Generac 60 kW 0056501 Standby Generator Manual

Generac 60 kW 0056501 Standby Generator Manual
Serial Number
2.4L
45kW
60kW
Models
STANDBY GENERATOR
OWNER'S MANUAL
A new standard of reliability
Not intended for use in critical life support applications. 
—CAUTION—
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
This manual should remain with the unit.
Cover141 Rev. A 09/08
Part No. 0H0125
Standby Generator Sets
Table of Contents
PAGE
INTRODUCTION .....................................................1-1
Read this Manual Thoroughly ...................................1-1
Operation and Maintenance ......................................1-1
How to Obtain Service ..............................................1-1
SAFETY RULES ................................................ 1-2
IDENTIFICATION RECORD .....................................2-1
Data Label ................................................................2-1
EQUIPMENT DESCRIPTION ...................................3-1
Equipment Description ................................................3-1
Engine Oil Recommendations ......................................3-1
Coolant Recommendations...........................................3-1
ENGINE PROTECTIVE DEVICES ............................4-1
Engine Protective Devices .............................................4-1
High Coolant Temperature Switch ............................4-1
Low Coolant Level Sensor.........................................4-1
Low Oil Pressure Switch ...........................................4-1
Overcrank Shutdown ................................................4-1
Overspeed Shutdown ................................................4-1
RPM Sensor Loss Shutdown.....................................4-1
DC Fuses...................................................................4-1
FUEL SYSTEMS .....................................................5-1
Fuel Requirements ....................................................5-1
Natural Gas Fuel System ..........................................5-1
Propane Vapor Withdrawal Fuel System....................5-1
LP Liquid Fuel System ..............................................5-1
SPECIFICATIONS ...................................................6-1
Generator .................................................................6-1
Engine.......................................................................6-1
Cooling System .........................................................6-1
Fuel System ..............................................................6-1
Electrical System ......................................................6-1
Cold Weather Kit .......................................................6-2
Coolant Heater Kit ....................................................6-2
2.4L Ignition Module Description .................................6-2
Diagnostic Blink Patterns (Red LED Located
on the Ignition Control Board ...................................6-2
GENERAL INFORMATION.......................................7-1
Generator AC Lead Connections ..................................7-1
Four-lead, Single-phase Stator ..................................7-1
Alternator Power Winding Connections ........................7-1
3-phase Alternators ..................................................7-1
3-phase Alternators ("Delta Configuration") ..............7-2
INSTALLATION.......................................................8-1
Installation ...................................................................8-1
Preparation Before Start-up .........................................8-1
Transfer Switch ........................................................8-1
Fuel System ..............................................................8-1
Generator Set Lubrication ........................................8-1
Prior to Initial Start-up .............................................8-1
Engine Coolant .........................................................8-1
Belt Tension ..............................................................8-1
Electrical System ......................................................8-1
Initial Inspection for Genset Start-up ...........................8-1
Start-up Checklist ........................................................8-2
Preparation for Start-up............................................8-2
OPERATION ...........................................................9-1
Generator Control and Operation ................................9-1
Operating Unit with Manual Transfer Switch ...............9-1
Engine Start-up and Transfer ...................................9-1
Retransfer and Shutdown .........................................9-1
Operating Unit with Automatic Transfer Switch ...........9-1
MAINTENANCE.....................................................10-1
Maintenance Performed by Service Facilities ..............10-1
Every Three Months ...............................................10-1
Once Every Six Months ...........................................10-1
Once Annually.........................................................10-1
First 30 Operating Hours ........................................10-1
First 100 Operating Hours ......................................10-1
Every 500 Operating Hours ....................................10-1
Cooling System ..........................................................10-1
Overload Protection for Engine DC
Electrical System ....................................................10-1
Checking Fluid Levels ................................................10-1
Check Engine Oil ....................................................10-1
Battery Fluid ...........................................................10-2
Engine Coolant .......................................................10-2
Maintenance Owner/Operator Can Perform ................10-2
Check Engine Oil Level ...........................................10-2
Check Battery .........................................................10-2
Exercise System ......................................................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 ........................................10-3
Changing Engine Oil ...............................................10-3
Changing the Engine Air Filter ................................10-3
Spark Plugs ............................................................10-3
Coolant Change .......................................................10-4
Miscellaneous Maintenance ........................................10-4
Cleaning the Generator ...........................................10-4
Battery ....................................................................10-4
Battery Maintenance ...............................................10-4
Battery Replacement ...............................................10-5
SERVICE SCHEDULE ...........................................11-1
TROUBLESHOOTING ...........................................12-1
Troubleshooting Guide...............................................12-1
NOTES
EXPLODED VIEWS & PARTS LISTS
WIRING DIAGRAMS & SCHEMATICS
Content022 Rev. A 09/08
SECTION
Standby Emergency Generator
Important Safety Instructions
copied and posted in potential hazard areas. Safety should be stressed to all operators, 
 bepotential
operators, and service and repair technicians for this equipment.
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation
INTRODUCTION
symbol points out potential explosion
 This
hazard.
Thank you for purchasing this model of the stationary
emergency generator product line.
 This symbol points out potential fire hazard.
symbol points out potential electrical shock
 This
hazard.
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.
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.
‹ READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest 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:
‹ 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 a 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.
DANGER
After this heading, read instructions that, if not
strictly complied with, will result in serious personal injury, including death, or property damage.
Proper maintenance and care of the generator ensure
a minimum number of problems and keep operating
expenses at a minimum. See a Service Dealer for service aids and accessories.
After this heading, read instructions that, if not
strictly complied with, may result in personal
injury or property damage.
Operating instructions presented in this manual
assume that the generator electric system has been
installed by a Service Dealer or other competent,
qualified contractor. Installation of this equipment is
not a “do-it-yourself” project.
After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:
‹ HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs,
simply contact a Service Dealer for assistance.
Service technicians are factory-trained and are capable of handling all service needs.
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.
When contacting a Service Dealer 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.
Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type
of information each indicates is as follows:
symbol points out important safety infor This
mation that, if not followed, could endanger
personal safety and/or property of others.
Safety004 Rev. C 09/08
1-1
Standby Emergency Generator
Important Safety Instructions


WARNING:
 GENERAL HAZARDS 
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.

WARNING:
• For safety reasons, the manufacturer recommends
that this equipment be installed, serviced and
repaired by a 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.
This should be considered prior to installing the
generator. The unit should be positioned to direct
exhaust gasses safely away from any building
where people, animals, etc., will not be harmed.
Any exhaust stacks that ship loose with the unit
must be installed properly per the manufacturer's
instruction, and 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.

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
the safe design of this generator,
 Despite
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.
lethal voltages are generated by
 Potentially
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
of the generator are rotating and/or hot
 Parts
during operation. Exercise care near running
generators.
1-2
Safety004 Rev. C 09/08
Standby Emergency Generator
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.
• Stationary emergency 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.
 ELECTRICAL HAZARDS 
• All stationary emergency 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 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 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.
 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 generators 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.
Safety004 Rev. C 09/08
1-3
Stationary Emergency Generator
General Information
IDENTIFICATION RECORD
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.
‹ 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, production
date, etc.
 Stationary Emergency 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.
Data Label
MANUFACTURING INFORMATION
Identy005 Rev. B 09/08
2-1
Stationary Emergency Generator
Equipment Description
EQUIPMENT DESCRIPTION
COOLANT RECOMMENDATIONS
This equipment is a revolving field, alternating current Stationary
Emergency Generator. 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.
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.
not use any chromate base rust inhibitor
 Do
with ethylene glycol base anti-freeze or chro-
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.
mium 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.
The Stationary Emergency Generator incorporates the following
alternator features:
• Rotor and Stator insulation class is rated as defined by NEMA
MG1-32.6, NEMA MG1-1.66. The generator is self ventilated
and drip-proof constructed. Refer to the Specifications section
or the data label for the class ratings.
• 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.
DANGER
not remove the radiator pressure cap while
 Do
the engine is hot or serious burns from boiling
ENGINE OIL RECOMMENDATIONS
liquid or steam could result.
The unit has been filled with 5W-20 engine oil at the factory. Use
a high-quality detergent oil classified “For Service SJ or SH.”
Detergent oils keep the engine cleaner and reduce carbon deposits.
When changing the engine oil, be sure to use 5W-30 engine oil.
glycol base antifreeze is poisonous.
 Ethylene
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.
attempt to crank or start the engine before
 Any
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.
Equip001 Rev. E 03/09
3-1
Stationary Emergency Generator
Engine Protective Devices
ENGINE PROTECTIVE DEVICES
‹ OVERCRANK SHUTDOWN
The Stationary Emergency 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.
After a prespecified duration of cranking, this function ends the cranking if the engine has failed to
start. The overcrank LED will turn ON. Turn OFF the
AUTO/OFF/MANUAL switch, then turn switch back to
AUTO to reset the generator control board.
NOTE:
If the fault is not corrected, the overcrank feature
will continue to activate.
Approximate Crank Cycle Times
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.
‹ HIGH COOLANT TEMPERATURE SWITCH
15 seconds ON
7 seconds OFF
7 seconds ON
7 seconds OFF
Repeat for 45 seconds
Approximately 90 seconds total.
‹ OVERSPEED SHUTDOWN
The switch will close if the temperature should
exceed approximately 140° C (284° F), initiating an
engine shutdown. The generator will automatically
restart and the LED will reset once the temperature
has returned to a safe operating level.
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 overspeed above a safe,
preset value, the circuit board initiates an automatic
engine shutdown. Contact the nearest Authorized
Dealer if this failure occurs.
‹ LOW COOLANT LEVEL SENSOR
To prevent overheating, the engine has a low coolant
level sensor. If the level of engine coolant drops below
the level of the low coolant level sensor, the engine
automatically shuts down.
‹ RPM SENSOR LOSS SHUTDOWN
If the speed signal to the control panel is lost, engine
shutdown will occur.
‹ LOW OIL PRESSURE SWITCH
‹ DC FUSES
This switch has normally closed contacts that are
held open by engine oil pressure during cranking and
operating. Should oil pressure drop below the 8 psi
range, switch contacts close, and the engine shuts
down. The unit should not be restarted until oil is
added, and the AUTO/OFF/MANUAL switch must be
turned to OFF and then back to AUTO.
Fuse F1 (15 amp) 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.
Fuse F2 (25 amp) is located in the engine wire harness adjacent to the DC alternator. It is used to prevent circuit failure due to DC alternator falure. If this
fuse is blown, battery charging will not occur while
the engine is running. Replace these fuses with the
same size, type, and rating. (See the exploded views
and parts lists at the end of this manual for replacement part number.)
EngProt001 Rev. B 09/08
4-1
Stationary Emergency Generator
Fuel Systems
FUEL SYSTEM
‹ PROPANE VAPOR WITHDRAWAL FUEL SYSTEM
‹ FUEL REQUIREMENTS
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 Stationary Emergency Generator may be equipped
with one of the following fuel systems:
• Natural gas fuel system
• Propane vapor (PV) 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.
• 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.
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 5 inches
to 14 inches water column (0.18 to 0.5 psi); and
for liquid propane, 5 inches to 14 inches of water
column (0.18 to 0.5 psi).
‹ LP LIQUID FUEL SYSTEM
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 five inches
water column for natural gas or 5 inches water
column for propane vapor for all load ranges.
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).
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.
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.
‹ 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).
FuelSys001 Rev. B 09/08
5-1
Standby Generator Sets
Specifications
SPECIFICATIONS
Engine Lubrication System
Type of Oil Pump ...................................................................... Gear
Oil Filter ............................................... Full Flow Spin-on, Cartridge
Crankcase Oil Capacity .......... 5.25 U.S. qts. (including filter capacity)
‹ GENERATOR
Type ............................................................................. Synchronous
Rotor Insulation ................................................................... Class H
Stator Insulation .................................................................. Class H
Total Harmonic Distortion ..........................................................<5%
Telephone Interference Factor (TIF) ..........................................< 50
Alternator Output Leads 3-phase ........................................... 4-wire
Bearings .........................................................................Sealed Ball
Coupling .......................................................................Flexible Disc
Load Capacity (Standby Rating) ............................................60kW*
* NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349,
‹ COOLING SYSTEM
Type ...................................................Pressurized Closed Recovery
Water Pump.................................................................... Belt Driven
Fan Speed .........................................................................2050 rpm
Fan Diameter .....................................................................22 inches
Fan Mode ................................................................................Puller
Air Flow (inlet air including alternator and
combustion air) ...........................................................4500 ft3/min.
Coolant Capacity ........................................................ (3.0 U.S. gal.)
Heat Rejection to Coolant (60kW)..............................270,000 Btu/h
Maximum Operating Air Temp. on Radiator ..............60° C (150° F)
Maximum Ambient Temperature................................50° C (140° F)
ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural
gas.
Excitation System ....................................................................Direct
Generator Output Voltage/kW - 60 Hz kW
Amp
CB Size
120/240V, 1-phase, 1.0 pf
60
250
300
120/208V, 3-phase, 0.8 pf
60
208
250
120/240V, 3-phase, 0.8 pf
60
180
200
277/480V, 3-phase, 0.8 pf
60
90
100
Generator Locked Rotor KVA Available @ Voltage Dip of 35%
Single-phase or 208, 3-phase (60kW) ............................. 120 KVA
480V, 3-phase (60kW)...................................................... 141 KVA
‹ FUEL SYSTEM
Type of Fuel .........................................Natural Gas, Propane Vapor
Carburetor ...................................................................... Down Draft
Secondary Fuel Regulator .................................................Standard
Fuel Shut-off Solenoid ........................................................Standard
Operating Fuel Pressure ...................... 5 in. - 14 in. Water Column
‹ ENGINE
Fuel Consumption - ft3/hr (Natural Gas/LPV)
Exercise
25%
50%
75%
100%
Cycle
Load
Load
Load
Load
60kW 123/49.3 267/101
483/183
672/255
862/327
Make ................................................................................... Generac
Model ..................................................................................... In Line
Cylinders and Arrangement............................................................ 4
Displacement ....................................................................... 2.4 Liter
Bore ...................................................................................... 3.41 in.
Stroke ................................................................................... 3.94 in.
Compression Ratio ...............................................................8.5-to-1
Air Intake System ................................ Turbo Charged/After Cooled
Valve Seats....................................................................... Hardened
Lifter Type .......................................................................... Hydraulic
‹ ELECTRICAL SYSTEM
Battery Charge Alternator ............................................12V, 30 Amp
Static Battery Charger .........................................................2.5 Amp
Recommended Battery...................................... Group 26, 525CCA
System Voltage .....................................................................12 Volts
Voltage Regulator
Type .................................................................................. Electronic
Sensing........................................................................ Single-phase
Regulation ................................................................................± 1%
Features ................................................. V/F Adjustable, Adjustable
Voltage and Gain LED Indicators
Engine Parameters
Rated Synchronous RPM ..............................................60 Hz, 3600
HP at rated kW (60kW) ................................................................ 94
Exhaust System
Exhaust Flow at Rated Output 60 Hz (60kW) ..................... 494 cfm
Exhaust Temp. at Rated Output (60kW) .............................. 1050° F
Power Adjustment for Ambient Conditions
Temperature Deration
3% for every 10° C above °C (60kW) ........................................ 25
1.65% for every 10° above °F (60kW) ....................................... 77
Altitude Deration
1% for every 100 m above m (60kW) ...................................... 915
3% for every 1000 ft. above ft. (60kW) ................................... 3000
Combustion Air Requirements (Natural Gas)
Flow at rated power, 60 Hz (60kW) ..................................... 180 cfm
Governor
Type .................................................................................. Electronic
Frequency Regulation ...................................................Isochronous
Steady State Regulation......................................................± 0.25%
Controller .............................................. R-200B
GenSpec056 Rev. A 09/08
6-1
Standby Generator Sets
Specifications
Figure 6.1 — Interconnections
Utility In
Transfer Switch
NEUTRAL
Gen
N1
N2
23
194
4- # 14 GA
WIRES TO
GENERATOR
CONNECTION
BOX
186
178
Load
Out
TO GENERATOR
CONNECTION BOX
To Generator Control Panel
This is a generic representation of the components contained in the transfer switch and connection box.
Refer to the wiring and schematic diagrams for generator specific connections.
‹ COLD WEATHER KIT
‹ DIAGNOSTIC BLINK PATTERNS (RED LED
LOCATED ON THE IGNITION CONTROL
BOARD)
For cold climates, optional cold weather kit (part
number 0F6148) is recommended. The kit includes:
• Battery Warmer
• 4” Junction Box with hardware
• 6 qt. pack 5W-30 synthetic oil (engine)
During normal ignition operation the RED LED,
located on the ignition control board, flashes at a 0.5
second ON and a 0.5 second OFF rate. This is considered one (1) blink.
‹ COOLANT HEATER KIT
RED LED Fault Codes with priority as shown:
The optional Coolant Heater Kit (part number
0G3065) is available to be used in conjunction with
the Optional Cold Weather Kit. This kit includes:
1. Overspeed Shutdown — LED blinks four (4)
times, is OFF for three (3) seconds and then
repeats.
2. Missing Flywheel Teeth Shutdown — LED blinks
five (5) times, is OFF for three (3) seconds and
then repeats.
3. No Flywheel Signal — LED blinks two (2) times,
is OFF for three (3) seconds and then repeats.
4. No Cam Signal — LED blinks three (3) times, is
OFF for three (3) seconds and then repeats.
Only one LED fault code is displayed at a time.
• 1500 watt, 120 volt Engine Block Heater
• Heater Mounting Bracket
• All fittings, hoses and hardware to mount and
plumb heater
2.4L IGNITION MODULE DESCRIPTION
Ignition Module (P/N 0G8951) operates with a 4-cylinder, 2.4L, 60kW, turbo engine and uses the same
flywheel mag pick-up signal as the R-200B controller. The 2.4L, 3600rpm engine uses a 164 tooth mag
pick-up flywheel sensor and a mag pick-up CAM sensor as input signals to control engine timing.
If multiple fault codes exist then the highest priority
fault must be resolved prior to a lower priority fault
code being displayed.
6-2
GenSpec056 Rev. A 09/08
Standby Generator Sets
Specifications
The LED fault code blink pattern is displayed for 60
– 120 seconds after a fault and then the ignition will
power itself down.
The Generator must have been in the OFF mode for
60 seconds prior to cranking for the Flywheel and
CAM LED fault diagnostics to be valid.
The Flywheel and CAM LED fault codes are not valid
during a re-crank.
NOTE:
There are openings inside the customer wiring
panel that allow the RED LED inside the ignition
module to be seen without removing the ignition module. A flashing overcrank signal on the
R-panel LED's is an idication of an ignition fault.
GenSpec056 Rev. A 09/08
6-3
Stationary Emergency Generator
General Information
ALTERNATOR AC LEAD CONNECTIONS
ALTERNATOR POWER WINDING
CONNECTIONS
See “Voltage Codes”. This Stationary Emergency
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.
‹ 3-PHASE ALTERNATORS
The Stationary Emergency 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, 7.3 and 7.4.
Voltage codes apply to the type of stator assembly
installed on a particular generator.
The rated voltage between circuit breaker terminals
E1-E2, E1-E3 and E2-E3 is 480V, 208V or 600V
depending on the model.
‹ FOUR-LEAD, SINGLE-PHASE STATOR
Four-lead alternators (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 and the neutral point 00 is 277V, 120V, or 346V
depending on the model.
Figure 7.2 — Stator Power Winding
Connections - 3-phase, 277/480V (6 Lead)
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.
S1 E1
Figure 7.1 — Four-lead, Single-phase Stator
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
S6
S3
E3
L-L
S4
S4
S5
00 (NEUTRAL)
S2
S6 S5
S3
S2
E2
L-N
ACConn006 Rev. C 10/08
7-1
Stationary Emergency Generator
General Information
‹ 3-PHASE ALTERNATORS
("DELTA" CONFIGURATION)
Figure 7.4 — Stator Power Winding
Connections - 3-phase, 346/600V (6 Lead)
The Stationary Emergency 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 “Delta” configuration as shown
in Figures 7.5.
S1 E1
INTERNAL
CONNECTIONS
The rated voltage between circuit breaker terminals
E1-E2, E1-E3 and E2-E3 is 240V.
The rated voltage between E1 or E3 and the neutral
point 00 is 120V.
L-L
S6
S4
NEUTRAL
Figure 7.5 — Stator Power Winding
Connections - 3-phase, 120/240V (6 Lead)
S5
E3 S3
S2
E2
E2
L-N
E1
7-2
E3
ACConn006 Rev. C 10/08
Stationary Emergency Generator
Installation
INSTALLATION
‹ PRIOR TO INITIAL START-UP
Refer to the separate “Installation Guide” supplied with the unit.
For safety reasons, the manufacturer recommends that this equipment be installed, serviced and repaired by a 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.
to initially starting the generator, it must
 Prior
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.
PREPARATION BEFORE START-UP
‹ ENGINE COOLANT
The instructions in this section assume that the Stationary
Emergency 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.
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
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”.
Check-the engine-fan belt tension and condition prior to placing
the unit into service and at recommended intervals. Belt tension is
correct when a force of approximately 22 pounds (10 kg), applied
midway between pulleys, deflects the belt about 3/8- to 5/8-inch
(10 to 16 mm).
‹ TRANSFER SWITCH
‹ ELECTRICAL SYSTEM
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 electrical components, must be properly located and
mounted in strict compliance with applicable codes, standards
and regulations.
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.
NOTE:
Battery charger must be connected to 120 VAC, 15 amp circuit
to operate.
‹ FUEL SYSTEM
Check to ensure that there are no loose electrical connections.
Restrain any loose wires to keep them clear of any moving generator set components.
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.
INITIAL INSPECTION FOR GENSET
STARTUP
‹ GENERATOR SET LUBRICATION
Inspect for the following.
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”.
•
•
•
•
•
Freight Damage.
Manuals present.
Fluid Levels (Oil, coolant, battery, Gear Drive).
Correct fuel piping.
Correct muffler installation for external applications (open units
only).
• 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.
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.
NOTE:
This engine is shipped from the manufacturer with “break-in”
oil. This oil should be changed after 30 hours of operation.
• Battery charger connection to 120 VAC.
• Communication wires connected between transfer switch and
generator (HTS only).
• Unit secured to pad.
Install002 Rev. E 03/09
8-1
Stationary Emergency Generator
Installation
START-UP CHECKLIST
• 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 manual 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.
working on the Stationary Emergency
 Before
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. 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).
8-2
Install002 Rev. E 03/09
Stationary Emergency Generator
Operation
STATIONARY EMERGENCY GENERATOR
CONTROL AND OPERATION
not crank the engine continuously for longer
 Do
than 30 seconds, or the heat may
Refer to the appropriate control panel operator’s
manual for this unit.
•
•
OPERATING UNIT WITH MANUAL
TRANSFER SWITCH
If the Stationary Emergency 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.
•
•
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 the
STANDBY position, i.e., load circuits supplied by
the generator.
Set the generator’s main line circuit breaker to its
ON (or CLOSED) position.
Load circuits are now powered by the generator.
‹ RETRANSFER AND SHUTDOWN
‹ 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.
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:
DANGER
Maintenance Disconnect Switch and the
 The
AUTO/OFF/MANUAL switches (if so equipped)
• Set the 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.
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.
not proceed until certain that utility source
 Do
voltage is available to the transfer switch and
the transfer switch main contacts are set to
UTILITY.
not attempt manual operation until all power
 Do
supplies to the transfer switch have been posi-
OPERATING UNIT WITH AUTOMATIC
TRANSFER SWITCH
tively turned off, or extremely dangerous - possibly lethal - electrical shock will result.
If the Stationary Emergency 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.
switch enclosure doors should be kept
 Transfer
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:
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.”
9-1
Oper001 Rev. A 09/08
• 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 generator’s main line circuit breaker to its
OFF (or OPEN) position.
• Start the generator.
Standby Generator Sets
Maintenance
MAINTENANCE PERFORMED BY
SERVICE FACILITIES
COOLING SYSTEM
working on the generator, ensure the fol Before
lowing:
Without sufficient cooling and ventilating air flow, the
engine/generator quickly overheats, which causes it
to shut down. (See the installation diagram.)
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.
• 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.
• The negative battery cable has been removed.
exhaust system parts from this product get
 The
extremely hot and remains hot after shutdown.
High grass, weeds, brush, leaves, etc. must
remain clear of the exhaust. Such materials may
ignite and burn from the heat of the exhaust
system.
‹ EVERY THREE MONTHS
1.
2.
3.
4.
5.
6.
Check battery condition.
Inspect and test fuel system.
Check transfer switch.
Inspect exhaust system.
Check engine ignition system.
Check fan belts.
OVERLOAD PROTECTION FOR ENGINE
DC ELECTRICAL SYSTEM
Engine cranking, start up and running are controlled
by a solid state Engine Controller circuit board.
Battery voltage is delivered to that circuit board via
a 15 amp fuse. These overcurrent protection devices
will open if the circuit is overloaded.
‹ ONCE EVERY SIX MONTHS
1. Test Engine Safety Devices (low oil pressure, low
coolant level, high coolant temperature).
a circuit breaker opens or a fuse element melts,
 Iffind
the cause of the overload before resetting
‹ ONCE ANNUALLY
1.
2.
3.
4.
the circuit breaker or replacing the fuse.
Test engine governor; adjust or repair, if needed.
Clean, inspect generator.
Flush cooling system.
Clean/re-gap spark plugs or replace as necessary.
CHECKING FLUID LEVELS
‹ CHECK ENGINE OIL
‹ FIRST 30 OPERATING HOURS
Check engine crankcase oil level (Figure 10.1) at least
every 20 hours of operation, or prior to use.
1. Change engine "break-in" oil and filter.
‹ FIRST 100 OPERATING HOURS
Figure 10.1 - Oil Dipstick and Oil Fill Cap
1. Change engine oil and oil filter. After initial
change, service engine oil and filter at 100 operating hours or six months, whichever comes first.
2. Retorque cylinder head.
3. Retorque intake and exhaust manifold.
Oil Fill Cap
‹ EVERY 500 OPERATING HOURS
1. Service air filter.
2. Check starter.
3. Check engine DC alternator.
Oil
Dipstick
Oil Filter
Maint021 Rev. A 09/08
10-1
Standby Generator Sets
Maintenance
‹ EXERCISE SYSTEM
• 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.
Start the generator engine at least once every seven
days and let it run at least 20 minutes. For more
detailed exercise information, see the respective sections in the Control Panel Technical Manual that is
supplied with the unit.
‹ INSPECT COOLING SYSTEM
• Inspect engine cooling system. See “Maintenance
Schedule”.
• Check hoses for damage, deterioration, leaks, etc.
Correct any discrepancies found.
• Check hose clamps for tightness.
‹ BATTERY FLUID
Check battery electrolyte fluid based on the
Maintenance Schedule. 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.
‹ CHECK ENGINE COOLANT LEVEL
‹ ENGINE COOLANT
See the “Checking Fluid Levels” section.
Check coolant level in coolant recovery bottle. See
the Specifications 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.
• Add recommended coolant mixture as necessary.
• Periodically remove radiator pressure cap (only
when engine has cooled down) to make sure the
coolant recovery system is functioning properly.
Coolant should be at bottom of radiator filler neck.
If coolant level is low, inspect gasket in radiator
pressure cap. Replace cap, if necessary. To have
pressure cap tested, contact a Service Facility.
Inspect cooling system and coolant recovery system for leaks.
‹ 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,
damage.
MAINTENANCE OWNER/
OPERATOR CAN PERFORM
‹ 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 of an inch. Adjust belt tension as required.
• Check fan belt alignment (see Figure 10.2).
working on the generator, ensure the fol Before
lowing:
• 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.
• The negative battery cable has been removed.
Figure 10.2 – Fan Belt
‹ CHECK ENGINE OIL LEVEL
Refer to “Checking Fluid Levels”.
‹ CHECK BATTERY
• See “Checking Fluid Levels”.
• Check battery cables for condition, tightness, corrosion or damage. Clean, tighten or replace as
necessary.
10-2
Maint021 Rev. A 09/08
Standby Generator Sets
Maintenance
‹ INSPECT ENGINE GOVERNOR
Visually inspect electronic governor.
refilling the crankcase with oil, always
 After
check oil level on dipstick. NEVER OPERATE
DANGER

ENGINE WITH OIL BELOW THE DIPSTICK “ADD”
MARK.
7. Start engine and check for oil leaks.
8. Shut OFF engine and wait 10 minutes for the
oil to settle down into the oil pan. Recheck oil
level on dipstick. DO NOT fill above the dipstick
"FULL" mark.
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 THE ENGINE AIR FILTER
To replace the engine air filter, remove the air filter
cover and replace the air filter making sure it is positioned properly before reattaching the cover (Figure
10.4).
See the “Service Schedule,” for air filter maintenance.
‹ CHANGING ENGINE OIL
Refer to maintenance performed by service facilities
for engine oil and filter change frequencies.
Figure 10.4 – Engine Air Filter
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:
Air Filter
1. Cut the zip-tie securing the oil drain hose.
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 secure drain hose with a
new zip-tie.
4. Turn OIL FILTER (Figure 10.3) counterclockwise
and remove. Properly dispose of old filter.
Figure 10.3 – Oil Filter
Oil
Dipstick
‹ SPARK PLUGS
Reset the spark plug gap or replace the spark plugs
as necessary (Figure 10.4).
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 1.07-1.17 mm (0.042-0.046
inch) by carefully bending the ground electrode
(Figure 10.5).
5. Apply light coating of new engine oil to seal of new
oil filter.-Install FILTER and tighten by hand only.
DO NOT OVER TIGHTEN.
6. Remove OIL FILL CAP and add recommended oil. Crankcase oil capacity is listed in the
"Specifications" section.
10-3
Maint021 Rev. A 09/08
Oil Filter
Standby Generator Sets
Maintenance
• 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.
Figure 10.5 – Setting the Spark Plug Gap
SET PLUG GAP AT 1.07 - 1.17 mm
(0.042 - 0.046 inch)
‹ COOLANT CHANGE
Every year, have a service facility drain, flush and
refill the cooling system. See “Specifications” for cooling system recommendations.
‹ BATTERY MAINTENANCE
The battery should be inspected per the "Scheduled
Maintenance" section. The following procedure should
be followed for inspection:
MISCELLANEOUS MAINTENANCE
1. Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.
2. Check the battery fluid level of unsealed batteries
and, if necessary, fill with DISTILLED WATER
ONLY. DO NOT USE TAP WATER IN BATTERIES.
3. Have the state of charge and condition checked.
This should be done with an automotive-type battery hydrometer.
‹ 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.
DANGER
batteries give off explosive hydrogen
 Storage
gas. This gas can form an explosive mixture
Once each year have the generator cleaned and
inspected by a 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.
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.
10-4
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 corrosive sulfuric acid solution that can cause severe
burns. Do not permit fluid to contact eyes, skin,
clothing, painted surfaces, etc. Wear protective
goggles, protective clothing and gloves when
handling a battery. If fluid is spilled, flush the
affected area immediately with clear water.
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.
Maint021 Rev. A 09/08
Standby Generator Sets
Maintenance
sure the AUTO/OFF/MANUAL switch is set to
 Be
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.
sure the 120VAC power supply to the battery
 Be
is turned OFF, or sparking may occur at the battery posts as the cables are attached and cause
an explosion.
‹ BATTERY REPLACEMENT
NOTE:
Unit DOES NOT include battery.
When supplying or replacing the battery, the recommended number and type of battery is listed in the
Specifications Section.
NOTE:
The BCI number should be located directly on the
battery.
Maint021 Rev. A 09/08
10-5
Stationary Emergency Generator
Service Schedule
SERVICE SCHEDULE
30 KW - 150 KW GASEOUS STATIONARY EMERGENCY GENERATOR SETS
The following is a recommended maintenance schedule for Gaseous Stationary Emergency 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 a 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 a 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 a 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 a Service Dealer.
SrvSchd003 Rev. B 10/08
11-1
Stationary Emergency Generator
Service Schedule
Maintenance
Tasks
Level 1
Recommended
to be done
monthly/
10 hrs.
Level 2
Level 3
Task
Required
Task
Required
Comp. to be done Comp. to be done
(Date- 3 months/ (DateSemiInitials) Break-in Initials) annually/
30 hrs.
50 hrs.
1. Disable the unit
from operating
per the first page
warning.
2. Check the engine
oil level. Adjust
as necessary.
3. Check the engine
coolant level.
Adjust as
necessary.
4. Check the engine
coolant thermal
protection level.
Correct as
necessary.
5. Check the natural
gas delivery
system for leaks
and correct
pressure on gas
engine driven
units. Tighten
connections as
necessary.
6. Check the air
inlets and outlets
for debris. Clean
as necessary.
7. Check the battery
electrolyte level
and specific
gravity if
accessible. Adjust
as necessary.
8. Check the battery
posts, cables,
and charger for
loose
connections,
corrosion, and
proper operation.
Correct as
necessary.
9. Check the unit
wiring for loose
connections,
corrosion, and
damage. Correct
as necessary.
11-2
Level 4
Task
Comp.
(DateInitials)
Required
to be done
Annually/
100 hrs.
Level5
Task
Comp.
(DateInitials)
Required
to be done
Biannually/
250 hrs.
Task
Comp.
(DateInitials)
SrvSchd003 Rev. B 10/08
Stationary Emergency Generator
Service Schedule
Maintenance
Tasks
Level 1
Recommended
to be done
monthly/
10 hrs.
Level 2
Level 3
Task
Required
Task
Required
Comp. to be done Comp. to be done
(Date- 3 months/ (DateSemiInitials) Break-in Initials) annually/
30 hrs.
50 hrs.
Level 4
Task
Comp.
(DateInitials)
Required
to be done
Annually/
100 hrs.
Level5
Task
Comp.
(DateInitials)
Required
to be done
Biannually/
250 hrs.
Task
Comp.
(DateInitials)
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/
lash. 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).
SrvSchd003 Rev. B 10/08
11-3
Stationary Emergency Generator
Service Schedule
Maintenance
Tasks
Level 1
Recommended
to be done
monthly/
10 hrs.
Level 2
Level 3
Task
Required
Task
Required
Comp. to be done Comp. to be done
(Date- 3 months/ (DateSemiInitials) Break-in Initials) annually/
30 hrs.
50 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.
11-4
Level 4
Task
Comp.
(DateInitials)
Required
to be done
Annually/
100 hrs.
Level5
Task
Comp.
(DateInitials)
Required
to be done
Biannually/
250 hrs.
Task
Comp.
(DateInitials)
SrvSchd003 Rev. B 10/08
Stationary Emergency Generator
Troubleshooting
TROUBLESHOOTING GUIDE
PROBLEM
CAUSE
CORRECTION
Engine won’t crank.
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. 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.*
Engine cranks but won't start
1. Out of fuel.
2. Fuel solenoid (FS) is defective
3. Open Wire #14A from Engine Control
circuit board.
4. Spark plugs defective.
5. Door on tank not closed.
1. Replenish fuel.
2. Replace solenoid.*
3. Reconnect wire.
Engine starts hard, runs rough.
1. Flame arrestor (air cleaner) plugged or
damaged.
2. Plugged fuel line.
3. Defective spark plugs.
4. Fuel pressure incorrect.
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.
Engine starts then shuts down.
1.
2.
3.
4.
5.
6.
7.
AUTO/OFF/MANUAL Switch at OFF,
engine continues to run
1. Defective AUTO/OFF/MANUAL switch
2. Open/disconnected wire #15A between
AUTO/OFF/MANUAL switch and Control
Module circuit board.
3. Defective Control Module circuit board
3. Replace board.*
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
Check main line circuit breaker.
Check circuit breaker & fuses.
Transfer switch set to NORMAL position
Generator internal failure.
Thermal circuit breaker open.
1.
2.
3.
4.
5.
6.
7.
Check oil and add oil as needed.
Check cooling system for leaks.
Replace switch.*
Replace switch.*
Replace board.*
Repair leak - Add coolant.
Replace Switch.*
1. Replace switch.*
2. Reconnect/close wire.
Reset to ON or CLOSED.
Reset and replace, if necessary.
Set to GENERATOR position.
*
Auto-reset - Wait 5 min. and
attempt restart.
*Contact the nearest Authorized Dealer for assistance.
12-1
Trblsht001 Rev. A 10/08
No AC output from generator.
Engine oil level is low.
Engine is overheated.
Defective Low Oil Pressure Switch
Defective Coolant Temperature Switch
Defective Control Module circuit board.
Coolant Level is Low.
Defective Low Coolant Level Switch
4. Clean, regap or replace plugs.
5. Close door on tank.
Stationary Emergency Generator
Notes
Stationary Emergency Generator
Notes
1
0F9677
0G0056
0G0959
0G1155
0G1931
0G2101
0G3734
0G6562
0G6564
1
1
1
1
1
1
1
1
1
ROTOR-2390-45KD1 CPL
ROTOR-2390-35KD1 CPL
ROTOR-2390-45KD1 CPL (G2)
ROTOR-2390-35KD1 CPL (G2)
ROTOR 25KW 3PH DIRECT 390 1800
ROTOR 25KW 1PH DIRECT 390 1800
RTR-2390-60KD2 CPL
RTR 390 35AD1 CPL
RTR 390 35KD1 CPL
2
0F9664
0G0057
0G0058
0G0059
0G0183
0G0184
0G1932
0G2098
0G2099
0G2100
0G3736
0G3737
0G3738
0G6104
0G6563
0G6565
0G6566
0G6567
0H0201
0H1299
0H1300
0H1301
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
STATOR-390 45K 2P 1PH DIRECT
STATOR-2390-35AD1 CPL
STATOR-2390-35KD1 CPL
STATOR-2390-35GD1 CPL
STATOR-2309-45KW 2P 3PH 208V
STATOR-2309-45-KD1 CPL
ASSY STR 390 25GD3 CPL
ASSY STR 390 25AD1 CPL
ASSY STR 390 25KD3 CPL
ASSY STR 390 25JD3 CPL
ASSY STR 2390 60AD2 CPL
ASSY STR 390 60KW 2P 3PH 208V
ASSY STR 390 60KW 2P 3PH 480V
STR-2390--45JD1 CPL
STR 390 35AD1 CPL
STR 390 35GD1 CPL
STR 390 35KD1 CPL
STR 390 35JD1 CPL
STR-2390--60JD2 CPL
ASSY STR 390 36AD1 CPL
ASSY STR 390 36JD1 CPL
ASSY STR 390 36 GD1 CPL
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23 *
24 *
25
26
0C9708
SEE ENGINE EV
SEE ENGINE EV
0F5767B
0E5706
0F7874
0G0587
038150
023454
077043E
04576100BU
052646
043123
051779
0A2601
072879
0F8408
046526
0C3992
022264
047248
070892
0G0588
077043A
REF
REF
REF
1
1
1
1
4
1
1
4
4
4
4
1
1
4
4
4
4
1
1
1
1
INSTR HYPOT TEST (NOT SHOWN)
ENGINE ADAPTER
FLEXPLATE
ASSY FLYWHEEL CPL W/40MM FAN B
REAR BEARING CARRIER 390/DRCT
ASSY BRUSH HOLDER 390/HSB
GUARD REAR BEARING CARRIER
WASHER FLAT #8 ZINC
KEY WOODRUFF #E
CONDUIT FLEX 1.0" ID (35” LG)
STUD M14-2.0 570 G5 ZINC
WASHER FLAT M14
WASHER LOCK M14
NUT HEX M14-2.0 G8 YEL CHR
SCREW HHC M16-2.0 X 45 G8.8
SPACER .69 X 2.75 X .37 ST/ZNC
SCREW HHC M10-1.50 X 16 G10.9
WASHER LOCK M10
SCREW HHTT M4-0.7 X 16 BP
WASHER LOCK #8-M4
BALL BEARING-45 MM
SLIP RING MACHINED
GUARD REAR BEARING CARRIER
CONDUIT FLEX .38" ID (60”)
* ROTOR REPLACEMENT PARTS
1
2
3
4
5
6
7
8
(1) 9
10
11
12
13
14
(2) 15
(2) 16
17
18
19
20
21
23
24
(1) 26
27
28
29
30
31
32
33
34
35
36
37
(3) 39
(4) 40
41
42
43
44
45
46
47
48
49
(5) 50
1)
A
C
D
E
F
G
H
J
K
L
2)
A
C
0F3137
0F3188
0F3189
023484N
0F6366B
0F6366A
043180
022264
0C3990
046357
022155
0C2428
0G7992
0A9457
057073
0D5466
0A7822
022237
022241
049226
0C2266
0C2454
022473
022097
0D4698
0H0026
025433
024469
067210A
0D6029
081008
077043J
051713
0F6156
029289
047411
0G0770
0H0348
036943
023897
022152
022158
0C2454
055934D
0F6145
048766
0G7991
0H1083
0G8951
1
1
1
1
1
1
2
2
2
REF
6
6
1
1
2
REF
REF
2
2
6
6
8
8
4
REF
1
1
1
1
4
1
1
2
1
1
4
1
1
2
4
2
2
1
1
A/R
REF
1
1
1
PAN CB CONN BOX
STAND RH CONTROL
STAND LH CONTROL
BUSHING SNAP SB-2.5-31
XFMR DUAL 120V/16V (FOR 120/240V & 277/480V UNITS)
XFMR DUAL 104V/16V (FOR 120/208V UNITS)
WASHER FLAT M4
WASHER LOCK #8-M4
SCREW PHTT M4-0.7 X 10 ZYC
BLOCK TERM 20A 6 X 6 X 1100V
WASHER LOCK #6
SCREW PHTT #6-32 X 1/2 ZYC
DECAL RTS CUSTOMER CONNECTION
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
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
BLOCK TERM 20A 6 X 3 X 1100V
DECAL CHARGER POWER 120VAC C2
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
GROMMET 1.25 X .25 X .75
CONDUIT FLEX 2.0" ID (36” LG)
WASHER FLAT M5
PLATE WIRE SNGL GALV
TAPE ELEC 1/2 FOAM (AS REQ’D)
SCREW HHC M6-1.0 X 16 G8.8
HARNESS, TRANSFORMER ADAPTER
PCB ENCLOSURE ASSY 4.2L IGN MD
SCREW PPHM #10/32 X 2
WASHER FLAT #10 ZINC
WASHER LOCK #10
NUT HEX #10-32 STEEL
SCREW THF M6-1 X 16 N WA Z/JS
CLAMP VINYL 1.06 X .406 Z
SEAL WEATHER .45"DIA
BLOCK TERM 20A 2 X 6 X 1100V
DECAL GTS CUSTOMER CONNECTION
ASSY PCB IGN MOD 2.4L NO-TURBO
ASSY PCB IGN MOD 2.4L TURBO
0F3328
0D5552
0D5553
0D5554
0D5556
0D9693
0F0492
048927
023897
022152
022158
0C2454
029289
0F1733
UL CIRCUIT BREAKER (ED)
1
COVER ED CB SHORT STND
1
CB 0050A 3P 480V S ED4 LL
CB 0060A 3P 480V S ED4 LL
CB 0070A 3P 480V S ED4 LL
CB 0090A 3P 480V S ED4 LL
CB 0125A 3P 480V S ED4 LL
1
INSULATOR CB S (ED-3P)
4
SCREW RHM #10-32 X 4-1/2
4
WASHER FLAT #10 ZINC
4
WASHER LOCK #10
4
NUT HEX #10-32 STEEL
9
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
0F3138
0D5572
0D5573
0D5574
0D5575
0D5576
UL CIRCUIT BREAKER (FD)
1
COVER CB CONN BOX
1
CB 0150A 3P 600V S FD6 LL
CB 0175A 3P 600V S FD6 LL
CB 0200A 3P 600V S FD6 LL
CB 0225A 3P 600V S FD6 LL
CB 0250A 3P 600V S FD6 LL
D
E
F
G
H
J
K
L
3)
A
C
D
E
F
G
H
J
K
L
4)
A
C
D
E
F
G
H
J
K
0F0199
081320
022473
022097
022127
0C2454
029289
0F1733
0F3329
0D5577
0F2353
022770
022473
022097
022127
0C2454
029289
0F1733
1
INSULATOR CB FD FRAME 30MIL
4
SCREW SHC 1/4-20 X 4.5 G8.8 NZ
4
WASHER FLAT 1/4-M6 ZINC
4
WASHER LOCK M6-1/4
4
NUT HEX 1/4-20 STEEL
9
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
UL CIRCUIT BREAKER (JD+LD)
1
COVER JD/LD CB SHRT STAND
1
CB 0300A 3P 600V S JD6 LL
2
INSULATOR CIRCUIT BR. JD/LD
4
SCREW RHM 1/4-20 X 3
4
WASHER FLAT 1/4-M6 ZINC
4
WASHER LOCK M6-1/4
4
NUT HEX 1/4-20 STEEL
9
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
0F8135
0E7283
0E7284
0E3628
0E3664
074908
0F8140
036261
0C2454
029289
0F1733
UL CIRCUIT BREAKER (QN)
1
COVER QN FRM CB
CB 0150A 2P 240V S QN2 LL
CB 0175A 2P S QN2 LL 240V
CB 0200A 2P 240V S QN2 LL
1
BASE, QN CIRCUIT BREAKER
2
SCREW HHTT M5-0.8 X 10 BP
1
COVER QN CB DISH
4
RIVET POP .125 X .275 SS
11
SCREW THF M6-1X16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
(1) ITEM INCLUDED WITH HARNESS
(2) ITEM INCLUDED WITH 0D5464B
(3) ITEM USED WITH EARLY MODEL 208V UNITS ONLY
(4) ITEMS USED ON 4.2L MODELS ONLY.
(5) ITEMS USED ON 2.4L MODEL ONLY.
5)
A
C
D
E
F
G
H
J
K
L
M
N
P
Q
0F8137
0E7994
0F8136
036261
022473
022097
022127
0F8139
0C2454
022237
048527
029289
022770
0F1733
UL CIRCUIT BREAKER (QJ-2P)
1
COVER QJ 2P FRM CB
CB 0225A 240V 2P S QJ22
1
COVER QJ 2P CB DISH
4
RIVET POP .125 X .275 SS
2
WASHER FLAT 1/4-M6 ZINC
2
WASHER LOCK M6-1/4
2
NUT HEX 1/4-20 STEEL
1
INSUL CB 2P QJ
9
SCREW THF M6-1 X 16 N WA Z/JS
2
WASHER LOCK 3/8
2
SCREW SHC 3/8-16 X 3/4 G8.8 NZ
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
2
SCREW RHM 1/4-20 X 3
1
DECAL CUSTOMER CONNECT INSIDE
P
(2) R
(2) S
(2) T
(2) U
(2) V
(1) W
X
0F4185
058306
0F4165$
0F4143
0F4148
0F4149
0F4151
0G5247$
0G5250
0G4478
0F4145
0F4186
0F4186AGS0R
036261
053640
038150
022264
022471
029289
0F1733
022129
0F8432
0F8432A
0C2454
0F8451
049897
022145
045771
0F8843
W/CB
0G3259
UL CIRCUIT BREAKER (225AF) (2P & 3P)
1
COVER CB C2-C4 (225AF)
3
SCREW SHC M8-1.25 X 25 G12.9
REF
CIRCUIT BREAKERS 200A FRAME (3P)
REF
CB 0040A 3P 480V 225AF (3P)
REF
CB 0125A 3P 480V G 225AF
REF
CB 0150A 3P 480V G 225AF
REF
CB 0200A 3P 480V G 225AF
REF
CB 200A FRAME G 240V (2P)
REF
CB 175A 2 POLE 240V 225AF (2P)
REF
CB 200A 2 POLE 240V 225AF (2P)
REF
CB 0060A 3P 480V G 225AF (3P)
1
COVER CB DISH 225AF (3P)
COVER CB DISH 225AF (2P)
4
RIVET POP .125 X .275 SS
2/4
SCREW RHM #8-32 X 3-1/4
2/4
WASHER FLAT #8 ZINC
2/4
WASHER LOCK #8-M4
2/4
NUT HEX #8-32 STEEL
2
TAPE ELEC 1/2 FOAM
1
DECAL CUSTOMER CONNECT INSIDE
6/9
WASHER LOCK M8-5/16
1
INSULATOR CB 225AF (3P)
1
INSULATOR CB 225AF (2P)
11
SCREW THF M6-1 X 16 N WA Z/JS
2/3
LUG SLDLSS 300 MCM-6 AL/CU
4/6
SCREW SHC M8-1.25 X 20 G8
4/6
WASHER FLAT 5/16-M8 ZINC
2/3
NUT HEX M8-1.25 G8 CLEAR ZINC
2/3
BUS BAR 200A LUG ADAPTOR
2
TERMINAL COVER CB
1
DECAL TERMINAL SHOCK HZD BI
7)
A
C
D
E
F
G
H
J
K
(2) L
(2) M
N
P
(1) S
T
U
V
(2) W
(2) X
Y
0F4187
0F4166$
0F1733
042419
023897
022152
022158
0C2454
029289
052647
046526
W/CB
0A7822
W/CB
023334
022097
022473
W/CB
W/CB
0G3259
UL CIRCUIT BREAKER (400AF)
1
COVER CB C2-C4 400AF
REF
CIRCUIT BREAKERS 400A FRAME
1
DECAL CUSTOMER CONNECT INSIDE
4
SCREW RHM 10-32 X 4
4
WASHER FLAT #10 ZINC
4
WASHER LOCK #10
4
NUT HEX #10-32 STEEL
9
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM
2/3
SCREW SHC M10-1.5 X 25 G12.9
2/3
WASHER LOCK M10
3
BUS BAR CB ADAPTER 225-400 A
3
LUG SLDLSS 600/250-1/0 X 1/4-28
2
TERM COVER CB
6
SCREW HHC 1/4-28 X 1/2 G5
6
WASHER LOCK M6-1/4
6
WASHER FLAT 1/4-M6 ZINC
2/3
SCREW SHC M10-1.5 X 25 G12.9
2/3
WASHER LOCK M10
1
DECAL TERMINAL SHOCK HZD BI
8)
A
B
C
D
E
F
G
H
9)
A
C
6)
A
B
C
D
E
(2) F
(2) G
(2) H
(2) J
K
L
(2) M
N
D
E
F
G
H
J
K
L
M
N
0D5466
039287
022145
022129
045771
045335
083896
0A7822
NEUTRAL BLOCK 390 / 200-400A
2
BUS BAR NEUTRAL BLOCK 390
1
SCREW HHC M8-1.25 X 45 G8.8 FT
1
WASHER FLAT 5/16-M8 ZINC
1
WASHER LOCK M8-5/16
1
NUT HEX M8-1.25 G8 YEL CHR
2
SCREW HHC 1/4-28 X 3/4 G5
2
WASHER LOCK 1/4-M6 SS
1
LUG SLDLSS 600/250-1/0 X 1/4-28
0G1968
0G1970
0A2077
040532
0C3990
0E7890
0E6002
022859
0G0008
023897
022152
022158
0F1733
029289
0C2454
UL CIRCUIT BREAKER (BQ)
1
COVER BQ CIR BREAKER CPL 3P
COVER BQ CIR BREAKER CPL 2P
1
CB 0125A 2P 240V S BQ2 LL
CB 0100A 3P 240V S BQ3 LL
2
SCREW PHTT M4-0.7 X 10 ZYC
1
BRKT CB MTG BACK
MTG TRACK BQ SIEMENS CB 3P
6
SCREW RHM #10-32 X 3/4
1
BRKT BQ CB STANDOFF
6
WASHER FLAT #10 ZINC
6
WASHER LOCK #10
6
NUT HEX #10-32 STEEL
1
DECAL CUSTOMER CONNECT INSIDE
1
TAPE ELEC 1/2 FOAM
11
SCREW THF M6-1 X 16 N WA Z/JS
(1) HARDWARE FOR MTG. CB TERMINAL COVERS IS
SUPPLIED WITH CIRCUIT BREAKERS.
(2) QTY. REQ’D FOR “2POLE / 3POLE” BREAKER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
29
30
0G37260ST03
052860
052251
052257
052252
052259
052891
0536210410
042909
047411
055414
022447
022097
022473
049813
022261
0F9597A
045764
062963
022302
022131
065852
0F9597
022129
026204
022145
045771
0F9596A
052212
1
4
4
4
4
4
4
1
1
1
1
1
1
2
1
1
1
1
4
5
5
1
1
1
1
1
1
1
1
WELDMENT FRAME 2.4L C2 60KW
NUT FLANGED HEX M12-1.75
DAMPENER VIBRATION 40 BLUE
SPACER .49 X .62 X 1.87 PWDR/ZNC
DAMPENER VIBRATION
WASHER FLAT M12
SCREW HHC M12-1.75 X 80 G8.8
ASSY WIRE 14.00"
SCREW HHC M8-1.25 X 30 G8.8
SCREW HHC M6-1.0 X 16 G8.8
LUG SLDLSS #2-#8 X 17/64 CU
WASHER SHAKEPROOF INT 1/4
WASHER LOCK M6-1/4
WASHER FLAT M6-1/4 ZINC
NUT HEX M6 -1.0 G8 YEL CHR
WASHER SHAKEPROOF INT 3/8
SUPPORT LH ENGINE 2.4L
SCREW HHTT M4-0.7 X 8 BP
SCREW HHC M10-1.25 X 30 G8.8
WASHER LOCK 7/16
WASHER FLAT 3/8-M10 ZINC
SPRING CLIP HOLDER .37-.62
SUPPORT RH ENGINE 2.4L
WASHER LOCK M8-5/16
WASHER SHAKEPROOF INT 5/16
WASHER FLAT 5/16-M8 ZINC
NUT HEX M8-1.25 G8 CLEAR ZINC
SPACER LH ENGINE MOUNT
SCREW HHC M10-1.25 X 25 C8.8
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
0F3408C
0F3411
025507
052212
046526
022131
050331A
050331
038805Y
03880400AE
045771
022129
077483
0F3976
042568
022145
0D3700
049811
1
1
REF
REF
REF
REF
REF
REF
1
1
REF
REF
REF
1
4
REF
4
4
BATTERY TRAY, C1 & C2
STRAP BATTERY RETAINMENT
WASHER SHAKEPROOF EXT 7/16 STL
SCREW HHC M10-1.25 X 25 G8.8
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
BATTERY POST COVER RED +
BATTERY POST COVER BLACK CABLE BATTERY BLACK #1 X 18.00
CABLE BATT RED #1 X 18.00
NUT HEX M8-1.25 G8 YEL CHR
WASHER LOCK M8-5/16
BATTERY 12VDC 75-AH 26
BOOT CONTACTOR CABLES
SCREW HHC M6-1.0 X 20 C8.8
WASHER FLAT 5/16-M8 ZINC
NUT FLANGE M6-1.0 NYLOK
WASHER FLAT M6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
0G0408A
046526
039414
0G0149
0E9868A
0F3217
0H2574
0A8584
057772
057765
043790
0C7649
069860E
063076
0G1394
052830
025507
062963
049821
022129
035472
0A6751
0E0502
1
6
4
1
1
1
1
1
1
1
1
1
1
7
7
2
5
5
3
30
1
1
1
ENGINE 2.4L G2
WASHER LOCK M10
SCREW HHC M8-1.25 X 35 G8.8
SCREW SHC M14-1.5 X 35 G10.9
ALTERNATOR DC W/OUT PULLEY
SPACER DC ALTERNATOR PULLEY
CONDUIT THERMAL FLEX 13MM ID
SWITCH OIL PRESSURE 10 PSI 2 POL (R-PANEL)
WASHER NYLON .565
ADAPTER M14-1.50 X 3/8 NPT
BARBED EL 90 3/8 NPT X 3/8
CLAMP HOSE .38-.87
HOSE DRAIN ASSY 28"
WASHER FLAT .531 ID X 1.062 OD
SCREW HHC M12-1.25 X 20 G10.9
SCREW HHC M10-1.25 X 45 G8.8
WASHER SHAKEPROOF EXT 7/16 STL
SCREW HHC M10-1.25 X 30 G8.8
SCREW SHC M8-1.25 X 30 G12.9
WASHER LOCK M8-5/16
CLAMP HOSE #6 .43-.78
SWITCH HI-TEMP 245D X 3/8 NPT (R-PANEL)
TEMPERATURE SENDER
23
24
25
26
27
28
29
30
31
32
33
34
35
(1) 36
37
38
39
40
41
42
43
(1) 44
45
46
47
48
49
50
51
52
(1) 53
54
55
56
57
58
59
(1) 60
61
62
63
64
(1) 65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
022145
0F2664H
045771
022131
0G8427A
0G1738
058306
022097
022473
090388
026073A
052243
0A8258
0A45310244
0G8853
042909
0G4003
0F0710
0G3823
052213
034413
0G0951
0G3745
0G6093E
0D2244M
0F9420
0G7461
0G1472A
0G1476
0G0707
0G0950
0F9583
0G9350
042907
0G8852
022152
0F9501
0G0952
0G0788
023897
026925
0D3701
052203
0G3995
0G7313
0G8877C
0H1275A
029333A
077043H
0G8854
0G4000
052265
0G39910ST03
0G39970ST03
047411
0G7902
0G9349
0G9330
0G9329
0G9910
084750
0G3921A
10
1
3
4
1
1
12
1
1
7
3
1
1
1(REF)
4
2
1
2
2
3
8
1(REF)
1
1
1
1
1
1
1(REF)
1
1(REF)
1
1
4
1
8
1
1(REF)
1
8
1
1
1(REF)
1
REF
1
1
3
2
1
1
1(REF)
1
1
1
1
1
1
1
2
4
1
WASHER FLAT 5/16-M8 ZINC
ASSY DIPSTICK W/TEXT GTH-530
NUT HEX M8-1.25 G8 CLEAR ZINC
WASHER FLAT 3/8-M10 ZINC
ASSY DIPSTICK TUBE 2.4 G2
CAP ANTIFREEZE RUBBER 9.5DIA
SCREW SHC M8-1.25 X 25 G12.9
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
SCREW HHTT M6-1.0 X 12 ZINC
PLUG STD PIPE 1/4 STEEL SQ HD
SCREW HHC M10-1.5 X 60 G8.8
SCREW HHC M8-1.25 X 25 G10.9
FILTER 1.5L/2.4L G2 OIL (NOT SHOWN)
COIL-2.4L G2 IGNITION
SCREW HHC M8-1.25 X 30 C8.8
SHIELD HEAT IGNITION COIL 2.4L
RIVET POP .125 X 0.337 STEEL
O-RING SIZE 9.0MM X 2.0MM NITR
SCREW HHC M10-1.25 X 20 C8.8
SCREW HHM #10-32 X 1-1/4
GASKET EXHAUST MANIFOLD
MANIFOLD EXH 60K G2 TURBO (MA)
FLEX PLATE 2 POLE 2.4L G2
ASSY MAGPICKUP(3/8-24 MALE)
ADAPTER ENGINE 2.4L MACHINE
MOTOR STARTER
CAM SENSOR PIN ASSY
COVER CAM GEAR G2 REWORKED
MANIFOLD INTAKE
GASKET INTAKE MANIFOLD
SPACER 2.4L G2 FLEX PLATE
O-RING 2.5"X 2.75"X 1/8" VITON
SCREW HHC M8-1.25 X 16 C8.8
BRACKET ASM-2.4L COIL G2
WASHER LOCK #10
ADAPTER 2.4L CRANKSHAFT MACH
POLY V-BELT G2 (3600 RPM)
PULLEY DC ALTERNATOR (3600 RPM)
WASHER FLAT #10 ZINC
PLUG STD PIPE 3/8 STEEL SQ HD
PLATE "HOT"
SCREW HHC M8-1.25 X 70 G8.8
SHIELD INNER HEAT 2.4L TURBO
DECAL EMISSION CTRL INFO 2.4L
HARN ENG 2.4L R-200B 3600 TURB (NOT SHOWN)
HARN ENG 2.4L R-200C 3600 RPM (NOT SHOWN)
TIE WRAP UL 7.4"X .19" BLK
CONDUIT FLEX .25"ID
SPARK PLUG WIRE SET 2.4L G2 IG
HEAT SHIELD TURBO 2.4L
SCREW HHC M8-1.25 X 65 C8.8
BRACKET EXH MANIFOLD 2.4 TURBO
BRACKET HEAT SHIELD 2.4L
SCREW HHC M6-1.0 X 16 C8.8
TUBE TURBO OIL RETURN G2 2.4L
O-RING 1" X 1.25" X 1/8" VITON
NUT OIL FILTER ADAPTOR 2.4L G2
ADAPTOR OIL FILTER 2.4L G2
ADAPTOR 45D JIC37 1/2NPT X 3/4
PLUG SPARK
VR SENSOR ASSY 3/8-24 LOW SENS
(1) SUPPLIED WITH ENGINE.
1
2
3
4
(1) 5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
(1) 24
25
26
(2) 27
28
29
(1) 30
31
32
0G68030ST03
0F2608
0F5263
046526
059981
0D3700
0F5050A
0G9332C
0F2573
0F4011
0G56820ST03
0G2990
0F2862
0F2560
022131
0E2507
035685
0F2561
0C8145
052250
0C7043
0G9332B
022473
0C8146
022097
076749
048031C
031971
0H0271
042911
0F2872
022304
1
1
1
5
4
4
1
1
1
1
1
1
1
1
4
1
2
1
8
2
12
1
8
4
16
1
2(REF)
1
1
1
1
2
WELDMENT RADIATOR SUPPORT C2
RADIATOR 598 X 568 X 49 CPL RH
V-BELT 31/64" X 57-3/8"
WASHER LOCK M10
SCREW HHC M10-1.5 X 30 G10.9
NUT FLANGE M6-1.0 NYLOK
SHIELD RADIATOR C4
OIL LINE REMOTE FILTER/ENGINE
PULLEY FAN V-GROOVE 9"
FAN COOL 22" DIA 10 BLADE LH
FLAT TENSIONER ARM
SHOULDER BOLT 3/8 X 1/2"
SPRING TENSION CPL
PULLEY V-BELT 4" FLANGED
WASHER FLAT 3/8-M10 ZINC
PROBE COOLANT LEVEL 3/8 NPTF
CLAMP HOSE #28 1.32-2.25
HUB FLEX PLATE
WASHER FLEX (THIN)
TAPE FOAM 1 X 1 (26.75” LG)
DISK FLEX
OIL LINE REMOTE COOLER/FILTER
WASHER FLAT 1/4-M6 ZINC
SCREW HHC 5/16-24 X 1.124
WASHER LOCK M6-1/4
TANK COOLANT RECOVERY
CLAMP HOSE BAND 1/4
BEARING #6205 2NSE C3 E SRI2 S
PULLEY 5.125" DIA MACHINED
SCREW HHC M10-1.5 X 30 G8.8
SCREW HHC 1/2-13 X 2" G8
WASHER FLAT 1/2 ZINC
33
34
35
36
37
38
39
40
(1) 41
42
43
44A
44B
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
(3) 75
76
77
78
79
80
022195
022196
0F8651
070015
0F9867
0F2461
022145
022129
039287
082774
0G0795
0G0816
0H1546
049813
052644
0C8566
0C2454
090283
080713
0G4376
0G56830ST03
039253
051698
049820
0G67930ST03
099502
0C8165
029032
0G3762
0G1285C
071296A
0G3985
0G3989
0C2454B
0G9332A
0C4975
0G3990
0C4973D
076749
080713
0G3986
0G9910
0G9331
0G9333
0A45310244
043107
0G9595
0A5259A
055934M
1
1
8
1
1
1
18
9
1
1
1
1
1
8
1
20
9
1
1
1
1
2
1
6
1
2
2
1
1
8
2
1
1
4
1
1
1
2
1
1
2
1
1
1
1
3
1
2
1
WASHER LOCK 1/2
NUT HEX 1/2-13 STEEL
SCREW HHFC M8-1.25 X 20 W/M6
NUT HEX LOCK 5/16-18 NY INS SS
SHAFT FAN DRIVE
RETAINER BEARING
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 45 C8.8
KEY WOODRUFF 4 X 19D
HOSE LOWER RADIATOR G2
HOSE UPPER RADIATOR G2
HOSE UPPER RADIATOR G2
NUT HEX M6 X 1.0 G8 YEL CHR
SPACER .5 X 1.5 X .25 STL/ZINC
SCREW HHFC M6-1.0 X 20 G8.8
SCREW THF M6-1 X 16 N WA Z/JS
CAP RADIATOR 13 PSI
BRACKET COOLANT TANK
WASHER BELLEVILLE .75X.38X.028
TENSIONER ARM SUPPORT BENT 90
SCREW HHC M8-1.25 X 20 C8.8
SCREW HHC M8-1.25 X 75 C8.8
NUT HEX LOCK M8-1.25 NY INS
BRACKET TENSIONER SPRING
CLAMP HOSE #24 B1.06-2.00
NUT HEX LOCK 5/16-24 NY INS
HOSE 9/32 ID (36”LG)
CAC 504W X 152H X 50D 2.4L G2
CLAMP CNST TENSION 1.75-2.625
HOSE 2"ID X 3.0"LG
TUBE CAC IN G2 TURBO
TUBE CAC OUT G2 TURBO
SCREW THF M6-1 X 30 N WA DELTA
OIL LINE REMOTE ENG/COOLER
ADAPTOR 1/2 NPT X 37JIC 3/4-16
COOLER OIL 2.4L G2 TURBO
ADAPTER 90D JIC37 1/2NPT X 3/4
TANK COOLANT RECOVERY
BRACKET COOLANT TANK
MOUNT OIL COOLER 2.4L G2
ADAPTER 45D JIC37 1/2NPT X 3/4
MOUNT REMOTE OIL FILTER 2.4 G2
NIPPLE-OIL FILTER
FILTER 1.5L/2.4L G2 OIL
SCREW HHC M8-1.25 X 25 C8.8
BRACKET RESERVOIR MOUNTING
HOSE 2"ID X 3.0"LG
CLAMP STL/VNL .75 X .343 Z
BEARING PRESS NOTE:
APPLY LOCTITE 620 BEARING RETAINMENT
COMPOUND TO BEARING SURFACE ON ITEM 37
PRIOR TO PRESSING ITEM 28 ONTO ITEM 37.
ALSO APPLY LOCTITE 620 BEARING RETAINMENT
COMPOUND TO THE OUTSIDE OF 28 PRIOR TO
INSTALLING ITEM 28 INTO ITEM 38.
(1) APPLY MEDIUM STRENGTH BLUE THREAD
LOCKING FLUID TO THREADS.
(2) INCLUDED WITH I/N 26.
(3) APPLY LOCTITE #266 TO I/N 75 PRIOR TO
ASSEMBLY.
ITEM
PART#
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
042574
064094
064096B
0A4707B
0A4707F
0C4973C
0C4975
0G7911
0G8236
0G8690
0G8691
0G8692
0E8388
058306
022129
0H0457
0H0456
0E5343
1
1
1
1
1
1
1
1
1
1
1
1
3
4
4
4
3
4
ADAPTER 1/8NPTF TO 1/8 BSPT
MALE ELBOW 45 #49X3
OIL SUPPLY 3LHA(38")
ADAPTER 1/4NPT X M12-1.5
ADAPTER 1/2NPT X M16-1.5
ADAPTER 90D JIC37 1/4NPT X 1/2
ADAPTOR 1/2 NPT X 37JIC 3/4-16
TURBOCHARGER G2 2.4L
MANIFOLD EXHAUST
GASKET 2.4L G2 TURBO/ EX MAN
GASKET 2.4L G2 EXH MAN/ BYPASS
GASKET 2.4L G2 TURBO/BYPASS
NUT HEX FL WHIZ M6-1.0
SCREW SHC M8-1.25 X 25 C12.9
WASHER LOCK M8-5/16
STUD M10-1.5 X 40
STUD M6-1.0 X 30
NUT LOCK FL-SERRATED M10-1.50
EXPLODED VIEW: AIR CLEANER 2.4L G2 TURBO
GROUP D
DRAWING #: 0H1954
APPLICABLE TO:
ITEM
PART#
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
0F4269
0H0030
0G39340ST03
035480
0H0028
0F4271
0H0219
0F5418
0F4270
0F6323
0H0035
0G0153
0D3700
049811
045757
022097
047411
022145
022129
039253
037561
0D3700
049811
045757
022097
047411
086133C
039253
022129
022145
022259
0H1712
057822
059057
0H0027
047527(3)(4)
0H1644(4)
0G10080103(4)
0H1787A
0H1787
0H1801
2
1
1
1
1
1
1
1
1
1
1
1
4
8
4
4
4
2
2
2
1
4
8
4
4
4
2
2
4
4
2
1
2
1
1
1
1
1(REF)
1
1
1
GASKET MIXER BODY
ADAPTOR-MIXER
BRACKET AIR INTAKE
BOLT U 5/16-18 X 2.06
ADAPTOR-AIR CLEANER
BASE PLATE, AIR CLEANER
PLUG PLASTIC 2.5" BLACK
ELEMENT AIR FILTER
HOLD DOWN AIR CLEANER PLATED
PLATE, AIR CLEANER TOP
HOSE AIR INTAKE
BARBED EL 90 1/2NPT X 3/4 HOSE
NUT FLANGE M6-1.0 NYLOK
WASHER, FLAT, M6
SCREW HHC M6-1.0 X 25 G8.8
WASHER LOCK M6-1/4
SCREW HHC M6-1.0 X 16 C8.8
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 20 G8.8
NUT WING 1/4-20 W/NY INS ST ZN
NUT FLANGE M6-1.0 NYLOK
WASHER, FLAT, M6
SCREW HHC M6-1.0 X 25 G8.8
WASHER LOCK M6-1/4
SCREW HHC M6-1.0 X 16 C8.8
CLAMP HI TORQUE 1.75 - 2.625
SCREW HHC M8-1.25 X 20 G8.8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
NUT HEX 5/16-18 STEEL
BARBED EL-90 POLY 1/2NPT X ¾
CLAMP HOSE #8 .53-1.00
HOSE 3/4 ID SAE-30R2 (7.62”LG”)
FITTING VENT VALVE COVER 2.4L
BARBED STR 1/2NPT X 3/4
FTG VNT VALVE COVER
GASKET, PCV VALVE
PIPE INSULATION ELBO
PIPE INSULATION (4.5”LG)
PIPE INSULATION TAPE (7”LG)
36(1)(2)
37(2)
38(2)
(1)TRIM PIPE INSULATION ELBOW TO FIT.
(2)INSULATION SHALL COMPLETELY COVER I/N’S 32, 34 & 35.
(3)APPLY PIPE SEALANT COMPOUND TO THREADS.
(4) ALTERNATE CONFIGURATION REQUIRES ALL NOTED PARTS.
NOTE: APPLY LOCTITE 620 BEARING RETAINMENT COMPOUND TO OUTSIDE
SURFACE OF FITTING (I/N 35) THAT PRESSES INTO VALVE COVER.
REVISION: H-3963 –B
DATE: 2/27/09
PAGE 2 OF 2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
059057
065908
039130
030131
088963
026915
0A8064
064346
0G9239C
046580
043107
022131
022129
045771
050279
0D1509
059057
0F6279
057823
0E4394
0E6586
086133C
0F3857
086133E
0F3885
0G3167
0F3691
022097
1
1
1
1
1
2
2
1
1
4
2
4
2
2
1
1
1
1
4
1
1
1
1
1
1
2
1
4
HOSE 3/4 ID SAE-30R2 (43”LG)
FLANGE FUEL INLET
NIPPLE CLOSE 1.25 NPT X 1.625
ELBOW 90D 1-1/4 NPT
NIPPLE PIPE 1.25 NPT X 5.5 BL IRN
NIPPLE CLOSE 3/4 X 1.375
BSHG RDCR HEX 1-1/4-3/4
PIPE TEE 1-1/4 NPT
REG ASSY 2.4L 60KW NG CPL
SCREW SHC M6-1.0 X 45 C12.9
SCREW HHC M8-1.25 X 25 C8.8
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 CLEAR ZINC
DECAL FUEL INLET NG
DECAL INLET PRESSURE
HOSE 3/4 ID SAE-30R2 (43” LG)
HARNESS FUEL JUMPER DUAL REG
CLAMP HOSE #10 .56-1.06
ACTUATOR BOSCH 40 GOVERNOR
GASKET BOSCH 32
CLAMP HI TORQUE 1.75 - 2.625
REDUCER RUBBER 3.0"-2.00"
CLAMP HI TORQUE 2.75 - 3.625
MIXER 40/60MM ACTUATOR ASSY
O-RING 2-3/4 X 3/32 X 2-15/16
VENTURI THROTTLE 32MM
WASHER LOCK M6-1/4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
059057
075580
026915
026812
0F8379
026915
022097
0F3691
0G9189C
046580
043107
022131
022129
045771
050280
0D1509
059057
0F6155
057823
0E4394
0E6586
086133C
0F3857
086133E
0F3885
0G3167
1
1
1
2
1
2
4
1
1
4
2
4
2
2
1
1
1
1
4
1
1
1
1
1
1
2
HOSE 3/4 ID SAE-30R2 (45”LG)
FLANGE, FUEL INLET
NIPPLE CLOSE 3/4 X 1.375
ELBOW 90D 3/4NPT
NIPPLE PIPE 3/4 NPT X 7
NIPPLE CLOSE 3/4 X 1.375
WASHER LOCK M6-1/4
VENTURI THROTTLE 32MM
REG ASSY 2.4L 60KW LPV CPL
SCREW SHC M6-1.0 X 45 C12.9
SCREW HHC M8-1.25 X 25 C8.8
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 CLEAR ZINC
DECAL FUEL INLET LPG
DECAL INLET PRESSURE
HOSE 3/4 ID SAE-30R2 (41” LG)
HARNESS FUEL JUMPER SINGLE REG
CLAMP HOSE #10 .56-1.06
ACTUATOR BOSCH 40 GOVERNOR
GASKET BOSCH 32
CLAMP HI TORQUE 1.75 - 2.625
REDUCER RUBBER 3.0"-2.00"
CLAMP HI TORQUE 2.75 - 3.625
MIXER 40/60MM ACTUATOR ASSY
O-RING 2-3/4 X 3/32 X 2-15/16
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
PART#
0E8816
0F2808D
0G0007
0G0113
0G6150
0G6776
0G8685
0G8686
0G86870ST03
036797
049721
022097
022473
080762
022237
022241
0G6401
0F4710
088775
0E0170A
0C2454
QTY.
1
1
1
1
1
1
1
1
1
1
2
2
2
3
6
6
2
2
2
1
4
DESCRIPTION
FLANGE EXHAUST
EXHAUST PIPE
DIFFUSER EXHAUST WELDMENT
EXHAUST ELBOW
MUFFLER 60kW
PIPE EXHAUST 2.4L 60kW
STRAP MUFFLER
BRACKET STIFFENER
BRACKET MUFFLER
BOLT U 5/16-18 X 2.25
SCREW HHC M6-1.0 X 35 C8.8 BLK
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
BOLT U 3/8-16 X 2.62
WASHER LOCK 3/8
NUT HEX 3/8-16 STEEL
SCREW HHC M10-1.5 X 45 SS
WASHER LOCK M10 SS
WASHER FLAT 3/8 SS
EXHAUST BLANKET 988MM
SCREW THF M6-1 X 16 N WA Z/JS
(2) 1
2
(2) 3
4
5
(2) 6
(2) 7
(2) 8
9
(1) 10
(3) 11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
0G80180ST14
0C2454
0F58490ST14
087233
0E3257
0F58520AL14
0F98330ST14
0F58510ST14
049813
077992
0F98350AL14
0F2786
0F2785
0F3364
0F4880
0F5049
0F4487A
022473
022097
022127
0F3072
078115
0G5892
0G5892A
0F5048D
0E5968
0G5892D
0G5892C
0F4051C
0F3890B
0F4051B
0F3890
078115A
0G5892E
042568
0912970094
022447
0G9473
0F8869D
052250
066760
1
58
2
2
4
2
2
1
2
21
1
2
1
1
2
2
1
3
1
1
10
26
2
1
2
1
2
2
2
4
2
4
6
1
2
2
2
1
1
1
1
REAR WRAP C2 G2 60KW
SCREW THF M6-1 X 16 N WA Z/JS
DOOR C2
RIVET POP .1875 X .450 SS
SCREW TH-FRM M6 W/CAP SHKPRF W
DUCT DSCHRG LH&RH
FRONT CORNERS C2
DUCT DISCHARGE C2
NUT HEX M6 X 1.0 G8 YEL CHR
NUT HEX LOCK M6-1.0 SS NY INS
ROOF C2
SLITTER C4
SPLITTER LOWER C4
SPLITTER STINGER C2
SUPPORT SPLITTER LH C2
TAB PULL
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 #4-40
INSULATION DOOR C2
INSULATION ROOF TOP
VISE-ACTION LATCH SLOTTED CIR
GASKET EXTRUDED TRIM (328” LG)
INSULATION SPLITTER
INSULATION SPLITTER
INSULATION DUCT
RETAINER INSULATION (820)
INSULATION DUCT SIDES
RETAINER INSULATION (450)
WASHER SELF LOCKING DOME #8-32
INSULATION LOWER SPLITTER
SCREW HHC M6-1.0 X 20 G8.8
ASSY WIRE 14 AWG 34.8" GRN/YEL
WASHER SHAKEPROOF INT 1/4
DEFLECTOR INTAKE 2.4L G2 TURBO
KEY VISE-ACTION LATCH SLOT CIR
TAPE FOAM 1X1 (17.25”LG)
STRIP SEALANT 1/8 X 1 (44.52”LG)
(1) ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE
SECURED USING ITEM 2 & 5 THREAD FORMING FASTENER AND I/N 10 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) REFER TO THE SAMPLE GUIDE BELOW FOR AVAILABLE COLOR AND/OR ALUMINUM PART NUMBER FORMAT.
0FXXXX0ST13 = BISQUE / STEEL
0FXXXXALT13 = BISQUE / ALUMINUM
0FXXXX0ST14 = GRAY / STEEL
0FXXXXALT14 = GRAY / ALUMINUM
0FXXXX0ST05 = WHITE / STEEL
0FXXXX0AL05 = WHITE / ALUMINUM
(3) PART NUMBER SHOWN IS FOR TAN. SEE GUIDE BELOW FOR AVAILABLE COLOR AND PART NUMBER FORMAT.
0FXXXXALT13 = BISQUE / ALUMINUM
0FXXXXALT14 = GRAY / ALUMINUM
0FXXXX0AL05 = WHITE / ALUMINUM
1
2
3
4
5
6
7
*8
*9
*10
11
12
13
*14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
0F1823B
0F3078BST06
0F2606
036261
0E7358
052777
0G8455D
0F1262
0F1263
0F1264
0G8023A
0G2885
0E6875A
055911
0F5459
0E3161
0G3648
0F5462
0A5062J
029673
0C1457A
0F1958
082573
0E4494
0G8997
0F6305
0F6305A
0F5886
051713
049226
0F5752F
0F5884
0F5896
074076
0C3990
080823
051716
079224
043182
051714
0F3192
0E7403C
0G9056
A
B
C
D
E
F
G
H
J
K
L
M
N
P
056739
022287
022473
022097
022127
0F6145
0F2627A
091526
049226
051713
SEE CHART
052777
043182
051714
COMPONENTS INCLUDED IN 0G8458E
1
ENCL HSB CONTROL PANEL
1
COVER CONTROL PANEL R-200B
1
HINGE CONTINUOUS H-PANEL
7
RIVET POP .125 X .275 SS
4
SCREW PPPH HI-LO #4-24 X 3/8
1
WASHER FLAT M3
1
ASSY PCB R-200B CNTRL 3600 RPM
REF.
HOLDER FUSE WICKMANN 178.6150
REF.
ADPTR RH SIDE WICKMANN 178.6191
REF.
ADPTR LH SIDE WICKMANN 178.6192
1
BATC 13.4VDC 2.5A W/4POS PLUG
1
ASSY PCB HI-PWR VOLTAGE RGLTR
2
RELAY 12VDC C FORM W/DIODE
REF.
BLOCK TERM 20A 12 X 6 X 1100V
1
DECAL CPL CNT PNL FUSES
1
ASSY PCB BOSCH GOV DRIVER
1
M5X0.8 CAPTIVE PANEL KNLD HD
1
DECAL CPL 3.9L TB1
4
SPACER 9.5H 3.2 ID
1
DIO BRIDGE 25A 600V
1
HOUR METER 10-80VDC
1
PLATE HARNESS CLAMP
1
SWITCH RKR DPST 125V SPD
1
SWITCH RKR DPDT ON-OFF-ON
1
DECAL CONTROL FLEX R-200B
2
SEAL COVER 3.18X12.7X382
1
SEAL COVER 3.18X12.7X283
2
SCREW HHPM M5-0.8 X 12
11
WASHER FLAT M5
11
WASHER LOCK M5
1
RES WW 15R 5% 25W QK CONN
2
SCREW PHTT M3.5-0.6 X 10
2
SCREW PHTT M3.5-0.6 X 16
2
SCREW PHM M3-0.5 X 10 BLACK
2
SCREW PHTT M4-0.7 X 10 ZYC
4
SCREW PPHM M5-0.8 X 50 ZNC
9
NUT HEX M5-0.8 G8 YEL CHR
2
SCREW PPHM M5-0.8 X 30 SS
7
WASHER LOCK M3
7
NUT HEX M3-0.5 G8 YEL CHR
1
SUPPORT ANGLE PCB
1
FUSE ATO TYPE 15 AMP (BLUE)
1
HARN CTRL PNL R-200B 2.4L/4.2L (NOT SHOWN)
COMPONENTS INSTALLED PER THIS DRAWING
1
RELAY SOLENOID 12VDC PNL MNT
2
SCREW HHC 1/4-20 X 3/4 G5
4
WASHER FLAT 1/4-M6 ZINC
2
WASHER LOCK M6-1/4
2
NUT HEX 1/4-20 STEEL
A/R
SEAL WEATHER .45"DIA
1
COVER CONTROL PANEL SIDE
4
SCREW PPHM M5-0.8 X 12 ZNC
4
WASHER LOCK M5
4
WASHER FLAT M5
1
DPE BREAKER
2
WASHER FLAT M3
2
WASHER LOCK M3
2
NUT HEX M3-0.5 G8 YEL CHR
NOTE: ITEMS MARKED BY * ARE PART OF WIRE HARNESS.
1.)
A
C2 UNITS
0F9832
0F9832GGS0R
0C2454
1
1
4
SHIELD CONN BOX C2
SHIELD CONTROL STAND C2
SCREW THF M6-1 X 16 N WA Z/JS
B
C3 UNITS
0F9832B
0F9832KGS0R
0C2454
1
1
3
SHIELD CONTROL STAND C3
SHIELD CONTROL STAND C3
SCREW THF M6-1 X 16 N WA Z/JS
3.)
A
B
C4 UNITS
0F9832A
0C2454
1
3
SHIELD CONTROL STAND C4
SCREW THF M6-1 X 16 N WA Z/JS
4.)
A
C5 UNITS
0F9832C
0F9832D
0F9832EGS0R
0F9832HGS0R
0F9832JGS0R
0F9832FGS0R
0C2464
1
1
1
1
1
1
3
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SCREW THF M6-1 X 16 N WA Z/JS
B
2.)
A
B
C
BackPg001 Rev. A 04/07
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
29
30
0G37260ST03
052860
052251
052257
052252
052259
052891
0536210410
042909
047411
055414
022447
022097
022473
049813
022261
0F9597A
045764
062963
022302
022131
065852
0F9597
022129
026204
022145
045771
0F9596A
052212
1
4
4
4
4
4
4
1
1
1
1
1
1
2
1
1
1
1
4
5
5
1
1
1
1
1
1
1
1
WELDMENT FRAME 2.4L C2 60KW
NUT FLANGED HEX M12-1.75
DAMPENER VIBRATION 40 BLUE
SPACER .49 X .62 X 1.87 PWDR/ZNC
DAMPENER VIBRATION
WASHER FLAT M12
SCREW HHC M12-1.75 X 80 G8.8
ASSY WIRE 14.00"
SCREW HHC M8-1.25 X 30 G8.8
SCREW HHC M6-1.0 X 16 G8.8
LUG SLDLSS #2-#8 X 17/64 CU
WASHER SHAKEPROOF INT 1/4
WASHER LOCK M6-1/4
WASHER FLAT M6-1/4 ZINC
NUT HEX M6 -1.0 G8 YEL CHR
WASHER SHAKEPROOF INT 3/8
SUPPORT LH ENGINE 2.4L
SCREW HHTT M4-0.7 X 8 BP
SCREW HHC M10-1.25 X 30 G8.8
WASHER LOCK 7/16
WASHER FLAT 3/8-M10 ZINC
SPRING CLIP HOLDER .37-.62
SUPPORT RH ENGINE 2.4L
WASHER LOCK M8-5/16
WASHER SHAKEPROOF INT 5/16
WASHER FLAT 5/16-M8 ZINC
NUT HEX M8-1.25 G8 CLEAR ZINC
SPACER LH ENGINE MOUNT
SCREW HHC M10-1.25 X 25 C8.8
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
0F3408C
0F3411
025507
052212
046526
022131
050331A
050331
038805Y
03880400AE
045771
022129
077483
0F3976
042568
022145
0D3700
049811
1
1
REF
REF
REF
REF
REF
REF
1
1
REF
REF
REF
1
4
REF
4
4
BATTERY TRAY, C1 & C2
STRAP BATTERY RETAINMENT
WASHER SHAKEPROOF EXT 7/16 STL
SCREW HHC M10-1.25 X 25 G8.8
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
BATTERY POST COVER RED +
BATTERY POST COVER BLACK CABLE BATTERY BLACK #1 X 18.00
CABLE BATT RED #1 X 18.00
NUT HEX M8-1.25 G8 YEL CHR
WASHER LOCK M8-5/16
BATTERY 12VDC 75-AH 26
BOOT CONTACTOR CABLES
SCREW HHC M6-1.0 X 20 C8.8
WASHER FLAT 5/16-M8 ZINC
NUT FLANGE M6-1.0 NYLOK
WASHER FLAT M6
EXPLODED VIEW: EV ENCLOSURE C2 2.4L G2 TURBO
GROUP F
DRAWING #: 0J8688
ITEM
PART#
QTY.
(2)1
(1)2
(2)3
4
(1)5
(2)6
(2)7
(2)8
9
(1)10
(2)11
12
13
14
15
16
17
18
19
20
21
22
23
24
24A
24B
24BA
24BB
24C
24D
24E
0G80180AL0R
0C2454
0F58490AL0R
087233
0E3257
0F58520AL0R
0F98330AL0R
0F58510AL0R
049813
077992
0F98350AL0R
0F2786
0F2785
0F3364
0F4880
0F5049B
0F4487A
022473
022097
022127
0F3072
078115
0C8566
0G6001A
0G5892
0L3103
0G5892A
0G5892F
0G5892C
0G5892D
0G5892E
1
48
2
2
10
2
2
1
2
17
1
2
1
1
2
2
1
7
5
1
10
26
4
1
2
1
1
1
2
2
1
REAR WRAP C2 G2 60KW
SCREW THF M6-1 X 16 N WA Z/JS
DOOR C2
RIVET POP .1875 X .450 SS
SCREW TH-FRM M6 W/CAP SHKPRF W
DUCT DSCHRG LH&RH
FRONT CORNERS C2
DUCT DISCHARGE C2
NUT HEX M6 X 1.0 G8 YEL CHR
NUT HEX LOCK M6-1.0 SS NY INS
ROOF C2
SLITTER C4
SPLITTER LOWER C4
SPLITTER STINGER C2
SUPPORT SPLITTER LH C2
PULL TAB DOOR LOCK SS
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 #4-40
SCREW HHFC M6-1.0 X 20 G8.8
KIT INSULATION C2
INSULATION DOOR C2
KIT INSULATION C2
INSULATION ROOF TOP
INSULATION ROOF TOP
INSULATION SPLITTER
INSULATION SPLITTER
INSULATION LOWER SPLITTER
25
26
27
28
0F5048D
0E5968
0H0412
0H1208A
0H1208B
0F4051C
0F3890B
0F4051B
0F3890
078115A
0E5298L
042568
0912970090
022447
0G9473
0F8869D
052250
066760
2
1
4
1
1
2
4
2
4
6
1
2
2
2
1
1
1
1
VISE-ACTION LATCH SLOTTED CIR
GASKET EXTRUDED TRIM (328” LG)
NUT U M6-1.0 GEOMET
RF COVER PLATE-PLASTIC-BISQUE
RF COVER PLATE-PLASTIC-GREY
INSULATION DUCT
RETAINER INSULATION (820)
INSULATION DUCT SIDES
RETAINER INSULATION (450)
WASHER SELF LOCKING DOME #8-32
FOAM 300 X 300 THERMAL ACO
SCREW HHC M6-1.0 X 20 G8.8
ASSY WIRE 14AWG GRN/YEL
WASHER SHAKEPROOF INT 1/4
DEFLECTOR INTAKE 2.4L G2 TURBO
KEY VISE-ACTION LATCH SLOT CIR
TAPE FOAM 1X1 (71.0”LG)
STRIP SEALANT 1/8 X 1 (44.52”LG)
29
30
31
32
33
34
35
36
37
38
39
40
41
DESCRIPTION
UNLESS OTHERWISE SPECIFIED:
(1) ENCLOSURE NOTE: PANELS THAT FASTEN TO THE BASEFRAME (EXCEPT ITEM 1) MUST BE SECURED USING I/N 2 & 5 (THREAD FORMING FASTENERS)
AND I/N 10 (LOCK NUT). LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE
PANELS. ALL PANEL TO PANEL CONNECTIONS TO INCLUDE AT LEAST ONE CONNECTION POINT USING I/N 5 (THREAD FORMING FASTENER).
(2) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
•
MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
•
CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR CORRECT MATERIAL
AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
REVISION: K-2283-L
DATE: 3/24/15
Page 2 of 2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
059057
065908
039130
030131
088963
026915
0A8064
064346
0G9239C
046580
043107
022131
022129
045771
050279
0D1509
059057
0F6279
057823
0E4394
0E6586
086133C
0F3857
086133E
0F3885
0G3167
0F3691
022097
1
1
1
1
1
2
2
1
1
4
2
4
2
2
1
1
1
1
4
1
1
1
1
1
1
2
1
4
HOSE 3/4 ID SAE-30R2 (43”LG)
FLANGE FUEL INLET
NIPPLE CLOSE 1.25 NPT X 1.625
ELBOW 90D 1-1/4 NPT
NIPPLE PIPE 1.25 NPT X 5.5 BL IRN
NIPPLE CLOSE 3/4 X 1.375
BSHG RDCR HEX 1-1/4-3/4
PIPE TEE 1-1/4 NPT
REG ASSY 2.4L 60KW NG CPL
SCREW SHC M6-1.0 X 45 C12.9
SCREW HHC M8-1.25 X 25 C8.8
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 CLEAR ZINC
DECAL FUEL INLET NG
DECAL INLET PRESSURE
HOSE 3/4 ID SAE-30R2 (43” LG)
HARNESS FUEL JUMPER DUAL REG
CLAMP HOSE #10 .56-1.06
ACTUATOR BOSCH 40 GOVERNOR
GASKET BOSCH 32
CLAMP HI TORQUE 1.75 - 2.625
REDUCER RUBBER 3.0"-2.00"
CLAMP HI TORQUE 2.75 - 3.625
MIXER 40/60MM ACTUATOR ASSY
O-RING 2-3/4 X 3/32 X 2-15/16
VENTURI THROTTLE 32MM
WASHER LOCK M6-1/4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
059057
075580
026915
026812
0F8379
026915
022097
0F3691
0G9189C
046580
043107
022131
022129
045771
050280
0D1509
059057
0F6155
057823
0E4394
0E6586
086133C
0F3857
086133E
0F3885
0G3167
1
1
1
2
1
2
4
1
1
4
2
4
2
2
1
1
1
1
4
1
1
1
1
1
1
2
HOSE 3/4 ID SAE-30R2 (45”LG)
FLANGE, FUEL INLET
NIPPLE CLOSE 3/4 X 1.375
ELBOW 90D 3/4NPT
NIPPLE PIPE 3/4 NPT X 7
NIPPLE CLOSE 3/4 X 1.375
WASHER LOCK M6-1/4
VENTURI THROTTLE 32MM
REG ASSY 2.4L 60KW LPV CPL
SCREW SHC M6-1.0 X 45 C12.9
SCREW HHC M8-1.25 X 25 C8.8
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 CLEAR ZINC
DECAL FUEL INLET LPG
DECAL INLET PRESSURE
HOSE 3/4 ID SAE-30R2 (41” LG)
HARNESS FUEL JUMPER SINGLE REG
CLAMP HOSE #10 .56-1.06
ACTUATOR BOSCH 40 GOVERNOR
GASKET BOSCH 32
CLAMP HI TORQUE 1.75 - 2.625
REDUCER RUBBER 3.0"-2.00"
CLAMP HI TORQUE 2.75 - 3.625
MIXER 40/60MM ACTUATOR ASSY
O-RING 2-3/4 X 3/32 X 2-15/16
1
2
3
4
5
6
7
*8
*9
*10
11
12
13
*14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
0F1823B
0F3078BST06
0F2606
036261
0E7358
052777
0G8455D
0F1262
0F1263
0F1264
0G8023A
0G2885
0E6875A
055911
0F5459
0E3161
0G3648
0F5462
0A5062J
029673
0C1457A
0F1958
082573
0E4494
0G8997
0F6305
0F6305A
0F5886
051713
049226
0F5752F
0F5884
0F5896
074076
0C3990
080823
051716
079224
043182
051714
0F3192
0E7403C
0G9056
A
B
C
D
E
F
G
H
J
K
L
M
N
P
056739
022287
022473
022097
022127
0F6145
0F2627A
091526
049226
051713
SEE CHART
052777
043182
051714
COMPONENTS INCLUDED IN 0G8458E
1
ENCL HSB CONTROL PANEL
1
COVER CONTROL PANEL R-200B
1
HINGE CONTINUOUS H-PANEL
7
RIVET POP .125 X .275 SS
4
SCREW PPPH HI-LO #4-24 X 3/8
1
WASHER FLAT M3
1
ASSY PCB R-200B CNTRL 3600 RPM
REF.
HOLDER FUSE WICKMANN 178.6150
REF.
ADPTR RH SIDE WICKMANN 178.6191
REF.
ADPTR LH SIDE WICKMANN 178.6192
1
BATC 13.4VDC 2.5A W/4POS PLUG
1
ASSY PCB HI-PWR VOLTAGE RGLTR
2
RELAY 12VDC C FORM W/DIODE
REF.
BLOCK TERM 20A 12 X 6 X 1100V
1
DECAL CPL CNT PNL FUSES
1
ASSY PCB BOSCH GOV DRIVER
1
M5X0.8 CAPTIVE PANEL KNLD HD
1
DECAL CPL 3.9L TB1
4
SPACER 9.5H 3.2 ID
1
DIO BRIDGE 25A 600V
1
HOUR METER 10-80VDC
1
PLATE HARNESS CLAMP
1
SWITCH RKR DPST 125V SPD
1
SWITCH RKR DPDT ON-OFF-ON
1
DECAL CONTROL FLEX R-200B
2
SEAL COVER 3.18X12.7X382
1
SEAL COVER 3.18X12.7X283
2
SCREW HHPM M5-0.8 X 12
11
WASHER FLAT M5
11
WASHER LOCK M5
1
RES WW 15R 5% 25W QK CONN
2
SCREW PHTT M3.5-0.6 X 10
2
SCREW PHTT M3.5-0.6 X 16
2
SCREW PHM M3-0.5 X 10 BLACK
2
SCREW PHTT M4-0.7 X 10 ZYC
4
SCREW PPHM M5-0.8 X 50 ZNC
9
NUT HEX M5-0.8 G8 YEL CHR
2
SCREW PPHM M5-0.8 X 30 SS
7
WASHER LOCK M3
7
NUT HEX M3-0.5 G8 YEL CHR
1
SUPPORT ANGLE PCB
1
FUSE ATO TYPE 15 AMP (BLUE)
1
HARN CTRL PNL R-200B 2.4L/4.2L (NOT SHOWN)
COMPONENTS INSTALLED PER THIS DRAWING
1
RELAY SOLENOID 12VDC PNL MNT
2
SCREW HHC 1/4-20 X 3/4 G5
4
WASHER FLAT 1/4-M6 ZINC
2
WASHER LOCK M6-1/4
2
NUT HEX 1/4-20 STEEL
A/R
SEAL WEATHER .45"DIA
1
COVER CONTROL PANEL SIDE
4
SCREW PPHM M5-0.8 X 12 ZNC
4
WASHER LOCK M5
4
WASHER FLAT M5
1
DPE BREAKER
2
WASHER FLAT M3
2
WASHER LOCK M3
2
NUT HEX M3-0.5 G8 YEL CHR
NOTE: ITEMS MARKED BY * ARE PART OF WIRE HARNESS.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
0G0408A
0H1619
046526
039414
0G 0149
0E9868A
0F3217
0H2574
0A8584
057772
057765
043790
0C7649
069860E
063076
0G 1394
052830
025507
062963
049821
022129
035472
0A6751
0E0502
1
1
6
4
1
1
1
1
1
1
1
1
1
1
7
7
2
5
5
3
30
1
1
1
ENGINE 2.4L G 2
ENGINE 2.4L G 2 CERTIFIED
WASHER LOCK M10
SCREW HHC M8-1.25 X 35 G8.8
SCREW SHC M14- 1.5 X 35 G 10.9
ALT ERNATOR DC W/OUT PUL LEY
SPACER DC ALTERNATOR PULLEY
CO NDUIT THERMAL F LEX 13MM ID
SWITCH OIL PRESSURE 10 PSI 2 PO L (R-PANEL)
WASHER NYL ON .565
ADAPTER M14-1.50 X 3/8 NPT
BARBED EL 90 3/8 NPT X 3/8
CLAMP HOSE .38- .87
HO SE DRAIN ASSY 28"
WASHER FLAT .531 ID X 1.062 O D
SCREW HHC M12-1.25 X 20 G 10.9
SCREW HHC M10-1.25 X 45 G 8.8
WASHER SHAKEPROOF EXT 7/16 ST L
SCREW HHC M10-1.25 X 30 G 8.8
SCREW SHC M8-1.25 X 30 G 12.9
WASHER LOCK M8- 5/16
CLAMP HOSE #6 .43-.78
SWITCH HI- TEMP 245D X 3/8 NPT (R-PANEL)
TEMPERATURE SENDER
23
24
25
26
27
28
29
30
31
32
33
34
35
(1) 36
37
38
39
40
41
42
43
(1) 44
45
46
47
48
49
50
51
52
(1) 53
54
55
56
57
58
59
(1) 60
61
62
63
64
(1) 65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
022145
0F2664H
045771
022131
0G8427A
0G1738
058306
022097
022473
090388
026073A
052243
0A8258
0A45310244
0G8853
042909
0G4003
0F0710
0G3823
052213
034413
0G0951
0H1432A
0G6093E
0D2244M
0F9420
0G7461
0G1472A
0G1476
0G0707
0G0950
0F9583
0G9350
042907
0G8852
022152
0F9501
0G0952
0G0788
023897
026925
0D3701
052203
0G3995
0G7313
0G8877C
0H1275A
029333A
077043H
0G8854
0G4000
052265
0G39910ST 03
0G39970ST 03
047411
0G7902
0G9349
0G9330
0G9329
0G9910
084750
10
1
3
4
1
1
12
1
1
7
3
1
1
1(REF)
4
2
1
2
2
3
8
1(REF)
1
1
2
1
1
1
1(REF)
1
1(REF)
1
1
4
1
8
1
1(REF)
1
8
1
1
1(REF)
1
REF
1
1
3
2
1
1
1(REF)
1
1
1
1
1
1
1
2
4
WASHER FLAT 5/16-M8 ZINC
ASSY DIPSTICK W/TEXT G TH- 530
NUT HEX M8-1.25 G8 CLEAR Z INC
WASHER FLAT 3/8-M10 ZINC
ASSY DIPSTICK TUBE 2.4 G2
CAP ANTIFREEZE RUBBER 9.5DIA
SCREW SHC M8-1.25 X 25 G12.9
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
SCREW HHTT M6-1.0 X 12 ZINC
PLUG STD PIPE 1/4 STEEL SQ HD
SCREW HHC M10-1.5 X 60 G 8.8
SCREW HHC M8- 1.25 X 25 G 10.9
FILTER 1.5L/2.4L G2 OIL (NOT SHOW N)
COIL-2.4L G 2 IGNITION
SCREW HHC M8- 1.25 X 30 C8.8
SHIELD HEAT IG NITIO N COIL 2.4L
RIVET POP .125 X 0.337 STEEL
O- RING SIZE 9.0MM X 2.0MM NIT R
SCREW HHC M10-1.25 X 20 C8.8
SCREW HHM #10-32 X 1-1/4
GASKET EXHAUST MANIFOLD
MANIFOL D EXH 60K G2 TURBO ( MA)
FLEX PLATE 2 POLE 2.4L G2
ASSY MAGPICKUP(3/8- 24 MAL E)
ADAPTER ENGINE 2.4L MACHINE
MOTOR STARTER
CAM SENSO R PIN ASSY
COVER CAM GEAR G2 REWO RKED
MANIFOL D INTAKE
GASKET INTAKE MANIFOLD
SPACER 2.4L G2 FLEX PLATE
O- RING 2.5" X 2.75"X 1/8" VITON
SCREW HHC M8- 1.25 X 16 C8.8
BRACKET ASM-2.4L COIL G2
WASHER LOCK #10
ADAPTER 2.4L CRANKSHAFT MACH
POLY V-BELT G2 (3600 RPM)
PULL EY DC ALTERNATOR (3600 RPM)
WASHER FLAT #10 ZINC
PLUG STD PIPE 3/8 STEEL SQ HD
PLAT E "HOT"
SCREW HHC M8- 1.25 X 70 G 8.8
SHIELD INNER HEAT 2.4L TURBO
DECAL EMISSION CT RL INFO 2.4L
HARN ENG 2.4L R-200B 3600 T URB (NOT SHO WN)
HARN ENG 2.4L R-200C 3600 RPM (NO T SHOWN)
TIE WRAP UL 7.4"X .19" BLK
CONDUIT F LEX .25"ID
SPARK PLUG WIRE SET 2.4L G2 IG
HEAT SHIELD T URBO 2.4L
SCREW HHC M8- 1.25 X 65 C8.8
BRACKET EXH MANIFO LD 2.4 TURBO
BRACKET HEAT SHIELD 2.4L
SCREW HHC M6- 1.0 X 16 C8.8
TUBE TURBO OIL RETURN G2 2.4L
O- RING 1" X 1.25" X 1/8" VITO N
NUT OIL FILTER ADAPTOR 2.4L G2
ADAPTOR OIL FILTER 2.4L G2
ADAPTOR 45D JIC37 1/2NPT X 3/4
PLUG SPARK
(1) SUPPLIED WITH ENGINE.
1
0F9677
0G0056
0G0959
0G1155
0G1931
0G2101
0G3734
0G6562
0G6564
1
1
1
1
1
1
1
1
1
ROTOR-2390-45KD1 CPL
ROTOR-2390-35KD1 CPL
ROTOR-2390-45KD1 CPL (G2)
ROTOR-2390-35KD1 CPL (G2)
ROTOR 25KW 3PH DIRECT 390 1800
ROTOR 25KW 1PH DIRECT 390 1800
RTR-2390-60KD2 CPL
RTR 390 35AD1 CPL
RTR 390 35KD1 CPL
2
0F9664
0G0057
0G0058
0G0059
0G0183
0G0184
0G1932
0G2098
0G2099
0G2100
0G3736
0G3737
0G3738
0G6104
0G6563
0G6565
0G6566
0G6567
0H0201
0H1299
0H1300
0H1301
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
STATOR-390 45K 2P 1PH DIRECT
STATOR-2390-35AD1 CPL
STATOR-2390-35KD1 CPL
STATOR-2390-35GD1 CPL
STATOR-2309-45KW 2P 3PH 208V
STATOR-2309-45-KD1 CPL
ASSY STR 390 25GD3 CPL
ASSY STR 390 25AD1 CPL
ASSY STR 390 25KD3 CPL
ASSY STR 390 25JD3 CPL
ASSY STR 2390 60AD2 CPL
ASSY STR 390 60KW 2P 3PH 208V
ASSY STR 390 60KW 2P 3PH 480V
STR-2390--45JD1 CPL
STR 390 35AD1 CPL
STR 390 35GD1 CPL
STR 390 35KD1 CPL
STR 390 35JD1 CPL
STR-2390--60JD2 CPL
ASSY STR 390 36AD1 CPL
ASSY STR 390 36JD1 CPL
ASSY STR 390 36 GD1 CPL
3
4
5
6
7
8
0C9708
SEE ENGINE EV
SEE ENGINE EV
0F5767B
0E5706
0F7874
0F7874A
0G0587
038150
023454
077043E
04576100BU
052646
043123
051779
0A2601
072879
0F8408
046526
0C3992
022264
047248
070892
0G0588
077043A
056326
REF
REF
REF
1
1
1
1
1
4
1
1
4
4
4
4
1
1
4
4
4
4
1
1
1
1
1
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23 *
24 *
25
26
27
INSTR HYPOT TEST (NOT SHOWN)
ENGINE ADAPTER
FLEXPLATE
ASSY FLYWHEEL CPL W/40MM FAN B
REAR BEARING CARRIER 390/DRCT
ASSY BRUSH HOLDER 390/HSB
ASSY BRUSH HOLDER 390/HSB
GUARD REAR BEARING CARRIER
WASHER FLAT #8 ZINC
KEY WOODRUFF #E
CONDUIT FLEX 1.0" ID (35” LG)
STUD M14-2.0 570 G5 ZINC
WASHER FLAT M14
WASHER LOCK M14
NUT HEX M14-2.0 G8 YEL CHR
SCREW HHC M16-2.0 X 45 G8.8
SPACER .69 X 2.75 X .37 ST/ZNC
SCREW HHC M10-1.50 X 16 G10.9
WASHER LOCK M10
SCREW HHTT M4-0.7 X 16 BP
WASHER LOCK #8-M4
BALL BEARING-45 MM
SLIP RING MACHINED
GUARD REAR BEARING CARRIER
CONDUIT FLEX .38" ID (60”)
TRIM VINYL BLACK 1/8GP (16.5”LG)
* ROTOR REPLACEMENT PARTS
1.)
A
C2 UNITS
0F9832
0F9832GGS0R
0C2454
1
1
4
SHIELD CONN BOX C2
SHIELD CONTROL STAND C2
SCREW THF M6-1 X 16 N WA Z/JS
B
C3 UNITS
0F9832B
0F9832KGS0R
0C2454
1
1
3
SHIELD CONTROL STAND C3
SHIELD CONTROL STAND C3
SCREW THF M6-1 X 16 N WA Z/JS
3.)
A
B
C4 UNITS
0F9832A
0C2454
1
3
SHIELD CONTROL STAND C4
SCREW THF M6-1 X 16 N WA Z/JS
4.)
A
C5 UNITS
0F9832C
0F9832D
0F9832EGS0R
0F9832HGS0R
0F9832JGS0R
0F9832FGS0R
0C2464
1
1
1
1
1
1
3
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SCREW THF M6-1 X 16 N WA Z/JS
B
2.)
A
B
C
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
PART#
0E8816
0F2808D
0G0007
0G0113
0G6150
0G6776
0G8685
0G8686
0G86870ST03
036797
049721
022097
022473
080762
022237
022241
0G6401
0F4710
088775
0E0170A
0C2454
QTY.
1
1
1
1
1
1
1
1
1
1
2
2
2
3
6
6
2
2
2
1
4
DESCRIPTION
FLANGE EXHAUST
EXHAUST PIPE
DIFFUSER EXHAUST WELDMENT
EXHAUST ELBOW
MUFFLER 60kW
PIPE EXHAUST 2.4L 60kW
STRAP MUFFLER
BRACKET STIFFENER
BRACKET MUFFLER
BOLT U 5/16-18 X 2.25
SCREW HHC M6-1.0 X 35 C8.8 BLK
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
BOLT U 3/8-16 X 2.62
WASHER LOCK 3/8
NUT HEX 3/8-16 STEEL
SCREW HHC M10-1.5 X 45 SS
WASHER LOCK M10 SS
WASHER FLAT 3/8 SS
EXHAUST BLANKET 988MM
SCREW THF M6-1 X 16 N WA Z/JS
1
2
3
4
5
6
7
8
(1) 9
10
11
12
13
14
(2) 15
(2) 16
17
18
19
20
21
23
24
(1) 26
27
28
29
30
31
32
33
34
35
36
37
(3) 39
(4) 40
41
42
43
44
45
46
47
48
49
(5) 50
1)
A
C
D
E
F
G
H
J
K
L
2)
A
C
0F3137
0F3188
0F3189
023484N
0F6366B
0F6366A
043180
022264
0C3990
046357
022155
0C2428
0G7992
0A9457
057073
0D5466
0A7822
022237
022241
049226
0C2266
0C2454
022473
022097
0D4698
0H0026
025433
024469
067210A
0D6029
081008
077043J
051713
0F6156
029289
047411
0G0770
0H0348
036943
023897
022152
022158
0C2454
055934D
0F6145
048766
0G7991
0H1083
0G8951
1
1
1
1
1
1
2
2
2
REF
6
6
1
1
2
REF
REF
2
2
6
6
8
8
4
REF
1
1
1
1
4
1
1
2
1
1
4
1
1
2
4
2
2
1
1
A/R
REF
1
1
1
PAN CB CONN BOX
STAND RH CONTROL
STAND LH CONTROL
BUSHING SNAP SB-2.5-31
XFMR DUAL 120V/16V (FOR 120/240V & 277/480V UNITS)
XFMR DUAL 104V/16V (FOR 120/208V UNITS)
WASHER FLAT M4
WASHER LOCK #8-M4
SCREW PHTT M4-0.7 X 10 ZYC
BLOCK TERM 20A 6 X 6 X 1100V
WASHER LOCK #6
SCREW PHTT #6-32 X 1/2 ZYC
DECAL RTS CUSTOMER CONNECTION
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
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
BLOCK TERM 20A 6 X 3 X 1100V
DECAL CHARGER POWER 120VAC C2
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
GROMMET 1.25 X .25 X .75
CONDUIT FLEX 2.0" ID (36” LG)
WASHER FLAT M5
PLATE WIRE SNGL GALV
TAPE ELEC 1/2 FOAM (AS REQ’D)
SCREW HHC M6-1.0 X 16 G8.8
HARNESS, TRANSFORMER ADAPTER
PCB ENCLOSURE ASSY 4.2L IGN MD
SCREW PPHM #10/32 X 2
WASHER FLAT #10 ZINC
WASHER LOCK #10
NUT HEX #10-32 STEEL
SCREW THF M6-1 X 16 N WA Z/JS
CLAMP VINYL 1.06 X .406 Z
SEAL WEATHER .45"DIA
BLOCK TERM 20A 2 X 6 X 1100V
DECAL GTS CUSTOMER CONNECTION
ASSY PCB IGN MOD 2.4L NO-TURBO
ASSY PCB IGN MOD 2.4L TURBO
0F3328
0D5552
0D5553
0D5554
0D5556
0D9693
0F0492
048927
023897
022152
022158
0C2454
029289
0F1733
UL CIRCUIT BREAKER (ED)
1
COVER ED CB SHORT STND
1
CB 0050A 3P 480V S ED4 LL
CB 0060A 3P 480V S ED4 LL
CB 0070A 3P 480V S ED4 LL
CB 0090A 3P 480V S ED4 LL
CB 0125A 3P 480V S ED4 LL
1
INSULATOR CB S (ED-3P)
4
SCREW RHM #10-32 X 4-1/2
4
WASHER FLAT #10 ZINC
4
WASHER LOCK #10
4
NUT HEX #10-32 STEEL
9
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
0F3138
0D5572
0D5573
0D5574
0D5575
0D5576
UL CIRCUIT BREAKER (FD)
1
COVER CB CONN BOX
1
CB 0150A 3P 600V S FD6 LL
CB 0175A 3P 600V S FD6 LL
CB 0200A 3P 600V S FD6 LL
CB 0225A 3P 600V S FD6 LL
CB 0250A 3P 600V S FD6 LL
D
E
F
G
H
J
K
L
3)
A
C
D
E
F
G
H
J
K
L
4)
A
C
D
E
F
G
H
J
K
0F0199
081320
022473
022097
022127
0C2454
029289
0F1733
0F3329
0D5577
0F2353
022770
022473
022097
022127
0C2454
029289
0F1733
1
INSULATOR CB FD FRAME 30MIL
4
SCREW SHC 1/4-20 X 4.5 G8.8 NZ
4
WASHER FLAT 1/4-M6 ZINC
4
WASHER LOCK M6-1/4
4
NUT HEX 1/4-20 STEEL
9
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
UL CIRCUIT BREAKER (JD+LD)
1
COVER JD/LD CB SHRT STAND
1
CB 0300A 3P 600V S JD6 LL
2
INSULATOR CIRCUIT BR. JD/LD
4
SCREW RHM 1/4-20 X 3
4
WASHER FLAT 1/4-M6 ZINC
4
WASHER LOCK M6-1/4
4
NUT HEX 1/4-20 STEEL
9
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
0F8135
0E7283
0E7284
0E3628
0E3664
074908
0F8140
036261
0C2454
029289
0F1733
UL CIRCUIT BREAKER (QN)
1
COVER QN FRM CB
CB 0150A 2P 240V S QN2 LL
CB 0175A 2P S QN2 LL 240V
CB 0200A 2P 240V S QN2 LL
1
BASE, QN CIRCUIT BREAKER
2
SCREW HHTT M5-0.8 X 10 BP
1
COVER QN CB DISH
4
RIVET POP .125 X .275 SS
11
SCREW THF M6-1X16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
(1) ITEM INCLUDED WITH HARNESS
(2) ITEM INCLUDED WITH 0D5464B
(3) ITEM USED WITH EARLY MODEL 208V UNITS ONLY
(4) ITEMS USED ON 4.2L MODELS ONLY.
(5) ITEMS USED ON 2.4L MODEL ONLY.
5)
A
C
D
E
F
G
H
J
K
L
M
N
P
Q
0F8137
0E7994
0F8136
036261
022473
022097
022127
0F8139
0C2454
022237
048527
029289
022770
0F1733
UL CIRCUIT BREAKER (QJ-2P)
1
COVER QJ 2P FRM CB
CB 0225A 240V 2P S QJ22
1
COVER QJ 2P CB DISH
4
RIVET POP .125 X .275 SS
2
WASHER FLAT 1/4-M6 ZINC
2
WASHER LOCK M6-1/4
2
NUT HEX 1/4-20 STEEL
1
INSUL CB 2P QJ
9
SCREW THF M6-1 X 16 N WA Z/JS
2
WASHER LOCK 3/8
2
SCREW SHC 3/8-16 X 3/4 G8.8 NZ
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
2
SCREW RHM 1/4-20 X 3
1
DECAL CUSTOMER CONNECT INSIDE
P
(2) R
(2) S
(2) T
(2) U
(2) V
(1) W
X
0F4185
058306
0F4165$
0F4143
0F4148
0F4149
0F4151
0G5247$
0G5250
0G4478
0F4145
0F4186
0F4186AGS0R
036261
053640
038150
022264
022471
029289
0F1733
022129
0F8432
0F8432A
0C2454
0F8451
049897
022145
045771
0F8843
W/CB
0G3259
UL CIRCUIT BREAKER (225AF) (2P & 3P)
1
COVER CB C2-C4 (225AF)
3
SCREW SHC M8-1.25 X 25 G12.9
REF
CIRCUIT BREAKERS 200A FRAME (3P)
REF
CB 0040A 3P 480V 225AF (3P)
REF
CB 0125A 3P 480V G 225AF
REF
CB 0150A 3P 480V G 225AF
REF
CB 0200A 3P 480V G 225AF
REF
CB 200A FRAME G 240V (2P)
REF
CB 175A 2 POLE 240V 225AF (2P)
REF
CB 200A 2 POLE 240V 225AF (2P)
REF
CB 0060A 3P 480V G 225AF (3P)
1
COVER CB DISH 225AF (3P)
COVER CB DISH 225AF (2P)
4
RIVET POP .125 X .275 SS
2/4
SCREW RHM #8-32 X 3-1/4
2/4
WASHER FLAT #8 ZINC
2/4
WASHER LOCK #8-M4
2/4
NUT HEX #8-32 STEEL
2
TAPE ELEC 1/2 FOAM
1
DECAL CUSTOMER CONNECT INSIDE
6/9
WASHER LOCK M8-5/16
1
INSULATOR CB 225AF (3P)
1
INSULATOR CB 225AF (2P)
11
SCREW THF M6-1 X 16 N WA Z/JS
2/3
LUG SLDLSS 300 MCM-6 AL/CU
4/6
SCREW SHC M8-1.25 X 20 G8
4/6
WASHER FLAT 5/16-M8 ZINC
2/3
NUT HEX M8-1.25 G8 CLEAR ZINC
2/3
BUS BAR 200A LUG ADAPTOR
2
TERMINAL COVER CB
1
DECAL TERMINAL SHOCK HZD BI
7)
A
C
D
E
F
G
H
J
K
(2) L
(2) M
N
P
(1) S
T
U
V
(2) W
(2) X
Y
0F4187
0F4166$
0F1733
042419
023897
022152
022158
0C2454
029289
052647
046526
W/CB
0A7822
W/CB
023334
022097
022473
W/CB
W/CB
0G3259
UL CIRCUIT BREAKER (400AF)
1
COVER CB C2-C4 400AF
REF
CIRCUIT BREAKERS 400A FRAME
1
DECAL CUSTOMER CONNECT INSIDE
4
SCREW RHM 10-32 X 4
4
WASHER FLAT #10 ZINC
4
WASHER LOCK #10
4
NUT HEX #10-32 STEEL
9
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM
2/3
SCREW SHC M10-1.5 X 25 G12.9
2/3
WASHER LOCK M10
3
BUS BAR CB ADAPTER 225-400 A
3
LUG SLDLSS 600/250-1/0 X 1/4-28
2
TERM COVER CB
6
SCREW HHC 1/4-28 X 1/2 G5
6
WASHER LOCK M6-1/4
6
WASHER FLAT 1/4-M6 ZINC
2/3
SCREW SHC M10-1.5 X 25 G12.9
2/3
WASHER LOCK M10
1
DECAL TERMINAL SHOCK HZD BI
8)
A
B
C
D
E
F
G
H
9)
A
C
6)
A
B
C
D
E
(2) F
(2) G
(2) H
(2) J
K
L
(2) M
N
D
E
F
G
H
J
K
L
M
N
0D5466
039287
022145
022129
045771
045335
083896
0A7822
NEUTRAL BLOCK 390 / 200-400A
2
BUS BAR NEUTRAL BLOCK 390
1
SCREW HHC M8-1.25 X 45 G8.8 FT
1
WASHER FLAT 5/16-M8 ZINC
1
WASHER LOCK M8-5/16
1
NUT HEX M8-1.25 G8 YEL CHR
2
SCREW HHC 1/4-28 X 3/4 G5
2
WASHER LOCK 1/4-M6 SS
1
LUG SLDLSS 600/250-1/0 X 1/4-28
0G1968
0G1970
0A2077
040532
0C3990
0E7890
0E6002
022859
0G0008
023897
022152
022158
0F1733
029289
0C2454
UL CIRCUIT BREAKER (BQ)
1
COVER BQ CIR BREAKER CPL 3P
COVER BQ CIR BREAKER CPL 2P
1
CB 0125A 2P 240V S BQ2 LL
CB 0100A 3P 240V S BQ3 LL
2
SCREW PHTT M4-0.7 X 10 ZYC
1
BRKT CB MTG BACK
MTG TRACK BQ SIEMENS CB 3P
6
SCREW RHM #10-32 X 3/4
1
BRKT BQ CB STANDOFF
6
WASHER FLAT #10 ZINC
6
WASHER LOCK #10
6
NUT HEX #10-32 STEEL
1
DECAL CUSTOMER CONNECT INSIDE
1
TAPE ELEC 1/2 FOAM
11
SCREW THF M6-1 X 16 N WA Z/JS
(1) HARDWARE FOR MTG. CB TERMINAL COVERS IS
SUPPLIED WITH CIRCUIT BREAKERS.
(2) QTY. REQ’D FOR “2POLE / 3POLE” BREAKER
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