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Serial Number
STANDBY GENERATOR
OWNER'S MANUAL
QT
5.4L
100kW
Models
A new standard of reliability
This manual should remain with the unit.
v. 0 08/05 Cover008 Re . 0F3607 t No Par
Standby Generator Sets
Table of Contents
SECTION PAGE
SAFETY RULES ................................................ 1-1
INTRODUCTION .....................................................1-3
Read this Manual Thoroughly ...................................1-3
Operation and Maintenance ......................................1-3
How to Obtain Service ..............................................1-3
IDENTIFICATION RECORD .....................................2-1
EQUIPMENT DESCRIPTION ...................................3-1
Equipment Description ................................................3-1
Engine Oil Recommendations ......................................3-1
Coolant Recommendations...........................................3-1
ENGINE PROTECTIVE DEVICES ............................4-1
Coolant Temperature Sensing ...................................4-1
Low Coolant Level .....................................................4-1
Oil Pressure Sensing .................................................4-1
RPM Sensor Loss Shutdown .....................................4-1
FUEL SYSTEMS .....................................................5-1
Natural Gas Fuel System ..........................................5-1
Propane Vapor Withdrawal Fuel System....................5-1
LP Fuel System .........................................................5-1
SPECIFICATIONS ...................................................6-1
Engine.......................................................................6-1
Generator Set Lubrication ........................................8-1
Prior to Initial Start-up .............................................8-1
Initial Inspection for QT Genset Start-up .....................8-2
OPERATION ...........................................................9-1
Generator Control and Operation ................................9-1
Operating Unit with Automatic Transfer Switch ...........9-1
Operating Unit with Manual Transfer Switch ...............9-1
Engine Start-up and Transfer ...................................9-1
Retransfer and Shutdown .........................................9-1
MAINTENANCE .....................................................10-1
Maintenance Performed by Authorized
Service Facilities .....................................................10-1
Cooling System ..........................................................10-1
Checking Fluid Levels ................................................10-1
Check Engine Oil ....................................................10-1
Maintenance Owner/Operator Can Perform ................10-2
Check Engine Oil Level ...........................................10-2
Inspect Cooling System ...........................................10-2
Check Engine Coolant Level....................................10-2
Perform Visual Inspection .......................................10-2
Inspect Exhaust System ..........................................10-2
Check Fan Belt ........................................................10-2
Inspect Engine Governor ........................................10-2
Changing Engine Oil ...............................................10-2
Changing the Engine Air Cleaner ............................10-3
Miscellaneous Maintenance ........................................10-3
Cleaning the Generator ...........................................10-3
Cold Weather Kit .......................................................6-2
5.4L & 6.8L Ignition Description .................................6-3
Ignition Power-up Input (“56 Line Input”) .................6-3
Ignition Enable (“14 Line Input”) ..............................6-3
Ignition Shutdown on Loss of Crank or CAM Signals .........................................................6-3
Diagnostic Blink Patterns (Red LED Located on the Ignition Control Board ...................................6-3
GENERAL INFORMATION .......................................7-1
Generator AC Lead Connections ..................................7-1
Alternator Power Winding Connections ........................7-1
INSTALLATION .......................................................8-1
Installation ...................................................................8-1
Preparation Before Start-up .........................................8-1
SERVICE SCHEDULE ...........................................11-1
30 kW - 150 kW Standby Gas Engine
Driven Generator Sets ............................................11-1
TROUBLESHOOTING ...........................................12-1
Troubleshooting Guide ...............................................12-1
NOTES
EXPLODED VIEWS & PARTS LISTS
WIRING DIAGRAMS & SCHEMATICS
WARRANTY
0 08/05 Content003 Rev.
Standby Generator Sets
Important Safety Instructions
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.
WARNING:
The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.
WARNING:
This product contains or emits chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.
Study these SAFETY RULES carefully before installing, 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 warnings in this manual, and on tags and decals affixed to the unit are, therefore, not all inclusive. If a procedure, work method or operating technique is used that the manufacturer does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique utilized does not render the generator unsafe.
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 maintain 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.
Parts of the generator are rotating and/or hot during operation. Exercise care near running generators.
1-1
GENERAL HAZARDS
• 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 regulations.
• 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 serviced 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 regulations.
• 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. Exhaust gases must be piped safely away from any building or enclosure that houses the generator to an area where people, animals, etc., will not be harmed.
This exhaust system must be installed properly, in strict compliance with applicable 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 ventilating air is critical in any room or building housing the generator to prevent buildup of explosive gases and to ensure correct generator operation.
Do not alter the installation or permit even partial blockage of ventilation provisions, as this can seriously affect safe operation of the generator.
• 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 factory-approved parts.
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Important Safety Instructions
• Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start-up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last.
• Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.
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 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 platform. Work on the equipment only while standing on such insulative mats.
• The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground. This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator set or by static electricity. 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.
• 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 hazardous and possibly fatal electrical shock.
• Connecting this unit to an electrical system normally supplied 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 damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy.
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1-2
• 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 generator 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 possible, 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.
• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving components causing injury.
FIRE HAZARDS
• 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 insulation. 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
• Properly ventilate any room or building housing the generator to prevent build-up of explosive gas.
• 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.
• Diesel fuels are highly FLAMMABLE. 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.
Standby Generator Sets
Important Safety Instructions
INTRODUCTION
Thank you for purchasing this model of the standby generator set product line.
Every effort was expended to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written. However, the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any time without prior notice.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest Authorized Service Dealer for starting, operating and servicing procedures.
Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.
Their definitions are as follows:
DANGER
After this heading, read instructions that, if not strictly complied with, will result in personal injury or property damage.
After this heading, read instructions that, if not strictly complied with, may result in personal injury or property damage.
After this heading, read instructions that, if not strictly complied with, could result in damage to equipment and/or property.
NOTE:
After this heading, read explanatory statements that require special emphasis.
These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the service are essential to preventing accidents.
Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type of information each indicates is as follows:
This symbol points out important safety information that, if not followed, could endanger personal safety and/or property of others.
This symbol points out potential explosion hazard.
1-3
This symbol points out potential fire hazard.
This symbol points out potential electrical shock hazard.
The operator is responsible for proper and safe use of the equipment. The manufacturer strongly recommends that the operator read this Owner's Manual and thoroughly understand all instructions before using this equipment. The manufacturer also strongly recommends instructing other users to properly start and operate the unit. This prepares them if they need to operate the equipment in an emergency.
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment checked periodically by an Authorized
Service Dealer. Normal maintenance service and replacement of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.
Proper maintenance and care of the generator ensure a minimum number of problems and keep operating expenses at a minimum. See an Authorized Service
Dealer for service aids and accessories.
Operating instructions presented in this manual assume that the standby electric system has been installed by an Authorized Service Dealer or other competent, qualified contractor. Installation of this equipment is not a “do-it-yourself” project.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs, simply contact an Authorized Service Dealer for assistance. Service technicians are factory-trained and are capable of handling all service needs.
When contacting an Authorized Service Dealer or the factory about parts and service, always supply the complete model number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit.
AUTHORIZED SERVICE DEALER LOCATION
To locate the nearest AUTHORIZED
SERVICE DEALER, please call this number:
1-800-333-1322
or locate us on the web at: www.generac.com
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General Information
IDENTIFICATION RECORD
DATA LABEL
Every generator set has a DATA LABEL that contains important information pertinent to the generator. The data label, which can be found attached to the generator’s lower connection box, lists the unit’s serial number and its rated voltage, amps, wattage capacity, phase, frequency, rpm, power factor, etc.
GENERATOR SET DATA
MADE IN USA
MODEL
RATED KW
RATED VOLTAGE
POWER FACTOR
ENGINE RPM
HERTZ
SERIAL
RATED KVA
RATED AMPS
PHASE
PRODUCTION DATE
ALT RPM
ALTERNATOR SUBTRANSIENT REACTANCE
ALTERNATOR TRANSIENT REACTANCE
CLASS ROTOR STATOR WINDING INSULATION AT 25
°C AMBIENT
GENERAC POWER SYSTEMS, INC.
WAUKESHA, WI
NOTE:
For actual information related to this particular model, please refer to the Manual Drawing Listing located at the end of this manual, or to the data label affixed to the unit.
Generator Model and Serial Number
This number is the key to numerous engineering and manufacturing details pertaining to your unit. Always supply this number when requesting service, ordering parts or seeking information.
Identification Code
Use this code to obtain important information about the generator. For example, if the code is:
M Q T 1 0 0 5 4 A N S N A
M — Designates generators capable of paralleling.
NOTE: Only 100kW and 150kW, 6.8L units are currently available for this configuration.
QT — Quiet Test Generator Series
100 — kw Rating
5.4 — Engine Size in Liters
A — Voltage Code: A = 120/240, Single-phase;
G = 120/208, Three-phase; K = 277/480,
Three-phase; J = 120/240, Three-phase;
L = 346/600, Three-phase
N — Fuel: N = Natural Gas; V = Vapor Propane
S — Enclosure Material: A = Aluminum; S
= Steel (Corrosion Resistant Aluminum
Enclosure Material, Steel is Standard)
N — Emission Equipment: N = No Equipment;
Y = Catalytic Converter and Air/Fuel Ratio
Controller
A — Industrial Dealer Product
Voltage Codes
The identification code letter following the unit’s engine size is the generator’s “voltage code.”
Groups and Assembly Numbers
The manual drawing listing lists the groups and corresponding assembly numbers for each unit. The assembly numbers refer to exploded view drawing numbers that are applicable to the specific generator model. These drawings are located in the back half of this manual.
2-1
C 04/06 Identy001 Rev.
Standby Generator Sets
Equipment Description
EQUIPMENT DESCRIPTION
This equipment is a revolving field, alternating current generator set. It is powered by a gaseous fueled engine operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for 2-pole direct drive units and
2300 - 3000 rpm for quiet drive gear units. See the
Specifications section for exact numbers. The unit comes complete with a sound attenuated enclosure, internally mounted muffler, control console, mainline circuit breaker, battery charger, and protective alarms as explained in the following paragraph.
All AC connections, including the power leads from the alternator, 120 volt battery charger input and control connections to the transfer switch are available in the main connection box.
The generator incorporates the following generator features:
• Rotor and Stator insulation is Class H rated as defined by NEMA MG1-32.6, NEMA MG1-1.66.
The generator is self ventilated and drip-proof constructed.
• The voltage waveform deviation, total harmonic content of the AC waveform and telephone influence factor have been evaluated and are acceptable according to NEMA MG1-32.
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:
Temperature (Recommended)
Above 80° F (27° C)
32° to 80° F (0° to 27° C)
Below 32° F (0° C)
SAE 30W or 15W-40
SAE 20W-20 or 15W-40
See Note
COOLANT RECOMMENDATIONS
Use a mixture of half low silicate ethylene glycol base anti-freeze and deionized water. Cooling system capacity is listed in the specifications. Use only deionized water and only low silicate anti-freeze. If desired, add a high quality rust inhibitor to the recommended coolant mixture. When adding coolant, always add the recommended 50-50 mixture.
Do not use any chromate base rust inhibitor with ethylene glycol base anti-freeze or chromium hydroxide (“green slime”) forms and will cause overheating. Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base anti-freeze. Using any high silicate anti-freeze boosters or additives will also cause overheating. The manufacturer also recommends that any soluble oil inhibitor is NOT used for this equipment.
DANGER
Do not remove the radiator pressure cap while the engine is hot or serious burns from boiling liquid or steam could result.
Ethylene glycol base antifreeze is poisonous.
Do not use mouth to siphon coolant from the radiator, recovery bottle or any container. Wash hands thoroughly after handling. Never store used antifreeze in an open container because animals are attracted to the smell and taste of antifreeze even though it is poisonous to them.
Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in an engine failure.
NOTE:
For temperatures below 32° F, it is strongly recommended to use the optional Cold Weather Start Kit
(part number listed in the Specification Section).
The oil grade for temperatures below 32° F is 5W-
30 synthetic oil.
0 08/05 Equip001 Rev.
3-1
Standby Generator Sets
Engine Protective Devices
ENGINE PROTECTIVE DEVICES
The standby generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant temperature, oil pressure or rpm. For that reason, the engine has several devices designed to protect it against potentially damaging conditions by automatically shutting down the unit when the oil pressure is too low, the coolant temperature is too high, the coolant level is too low, or the engine is running too fast.
NOTE:
Engine protective switches and sensors are mentioned here for the reader's convenience. Also refer to the applicable control panel manual for additional automatic engine shutdown information.
COOLANT TEMPERATURE SENSING
An analog Water Temperature Sender (WTS) is located in the engine's cooling system. This sender is connected to the panel and allows the panel to monitor and display the temperature of the coolant system.
The WTS is a resistive device whose resistance changes based on coolant temperature. The resistance of the sender results in a voltage being developed across the sender. As the Coolant temperature increases, the resistance will decrease, causing the voltage to decrease. This changing voltage is converted to 4-
20mA signal by a signal conditioner module. The corresponding 4-20mA signal is read by the control panel and displayed as the coolant temperature.
The control panel will monitor and display the coolant temperature anytime the DC input to the control panel is present.
If the temperature exceeds approximately 140° C
(284° F), the engine shutdown will be initiated. The generator will automatically restart and the display will reset once the temperature has returned to an operating level.
LOW COOLANT LEVEL
A Low Coolant Level (LCL) sensor is placed in the generators coolant system. This sensor allows the panel to detect a Low Coolant Level condition.
The LCL is a resistive device whose resistance changes rapidly based on the presence or absence of coolant.
The resistance of the LCL results in a voltage being developed across the LCL. This voltage changes as the resistance changes. This changing voltage is converted to 4-20mA signal by a signal conditioner module. The corresponding 4-20mA signal is read by the control panel and displayed as the low coolant level.
If the level of the engine coolant drops below the level of the low coolant level sensor, the engine shutdown will be initiated.
4-1
OIL PRESSURE SENSING
An analog Oil Pressure Sender (OPS) is used for monitoring the engine oil pressure. This sender allows the control panel to measure and display the
Engine oil pressure.
The OPS is a resistive device, whose resistance changes based on engine oil pressure. The resistance of the sender results in a voltage being developed across the sender. As the oil pressure increases, the resistance will decrease, causing the voltage to decrease. This changing voltage is converted to 4-
20mA signal by a signal conditioner module. The corresponding 4-20mA signal is read by the control panel and displayed as the oil pressure.
The control panel will monitor and display oil pressure anytime the DC input to the control panel is present.
Should the oil pressure drop below the 8 psi range, the engine shutdown is initiated. The unit should not be restarted until oil is added. Turn the AUTO/OFF/
MANUAL switch to the OFF position, then back to
AUTO to restart.
OVERCRANK SHUTDOWN
When the control panel receives a start signal, it initiates the programmed starting sequence. The start sequence consists of the number of crank attempts, the length of each crank attempt, and the rest time between each crank attempt. If the engine has not started by the end of the final crank attempt, an
Overcrank alarm is generated, the control panel will sound the alarm and display the message "Failed to start".
OVERSPEED SHUTDOWN
A speed circuit controls engine cranking, start-up, operation and shutdown. Engine speed signals are delivered to the circuit board whenever the unit is running. Should the engine over speed above a safe, preset value, the circuit board initiates an automatic engine shutdown. Contact the nearest Authorized
Dealer if this failure occurs.
RPM SENSOR LOSS SHUTDOWN
If the speed signal to the control panel is lost, engine shutdown will occur.
DC FUSE
This fuse is located inside of the control panel. It protects the panel wiring and components from damaging overload. Always remove this fuse before commencing work on the generator. The unit will not start or crank if the fuse is blown. Replace the fuse with one of the same size, type, and rating. (See the exploded views and parts lists at the end of this manual for replacement part number.)
B 10/05 EngProt002 Rev.
Standby Generator Sets
Fuel Systems
FUEL SYSTEM
FUEL REQUIREMENTS
The standby generator may be equipped with one of the following fuel systems:
• Natural gas fuel system
• Propane vapor (PV) fuel system
• Liquid propane (LP) fuel system
The Manual Drawing Listing that is affixed to the unit includes the “Identification Code,” which may be used to identify the type of fuel system installed on the unit.
Recommended fuels should have a Btu content of at least 1,000 Btu's per cubic foot for natural gas; or at least 2,520 Btu's per cubic foot for LP gas. Ask the fuel supplier for the Btu content of the fuel.
Required fuel pressure for natural gas is 11 inches to 14 inches water column (0.4 to 0.5 psi); and for liquid propane, 11 inches to 14 inches of water column (0.4 to 0.5 psi).
NOTE:
Any piping used to connect the generator to the fuel supply should be of adequate size to ensure the fuel pressure NEVER drops below 11 inches water column for natural gas or 11 inches water column for liquid propane for all load ranges.
NOTE:
It is the responsibility of the installer to make sure that only the correct recommended fuel is supplied to the generator fuel system. Thereafter, the owner/operator must make certain that only the proper fuel is supplied.
NATURAL GAS FUEL SYSTEM
Natural gas is supplied in its vapor state. In most cases, the gas distribution company provides piping from the main gas distribution line to the standby generator site. The following information applies to natural gas fuel systems.
• Gas pressure in a building is usually regulated by national, state and local codes.
• To reduce gas pressure to a safe level before the gas enters a building, a primary regulator is needed. The natural gas supplier may or may not supply such a regulator.
• It is the responsibility of the gas supplier to make sure sufficient gas pressure is available to operate the primary regulator.
• Gas pressure at the inlet to the fuel shutoff solenoid should not exceed approximately 14 inches water column (0.5 psi). Optimum pressure at the fuel shutoff solenoid is 11 inches water column
(0.4 psi).
5-1
PROPANE VAPOR WITHDRAWAL FUEL SYSTEM
This type of system utilizes the vapors formed above the liquid fuel in the supply tank. Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor state. The vapor withdrawal system is generally best suited for smaller engines that require less fuel. The installer should be aware of the following:
• The natural gas and LP gas systems are similar.
However, the natural gas system delivers gas at a pressure of approximately five inches water column to the carburetor.
• When ambient temperatures are low and engine fuel consumption is high, the vapor withdrawal system may not function efficiently.
• Ambient temperatures around the supply tank must be high enough to sustain adequate vaporization, or the system will not deliver the needed fuel volume.
• In addition to the cooling effects of ambient air, the vaporization process itself provides an additional cooling effect.
LP FUEL SYSTEM
LP is supplied as a liquid in pressure tanks. It is usually made up of propane, butane, or a mixture of the two gases. Propane tends to vaporize readily even at temperatures as low as -20° F (-29° C). However, butane reverts to its liquid state when temperatures drop below 32° F (0° C).
LP in a liquid withdrawal system must be converted to its gaseous state before it is introduced into the engine carburetor. A vaporizer-converter is generally used to accomplish this. In such a converter, heated engine coolant is ported through the converter to provide the necessary heat for conversion of the fuel from a liquid to a gaseous state.
A 05/06 FuelSys002 Rev.
Standby Generator Sets
Specifications
SPECIFICATIONS
GENERATOR
Type ............................................................................. Synchronous
Rotor Insulation ................................................................... Class H
Stator Insulation .................................................................. Class H
Total Harmonic Distortion ......................................................< 3.5%
Telephone Interference Factor (TIF) ..........................................< 50
Alternator Output Leads 3-phase ........................................... 6-wire
Bearings .........................................................................Sealed Ball
Coupling .......................................................................Flexible Disc
Load Capacity (Standby Rating) ..........................................100kW*
*
NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349,
ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural gas.
Excitation System ............................................................. Brushless
Generator Output Voltage/kW - 60 Hz kW Amp CB Size
120/240V, 1-phase, 1.0 pf 100 417 500
120/208V, 3-phase, 0.8 pf
277/480V, 3-phase, 0.8 pf
100 347 400
100 150 200
Generator Locked Rotor KVA Available @ Voltage Dip of 35%
Single-phase or 208 3-phase ........................................... 190 KVA
480V, 3-phase .................................................................. 225 KVA
ENGINE
Make ................................................................................... Generac
Model ...................................................................................... V-type
Cylinders and Arrangement ............................................................ 8
Displacement ....................................................................... 5.4 Liter
Bore ...................................................................................... 3.55 in.
Stroke ................................................................................... 4.17 in.
Compression Ratio ..................................................................9-to-1
Air Intake System ...............................................Naturally Aspirated
Valve Seats ....................................................................... Hardened
Lifter Type .......................................................................... Hydraulic
Engine Parameters
Rated Synchronous RPM ..............................................60 Hz, 3600
HP at rated kW ................................................................60 Hz, 175
Exhaust System
Exhaust Flow at Rated Output 60 Hz .................................. 953 cfm
Exhaust Temperature at Rated Output ................................ 1000° F
Combustion Air Requirements (Natural Gas)
Flow at rated power, 60 Hz ................................................. 325 cfm
Governor
Type .................................................................................. Electronic
Frequency Regulation ...................................................Isochronous
Steady State Regulation ........................................................± 1/2%
Adjustments:
Speed ............................................................................ Selectable
Engine Lubrication System
Type of Oil Pump ...................................................................... Gear
Oil Filter .............................................................Full Flow, Cartridge
Crankcase Oil Capacity ....................................................5 U.S. qts.
COOLING SYSTEM
Type ....................................................................................... Closed
Water Pump .................................................................... Belt Driven
Fan Speed ................................................................................ 1700
Fan Diameter .....................................................................26 inches
Fan Mode ................................................................................ Puller
Air Flow (inlet air including alternator and
combustion air) ........................................................... 4800 ft 3 /min.
Coolant Capacity ........................................................ (4.0 U.S. gal.)
Heat Rejection to Coolant ..........................................376,000 Btu/h
Maximum Operating Air Temp. on Radiator ..............60° C (150° F)
Maximum Ambient Temperature ................................50° C (140° F)
FUEL SYSTEM
Type of Fuel ...................................................................Natural Gas
Carburetor ...................................................................... Down Draft
Secondary Fuel Regulator .................................................Standard
Fuel Shut-off Solenoid ........................................................Standard
Operating Fuel Pressure .................... 11 in. - 14 in. Water Column
Fuel Consumption - ft 3 /hr (Natural Gas/LPV)
Exercise 25% 50% 75% 100%
Cycle Load Load Load Load
140/56 371/149 713/287 994/400 1374/553
* Engine is not field convertible between natural gas and propane. Jet size and ignition timing are factory set for the specific fuel.
ELECTRICAL SYSTEM
Battery Charge Alternator ............................................12V, 30 Amp
Static Battery Charger ....................................................12V, 2 Amp
Recommended Battery ................................................ 24F 525CCA
System Voltage .....................................................................12 Volts
Voltage Regulator
Type ................................................................................. Full Digital
Sensing ................................................................................ 3-phase
Regulation .............................................................................± 1/4%
Features ............................................ Built into H-100 Control Panel
V/F Adjustable, Adjustable
Voltage and Gain
Power Adjustment for Ambient Conditions
Temperature Deration
3% for every 10° C above °C ..................................................... 25
1.65% for every 10° above °F .................................................... 77
Altitude Deration
1% for every 100 m above m ................................................... 183
3% for every 1000 ft. above ft. ................................................. 600
6-1
Controller .............................................. H-panel
C 11/05 GenSpec007 Rev.
Standby Generator Sets
Specifications
Figure 1 — Interconnections
GROUND ONLY
AT GENERATOR BOX
C 11/05
COLD WEATHER KIT
For cold climates, optional cold weather kit (part number 0F6148A) is recommended. The kit includes:
• Battery Warmer
• 4” Junction Box with hardware
• Thermostat; 20 deg “ON”, 40 deg “OFF”
• 6 qt. pack 5W-30 synthetic oil (engine)
GenSpec007 Rev.
6-2
Standby Generator Sets
Specifications
5.4L & 6.8L IGNITION DESCRIPTION
This single-fire Ignition is intended to operate with a 10-cylinder, 6.8L engine and an 8-cylinder, 5.4L engine.
The 6.8L engine uses a 40-1 crank sensor, a magpickup CAM sensor and individual coil-on-plug coils for each spark-plug.
The 5.4L engine uses a 36-1 crank sensor, a magpick-up CAM sensor and individual coil-on-plug coils for each spark-plug.
With a single-fire ignition, each high-voltage coil output is connected to one spark plug resulting in that spark plug being fired only during the compression cycle.
Engine Timing versus Engine Speed for the 6.8L engine is:
RPM
1800 rpm
NG/LP Engine Timing (BTDC)
22 degrees
3600 rpm 24 degrees
Engine Timing versus Engine Speed for the 5.4L engine is:
RPM
1800 rpm
3600 rpm
NG/LP Engine Timing (BTDC)
26 degrees
26 degrees
IGNITION POWER-UP INPUT ("56 LINE
INPUT")
When battery voltage is applied to this input the ignition will power-up. For the ignition to power itself down, battery voltage must be removed from this input.
IGNITION ENABLE ("14 LINE INPUT")
This input must be connected to the +12V battery for the ignition to turn-on the coils. If this input is connected to battery ground the ignition will stop firing the coils and will power down within approximately
2 seconds. In the event that an ignition fault has occurred, however, the ignition will wait 60 seconds before powering down. This allows time to view the diagnostic LED located on the ignition board.
NOTE:
The ignition cover does not need to be removed to see the LED.
IGNITION SHUTDOWN ON LOSS OF CRANK
OR CAM SIGNALS
The ignition will stop firing the coils immediately following the loss of the crank signal. The ignition will stop firing the coils after approx. 3 seconds following the loss of the cam signal.
DIAGNOSTIC BLINK PATTERNS (RED LED
LOCATED ON THE IGNITION CONTROL
BOARD)
During normal ignition operation the RED LED flashes at a 0.5 sec ON and a 0.5 sec OFF rate. This is considered one (1) blink.
LED Fault Code with Priority as shown:
1. No Crank Signal: LED blinks 2 times, is OFF for
3.0 seconds and then repeats
2. No CAM Signal: LED blinks 3 times, is OFF for
3.0 seconds and then repeats
Only one fault is displayed at a time. If multiple faults exist then the highest priority fault must be resolved prior to a lower priority fault being displayed. In the event that an ignition fault has occurred the ignition will wait 60 seconds before powering down.
NOTE:
The ignition cover does not need to be removed to see the LED.
C 11/05 GenSpec007 Rev.
6-3
Standby Generator Sets
General Information
GENERATOR AC LEAD CONNECTIONS
See “Voltage Codes”. This generator may be rated at any one of three voltages, either single-phase or three-phase. The electrical wires in the unit’s AC connection (lower) panel should be installed according to the number of leads and the voltage/phase required for the application. If there are any questions regarding lead connection, refer to the wiring diagrams at the back of this manual.
Voltage codes apply to the type of stator assembly installed on a particular generator.
FOUR-LEAD, SINGLE-PHASE STATOR
Four-lead generators (see Figure 7.1) are designed to supply electrical loads with voltage code “A” (240V,
1-phase, 60 Hz). Electrical power is produced in the stator power windings. These windings were connected at the factory to the main circuit breaker as shown in Figure 7.1.
The rated voltage between each circuit breaker terminal is 240V. The rated voltage between each circuit breaker terminal and the neutral point 00 is 120V.
Figure 7.1 — Four-lead, Single-phase Stator
ALTERNATOR POWER WINDING
CONNECTIONS
3-PHASE ALTERNATORS
The generator is designed to supply 3-phase electrical loads. Electric power is produced in the alternator power windings. These windings were connected at the factory to the main circuit breaker with a “Y” configuration as shown in Figures 7.2 and 7.3.
The rated voltage between circuit breaker terminals
E1-E2, E1-E3 and E2-E3 is either 480V or 208V depending on the model.
The rated voltage between each circuit breaker terminal and the neutral point 00 is either 277V or 120V depending on the model.
Figure 7.2 — Stator Power Winding
Connections - 3-phase, 277/480V (6 Lead)
S1 E1
INTERNAL
CONNECTIONS
L-L
S6 S4
NEUTRAL
S5
E3 S3
S2 E2
L-N
Figure 7.3 — Stator Power Winding
Connections - 3-phase, 120/208V (6 Lead)
E1
S1 S1
7-1
S3
E3
S3
S4
S6
S4
S5
00 (NEUTRAL)
L-L
S6
S5
S2
L-N
S2
E2 v. 0 08/05 ACConn001 Re
Standby Generator Sets
Installation
INSTALLATION
Refer to the separate “Installation Guide QT Product
Line” supplied with the unit.
PREPARATION BEFORE START-UP
The instructions in this section assume that the standby generator has been properly installed, serviced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor.
Be sure to read the “Safety Rules”, as well as all other safety information in this manual, before attempting to operate this (and related) equipment.
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 the “Maintenance” section and the “Service Schedule”.
TRANSFER SWITCH
If this generator is used to supply power to any electrical system normally powered by an electric utility, the National Electrical Code requires that a transfer switch be installed. The transfer switch prevents electrical backfeed between two different electrical systems. (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.
FUEL SYSTEM
Make sure the fuel supply system to the generator (a) delivers the correct fuel at the correct pressure and (b) is properly purged and leak tested according to code. No fuel leakage is permitted. See
“Specifications” for more information.
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:
This engine is shipped from the manufacturer with “break-in” oil. This oil should be changed after 30 hours of operation.
Check the oil level in the generator gearbox (if so equipped) prior to initial use and at the intervals indicated by the “Service Schedule.” The recommended oil is SAE 90 gear lubricant.
Also, if the engine is equipped with a mechanical governor, make sure the governor is properly lubricated with clean engine oil.
8-1
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.
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” sections.
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 5/8inch (10 to 16 mm).
ELECTRICAL SYSTEM
Make sure the generator is properly connected to an approved earth ground.
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 connections. Restrain any loose wires to keep them clear of any moving generator set components.
INITIAL INSPECTION FOR QT GENSET
STARTUP
Inspect for the following.
• Freight Damage.
• Manuals present.
• Fluid Levels (Oil, coolant, battery, Gear Drive).
• Correct fuel piping.
• Correct muffler installation for external application.
• Adequate air flow, clearances and ventilation per installation drawings and applicable codes.
• Correct AC and DC wire size, connections and grounding. Control and communication wiring to/ from the transfer switch must be run in a separate conduit from the AC power leads.
• Battery charger connection to 120 VAC.
• Communication wires connected between transfer switch and generator (HTS only).
• Unit secured to pad.
C 05/06 Install001 Rev.
Standby Generator Sets
Installation
START-UP CHECKLIST
Before working on the generator, ensure the following:
• The AUTO/OFF/MANUAL switch is in the OFF position.
• The 120VAC supply to the battery charger is switched OFF.
PREPARATION FOR START-UP
• Ensure that the 120VAC circuit breaker to the battery charger is open.
• Remove the fuse from the the control panel. For the H-100 and R-series: Open the front door of the control box and remove the 15 Amp ATO fuse in the lower left-hand corner of the control box.
• Connect the battery cables to the battery. Attach negative battery cable last.
• Close the 120VAC circuit breaker to the battery charger.
• Measure the voltage at the battery before and after the charger is turned on.
• Verify all AC electrical connections are tight at the circuit breaker and transfer switch.
• Visually inspect entire area looking for loose paper, plastic wrappings, leaves, etc.
• Check all hoses clamps fittings for leaks or damage.
• Check all electrical plugs throughout the generator. Ensure each plug is seated correctly and fully inserted into its receptacle.
• Verify the AUTO/OFF/MANUAL switch is in OFF position.
• Open the valve to the engine fuel line.
• Bleed the fuel system of air. (necessary for long fuel lines).
• Open the generator main line circuit breaker.
• Connect a manometer to the gas line and record the static pressure. It must be as listed in the
Specifications.
• Insert the fuse into the control panel.
• Move the AUTO/OFF/MANUAL switch to the MAN-
UAL position. The engine should now crank and start.
• Check voltage at the generator terminals.
• For 3-phase units, check phase rotation at the transfer switch terminals. The generator phase rotation must match the utility phase rotation.
• Check for coolant, fuel, oil, and exhaust leaks.
• Close the generators main line circuit breaker.
• Turn the generator set off.
• Connect the UTILITY supply to the transfer switch.
• Set the AUTO/OFF/MANUAL switch to AUTO.
• Disconnect utility power before the transfer switch.
Engine should start, transfer to load.
Run at least 15 minutes on generator power.
Make certain all 3-phase loads are functioning correctly (correct phase rotation).
• Reconnect Utility power
Transfer switch will transfer back to Utility and engine will shut down within the given time parameters set up for the specific transfer switch and controller.
• Install all covers, access plates and door panels.
• Put the Owners Manual in a safe and accessible place.
• Make certain the AUTO/OFF/MANUAL switch is in the AUTO position.
START-UP INSPECTION
When a start-up is performed by an Authorized
Service Dealer, a standard three-part form titled
“Start-up Inspection for Standby Power Systems”
(part no. 067377), should be completed by the installation technician or engineer. See page 1-3 for information on locating the nearest Authorized Service
Dealer. The installer should complete the form and disseminate copies as follows:
• White copy: Mail to Generac Warranty Department,
P.O. Box 340, 211 Murphy Dr., Eagle, WI 53119-
2062.
• Pink Copy: For service file of installing dealer.
• Yellow Copy: For the customer’s records.
C 05/06 Install001 Rev.
8-2
Standby Generator Sets
Operation
GENERATOR CONTROL AND
OPERATION
Refer to the appropriate control panel operator’s manual for this unit.
OPERATING UNIT WITH MANUAL
TRANSFER SWITCH
If the generator was installed in conjunction with a transfer switch capable of manual operation only, the following procedure applies. A manually operated transfer switch is one that will not provide automatic start-up and does not include an intelligence circuit.
ENGINE START-UP AND TRANSFER
For additional information, refer to the applicable control panel manual for this unit, as well as any literature pertaining to the specific transfer switch.
DANGER
The Maintenance Disconnect Switch and the
AUTO/OFF/MANUAL switches (if so equipped) must be set properly, or the generator will crank and start as soon as the utility power to the transfer switch is turned off. Refer to applicable control panel and transfer switch manuals for more information.
Do not proceed until certain that utility source voltage is available to the transfer switch and the transfer switch main contacts are set to
UTILITY.
Do not attempt manual operation until all power supplies to the transfer switch have been positively turned off, or extremely dangerous - possibly lethal - electrical shock will result.
Transfer switch enclosure doors should be kept closed and locked. Only authorized personnel should be allowed access to the transfer switch interior. Extremely high and dangerous voltages are present in the transfer switch.
In order to transfer load from the utility source to the generator, follow these directions:
• Turn OFF or disconnect the utility power circuit to the transfer switch, using the means provided
(such as the utility source main line circuit breaker).
• Set the transfer handle to its UTILITY (NORMAL) position with load circuits connected to the utility power supply.
• Set the standby generator’s main line circuit breaker to its OFF (or OPEN) position.
• Start the generator.
9-1
Do not crank the engine continuously for longer than 30 seconds, or the heat may damage the starter motor.
• Let engine stabilize and warm up.
• Check all applicable instrument and gauge readings. When certain that all readings are correct, move the transfer switch manual handle to its
STANDBY (GENERATOR) position, i.e., load circuits supplied by the generator.
• Set the standby generator’s main line circuit breaker to its ON (or CLOSED) position.
• Load circuits are now powered by the standby generator.
RETRANSFER AND SHUTDOWN
For additional information, refer to the applicable control panel manual for this unit, as well as any literature pertaining to the specific transfer switch.
To transfer the load back to the utility power source and shut down the generator, follow these directions:
• Set the standby generator’s main line circuit breaker to its OFF (or OPEN) position.
• Manually move the transfer switch handle to its
UTILITY (NORMAL) position, i.e., load circuits connected to the utility.
• Turn ON the utility power supply to the transfer switch, using the means provided (such as the utility power source main line circuit breaker).
• Let the generator run at no-load for a few minutes to stabilize internal temperatures.
• Shut down the generator.
OPERATING UNIT WITH AUTOMATIC
TRANSFER SWITCH
If the generator has been installed with an automatic transfer switch, such as an RTS, HTS, or GTS-type transfer switch, the engine may be started and stopped automatically or manually.
NOTE:
Refer to the applicable manual for your transfer switch and to “Transfer Switch Start Signal
Connections”. In addition, please note the dangers under “Engine Start-up and Transfer.”
0 08/05 Oper001 Rev.
Standby Generator Sets
Maintenance
MAINTENANCE PERFORMED BY
AUTHORIZED SERVICE FACILITIES
Before working on the generator, ensure the following:
• The AUTO/OFF/MANUAL switch is in the OFF position.
• The 15A fuse has been removed from the control box.
• The 120VAC supply to the battery charger is switched OFF.
EVERY THREE MONTHS
1. Check battery state of charge and condition.
2. Inspect and test fuel system.
5. Check engine ignition system.
ONCE EVERY SIX MONTHS
1. Test Engine Safety Devices (low oil pressure, low coolant level, high coolant temperature).
ONCE ANNUALLY
1. Test engine governor. Adjust or repair, if needed.
The exhaust system parts from this product get extremely hot and remain 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.
CHECKING FLUID LEVELS
CHECK ENGINE OIL
Check engine crankcase oil level (Figure 10.1) at least every 20 hours of operation, or prior to use.
• Remove oil dipstick and wipe dry with a clean, lintfree 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
Recommendations” for recommended oils.
Figure 10.1 - Oil Dipstick and Oil Fill Cap
Oil Fill
FIRST 100 OPERATING HOURS
1. Change engine oil and oil filter. (After initial change, service engine oil and filter at 150 operating hours or 6 months, whichever comes first.)
EVERY 500 OPERATING HOURS
3. Check engine DC alternator.
COOLING SYSTEM
Air intake and outlet openings in the generator compartment must be open and unobstructed for continued proper operation. This includes such obstructions as high grass, weeds, brush, leaves and snow.
Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down.
Oil
Dipstick
Oil Filter
BATTERY FLUID
Check battery electrolyte fluid at least once weekly.
Fluid should cover separators in all battery cells. If fluid level is low, add distilled water to cover tops of separators. DO NOT USE TAP WATER IN BATTERY.
0 08/05 Maint003 Rev.
10-1
Standby Generator Sets
Maintenance
ENGINE COOLANT
Check coolant level in coolant recovery bottle. See the
“Specifications” section.
• Add recommended coolant mixture as necessary.
• Periodically remove radiator pressure cap 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 recovery system for leaks.
MAINTENANCE OWNER/
OPERATOR CAN PERFORM
CHECK ENGINE OIL LEVEL
Refer to the “Checking Fluid Levels” section.
CHECK BATTERY
• Check battery fluid level each week as outlined under “Check Fluid Levels”.
• Check battery cables for condition, tightness, corrosion or damage. Clean, tighten or replace as necessary.
EXERCISE SYSTEM
Start the generator engine at least once every seven days and let it run at least 20 minutes. See the
“Weekly Exercise Cycle” section.
INSPECT COOLING SYSTEM
• Inspect engine cooling system at least once each month.
• Check hoses for damage, deterioration, leaks, etc.
Correct any discrepancies found.
• Check hose clamps for tightness.
CHECK ENGINE COOLANT LEVEL
See the “Checking Fluid Levels” section.
PERFORM VISUAL INSPECTION
Complete a thorough visual inspection of the entire engine-generator monthly. Look for obvious damage, loose, missing or corroded nuts, bolts and other fasteners. Look for fuel, oil or coolant leaks.
CHECK FAN BELT
• Inspect fan belts every three months. Replace any damaged, deteriorated, worn or otherwise defective belt.
• Check fan belt tension. Thumb pressure, exerted midway between pulleys, should deflect about 3/8 to 5/8 inch. Adjust belt tension as required.
INSPECT ENGINE GOVERNOR
Visually inspect electronic governor.
DANGER
Do not attempt to adjust the governor. Only qualified service facilities should adjust the 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 qualified service technicians should adjust the governed speed.
CHANGING ENGINE OIL
Refer to maintenance performed by authorized service facilities for engine oil and filter change frequencies.
Drain the oil while the engine is still warm from running. This means warm up the engine, shut it down and drain immediately as follows:
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. Turn OIL FILTER (Figure 10.2) counterclockwise and remove. Dispose of old filter.
5. Apply light coating of new engine oil to seal of new oil filter.-Install FILTER and tighten by hand only.
DO NOT OVERTIGHTEN.
SPECIFICATIONS). DO NOT FILL ABOVE THE
DIPSTICK “FULL” MARK. Crankcase oil capacity is listed in the “Specifications”.
INSPECT EXHAUST SYSTEM
Inspect the exhaust system at least once every three months. Check all exhaust system pipes, mufflers, clamps, etc. for condition, tightness, leaks, security,
0 08/05 damage.
Maint003 Rev.
10-2
After refilling the crankcase with oil, always check oil level on dipstick. NEVER OPERATE
ENGINE WITH OIL BELOW THE DIPSTICK “ADD”
MARK.
Standby Generator Sets
Maintenance
7. Start engine and check for oil leaks.
Figure 10.2 - Oil Filter
Oil
Dipstick
SPARK PLUGS
Reset the spark plug gap or replace the spark plugs as necessary.
1. Clean the area around the base of the spark plugs to keep dirt and debris out of the engine. Clean by scraping or washing using a wire brush and commercial solvent. Do not blast the spark plugs to clean.
2. Remove the spark plugs and check the condition.
Replace the spark plugs if worn or if reuse is questionable. See the “Service Schedule” section for recommended inspection.
3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 1.14 mm (0.045 inch) by carefully bending the ground electrode (Figure
10.4).
Figure 10.4 – Setting the Spark Plug Gap
SET PLUG GAP AT 1.14 mm
(0.045 inch)
Oil Filter
CHANGING THE ENGINE AIR CLEANER
To replace the engine air cleaner, (part number
0A4637), remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover.
Figure 10.3 — Engine Air Filter
Air Filter
COOLANT CHANGE
Every year, have an Authorized Service Facility drain, flush and refill the cooling system. See the
“Specifications” section for cooling system recommendations.
MISCELLANEOUS MAINTENANCE
CLEANING THE GENERATOR
Keep the generator as clean and as dry as possible.
Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation resistance.
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.
See the “Service Schedule” section for air cleaner maintenance.
10-3
Once each year, have the generator cleaned and inspected by an Authorized Service Dealer. That dealer 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.
0 08/05 Maint003 Rev.
Standby Generator Sets
Maintenance
0 08/05
Finally, have the insulation resistance of stator and rotor windings checked. If insulation resistances are excessively low, the generator may require drying.
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 battery fluid is spilled, flush the affected area with clear water immediately.
• 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.
BATTERY MAINTENANCE
The battery should be inspected per the “Service
Schedule” section. The following procedure should be followed for inspection:
1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary.
2. Check the battery fluid level of unsealed batteries and, if necessary, fill with DISTILLED WATER
ONLY. DO NOT USE TAP WATER IN BATTER-
IES.
3. Have the state of charge and condition checked.
This should be done with an automotive-type battery hydrometer.
Maint003 Rev.
DANGER
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.
Battery electrolyte fluid is an extremely caustic 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 the fluid is spilled, flush the affected area immediately with clear water.
Do not use any jumper cables or booster battery to crank and start the generator engine. If the battery has completely discharged, remove it from the generator for recharging.
10-4
Be sure the AUTO/OFF/MANUAL switch is set to the OFF position before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected.
Be sure the 120VAC power supply to the battery is turned OFF, or sparking may occur at the battery posts as the cables are attached and cause an explosion.
BATTERY REPLACEMENT
When replacing batteries, use the same number and the type of battery that follows:
BCI Group No.
24F-6
CCA
525 @ 0 deg. F
NOTE:
The BCI number should be located directly on the battery.
REPAIR PARTS
The latter portion of this manual consists of exploded views, parts lists and electrical data pertaining to this generator set. The parts lists consist of (a) an item number, (b) a part number, (c) the quantity required, and (d) a description of the part. The item number corresponds to an identical number on the exploded view drawing.
Standby Generator Sets
Service Schedule
SERVICE SCHEDULE
30 KW - 150 KW STANDBY GAS ENGINE DRIVEN GENERATOR SETS
The following is a recommended maintenance schedule for standby gas engine driven generator sets from 30kW to
150 kW in size. 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 potential problem areas.
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 15 amp control panel fuse.
• Turn off the battery charger.
• Remove the negative battery cable.
The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition from burning out sensitive control panel components and circuits.
Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal operation when required.
2 A wear-in service inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas.
Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of
the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Dealer.
3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas.
Performed semi-annually or following each 50 hours of operation of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Dealer.
4 A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas.
Performed annually or following each 100 hours of operation of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Dealer.
5 A comprehensive inspection of the generator set to insure it is properly serviced and ready to operate and carry the load when required, and to identify any potential problem areas.
Performed annually or following each 250 hours of operation of the unit.
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.
v. A 09/05 SrvSchd001 Re
11-1
Standby Generator Sets
Service Schedule
Maintenance Level 1 Level 2 Level 3 Level 4 Level5
Tasks
RecomTask Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.
to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Datemonthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) annually/ Initials)
10 hrs. 30 hrs. 50 hrs. 100 hrs. 250 hrs.
1. Disable the unit from operating per the first page warning.
Check the engine oil level. Adjust as necessary.
Check the engine coolant level.
Adjust as necessary.
4. coolant thermal protection level.
Correct as necessary.
5. gas delivery system for leaks and correct pressure on gas engine driven units. Tighten connections as necessary.
Check the air inlets and outlets for debris. Clean as necessary.
electrolyte level and specific gravity if accessible. Adjust as necessary.
Check the battery posts, cables, and charger for loose connections, corrosion, and proper operation.
Correct as necessary.
wiring for loose connections, corrosion, and damage. Correct as necessary.
v. A 09/05 SrvSchd001 Re
11-2
Standby Generator Sets
Service Schedule
Maintenance Level 1 Level 2 Level 3 Level 4 Level5
Tasks
RecomTask Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.
to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Datemonthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) annually/ Initials)
10 hrs. 30 hrs. 50 hrs. 100 hrs. 250 hrs.
10. Check the engine accessory drive belts and fan coupling device if equipped for correct tension, wear, weather cracking, and damage. Replace as necessary.
11. Check the engine valve clearance.
Adjust as necessary.
12. Visually inspect the unit looking for leaks, wear or damage, loose connections or components, and corrosion. Correct as necessary.
13. Test the engine and transfer switch safety devices. Correct and/or adjust as necessary.
14. 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.
15. Replace the engine accessory drive belts.
16. Check gearbox oil level (if equipped).
17. Change gearbox oil (if equipped).
v. A 09/05
11-3
SrvSchd001 Re
Standby Generator Sets
Service Schedule
Maintenance Level 1 Level 2 Level 3 Level 4 Level5
Tasks
RecomTask Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.
to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Datemonthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) annually/ Initials)
10 hrs. 30 hrs. 50 hrs. 100 hrs. 250 hrs.
18. 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.
19. Perform an engine oil analysis (send a sample to a lab for results).
Change the engine oil and filters if the analysis results indicate this is required.
20. Change the engine oil.
21. Replace the engine oil filter(s).
22. Replace engine spark plugs.
Clean and re-gap or replace as necessary.
23. Replace the engine air filter(s).
24. Perform a 5 minute no-load operational run of the unit looking for any post service problems.
25. Return the unit to standby setup for operation when required.
v. A 09/05 SrvSchd001 Re
11-4
Standby Generator Sets
Troubleshooting
TROUBLESHOOTING GUIDE
PROBLEM CAUSE
Engine won’t crank.
Engine cranks but won't start
Engine starts hard, runs rough.
1. 15 amp fuse blown.
2. Loose or corroded or defective battery cables.
3. Defective starter contactor.
4. Defective starter motor.
5. Dead or Defective Battery.
6. 5 amp fuse blown.
1. Out of fuel.
2. Fuel solenoid (FS) is defective
3. Open Wire #14A from Engine Control circuit board.
4. Spark plugs defective.
5. Door on tank not closed.
1. Flame arrestor (air cleaner) plugged or damaged.
2. Plugged fuel line.
3. Defective spark plugs.
4. Fuel pressure incorrect.
Engine starts then shuts down. 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.
7. Defective Low Coolant Level Switch
AUTO/OFF/MANUAL Switch at OFF, 1. Defective AUTO/OFF/MANUAL switch engine continues to run 2. Open/disconnected wire #15A between
AUTO/OFF/MANUAL switch and Control
Module circuit board.
3. Defective Control Module circuit board
No AC output from generator.
CORRECTION
1. Replace fuse.
2. Tighten, clean or replace battery cables as necessary.
3. Replace contactor.*
4. Replace starter motor.*
5. Remove, change or replace battery.
6. Replace fuse.*
1. Replenish fuel.
2. Replace solenoid.*
3. Reconnect wire.
4. Clean, regap or replace plugs.
5. Close door on tank.
1. Clean or replace as needed.
2. Unclog fuel line.
3. Clean, regap or replace plugs.
4. Confirm fuel pressure to regulator is as recommended in SPECIFICATIONS.
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.*
1. Replace switch.*
2. Reconnect/close wire.
1. Check main line circuit breaker.
2. Check circuit breaker & fuses.
3. Transfer switch set to NORMAL position
3. Replace board.*
1. Reset to ON or CLOSED.
2. Reset and replace, if necessary.
3. Set to GENERATOR position.
5. Thermal circuit breaker open. 5. Auto-reset - Wait 5 min. and attempt restart.
*Contact the nearest Authorized Dealer for assistance.
0 08/05 lsht001 Rev.
T rb
12-1
Standby Generator Sets
Notes
Standby Generator Sets
Notes
1
2
7
8
9
10
5
6
3
4
11
12
13
14
15
0F9952
0F3417
0F2984
0F9949
0F3418
0F2985
0F9950
0F9951
0F6183
0F6187
0F6184
0F6212
068405C
0F3013
072878
0C9708
0F3726B
0F2689
023454
0F8408
046526
0A2601
0A2602
022473
022097
1
1
1
REF
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
8/12
4/6
1
4
1
1
ASSY ROTOR 2390 80KB3 CPL
ASSY ROTOR 390 2P 100K BRSHLS
ASSY ROTOR 390 2P 150K BRSHLS
ASSY STATOR 80KW 1PH 2P BRSHLS
ASSY STATOR 390 2P 100K BRSHLS
ASSY STATOR 390 2P 150K BRSHLS UL
STATOR 2390 80 GB3 CPL
STATOR 2390 80 KB3 CPL
ASSY STR 390 100KW 2P 3PH 208V
ASSY STR 100KW 1PH 2P BRSHLS
ASSY STR 390 150KW 2P 3PH 208V
ASSY STR 150KW 1PH 2P BRSHLS
EXITER FIELD 2” LG SPD CONN
ASSY EXCITER 2.0" STACK 2P
KEY SQ 3/8 X 3-1/4 STEEL
HYPOT TEST PROCEDURE (NOT SHOWN)
ASSY FLYWHEEL CPL
RING PRESSURE 390 STATOR CAN
KEY WOODRUFF #E
SCREW HHC M10-1.50 X 16 G10.9
WASHER LOCK M10
SCREW HHC M16-2.0 X 45 G8.8
WASHER FLAT .688 ID X 3.25 OD
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4 39
40
41
42
43
35
36
37
38
31
32
33
34
27
28
29
30
48
49
50 *
51
44
45
46
47
52
53
20
21
22
23
16
17
18
19
24
25
26
60
65
66
67
68
69
61
62
63
64
033133
033143
086032
090063
090064
090152
022661L
028739A
085662D
068113
068406
0F7272
023484N
023484N
0F6819
REF.
0C2454
092950
04576100CF
052646
043123
051779
022392
052259
051769
0E7230
0F3033
0F9492
0F2722
077043F
020151
023365
0C2428
022155
042568
049813
052624
0F7030
0F7047
0F7029
0F3834
KIT PARTS
0F3846B
0F3892
0A2496A
056326
022097
022473
045757
047411
0A2110
1
2
1
2/3
1
6
1
1
1
2
1
1
2
1
1
2
1
1
1
1
2
2
4/6
4/6
1
3
1
1
1
1
3
3
2
2
4
4
4
4
11
1
1
2
2
2
8.4 FT.
2
4
6
6
12
SCREW THF M6-1 X 16 N WA Z/JS
COLLAR SLIP FIT 390 MM
STUD M14-2.0 X 760 G5 ZINC
WASHER FLAT M14
WASHER LOCK M14
NUT HEX M14-2.0 G8 YEL CHR
PIN DOWEL 1/2 X 1-1/4
WASHER FLAT M12
WASHER LOCK M12
SCREW HHC M12-1.75 X 80 G10.9
SHIELD ALT EXCITER 390
SHIELD ALT EXCITER 5.4/6.8 (1 PHASE)
COVER EXCITER SHIELD
CONDUIT FLEX 1.25” ID
CLAMP VINYL .312 X .203 Z
WASHER SHAKEPROOF INT #8
SCREW HHM #8-32 X 3/8
SCREW HHM #8-32 X 7/8
LUG RT-ANG #10/10-12
BRIDGE SUPPORT DIODE 15"
CAP END ROTOR 390MM
ASSY BRIDGE RECTIFIER
SLEEVING UL #0 .330 ID (3” LG)
TIE WRAP UL 3.9" X .10" BLK
TIE WRAP UL 17.7 X .35 BLK HT
CARRIER REAR BRG 15" (BRUSHLESS)
SCREW HHC M12-1.75 X 60 G10.9
SCREW 1/4-20 X 5/8" TAPTITE SS
BUSHING SNAP SB-2.5-31
BUSHING SNAP SB-2.5-31 (FOR 5.4/6.8 1 PHASE)
MOUNT CT'S 5.4L 100KW
TRANSFORMER
SCREW PHTT #6-32 X 1/2 ZYC
WASHER LOCK #6
SCREW HHC M6-1.0 X 20 G8.8
NUT HEX M6 X 1.0 G8 YEL CHR
BEARING BALL 6212 SEALED
SHROUD UPPER ALTERNATOR EXCITR
SHROUD CENTER ALTERNATR EXCITR
SHROUD LOWER ALTERNATOR EXCITR
ASSY SCROLL 390 X 60MM CPL
I/N’S: 61 THRU 69
SHROUD ALT SHEET METAL CPL 2P
SCREEN, 390 SAE ALT 60MM WIDE
BRACKET SAE SCROLL TENSIONER
VINYL TRIM 1/8” GAP
WASHER, SPLIT 1/4”-M6
WASHER FLAT 1/4 ZINC
SCREW HHC M6-1.0 x 25 LONG
SCREW HHC M6-1.0 X 16 G8.8
SCREW SWAGE 1/4-20 X 1/2 Z/YC
* ROTOR REPLACEMENT PARTS.
** 1 PHASE UNITS REQUIRE SEPERATION OF LEADS.
QTY. REQ: 1 PHASE / 3 PHASE
3
4
1
2
5
(1) 26
27
28
29
22
23
24
25
30
31
32
33
34
14
(2) 15
(2) 16
17
18
19
20
21
(1) 9
8
6
7
10
11
12
13
35
36
(3) 37
38
39
40
41
42
0F2885
0F2883
0F9637 (4)
0F3685
023484N
023484N
049226
0C2266
0C2454
042568
022473
022097
049813
0D4698
0F4464
025433
024469
067210A
0D6029
051713
081008
077043J
077043J
086961
067617030A
067617030B
043180
022264
0C3990
057701
022155
0C2428
0F3618
0A9457
057073
0D5466
0A7822
022237
022241
0F6156
029289
0F8656
0F3113
047411
036943
023897
022152
022158
1
1
2
1
1
1
1
3
4
2
4
1
1
1
1
12
8
4
1
10
4
6
6
REF.
REF.
4
4
1
2
2
1
4
4
REF.
2
-
4
1
-
2
2
4
2
2
1
1
REF
REF
PANEL CB CONN BOX
STAND RH CONTROL
STAND RH CONTROL, TWO HOLE (FOR 5.4L 100KW &
4.6L 80KW 1PHASE)
STAND LH CONTROL C5 GRBX
BUSHING SNAP SB-2.5-31
BUSHING SNAP SB-2.5-31 (FOR 5.4L 100KW & 4.6L
80KW 1PHASE)
INTERFACE 1PH 240V
INTERFACE 3PHS 416/480V
INTERFACE 3PHS 208/240V
WASHER FLAT M4
WASHER LOCK #8-M4
SCREW PHTT M4-0.7 X 10 ZYC
BLOCK TERM 20A 8 X 6 X 1100V
WASHER LOCK #6
SCREW PHTT #6-32 X 1/2 ZYC
DECAL CPL CUST CONN H CTRL
DECAL NEUTRAL
JUNCTION BLOCK 3/8-16
BUS BAR NEUTRAL BLOCK 390
LUG SLDLSS 600/250-1/0 X 1/4-28
WASHER LOCK 3/8
NUT HEX 3/8-16 STEEL
WASHER LOCK M5
SCREW PHTT M5-0.8 X 16 ZYC
SCREW THF M6-1 X 16 N WA Z/JS
SCREW HHC M6-1.0 X 20 G8.8
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX M6 X 1.0 G8 YEL CHR
BLOCK TERM 20A 6 X 3 X 1100V
DECAL CUST CONN 120V UTILITY
LUG SLDLSS #6-14 X 13/64 CU
SCREW HHTT #10-32 X 3/8 CZ
DECAL GROUND LUG
SCREW HHTT M6-1.0 X 16 ZYC
WASHER FLAT M5
GROMMET 1.25 X .25 X .75
CONDUIT FLEX 2.0" ID
CONDUIT FLEX 2.0" ID (FOR 5.4L 100KW & 4.6L 80KW
1 PHASE)
PLATE WIRE SNGL GALV
TAPE ELEC 1/2 FOAM (AS REQ’D)
ASSY PCB 4.6L IGNITION MODULE
ASSY PCB HSB CTRL IGN MODULE (ALL OTHER
APPLICATIONS EXCEPT 4.6L G3)
SCREW HHC M6-1.0 X 16 G8.8
SCREW PPHM #10/32 X 2
WASHER FLAT #10 ZINC
WASHER LOCK #10
NUT HEX #10-32 STEEL
K
L
H
J
F
G
D
E
K
L
H
J
F
G
D
E
2.)
A
B
C
1.)
A
B
C
0F2721
065469
0D5577
0D5578
0D5579
0D5581
0D5585
0F2353
022770
022473
022097
022127
0C2454
029289
0F1733
0F2887
065469
0D5572
0D5573
0D5575
0D5576
0F0199
065960
022473
022097
022127
0C2454
029289
0F1733
4
1
4
4
1
4
4
-
1
UL CIRCUIT BREAKER (FD)
1
-
-
1
-
COVER FD FRM CB
DECAL DANGER HIGH VOLTAGE
CB 0150A 3P 600V S FD6 LL
CB 0175A 3P 600V S FD6 LL
CB 0225A 3P 600V S FD6 LL
CB 0250A 3P 600V S FD6 LL
INSULATOR CB FD FRAME 30MIL
SCREW SHC 1/4-20 X 4 G8.8 NZ
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX 1/4-20 STEEL
SCREW THF M6-1 X 16 N WA Z/JS
TAPE ELEC 1/2 FOAM (AS REQ’D)
DECAL CUSTOMER CONNECT INSIDE
4
7
4
4
1
1
2
4
-
-
UL CIRCUIT BREAKER (JD+LD)
1
-
-
1
-
COVER CIR BRKR JD/LD
DECAL DANGER HIGH VOLTAGE
CB 0300A 3P 600V S JD6 LL
CB 0350A 3P 600V S JD6 LL
CB 0400A 3P 600V S JD6 LL
CB 0600A 3P 600V S LD6
CB 0450A 3P 600V S LD6 LL
INSULATOR CIRCUIT BR. JD/LD
SCREW RHM 1/4-20 X 3
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX 1/4-20 STEEL
SCREW THF M6-1 X 16 N WA Z/JS
TAPE ELEC 1/2 FOAM (AS REQ’D)
DECAL CUSTOMER CONNECT INSIDE
(1) ITEM INCLUDED WITH HARNESS.
(2) ITEM INCLUDED WITH 0D5464B.
(3) ITEM IS PART OF 9R.
(4) ROUTE ONE SET (11, 22, 33, 44) THROUGH ONE HOLE; AND
ROUTE THE SECOND SET (11, 22, 33, 44) THROUGH THE OTHER
HOLE.
(2) L
(2) M
N
P
H
J
F
G
K
C
D
E
4.)
A
B
R
(1) S
T
U
V
(2) W
(2) X
L
M
J
K
N
F
G
H
3.)
A
D
E
B
C
U
V
(1) W
S
T
P
R
0F4175
065469
0F4166$
0F1733
042419
023897
022152
022158
0C2454
029289
052647
046526
W/CB
0A7822
022131
W/CB
023334
022097
022473
W/CB
W/CB
0F4173
065469
0F4165$
0F4186
036261
053640
038150
022264
022471
029289
0F1733
022129
0F8432
0C2454
0F8451
049897
022145
045771
0F8843
W/CB
9
6
7
3
1
9
4
2
1
1
1
REF
4
4
1
4
4
3
3
2
3
2
6
2/3
2/3
3
3
4
7
4
4
1
1
1
REF
1
4
6
6
2/3
2/3
UL CIRCUIT BREAKER (225AF)
COVER CB C5 225AF
DECAL DANGER HIGH VOLTAGE
CIRCUIT BREAKERS 200A FRAME
COVER CB DISH 225AF
RIVET POP .125 X .275 SS
SCREW RHM #8-32 X 3-1/4
WASHER FLAT #8 ZINC
WASHER LOCK #8-M4
NUT HEX #8-32 STEEL
TAPE ELEC 1/2 FOAM
DECAL CUSTOMER CONNECT INSIDE
WASHER LOCK M8-5/16
INSULATOR CB 225AF
SCREW THF M6-1 X 16 N WA Z/JS
LUG SLDLSS 300 MCM-6 AL/CU
SCREW SHC M8-1.25 X 20 G8
WASHER FLAT 5/16-M8 ZINC
NUT HEX M8-1.25 G8 CLEAR ZINC
BUS BAR 200A LUG ADAPTOR
TERMINAL COVER CB
UL CIRCUIT BREAKER (400AF)
COVER CB C5 400AF
DECAL DANGER HIGH VOLTAGE
CIRCUIT BREAKERS 400A FRAME
DECAL CUSTOMER CONNECT INSIDE
SCREW RHM 10-32 X 4
WASHER FLAT #10 ZINC
WASHER LOCK #10
NUT HEX #10-32 STEEL
SCREW THF M6-1 X 16 N WA Z/JS
TAPE ELEC 1/2 FOAM
SCREW SHC M10-1.5 X 25 G12.9
WASHER LOCK M10
BUS BAR CB ADAPTER 225-400 A
LUG SLDLSS 600/250-1/0 X 1/4-28
WASHER FLAT 3/8-M10 ZINC
TERM COVER CB
SCREW HHC 1/4-28 X 1/2 G5
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
SCREW SHC M10-1.5 X 25 G12.9
WASHER LOCK M10
S
T
P
R
(1) U
J
K
L
M
N
F
G
H
5.)
A
D
E
B
C
E
F
C
D
6.)
A
B
G
H
0F4176
065469
0F4167$
0F8433
024196
022473
022097
022127
0C2454
029289
060619
022131
022237
045772
0F8452
097950
0F1733
W/CB
0D5466
039287
022145
022129
045771
045335
022097
0A7822
3
1
6
3
2
3
9
7
2
6
1
1
REF
4
4
2
4
4
UL CIRCUIT BREAKER (800AF)
COVER CB C5 800AF
DECAL DANGER HIGH VOLTAGE
CIRCUIT BREAKERS 800A FRAME
INSULATOR CB 800AF
SCREW RHM 1/4-20 X 3-1/2
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX 1/4-20 STEEL
SCREW THF M6-1X16 N WA Z/JS
TAPE ELEC 1/2 FOAM
SCREW SHC M10-1.50 X 40 G12.9
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK 3/8
NUT HEX M10-1.5 G8 YEL CHR
LUG SLDLSS 500-750 X 2 MCM AL/CU
SCREW SHC M10-1.25 X 70 G8.8
DECAL CUSTOMER CONNECT INSIDE
TERM COVER VITZROTECH 400AF CB
2
1
1
2
1
1
2
1
NEUTRAL BLOCK 390 / 200-400A
BUS BAR NEUTRAL BLOCK 390
SCREW HHC M8-1.25 X 45 G8.8 FT
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
SCREW HHC 1/4-28 X 3/4 G5
WASHER LOCK M6-1/4
LUG SLDLSS 600/250-1/0X1/4-28
(1) HARDWARE FOR MTG. CB TERMINAL COVERS IS SUPPLIED
WITH CIRCUIT BREAKERS.
(2) 2/3 QTY. 2POLE & 3 POLE CB.
3
4
5
1
2
30
31
32
33
34
35
26 *
27
28
29
22
23
24
25
14
15 **
16 **
17
18
19
20
21
10
11
12
13
6
7
8
9 *
057073
0D5466
0A7822
022237
022241
049226
0C2266
0C2454
042568
022473
022097
049813
0D4698
0F4464
025433
024469
0F2885
0G0171
0G0171A
0G0172
023484N
0F4677
067617030A
067617030B
043180
022264
0C3990
057701
022155
0C2428
0F3618
0A9457
067210A
0D6029
051713
081008
077043J
0F6156
2
1
1
4
3
1
1
1
1
1
1
1
2
2
4
4
4
REF.
-
-
1
1
1
1
1
1
4
12
8
4
6
10
4
6
PANEL CB CONN BOX
STAND, RH CONTROL CPL C5
STAND RH CONTROL CPL C5 2 HOLE
STAND, LH CONTROL CPL C5
BUSHING SNAP SB-2.5-31
ASSY PCB INTERFACE 1PH 240V
INTERFACE 3PHS 416/480V
INTERFACE 3PHS 208/240V
WASHER FLAT M4
WASHER LOCK #8-M4
SCREW PHTT M4-0.7 X 10 ZYC
BLOCK TERM 20A 8 X 6 X 1100V
WASHER LOCK #6
SCREW PHTT #6-32 X 1/2 ZYC
DECAL CPL CUST CONN H CTRL
DECAL NEUTRAL
2
REF.
JUNCTION BLOCK 3/8-16
BUS BAR NEUTRAL BLOCK 390
REF.
LUG SLDLSS 600/250-1/0 X 1/4-28
4 WASHER LOCK 3/8
NUT HEX 3/8-16 STEEL
WASHER LOCK M5
SCREW PHTT M5-0.8 X 16 ZYC
SCREW THF M6-1 X 16 N WA Z/JS
SCREW HHC M6-1.0 X 20 G8.8
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX M6 X 1.0 G8 YEL CHR
BLOCK TERM 20A 6 X 3 X 1100V
DECAL CUST CONN 120V UTILITY
LUG SLDLSS #6-14 X 13/64 CU
SCREW HHTT #10-32 X 3/8 CZ
DECAL GROUND LUG
SCREW HHTT M6-1.0 X 16 ZYC
WASHER FLAT M5
GROMMET 1.25 X .25 X .75
CONDUIT FLEX 2.0" ID
PLATE WIRE SNGL GALV
P
R
M
N
K
L
H
J
S
T****
F
G
D
E
1.)
A
B
C
36
37***
38
39
40
41
42
2.)
A
B
C
F
G
D
E
H
029289
0F3113
047411
036943
023897
022152
022158
0G0173
065469
0F4167$
0F8433
022477
022473
022097
022127
0F1733
029289
060619
022131
022237
045772
0F8452
0D2576
W/CB
0D5466
039287
022145
022129
045771
045335
083896
0A7822
1
REF
4
2
2
2
2
TAPE ELEC 1/2 FOAM (AS REQ’D)
ASSY PCB HSB CTRL IGN MODULE
SCREW HHC M6-1.0 X 16 G8.8
SCREW PPHM #10/32 X 2
WASHER FLAT #10 ZINC
WASHER LOCK #10
NUT HEX #10-32 STEEL
9
6
2
3
4
1
4
4
3
2
6
3
UL CIRCUIT BREAKER (800AF)
1
1
REF
2
4
COVER, CB 803 C5
DECAL DANGER HIGH VOLTAGE
CIRCUIT BREAKERS 800A FRAME
INSUL CB 800AF
SCREW RHM 1/4-20 X 1-1/2
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX 1/4-20 STEEL
DECAL CUSTOMER CONNECT INSIDE
TAPE ELEC 1/2 FOAM
SCREW SHC M10-1.50 X 40 G12.9
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK 3/8
NUT HEX M10-1.5 G8 YEL CHR
LUG SLDLSS 500-750X2 MCM AL/CU
SCREW SHC M10-1.5 X 70 G10.9
TERM. COVER VITZROTECH 400AF CB
NEUTRAL BLOCK 390 / 200-400A
1
2
2
1
1
1
1
1
BUS BAR NEUTRAL BLOCK 390
SCREW HHC M8-1.25 X 45 G8.8 FT
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
SCREW HHC 1/4-28 X 3/4 G5
WASHER LOCK 1/4-M6 SS
LUG SLDLSS 600/250-1/0 X 1/4-28
* ITEM INCLUDED WITH HARNESS
** ITEM INCLUDED WITH 0D5464B
*** ITEM IS PART OF 9R.
**** HARDWARE FOR MTG. CB TERMINAL COVERS IS
SUPPLIED WITH CIRCUIT BREAKERS.
16
17
18
19
12
13
14
15
8
9
10
11
6
7
4
5
24
25
26
27
20
21
22
23
28
29
1
2
3
53
54
55
56
49
50
51
52
57
58
59
60
61
45
46
47
48 *
40
42
43
44
34
35
36
39
30
31
32
33
069860E
069811
080713
022473
022097
042568
0F5050
039253
051769
0C8145
0E2507
090283
0C8566
0F2776A
052644
0F4032
0F4496
042911
0F2872
022304
022195
022196
049813
049820
022145
022129
035685
045764
065852
0C7649
055596
022131
039414
052625
0F2561
0C8165
0D6795
0C7043
0E8909
048031C
0C8146
082774
0F2686
0F5463
0F8695
0F4028
0F4030
0F2687
0F2611
0F5254
0F5253
0F7077
046526
051756
0C2454
052250
076749
0F2573
0F2610
0F2572
0F5689
0F2862
0F2560
8
1
1
1
1
1
8
1
1
16
8
1
REF
1
16
1
1
1
1
1
4
1
1
1
8
2
1
1
1
1
1
1
1
1
1
2
1
1
4
12
1
5
1
3
1
14
1
1
1
1
1
1
1
2
1
8
2
1
12
1
1
1
1
* ITEM 48 IS INCLUDED WITH 47.
WELDMENT RADIATOR SUPPORT150
RADIATOR 680 X 680 X 70 CPL
V-BELT 31/64" X 62-3/8"
V-BELT 31/64" X 61-3/8" (5.4L 100KW ONLY)
V-BELT 1/2" X 63-3/8" (6.8L 100 130KW)
WASHER LOCK M10
SCREW HHC M10-1.5 X 20 G8.8
SCREW THF M6-1 X 16 N WA Z/JS
TAPE FOAM 1 X 1 (26.75” LG)
TANK COOLANT RECOVERY
PULLEY FAN V-GROOVE 9"
FAN 26" LH ROTATION
ARM TENSIONER
SCREW SHC SHLDR LKG M8 X 16 LG
SPRING TENSION CPL
PULLEY V-BELT 4" FLANGED
WASHER FLAT 3/8-M10 ZINC
SCREW HHC M8-1.25 X 35 G8.8
SCREW SHC M10-1.5 X 35 G12.9
HUB FLEX PLATE
NUT HEX LOCK 5/16-24 NY INS
SCREW HHC M12-1.5 X 60 G8.8
DISK FLEX
COUPLING HUB FLEX (MACH)
CLAMP HOSE BAND 1/4
SCREW HHC 5/16-24 X 1.124
KEY WOODRUFF 4 X 19D
HOSE RADIATOR UPPER CPL
HOSE LOWER RAD CPL C5 6.8L
ASSY BRG/SHAFT CPL FANDRIVE
PULLEY 6.5" DIA MACHINED (6.8L 100KW)
PULLEY 6" DIA MACHINED (6.8L 130KW)
PULLEY 5.5" DIA MACHINED (5.4L 80KW & 6.8L 150KW)
PULLEY 4.5" DIA MACHINED (5.4L 100KW)
SCREW HHC M10-1.5 X 30 G8.8
SCREW HHC 1/2-13 X 2" G8
WASHER FLAT 1/2 ZINC
WASHER LOCK 1/2
NUT HEX 1/2-13 STEEL
NUT HEX M6 X 1.0 G8 YEL CHR
NUT HEX LOCK M8-1.25 NY INS
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
CLAMP HOSE #28 1.32-2.25
SCREW HHTT M4-0.7 X 8 BP
SPRING CLIP HOLDER .37-.62
CLAMP HOSE .38-.87
BARBED STR 3/8 NPT X 3/8
HOSE DRAIN ASSY 28"
CAP HEX 1/4 NPT BRASS
BRACKET COOLANT TANK
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
SCREW HHC M6-1.0 X 20 G8.8
SHIELD RADIATOR C5
SCREW HHC M8-1.25 X 20 G8.8
WASHER LOCK M12
WASHER FLEX (THIN)
PROBE, COOLANT LEVEL 3/8 NPTF
CAP RADIATOR 13 PSI
SCREW HHFC M6-1.0 X 20 G8.8
BRACKET, SIGNAL CONDITIONER
SPACER .5 X 1.5 X .25 STL/ZINC
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
21
22
23
24
17
18
19
20
25
26
0F3099
065852
052252
052257
052259
055597
052251A
052860
0F2895
045764
022447
061383
043107
022473
049813
057192
022131
046526
0536210360
042909
022261
022129
022145
045771
038750
022097
1
8
1
1
1
1
2
1
5
4
5
5
5
5
1
1
2
2
2
1
1
1
1
1
8
8
MTG BASE CP 5.4L 100KW DD
SPRING CLIP HOLDER .37-.62
DAMPENER VIBRATION
SPACER .49 X .62 X 1.87 PWDR/ZINC
WASHER FLAT M12
SCREW HHC M12-1.75 X 85 G8.8
DAMPENER VIBRATION 50 WHITE
NUT LOCKING M12-1.75
SUPPORT ENG 5.4L LH/RH 6.8L RH
SCREW HHTT M4-0.7 X 8 BP
WASHER SHAKEPROOF INT 1/4
LUG SOLDERLESS 3/0-#4 X 13/32 CU
SCREW HHC M8-1.25 X 25 G8.8
WASHER FLAT 1/4-M6 ZINC
NUT HEX M6 X 1.0 G8 YEL CHR
SCREW SHC M10-1.5 X 30 G12.9
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
WIRE ASSEM #4GA GRD
SCREW HHC M8-1.25 X 30 G8.8
WASHER SHAKEPROOF INT 3/8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
NUT HEX M8-1.25 G8 YEL CHR
SCREW HHC M6-1.0 X 30 G8.8
WASHER LOCK M6-1/4
9
10
11
12
13
14
7
8
5
6
3
4
1
2
0F3408
0F3411
058208
022131
050331A
050331
038805U
038804U
045771
022129
027482
075763
0C2454
0F3409
1
1
1
1
8
1
1
1
1
1
1
1
1
1
TRAY BATTERY
STRAP BATTERY RETAINMENT
BATT 12VDC 24F 625
WASHER FLAT 3/8-M10 ZINC
BATT POST COVER RED +
BATT POST COVER BLK -
CABLE BATT BLK #1 X 18.00
CABLE BATT RED #1 X 28.00
NUT HEX M8-1.25 G8 YEL CHR
WASHER LOCK M8-5/16
WASHER SHAKEPROOF EXT 5/16 STL
BOOT BATTERY CABLE
SCREW THF M6-1X16 N WA Z/JS
SUPPORT BATTERY TRAY
C
D
E
A
B
26
27
28
29
22
23
24
25
50
51
52
63
64
65
66
4
5
7
8
9
10
036261
0F5763
0E9764
0F1725C
0F1958
0F2256
COMPONENTS
1 0F1823 1
2 0F1824 1
6
1
1
1
1
1
COVER
3 0F2606 1 CONTINUOUS
RIVET POP .125 X .275 SS
ASSY PROGRAMMED PM H-100
6 0F1732 1 FUSES
RAIL SNAPTRACK PCB HOLDER BULK (12” LG)
ASSY PCB 2AMP 12V UL BATT CHGR
PLATE HARNESS CLAMP
11
12
0E3161
029673
1
1
ASSY PCB PWR AVR W/AMP HEADER
ASSY PCB BOSCH GOV DRIVER
DIO BRIDGE 25A 600V
13 049226 8
14
15
16
17
079224
051713
0F5886
051716
3
5
4
8
18
19
0C3990
043280
3
3
20 055014 10
21 043184 10
54
55
WASHER
57 043182 3
58
59
60
61
0F2557
0F5884
0C2265
0F4333
0F5883
0F6305
0F6305A
0F6277
0F1263
0F1262
0F1264
0E9049B
055911
056739
-
-
022287
022473
051714
052777
0C2323
0F5459
022127
0F5460
0E7403C
0E7403B
1
1
4
1
1
2
1
1
1
COMPONENTS NOT INCLUDED IN 0F1826E OR WIRE HARNESS
1
1
1
2
4
3
3
2
1
2
1
1
2
LOCK
SCREW PPHM M5-0.8 X 30 SS
WASHER FLAT M5
SCREW HHPM M5-0.8 X 12
NUT HEX M5-0.8 G8 CLEAR ZINC
SCREW PHTT M4-0.7 X 10 ZYC
WASHER FLAT M4
SCREW PPHM M4-0.7 X 8 BLK OX
53 0F2627A 1
SCREW HHC 1/4-20 X 3/4 G5
56 022097 2
62 0F5461 1
67 0F6145 A/R
LOCK
DECAL WARNING BATT CHRG 12/24V
SCREW PHTT M3.5-0.6 X 10
SCREW PHTT M4-0.7 X 12 ZYC
CONN DUST CAP W/CHAIN DB9
WASHER FLAT M3.5
SEAL COVER 3.18 X 12.7 X 382
SEAL COVER 3.18 X 12.7 X 283
ASSY HARNESS H-PNL SW (NOT SHOWN)
COMPONENTS INCLUDED IN WIRE HARNESS
1
4
1
1
ADPTR RH SIDE WICKMAN 178.6191
HOLDER FUSE WICKMANN 178.6150
ADPTR LH SIDE WICKMAN 178.6192
ASSY PCB G-PANEL RELAY 12VDC
BLOCK TERM 20A 12 X 6 X 1100V
RELAY SOLENOID 12VDC PNL MNT
DPE BREAKER SEE DRAWING 0F9280
BOOST RESISTOR SEE DRAWING 0F9280
PANEL
WASHER FLAT 1/4-M6 ZINC
LOCK
NUT HEX M3-0.5 G8 YEL CHR
WASHER FLAT M3
SCREW PHTT #6-32 X 5/8 ZYC
DECAL CPL CONTROL PANEL FUSES
5.4/6.8L
NUT HEX 1/4-20 STEEL
DECAL CPL 5.4/6.8L RELAY BOARD
FUSE ATO TYPE 15 AMP (BLUE)
FUSE ATO TYPE 10 AMP (RED)
68
69
70 051713 4
71 049226 4
091526
0C2699
4
2
WEATHER
SCREW PPHM M5-0.8 X 12 ZNC
SCREW PHTT #6-32 X 3/8 ZYC
WASHER FLAT M5
WASHER
1
2
23
24
25
26
19
20
21
22
27
28
29
15
16
17
18
11
12
13
14
9
10
7
8
5
6
3
4
0F2830
0F4462
0C2454
0F4367
0F4368
0F2773C
0F2773D
0D3159
088775
0F2808
0F5447
022473
0F6214
080762
0F6803
049813
049721
088510
0F2807C
0F2807E
0F9207
0F2807B
0F2807D
0F9208
0F4505
0A6765
0F4710
0F7200
080762
0F2809
0F2981A
0F2962
0C2454
022097
2
REF
4
4
8
6
1
12
6
2
2
REF
REF
REF
REF
2
2
2
4
8
2
2
8
1
6
6
1
1
REF
2
1
1
1
1
PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5)
PIPE EXH MAN R/H 5.4L G/B & 2P (5.4L C5)
PIPE EXH MANIFOLD 4.6L RH
PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5)
PIPE EXH MAN L/H 5.4L G/B & 2P (5.4L C5)
PIPE EXH MANIFOLD 4.6L LH
GLASS PACK 23.5" LG 2.5" IN/OUT
RING GASKET 2.5 DIA
WASHER LOCK M10 SS
SCREW HHC M10-1.5 X 50 SS FTH
BOLT U 3/8-16 X 2.62
PIPE EXHAUST CROSSOVER
MFLR 7" X 9" X 25" (2) 2.5" IN/2.5" OUT
MUFFLER STRAP
SCREW THF M6-1 X 16 N WA Z/JS
WASHER LOCK M6-1/4
MUFFLER BRACKET STIFFENER
RAIN CAP ALUM FOR 2-1/2" PIPE
SCREW THF M6-1 X 16 N WA Z/JS
HEAT SHIELD EXHAUST STACK
CAP HEAT SHIELD EXHAUST STACK
EXHAUST BLANKET 900MM LONG (6.8L C5)
EXHAUST BLANKET 850MM LONG (5.4L C5)
FLANGE EXHAUST
WASHER FLAT 3/8 SS
EXHUAST OUTLET PIPE CPL
BRKT MUFFLER
WASHER FLAT 1/4-M6 ZINC
PIPE ELBOW EXHAUST MUFFLER
BOLT U 3/8-16 X 2.62
MUFFLER STRAP UPPER/LOWER
NUT HEX M6 X 1.0 G8 YEL CHR
SCREW HHC M6-1.0 X 35 G8.8 BLK
NUT HEX M10-1.5 SS
* PARTS INCLUDED IN 0F6322 KIT, GLASS PACK SHIP LOOSE.
7
8
5
6
3
4
1
2
9
10
11
0D2513D
0F5419
0F4268
0F4270A
0F6977
037561
047411
022097
049811
0F4269
022473
4
4
1
1
1
1
1
1
4
1
1
AIR CLNR BTM PLT W/CPLR 8.1L
ELEMENT AIR FILTER
TOP PLATE VENTURI
HOLD DOWN AIR CLEANER PLATED
PLATE AIR CLEAN TOP 5.4L/6.8L
NUT WING 1/4-20 NYLK
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
WASHER FLAT M6
GASKET MIXER BODY
WASHER FLAT 1/4-M6 ZINC
1 *
2 *
3
4
5 **
6
7
10
11
8
9
12 *
0F3883
0F1960
0F2842
0F2843
0D5419
0F2849
0D3488G
0D3488L
0D3488K
057795A
0A6283
0F2844
0F2847
0F2839
1
1
1
1
1
1
1
1
1
1
8
1
1
1
TUBE HEATER WATER
ENGINE 5.4L FORD
IGNITION COIL ASSY FORD
GASKET THERMOSTAT HOUSING FORD
OIL FILTER FORD V-10 ENGINE
TUBE OIL LEVEL INDICATOR FORD
BELT SERPENTINE 65.0" (1800 RPM)
SERPENTINE BELT (66.0") (2650 RPM)
SERPENTINE BELT (68.3") (3600 RPM)
BARBED EL 90 3/4 PLASTIC
HOSE PREFORMED BLOCK HEATER
THERMOSTAT ASSY FORD
PULLEY FAN BELT FORD
GASKET INTAKE MANIFOLD LEFT
49
50
51
52
53
54
55 ***
56
57
58
59
36 *
37 *
38 *
39 *
40
41
42
43
44
45
46
47
48
28
29
30
31
32
33
34 *
35 *
25
26
27
21
22
23
24
13 *
14 *
15
16
17
18
19
20
0F3216D
0F3217
0F3287
0F3017
0F5991
051713
042914
051731
022129
022145
051756
046526
022131
039253
064416
022131
0F2840
0F1959
055476
0F2851
0F2848
055440
022097
022473
042568
022129
0F4612
0E9868A
022145
057796
0F3216
0F3216B
046526
0D8027
0D8025
0D8026
0D8030
0F2846
0D8029
0D8028
0F2776A
045772
045771
0E0992A
057823
029333A
0F6151
0E0502
0F4308
036277
1
2
2
3
2
2
9
9
2
9
1
8
1
1
1
1
1
1
7
1
1
1
3
6
3
3
1
8
1
1
1
1
2
1
2
2
1
1
2
8
2
1
1
1
1
1
2
3
1
4
GASKET INTAKE MANIFOLD RIGHT
INTAKE MANIFOLD 5.4L (PLASTIC)
BUSHING REDUCER 3/8 TO 1/8 GAL
CONNECTION WATER OUTLET FORD
INDICATOR ASSY OIL LEVEL FORD
SCREW HHC M5-0.8 X 25 G8.8
WASHER LOCK M6-1/4
WASHER FLAT 1/4 ZINC
SCREW HHC M6-1.0 X 20 G8.8
WASHER LOCK M8-5/16
SENDER OIL PRESSURE 1/8"NPT
ALTERNATOR DC W/OUT PULLEY
WASHER FLAT 5/16 ZINC
GROMMET
PULLEY 80 OD DC ALTERNATOR (1800RPM)
PULLEY 117 OD DC ALTERNATOR (2650 RPM)
PULLEY 160 OD DC ALTERNATOR (3600 RPM)
SPACER DC ALTERNATOR PULLEY
BRKT DC ALTERNATOR UPPER
BRKT DC ALTERNATOR LOWER
HARN ENG 5.4L H-100 (NOT SHOWN)
WASHER FLAT M5
SCREW HHC M8-1.25 X 90 G8.8
SCREW HHC M8-1.25 X 50 G8.8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
SCREW HHC M10-1.5 X 20 G8.8
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
SCREW HHC M8-1.25 X 20 G8.8
SCREW HHC M10-1.5 X 45 G8.8 FT
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
SCREW WP PULLEY M8-1.25 X 19
BOLT HEX FL HD M8-1.25 X 28
BOLT HEX FL HD M8-1.25 X 31
TENSIONER ENG. AUTOMATIC BELT
PULLEY WATER PUMP FORD (1800RPM)
PULLEY ENGINE WATER PUMP (2650 & 3600RPM)
PULLEY GROOVED ENGINE IDLER
BRACKET SIGNAL CONDITIONER
NUT HEX M10-1.5 G8 YEL CHR
NUT HEX M8-1.25 G8 YEL CHR
PLUG EXPANSION 14 OD
CLAMP HOSE #10 .56-1.06
TIE WRAP UL 7.4" X .19" BLK (NOT SHOWN)
CAP RUBBER
TEMPERATURE SENDER, DELPHI
BRACKET DC ALT STABILIZER
ELBOW 90D STREET 1/8
* NOTE: PART OF ENGINE MAKE P/N 0F3902.
** NOTE: I/N 5 IS PART OF I/N 2.
*** NOTE: I/N 55 IS FOR HOLDING SENSOR TO I/N 50.
33
34
35
36
29
30
31
32
37
41
42
25
26
27
28
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
5
6
7
8 *
3
4
1
2
049821
022129
039253
0D2244M
044118
055934M
047411
071623
0D6742
022097
0F1820
0F1818
022473
048031J
0F2929
077996
0D9913
0E9747
0F3514
0F3903C
0F3903C
0F2776A
0D5417
0F3844
029333A
022131
055596
057772
057823
057765
0F3534
069860E
046526
070008
070006
0D2608
0F5114
0F5454
047290
059057
1
2
1
1
2
2
1
1
REF
1
1
4
1
1
2
4
1
1
1
1
6
8
24
8
2
1
2
1
1
1
1
1
8
8
2
1
1
1
16
1
SCREW SHC M8-1.25 X 35 SS
STARTER 12 VOLT
SPACER FLEXPLATE 5.4L/6.8L (1800 RPM ONLY)
FLEX PLATE 2 POLE 5.4L & 6.8L (1800 RPM UNITS ONLY)
FLEX PLATE 2 POLE 5.4L & 6.8L (3600 RPM UNITS ONLY)
BRACKET, SIGNAL CONDITIONER
SCREW HHC M10-1.0 X 25 G10.9
WASHER FLAT .43 X 1.00
TIE WRAP UL 7.4" X .19" BLK (NOT SHOWN)
WASHER FLAT 3/8-M10 ZINC
BARBED STR 3/8 NPT X 3/8
WASHER NYLON .565
CLAMP HOSE #10 .56 - 1.06
ADAPTER M14-1.50 X 3/8 NPT
HEAT SHLD EXHAUST MANIFOLD
HOSE DRAIN ASSY 28"
SCREW SHC M8-1.25 X 30 G12.9
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 20 G8.8
ASSY MAGPICKUP(3/8-24 MALE)
BARBED STR 1/2 NPT X 5/8
CLAMP VINYL .75 X .343 Z
SCREW HHC M6-1.0 X 16 G8.8
SCREW SHC M10-1.5 X 55 G12.9
VALVE PCV (FORD 6.8L)
WASHER LOCK M6-1/4
MACHINED MANIFOLD EXHAUST 5.4L
GASKET EXHAUST MANIFOLD
WASHER FLAT 1/4-M6 ZINC
HOSE CLAMP BAND 5/8"
ENGINE ADAPTER 5.4L/6.8L
CAP HOSE
WASHER LOCK M10
WASHER FLAT M8 SS
WASHER LOCK M8 SSTL
SCREW HHC 5/16-18 X 1/2 SSTL
DECAL REFER TO OWNERS MANUAL
PLATE MAG PICK-UP ADAPTOR
HOSE 3/8 ID SINGLE BRAID (15” LG)
HOSE 3/4 ID SAE-30R2
* NOTE: I/N 8 IS FOR HOLDING SENSOR TO I/N 5.
14
15
16
17
18
10
11
12
13
6
7
4
5
8
9
19
20
21
22
23
24
1
2
3
28
29
30
31
25
26
27
32
33
34
35
36
059057
0A8064
0D1509
050279
0F2756A
0D2696B
0E4390
0E4392
0F0960
0F3885
0F3694
0F3691C
0F3691D
0F3691E
026915
059057
049721
065908
0F6261G
0F6261C
0F6261D
052617
022304
022129
045773
022195
040173
0C7649
030131
031015
039130
057822
035461
081017
046580
039294
022097
047290
052223
0D2698
059057
064346
0F4408
0F6279
2
1
1
1
2
1
1
1
1
1
1
1
1
1
2
2
1
9
1
1
2
2
2
2
2
4
1
2
1
1
4
1
1
1
4
1
4
2
1
1
1
1
1
1
SCREW HHC M6-1.0 X 35 G8.8 BLK
SUPPORT NAT GAS SOLENOID
REGULATOR ASSM 5.4L 80KW NG
REGULATOR ASSM 5.4L 100KW NG
REGULATOR ASSM 6.8L 100KW NG
SCREW HHC M12-1.75 X 20 G8.8
WASHER FLAT 1/2 ZINC
WASHER LOCK M8-5/16
NUT HEX M12-1.75 G8 YEL CHR
WASHER LOCK 1/2
CLAMP HOSE #5.5 .62-.62 (5.4L)
CLAMP HOSE .38-.87 (6.8L 100KW)
ELBOW 90D 1-1/4 NPT
NIPPLE PIPE 1-1/4 NPT X 3
NIPPLE CLOSE 1.25 NPT X 1.625
CLAMP HOSE #8 .53-1.00
HOSE 3/4 ID SAE-30R2 (42” LG)
BSHG RDCR HEX 1-1/4-3/4
DECAL INLET PRESSURE
DECAL FUEL INLET NG
MACHINING, INTAKE ADAPTOR 60MM (5.4L FORD)
ADAPTOR THROTTLE BODY (BOSCH) (6.8L FORD GEARBOX)
GASKET GOVERNOR ACTUATOR
ACTUATOR BOSCH 60 GOVERNOR
REDUCER 3.0" TO 2.75" TURBO
MIXER 40/60MM ACTUATOR ASSY
O-RING 2-7/8 X 3-1/16 X 3/32
VENTURI THROTTLE 38MM (5.4L 80KW)
VENTURI THROTTLE 40MM (5.4L FORD 2-POLE 100KW)
VENTURI THROTTLE 42MM (6.8L FORD GEARBOX 100KW)
NIPPLE CLOSE 3/4 X 1.375
HOSE 3/4 ID SAE-30R2 (42” LG)
BARBED STR 1/4 NPT X 3/8 (5.4L 80KW & 100KW NG)
BARBED STR 1/4 NPT X 1/2 (6.8L 100KW NG)
SCREW SHC M6-1.0 X 45 G12.9
CLAMP HOSE #44 2.31-3.25
WASHER LOCK M6-1/4
HOSE 3/8 ID SINGLE BRAID (42” LG)
HOSE 1/2 ID SAE-30R2 FUELOIL (42” LG) (6.8L 100KW)
GASKET ADAPTER THROT BODY (6.8L FORD ONLY)
HOSE 3/4 ID SAE-30R2 (42” LG)
PIPE TEE 1-1/4 NPT
Y CONNECTOR 500 SERIES BARBS
HARNESS FUEL JUMPER DUAL REG
29
30
31
32
33
25
26
27
28
026915
057823
059057
0D2698
0D1509
050280
0D2696B
0F2756A
0E4390
0E4392
0F0960
0F3885
0F3694
0F3691B
0F3691D
0F3691E
033212
065908
0F6261H
0F6261J
0F6261K
0F6261L
0F6261M
052617
022304
022129
045773
064346
0A8064
030131
031015
088963
0F3691F
0F3691J
022195
0F6279
081017
046580
039294
022097
047290
040173
039130
16
17
18
12
13
14
15
10
11
8
9
6
7
4
5
19
20
21
22
23
24
1
2
3
1
1
2
1
1
1
1
1
1
1
1
1
2
1
2
4
1
1
2
1
2
1
2
4
1
2
1
1
1
1
4
1
2
4
1
4
2
1
1
1
1
2
1
SCREW HHC 5/16-18 X 1-1/4 G5
SUPPORT NAT GAS SOLENOID
REGULATOR ASSM 5.4L 80KW LPV (5.4L 80KW)
REGULATOR ASSM 5.4L 100KW LPV (5.4L 100KW)
REGULATOR ASSM 6.8L 100KW LPG (6.8L 100KW)
REGULATOR ASSM 6.8L 130KW LPV (6.8L 130KW)
REGULATOR ASSM 6.8L 150KW LPV (6.8L 150KW)
SCREW HHC M12-1.75 X 20 G8.8
WASHER FLAT 1/2 ZINC
WASHER LOCK M8-5/16
NUT HEX M12-1.75 G8 YEL CHR
PIPE TEE 1-1/4 NPT
BSHG RDCR HEX 1-1/4-3/4
ELBOW 90D 1-1/4 NPT
NIPPLE PIPE 1-1/4 NPT X 3
NIPPLE PIPE 1.25 NPT X 5.5 BL IRN (6.8L 150KW ONLY)
NIPPLE CLOSE 3/4 X 1.375
CLAMP HOSE #10 .56-1.06
HOSE 3/4 ID SAE-30R2 (45” LG)
GASKET ADAPTER THROT BODY
DECAL INLET PRESSURE
DECAL FUEL INLET LPG (LP VAPOR APPLICATION)
ADAPTOR THROTTLE BODY (BOSCH) (6.8L)
MACHINING INTAKE ADAPTOR 60MM (5.4L)
GASKET GOVERNOR ACTUATOR
ACTUATOR BOSCH 60 GOVERNOR
REDUCER 3.0" TO 2.75" TURBO
MIXER 40/60MM ACTUATOR ASSY
O-RING 2-7/8 X 3-1/16 X 3/32
VENTURI THROTTLE 36MM (5.4L 80KW)
VENTURI THROTTLE 40MM (5.4L 100KW)
VENTURI THROTTLE 42MM (6.8L 100KW)
VENTURI THROTTLE 44MM (6.8L 130KW)
VENTURI THROTTLE 50MM (6.8L 150KW)
WASHER LOCK 1/2
HARNESS FUEL JUMPER DUAL REG
BARBED STR 1/4 NPT X 1/2
SCREW SHC M6-1.0 X 45 G12.9
CLAMP HOSE #44 2.31-3.25
WASHER LOCK M6-1/4
HOSE 3/8 ID SINGLE BRAID (42” LG)
CLAMP HOSE #5.5 .62-.62
NIPPLE CLOSE 1.25 NPT X 1.625
39
40
41
42
35
36
37
38
31
32
33
34
27
28
29
30
43
(1)44
45
46
47
48
49
23
24
25
26
19
20
21
22
15
16
17
18
11
12
13
14
(2) 1
(2) 2
(2) 3
(2) 4
(2) 5
(2) 6
(2) 7
0F5873
0F5868
0F5872
0F5871
0F5869
0F5870
0F5867
0F5049
0F3949L
0F3949E
0F3890A
087233
0F3949C
0F3949D
0F3949G
0F3949J
0F3949K
0F3949F
0F3890B
0F3890
042568
0912970088
022447
0C2454
0F2766
0F3181
0F3185
0F3416
0F3949
0C2634A
022473
022097
022127
0F3072
078115
0F3949B
0F3949A
0F5048D
0E5968
049813
077992
0912970094
0F2766A
0F3949M
0F8869D
0E3257
2
4
14
4
2
4
2
1
4
1
2
1
1
8
4
2
1
1
6
2
1
4
28
4
1
3
4
20
70
1
1
1
5
2
2
4
2
78
2
2
1
1
2
2
1
4
REAR WRAP C5
DOOR C5
CENTER SUPPORT C5
DISCHARGE DUCT LH & RH SIDE C5
FRONT CORNERS C5
DISCHARGE CENTER DUCT C5
ROOF C5 ALUM
SCREW THF M6-1 X 16 N WA Z/JS
SPLITTER
SPLITTER SHORT
STRINGER SPLITTER C3
SUPPORT SPLITTER C5 130KW
INSULATION CORNER POST
ASSEMBLY COVER ACCESS
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX 1/4-20 STEEL
INSULATION RETAINMENT HANGER
WASHER SELF LOCKING DOME
INSULATION SPLITTER
INSULATION SHORT LOUVER
VISE-ACTION LATCH SLOTTED CIR
GASKET EXTRUDED TRIM (566” LG)
TAB PULL
INSULATION SPLITTER SML
INSULATION ROOF TOP REAR
RETAINER INSULATION (740)
RIVET POP .1875 X .450 SS
INSULATION ROOF TOP
INSULATION DOOR
INSULATION DISCHARGE DUCT
INSULATION CENTER SUPPORT
INSULATION DISCHARGE DUCT TOP
INSULATION INNER DUCT SIDE
RETAINER INSULATION (820)
RETAINER INSULATION (450)
SCREW HHC M6-1.0 X 20 G8.8
ASSY WIRE 14 AWG 20.9" GRN/YEL
WASHER SHAKEPROOF INT 1/4
NUT HEX M6 X 1.0 G8 YEL CHR
NUT HEX LOCK M6-1.0 SS NY INS
ASSY WIRE 14 AWG 34.8" GRN/YEL
SPLITTER C5
INSULATION SPLITTER SHRT MPS
KEY VISE-ACTION LATCH SLOT CIR
SCREW TH-FRM M6 W/CAP SHKPRF W
(1) ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO
THE BASE FRAME MUST BE SECURED USING ITEM 11 & 49 THREAD FORMING
FASTENER AND ITEM 44 LOCK NUT. LOCK NUT IS TO BE INSTALLED AFTER THREAD
FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS.
ALL ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER.
(2) I/N’S 1 THRU 7, REFER TO CHART BELOW FOR ENCLOSURE COLOR & MATERIAL TYPE.
Standby Generator Sets
Warranty
GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR
COMMERCIAL PRODUCT 50kW AND ABOVE
For a period of two (2) years from the date of sale, or start-up by Authorized/Certified Generac Power Systems Dealer, or branch thereof, Generac
Power Systems, Inc. will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or an Authorized/Certified Generac Power Systems Dealer, or branch thereof, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Authorized/
Certified Generac Power Systems Dealer, or branch thereof. This warranty applies only to Generac Power Systems Generators used in "Standby" applications, as Generac Power Systems, Inc. has defined Standby, provided said generator has been properly installed and inspected on-site by appropriate personnel. Scheduled maintenance, as outlined by the generator owner's manual, is highly recommended. This should be performed by an Authorized/ Certified Generac Power Systems Dealer, or branch thereof. This will verify service has been performed on the unit throughout the warranty period.
WARRANTY SCHEDULE
YEAR ONE — Limited comprehensive coverage on mileage, labor, and parts listed.
• - ALL COMPONENTS
YEAR TWO — Limited comprehensive coverage on parts listed.
• - ALL COMPONENTS
*Start-up and/or On-line Registration, or Registration Card, along with Proof of Purchase, must be performed and/or sent in.
Guidelines:
branch thereof.
Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the genset, no warranty coverage shall apply.
Manual.
• Units that have been resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable.
• Unit enclosure is only covered against rust or corrosion the first year of the warranty provision.
• Use of Non-Generac replacement part(s) will void the warranty in its entirety.
applicable).
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
1. Any unit built/manufactured prior to March 1, 2005.
2. Costs of normal maintenance (i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up).
3. Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze.
Trailer Mounted or Rental Unit. Contact a Generac Power Systems Distributor for Prime Power, Trailer Mounted or Rental Unit definition and warranty.
normally exist.
earthquake, windstorm, hail, volcanic eruption, water or flood, tornado, hurricane, terrorist acts or nuclear holocaust.
7. Products that are modified or altered in a manner not authorized by Generac Power Systems in writing.
8. Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing.
defective part(s).
10. Failure due to misapplication, misrepresentation, or bi-fuel conversion.
11. Telephone, facsimile, cell phone, satellite, internet, or any other communication expenses.
12. Rental equipment used while warranty repairs are being performed (i.e. rental generators, cranes, etc.).
13. Overtime, holiday, or emergency labor.
14. Planes, ferries, railroad, busses, helicopters, snowmobiles, snow-cats, off-road vehicle or any other mode of transportation deemed abnormal.
15. Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct cause of the problem.
16. Starting batteries, fuses, light bulbs, engine fluids, and overnight freight cost for replacement part(s).
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC POWER SYSTEMS
MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to purchaser/owner.
GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT
SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A
DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/ owner. Purchaser/owner agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gives purchaser/owner specific legal rights. Purchaser/owner also may have other rights that vary from state to state
Generac Power Systems, Inc. • P.O. Box 8 • Waukesha, WI 53187
Ph: (262) 544-4811 • Fax: (262) 544-4851
Bulletin 0171370SVE / Printed in U.S.A. 7.05
Printed in U.S.A.
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