a hand, push the governor arm to the  
closed throttle position. Make sure the idle spring  
does not stretch at all.  
NOTE:  
7. Restart the unit.  
The voltage regulator is housed above the generator's  
control panel. The regulator maintains a voltage in  
direct proportion to frequency. For example, at 62  
Hertz, line-to-neutral voltage will be 124 volts.  
8. Slowly turn the idle adjust screw to adjust the no-  
load idle frequency to 63-63.5 Hz.  
9. The governor is now set.  
13  
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