Generac 35 kW QT03524KNSN Standby Generator Manual

Generac 35 kW QT03524KNSN Standby Generator Manual
Serial Number
2.4L
35/45kW
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.
Cover115 Rev. C 10/07
Catalog No. OMASPE035-045-1
Part No. 0G5407
Standby Generator Sets
Table of Contents
INTRODUCTION .....................................................1-3
Read this Manual Thoroughly ...................................1-3
Operation and Maintenance ......................................1-3
How to Obtain Service ..............................................1-3
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
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 Fuse ....................................................................4-1
FUEL SYSTEMS .....................................................5-1
Fuel Requirements ....................................................5-1
Natural Gas Fuel System ..........................................5-1
Propane Vapor Withdrawal Fuel System....................5-1
LP 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
Reconfiguring the Fuel System ..................................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
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 QT Genset Start-up .....................8-1
Start-up Checklist ........................................................8-2
Preparation for Start-up............................................8-2
Start-up Inspection ...................................................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 Authorized
Service Facilities .....................................................10-1
Every Three Months ...............................................10-1
Once Every Six Months ...........................................10-1
Once Annually.........................................................10-1
First 100 Operating Hours ......................................10-1
Every 500 Operating Hours ....................................10-1
Every 800 Operating Hours ....................................10-1
Exhaust Manifold Procedure ......................................10-1
Intake Manifold Procedure .........................................10-1
Cylinder Head Procedure ...........................................10-1
Cooling System ..........................................................10-2
Overload Protection for Engine DC
Electrical System ....................................................10-2
Checking Fluid Levels ................................................10-2
Check Engine Oil ....................................................10-2
Battery Fluid ...........................................................10-2
Engine Coolant .......................................................10-2
Maintenance Owner/Operator Can Perform ................10-3
Check Engine Oil Level ...........................................10-3
Check Battery .........................................................10-3
Exercise System ......................................................10-3
Inspect Cooling System ...........................................10-3
Check Engine Coolant Level....................................10-3
Perform Visual Inspection .......................................10-3
Inspect Exhaust System ..........................................10-3
Check Fan Belt........................................................10-3
Inspect Engine Governor ........................................10-3
Changing Engine Oil ...............................................10-3
Changing the Engine Air Cleaner ............................10-3
Spark Plugs ............................................................10-4
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
Content016 Rev. A 06/07
SECTION
PAGE
SAFETY RULES ................................................ 1-1
Standby Generator Sets
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.
1-1
Safety004 Rev. B 08/07

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation
be copied and posted in potential hazard areas. Safety should be stressed to all operators,
potential operators, and service and repair technicians for this equipment.
Standby Generator Sets
Important Safety Instructions
• 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.
• Before performing any maintenance on the generator, disconnect its battery cables to prevent
accidental start-up. Disconnect the cable from the
battery post indicated by a NEGATIVE, NEG or (–)
first. Reconnect that cable last.
• Never use the generator or any of its parts as a
step. Stepping on the unit can stress and break
parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.
 ELECTRICAL HAZARDS 
• All generators covered by this manual produce
dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely
high and dangerous voltages to the transfer switch
as well as the standby generator. Avoid contact
with bare wires, terminals, connections, etc., on
the generator as well as the transfer switch, if
applicable. Ensure all appropriate covers, guards
and barriers are in place before operating the generator. If work must be done around an operating
unit, stand on an insulated, dry surface to reduce
shock hazard.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
• If personnel must stand on metal or concrete while
installing, operating, servicing, adjusting or repairing this equipment, place insulative mats over a
dry wooden platform. Work on the equipment only
while standing on such insulative mats.
• The National Electrical Code (NEC) requires the
frame and external electrically conductive parts
of the generator to be connected to an approved
earth ground. This grounding will help prevent
dangerous electrical shock that might be caused
by a ground fault condition in the generator set or
by static electricity. Never disconnect the ground
wire.
• Wire gauge sizes of electrical wiring, cables and
cord sets must be adequate to handle the maximum electrical current (ampacity) to which they
will be subjected.
• Before installing or servicing this (and related)
equipment, make sure that all power voltage
supplies are positively turned off at their source.
Failure to do so will result in hazardous and possibly fatal electrical shock.
• Connecting this unit to an electrical system normally supplied by an electric utility shall be by
means of a transfer switch so as to isolate the
generator electric system from the electric utility
distribution system when the generator is operating. Failure to isolate the two electric system power
sources from each other by such means will result
in damage to the generator and may also result
in injury or death to utility power workers due to
backfeed of electrical energy.
 FIRE HAZARDS 
• Keep a fire extinguisher near the generator at all
times. Do NOT use any carbon tetra-chloride type
extinguisher. Its fumes are toxic, and the liquid
can deteriorate wiring insulation. Keep the extinguisher properly charged and be familiar with its
use. If there are any questions pertaining to fire
extinguishers, consult the local fire department.
 EXPLOSION HAZARDS 
• Properly ventilate any room or building housing
the generator to prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any
fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.
• These generator sets may operate using one of
several types of fuels. All fuel types are potentially
FLAMMABLE and/or EXPLOSIVE and should be
handled with care. Comply with all laws regulating the storage and handling of fuels. Inspect the
unit’s fuel system frequently and correct any leaks
immediately. Fuel supply lines must be properly installed, purged and leak tested according to
applicable fuel-gas codes before placing this equipment into service.
• Diesel fuels are highly FLAMMABLE. Gaseous
fluids such as natural gas and liquid propane
(LP) gas are extremely EXPLOSIVE. Natural gas
is lighter than air, and LP gas is heavier than air;
install leak detectors accordingly.
1-2
Safety004 Rev. B 08/07
Standby Generator Sets
Important Safety Instructions
INTRODUCTION
symbol points out potential explosion
 This
hazard.
Thank you for purchasing this model of the standby
generator set 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 standby 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. B 08/07
1-3
Standby Generator Sets
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, etc.
 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
Identy 005 Rev. A 03/07
2-1
Standby Generator Sets
Equipment Description
EQUIPMENT DESCRIPTION
COOLANT RECOMMENDATIONS
This equipment is a revolving field, alternating current generator set. It is powered by a gaseous fueled
engine operating at 1800 rpm for 4-pole direct drive
units, 3600 rpm for 2-pole direct drive units and
2300 - 3000 rpm for quiet drive gear units. See the
Specifications section for exact numbers. The unit
comes complete with a sound attenuated enclosure,
internally mounted muffler, control console, mainline circuit breaker, battery charger, and protective
alarms as explained in the following paragraph.
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 generator incorporates the following generator
features:
• Rotor and Stator insulation is Class H rated as
defined by NEMA MG1-32.6, NEMA MG1-1.66.
The generator is self ventilated and drip-proof constructed.
• The voltage waveform deviation, total harmonic
content of the AC waveform and telephone influence factor have been evaluated and are acceptable
according to NEMA MG1-32.
DANGER
not remove the radiator pressure cap while
 Do
the engine is hot or serious burns from boiling
liquid or steam could result.
glycol base antifreeze is poisonous.
 Ethylene
Do not use mouth to siphon coolant from the
ENGINE OIL RECOMMENDATIONS
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 (synthetic oil is recommended).
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 5W30 synthetic oil.
Equip001 Rev. B 07/08
3-1
Standby Generator Sets
Engine Protective Devices
ENGINE PROTECTIVE DEVICES
‹ OVERCRANK SHUTDOWN
The standby generator may be required to operate for
long periods of time without an operator on hand to
monitor such engine conditions as coolant temperature, oil pressure or rpm. For that reason, the engine
has several devices designed to protect it against
potentially damaging conditions by automatically
shutting down the unit when the oil pressure is too
low, the coolant temperature is too high, the coolant
level is too low, or the engine is running too fast.
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.
NOTE:
Approximate Crank Cycle Times
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
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.
15 seconds ON
7 seconds OFF
7 seconds ON
7 seconds OFF
Repeat for 45 seconds
Approximately 90 seconds total.
‹ OVERSPEED SHUTDOWN
A speed circuit controls engine cranking, start-up,
operation and shutdown. Engine speed signals are
delivered to the circuit board whenever the unit is
running. Should the engine 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
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.
‹ DC FUSES
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. A 06/08
4-1
Standby Generator Sets
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 standby 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. A 06/08
5-1
Standby Generator Sets
Specifications
SPECIFICATIONS
‹ COOLING SYSTEM
‹ GENERATOR
Type ...................................................Pressurized Closed Recovery
Water Pump.................................................................... Belt Driven
Fan Speed .........................................................................2150 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 (35/45kW)...........134,000/173,000 Btu/h
Maximum Operating Air Temp. on Radiator ..............60° C (150° F)
Maximum Ambient Temperature................................50° C (140° F)
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) .......................................35/45kW*
* NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349,
‹ FUEL SYSTEM
ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural
gas.
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
Excitation System ....................................................................Direct
Generator Output Voltage/kW - 60 Hz kW
Amp
CB Size
120/240V, 1-phase, 1.0 pf
35/45 146/188 175/200
120/208V, 3-phase, 0.8 pf
35/45 121/156 150/175
277/480V, 3-phase, 0.8 pf
35/45
53/68
60/80
Generator Locked Rotor KVA Available @ Voltage Dip of 35%
Single-phase or 208, 3-phase (35/45kW) ..................... 69/80 KVA
480V, 3-phase (35/45kW)............................................ 76/100 KVA
Fuel Consumption - ft3/hr (Natural Gas/LPV)
Exercise
25%
50%
75%
100%
Cycle
Load
Load
Load
Load
35kW 87/34.5 150/59.6 291/115.7 405/160.8 560/222.3
45kW 102/40.4 194/77.1
373/148 520/206.3 720/286
‹ ENGINE
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 ...............................................Naturally Aspirated
Valve Seats....................................................................... Hardened
Lifter Type .......................................................................... Hydraulic
‹ ELECTRICAL SYSTEM
Battery Charge Alternator ............................................12V, 30 Amp
Static Battery Charger ............................................................2 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 (35/45kW) ...................................................... 55/71
Power Adjustment for Ambient Conditions
Temperature Deration
3% for every 10° C above °C (35/45kW) .............................. 40/25
1.65% for every 10° above °F (35/45kW) ........................... 104/77
Altitude Deration
1% for every 100 m above m (35/45kW) .......................... 915/183
3% for every 1000 ft. above ft. (35/45kW) ....................... 3000/600
Exhaust System
Exhaust Flow at Rated Output 60 Hz (35/45kW) ......... 360/429 cfm
Exhaust Temp. at Rated Output (35/45kW) ............1050° F/1150° F
Combustion Air Requirements (Natural Gas)
Flow at rated power, 60 Hz (35/45kW) ......................... 129/144 cfm
Governor
Type .................................................................................. Electronic
Frequency Regulation ...................................................Isochronous
Steady State Regulation......................................................± 0.25%
Controller .................................................R-200
Engine Lubrication System
Type of Oil Pump ...................................................................... Gear
Oil Filter ............................................... Full Flow Spin-on, Cartridge
Crankcase Oil Capacity ....................................................4 U.S. qts.
GenSpec039 Rev. A 04/07
6-1
Standby Generator Sets
Specifications
Figure 1 — Interconnections
Utility In
Transfer Switch
CONTROL PANEL
NEUTRAL
TO
ALTERNATOR
Gen
N1
N2
23
194
GENERATOR
CONNECTION
BOX
183
178
NEUTRAL
N1
N2
23
194
4- # 14 GA
WIRES TO
GENERATOR
CONNECTION
BOX
CIRCUIT
BREAKER
Battery
Charger
Input
186
178
Load
Out
TO GENERATOR
CONNECTION BOX
GROUND
120 Volt +
Neutral
Grd
To Generator Control Panel
FRAME RAIL
Ground Level
Concrete Slab
KW
45
45
45
STUB-UP AREA
See Install Dwg for
Dimensions
‹ COLD WEATHER KIT
CIRCUIT BREAKER SIZE
VOLTS / AMPS
LUG SIZE
240 1 Ø
200
#6 to 300 mcm
208 3 Ø
175
#6 to 300 mcm
480 3 Ø
80
#6 to 300 mcm
NOTE:
For cold climates, optional cold weather kit (part
number 0F6148) is recommended. The kit includes:
The jet sizes are stamped on the individual jets.
The larger jet size is used for running on NG.
• Battery Warmer
• 4” Junction Box with hardware
• 6 qt. pack 5W-30 synthetic oil (engine)
8. Install the previously removed NG jet into the jet
keeper port on the side of the regulator housing.
9. Install the previously removed black pipe onto
the outlet port of the demand regulator.
10. Reverse steps 1-4 in this procedure to reactivate
the demand regulator.
‹ RECONFIGURING THE FUEL SYSTEM
NOTE:
Figure 6.2 — Reconfigure the Fuel System
All models are configured to run on natural gas
from the factory.
To reconfigure the fuel system from NG to LP, follow
these steps:
1. Turn the main gas supply off.
2. Remove the carburetor fuel hose from the outlet
port of the demand regulator (see Figure 6.2).
3. Disconnect the power wires from the fuel solenoid located on top of the regulator assembly.
4. Loosen the spring clamp on the small fuel enrichment line and remove the hose from the hose
barb.
5. Remove the black pipe assembly from the outlet
port of the demand regulator.
6. Remove the NG fuel jet (loosen counter clockwise) from the outlet port.
7. Remove the LP fuel jet (loosen counter clockwise)
from the jet keeper port on the side of the regulator housing. Install this jet into the outlet port in
the regulator casting.
DANGER
injury or damage may occur if not con Serious
figured properly. Please consult an Authorized
Dealer with any questions.
6-2
GenSpec039 Rev. A 04/07
Standby Generator Sets
General Information
GENERATOR AC LEAD CONNECTIONS
‹ 3-PHASE ALTERNATORS ("Y" CONFIGURATION)
See “Voltage Codes”. This generator may be rated at
any one of five voltages, either single-phase or threephase. 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.
The generator is designed to supply 3-phase electrical loads. Electric power is produced in the alternator power windings. These windings were connected
at the factory to the main circuit breaker with a “Y”
configuration as shown in Figures 7.2, 7.3, and 7.4.
The rated voltage between circuit breaker terminals
E1-E2, E1-E3 and E2-E3 is either 480V or 208V
depending on the model.
Voltage codes apply to the type of stator assembly
installed on a particular generator.
The rated voltage between each circuit breaker terminal and the neutral point 00 is either 277V or 120V
depending on the model.
ALTERNATOR POWER WINDING
CONNECTIONS
Figure 7.2 — Stator Power Winding
Connections - 3-phase, 120/208V (12 Lead)
‹ FOUR-LEAD, SINGLE-PHASE STATOR
E1
Four-lead generators are built to supply electrical
loads with voltage code "A" (240V, 1-phase, 60Hz).
Electrical power is produced in the stator power
windings. These windings were connected at the factory to the main circuit breaker as shown in Figure
7.1.
The rated voltage between each circuit breaker terminal is 240V. The rated voltage between each circuit
breaker terminal and the neutral point 00 is 120V.
Figure 7.1 — Four-lead, Single-phase Stator
S7
S1
S10
S12
S4
S5
L-L
S9
S2
S6
S11
E3
E2
S3
S8
L-N
Figure 7.3 — Stator Power Winding
Connections - 3-phase, 277/480V (12 Lead)
E1
S1
S4
S7
L-L
S6
S3
E3
7-1
S9
S10
S11
S8
S5
L-N
S2
E2
ACConn005 Rev. 0 04/06
S12
Standby Generator Sets
General Information
‹ 3-PHASE ALTERNATORS
("DELTA" CONFIGURATION)
Figure 7.1 — Stator Power Winding
Connections - 3-phase, 346/600V (6 Lead)
The generator is designed to supply 3-phase electrical
loads. Electric power is produced in the alternator
power windings. These windings were connected at
the factory to the main circuit breaker with a “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 208V.
The rated voltage between E1 or E3 and the neutral
point 00 is 120V.
L-L
S6
S4
Figure 7.5 — Stator Power Winding
Connections - 3-phase, 120/240V (12 Lead)
NEUTRAL
S5
E3 S3
S2
E2
L-N
7-2
ACConn005 Rev. 0 04/06
Standby Generator Sets
Installation
‹ PRIOR TO INITIAL START-UP
INSTALLATION
Refer to the separate “Installation Guide” supplied
with the unit.
to initially starting the generator, it must
 Prior
be properly prepared for use. Any attempt to
PREPARATION BEFORE START-UP
The instructions in this section assume that the
standby generator has been properly installed, serviced, tested, adjusted and otherwise prepared for
use by a competent, qualified installation contractor.
Be sure to read the “Safety Rules”, as well as all other
safety information in this manual, before attempting
to operate this (and related) equipment.
crank or start the engine before it has been
properly serviced with the recommended types
and quantities of engine fluids (oil, coolant, fuel,
etc.) may result in an engine failure.
‹ ENGINE COOLANT
Have the engine cooling system properly filled with
the recommended coolant mixture. Check the system
for leaks and other problems. See “Specifications”
and “Coolant” sections.
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”.
‹ BELT TENSION
‹ TRANSFER SWITCH
Check-the engine-fan belt tension and condition prior
to placing the unit into service and at recommended
intervals. Belt tension is correct when a force of
approximately 22 pounds (10 kg), applied midway
between pulleys, deflects the belt about 3/8- to 5/8inch (10 to 16 mm).
If this generator is used to supply power to any electrical system normally powered by an electric utility,
the National Electrical Code requires that a transfer
switch be installed. The transfer switch prevents electrical backfeed between two different electrical systems. (For additional information, see the applicable
transfer switch manual for this unit.) The transfer
switch, as well as the generator and other standby
components, must be properly located and mounted
in strict compliance with applicable codes, standards
and regulations.
‹ ELECTRICAL SYSTEM
Make sure the generator is properly connected to an
approved earth ground.
Make sure the generator battery is fully charged,
properly installed and interconnected, and ready for
use.
‹ FUEL SYSTEM
NOTE:
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.
Battery charger must be connected to 120 VAC, 15
amp circuit to operate.
Check to ensure that there are no loose electrical connections. Restrain any loose wires to keep them clear
of any moving generator set components.
‹ GENERATOR SET LUBRICATION
INITIAL INSPECTION FOR GENSET
STARTUP
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”.
Inspect for the following.
•
•
•
•
•
Freight Damage.
Manuals present.
Fluid Levels (Oil, coolant, battery, Gear Drive).
Correct fuel piping.
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.
This engine is shipped from the manufacturer
with “break-in” oil. This oil should be changed
after 30 hours of operation.
8-1
Install002 Rev. C 01/07
NOTE:
Standby Generator Sets
Installation
• Open the valve to the engine fuel line.
• Bleed the fuel system of air. (necessary for long fuel
lines).
• Open the generator main line circuit breaker.
• Connect a manometer to the gas line and record
the static pressure. It must be as listed in the
Specifications.
• Insert the fuse into the control panel.
• Move the AUTO/OFF/MANUAL switch to the 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.
• Battery charger connection to 120 VAC.
• Communication wires connected between transfer
switch and generator (HTS only).
• Unit secured to pad.
START-UP CHECKLIST
working on the generator, ensure the fol Before
lowing:
• 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.
8-2
Install002 Rev. C 01/07
Standby Generator Sets
Operation
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 generator was installed in conjunction with a
transfer switch capable of manual operation only, the
following procedure applies. A manually operated
transfer switch is one that will not provide automatic
start-up and does not include an intelligence circuit.
•
•
‹ ENGINE START-UP AND TRANSFER
damage the starter motor.
Let engine stabilize and warm up.
Check all applicable instrument and gauge readings. When certain that all readings are correct,
move the transfer switch manual handle to its
STANDBY (GENERATOR) position, i.e., load circuits supplied by the generator.
Set the standby generator’s main line circuit breaker to its ON (or CLOSED) position.
Load circuits are now powered by the standby
generator.
‹ RETRANSFER AND SHUTDOWN
For additional information, refer to the applicable
control panel manual for this unit, as well as any literature pertaining to the specific transfer switch.
For additional information, refer to the applicable
control panel manual for this unit, as well as any literature pertaining to the specific transfer switch.
DANGER
To transfer the load back to the utility power source
and shut down the generator, follow these directions:
Maintenance Disconnect Switch and the
 The
AUTO/OFF/MANUAL switches (if so equipped)
must be set properly, or the generator will crank
and start as soon as the utility power to the
transfer switch is turned off. Refer to applicable
control panel and transfer switch manuals for
more information.
• Set the standby generator’s main line circuit breaker to its OFF (or OPEN) position.
• Manually move the transfer switch handle to its
UTILITY (NORMAL) position, i.e., load circuits
connected to the utility.
• Turn ON the utility power supply to the transfer
switch, using the means provided (such as the utility power source main line circuit breaker).
• Let the generator run at no-load for a few minutes
to stabilize internal temperatures.
• Shut down the generator.
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 positively turned off, or extremely dangerous - possibly lethal - electrical shock will result.
OPERATING UNIT WITH AUTOMATIC
TRANSFER SWITCH

Transfer switch enclosure doors should be kept
closed and locked. Only authorized personnel
should be allowed access to the transfer switch
interior. Extremely high and dangerous voltages
are present in the transfer switch.
In order to transfer load from the utility source to the
generator, follow these directions:
If the generator has been installed with an automatic
transfer switch, such as an RTS, HTS, or GTS-type
transfer switch, the engine may be started and
stopped automatically or manually.
NOTE:
Refer to the applicable manual for your transfer switch and to “Transfer Switch Start Signal
Connections”. In addition, please note the dangers
under “Engine Start-up and Transfer.”
9-1
Oper001 Rev. 0 08/05
• Turn OFF or disconnect the utility power circuit
to the transfer switch, using the means provided
(such as the utility source main line circuit breaker).
• Set the transfer handle to its UTILITY (NORMAL)
position with load circuits connected to the utility
power supply.
• Set the standby generator’s main line circuit breaker to its OFF (or OPEN) position.
• Start the generator.
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.
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).
‹ ONCE ANNUALLY
a circuit breaker opens or a fuse element melts,
 Iffind
the cause of the overload before resetting
1. Test engine governor; adjust or repair, if needed.
2. Clean, inspect generator.
3. Flush cooling system.
the circuit breaker or replacing the fuse.
CHECKING FLUID LEVELS
‹ FIRST 30 OPERATING HOURS
1. Change engine "break-in" oil and filter.
‹ CHECK ENGINE OIL
‹ FIRST 100 OPERATING HOURS
Check engine crankcase oil level (Figure 10.1) at least
every 20 hours of operation, or prior to use.
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.
Figure 10.1 - Oil Dipstick and Oil Fill Cap
Oil Fill Cap
‹ EVERY 500 OPERATING HOURS
Oil
Dipstick
10-1
Maint012 Rev. E 07/08
1. Service air cleaner.
2. Check starter.
3. Check engine DC alternator.
Standby Generator Sets
Maintenance
‹ INSPECT COOLING 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.
• Inspect engine cooling system. See “Maintenance
Schedule”.
• Check hoses for damage, deterioration, leaks, etc.
Correct any discrepancies found.
• Check hose clamps for tightness.
‹ CHECK ENGINE COOLANT LEVEL
See “Checking Fluid Levels”.
‹ BATTERY FLUID
‹ PERFORM VISUAL INSPECTION
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.
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.
‹ ENGINE COOLANT
‹ INSPECT EXHAUST SYSTEM
Check coolant level in coolant recovery bottle. See
Specifications.
Inspect the exhaust system at least once every three
months. Check all exhaust system pipes, mufflers,
clamps, etc. for condition, tightness, leaks, security,
damage.
• Add recommended coolant mixture as necessary.
• Periodically remove radiator pressure cap (only
when engine has cooled down) to make sure the
coolant recovery system is functioning properly.
Coolant should be at bottom of radiator filler neck.
If coolant level is low, inspect gasket in radiator
pressure cap. Replace cap, if necessary. To have
pressure cap tested, contact a Service Dealer.
Inspect cooling system and coolant recovery system for leaks.
‹ CHECK FAN BELT
• Inspect fan belts every three months. Replace any
damaged, deteriorated, worn or otherwise defective belt.
• Check fan belt tension. Thumb pressure, exerted
midway between pulleys, should deflect about 3/8
to 5/8 of an inch. Adjust belt tension as required.
MAINTENANCE OWNER/
OPERATOR CAN PERFORM
‹ INSPECT ENGINE GOVERNOR
Visually inspect electronic governor.
‹ CHECK ENGINE OIL LEVEL
DANGER
Refer to “Checking Fluid Levels”.
not attempt to adjust the governor. Only
 Do
qualified service facilities should adjust the
‹ CHECK BATTERY
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.
• See “Checking Fluid Levels”.
• Check battery cables for condition, tightness, corrosion or damage. Clean, tighten or replace as
necessary.
‹ EXERCISE SYSTEM
Start the generator engine at least once every seven
days and let it run at least 20 minutes. For more
detailed exercise information, see the respective sections in the Control Panel Technical Manual that is
supplied with the unit.
10-2
Maint012 Rev. E 07/08
Standby Generator Sets
Maintenance
‹ CHANGING ENGINE OIL
Figure 10.3 – Engine Air Cleaner
Refer to maintenance performed by service facilities
for engine oil and filter change frequencies.
Air Cleaner
Drain the oil while the engine is still warm from running. This means warm up the engine, shut it down
and drain immediately as follows:
1. Remove OIL DRAIN HOSE from its retaining
clip.
2. Loosen and remove OIL DRAIN HOSE CAP. Drain
oil completely into suitable container.
3. When all oil has drained, install and tighten OIL
DRAIN HOSE CAP, and re-install into its retaining
clip.
4. Turn OIL FILTER (Figure 10.2) counterclockwise
and remove. Properly dispose of old filter.
(Doors Removed for Clarity)
Figure 10.2 – Oil Filter
‹ 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 (0.0420.046 inch) by carefully bending the ground electrode (Figure 10.4).
Oil
Filter
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. Add recommended oil (see
SPECIFICATIONS). DO NOT FILL ABOVE THE
DIPSTICK “FULL” MARK. Crankcase oil capacity
is 4.0 U.S. quarts (3.8 liters).
Figure 10.4 – Setting the Spark Plug Gap
SET PLUG GAP AT 1.07 - 1.17 mm
(0.042 - 0.046 inch)
refilling the crankcase with oil, always
 After
check oil level on dipstick. NEVER OPERATE
ENGINE WITH OIL BELOW THE DIPSTICK “ADD”
MARK.
7. Start engine and check for oil leaks.
‹ CHANGING THE ENGINE AIR CLEANER
‹ COOLANT CHANGE
To replace the engine air cleaner, remove the air
cleaner cover and replace the air filter making sure
it is positioned properly before reattaching the cover
(Figure 10.3).
Every year, have a service facility drain, flush and
refill the cooling system. See “Specifications” for cooling system recommendations.
See the “Service Schedule,” for air cleaner maintenance.
Maint012 Rev. E 07/08
10-3
Standby Generator Sets
Maintenance
MISCELLANEOUS MAINTENANCE
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.
DANGER
batteries give off explosive hydrogen
 Storage
gas. This gas can form an explosive mixture
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.
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.
• 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.
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.
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.
Be sure the 120VAC power supply to the battery
is turned OFF, or sparking may occur at the battery posts as the cables are attached and cause
an explosion.
‹ BATTERY REPLACEMENT
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.
‹ BATTERY MAINTENANCE
The battery should be inspected per the "Scheduled
Maintenance" section. The following procedure should
be followed for inspection:
REPAIR PARTS
The later portion of this manuals consists of exploded views, parts lists and electrical data pertaining to
this generator set.
1. Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.
10-4
Maint012 Rev. E 07/08
Standby Generator Sets
Service Schedule
SERVICE SCHEDULE
30 KW - 150 KW STANDBY GAS ENGINE DRIVEN GENERATOR SETS
The following is a recommended maintenance schedule for standby gas engine driven generator sets from 30kW to
150 kW in size. The established intervals in the schedule are the maximum recommended when the unit is used
in an average service application. They will need to be decreased (performed more frequently) if the unit is used
in a severe application. Use calendar time, from the previous maintenance interval to determine the next required
maintenance interval.
Service Maintenance Interval Information:
The various service maintenance intervals are designated by interval numbers as follows:
1 An early inspection of the generator set to insure it is ready to operate when required and to identify any potential problem areas.
This inspection may be performed by the end user providing the following safety steps are taken to prevent
the engine from starting automatically without warning:
To prevent injury, perform the following steps in the order indicated before starting any maintenance:
• Disable the generator set from starting and/or connecting to the load by setting the control panel Auto/Off/
Manual switch to the “OFF” position.
• Remove the 15 amp control panel fuse.
• Turn off the battery charger.
• Remove the negative battery cable.
The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition
from burning out sensitive control panel components and circuits.
Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal
operation when required.
2 A wear-in service inspection of the generator set to insure it is ready to operate and carry the load when
required, and to identify any potential problem areas.
Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of
the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by 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.
SrvSchd001 Rev. C 06/08
11-1
Standby Generator Sets
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)
SrvSchd001 Rev. C 06/08
Standby Generator Sets
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).
** Not required for engines equipped with hydraulic lifters. See the "Specification" section for lifter type.
SrvSchd001 Rev. C 06/08
11-3
Standby Generator Sets
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)
SrvSchd001 Rev. C 06/08
Standby Generator Sets
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.
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.
Engine starts hard, runs rough.
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. 0 08/05
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.
Standby Generator Sets
Notes
Standby Generator Sets
Notes
Standby Generator Sets
Notes
Standby Generator Sets
Notes
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
(4) 41
(4) 42
(4) 43
(4) 44
(4) 45
(4) 46
47
1)
A
C
D
E
F
G
H
J
K
L
2)
A
C
D
E
F
G
0F3137
0F3188
0F3189
023484N
0F6366B
0F6366A
043180
022264
0C3990
057701
022155
0C2428
0F3824
0A9457
057073
0D5466
0A7822
022237
022241
049226
0C2266
0C2454
022473
022097
0D4698
0F4464
025433
024469
067210A
0D6029
081008
077043J
051713
0F6156
029289
047411
0G0770
0G5952
036943
023897
022152
022158
0C2454
055934D
0F6145
1
1
1
1
1
1
2
2
2
REF
4
4
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
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 8 X 6 X 1100V
WASHER LOCK #6
SCREW PHTT #6-32 X 1/2 ZYC
DECAL UTIL SENSE/CUST CONN
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 CUST CONN 120V UTILITY
LUG SLDLSS #6-14 X 13/64 CU
SCREW HHTT #10-32 X 3/8 CZ
DECAL GROUND LUG
SCREW HHTT M6-1.0 X 16 ZYC
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
ASSY PCB IGN MOD 4.2L
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
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
0F0199
081320
022473
022097
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
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
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
022127
0C2454
029289
0F1733
0F3329
0D5577
0F2353
022770
022473
022097
022127
0C2454
029289
0F1733
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
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
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)
(2)
(3)
(4)
ITEM INCLUDED WITH HARNESS
ITEM INCLUDED WITH 0D5464B
ITEM USED WITH EARLY MODEL 208V UNITS ONLY
ITEMS USED ON 4.2L MODELS 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
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)
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
6)
A
B
C
D
E
(2) F
(2) G
(2) H
(2) J
K
L
(2) M
N
8)
A
B
C
D
E
F
G
H
9)
A
C
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
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
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
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
0C3993
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 25 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
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
44
45
46
47
0F1823A
0F3078
0F2606
036261
0E7358
052777
0G1303D
0F1262
0F1263
0F1264
0F1725C
067680
0E6875A
055911
0F5459
0E3161
0F5090
0F5462
0A5062J
029673
048467
0F1958
082573
0E4494
0F3215
0F6305
0F6305A
0F5886
051713
049226
0F5752F
0F5884
0F5896
0C2265
0C3990
091526
051716
079224
075476
043180
022264
051715
043182
051714
0F3192
0E7403C
0F9785
COMPONENTS INCLUDED IN 0G3364E
1
ENCL HSB CONTROL PANEL
1
COVER CONTROL PANEL
1
HINGE CONTINUOUS H-PANEL
6
RIVET POP .125 X .275 SS
4
SCREW PPPH HI-LO #4-24 X 3/8
3
WASHER FLAT M3
1
ASSY PCB R-200 3600 RPM
4
HOLDER, FUSE WICKMANN 178.6150
1
ADPTR,RH SIDE WICKMAN 178.6191
1
ADPTR,LH SIDE WICKMAN 178.6192
1
ASSY PCB 2AMP 12V UL BATT CHGR
1
ASSY VOLTAGE REGULATOR 60HZ
2
RELAY, 12VDC C FORM W/DIODE
1
BLOCK TERM 20A 12 X 6 X 1100V
1
DECAL CPL CONTROL PANEL FUSES
1
ASSY PCB BOSCH GOV DRIVER
1
ASSY PCB SCR BRIDGE
1
DECAL CPL 3.9L TB1
4
SPACER 9.5H 3.2 ID
1
DIO BRIDGE 25A 600V
1
CIRCT BRK 7 X 1 ETA 46-500-P
1
PLATE,HARNESS CLAMP
1
SWITCH RKR DPST 125V SPD
1
SWITCH RKR DPDT ON-OFF-ON
1
DECAL, CONTROL HSB
2
SEAL COVER 3.18X12.7X382
1
SEAL COVER 3.18X12.7X283
3
SCREW HHPM M5-0.8 X 12
12
WASHER FLAT M5
12
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
4
SCREW PHTT M4-0.7 X 12 ZYC
2
SCREW PHTT M4-0.7 X 10 ZYC
4
SCREW PPHM M5-0.8 X 12 ZNC
9
NUT HEX M5-0.8 G8 CLEAR ZINC
2
SCREW PPHM M5-0.8 X 30 SS
2
SCREW PPHM M4-0.7 X 16
2
WASHER FLAT M4
2
WASHER LOCK #8-M4
2
NUT HEX M4-0.7 G8 YEL CHR
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 3600RPM R200 CONTROL PNL
A
B
C
D
E
F
G
H
J
K
L
056739
022287
022473
022097
022127
0F6145
0F2627A
091526
049226
051713
0G3545
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
DANGER HIGH VOLTAGE (SPANISH)
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
0F9517
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
0F9596
0F9596A
1
4
5
5
5
5
5
1
1
1
1
1
1
2
1
1
1
1
4
4
4
1
1
1
1
1
1
1
1
WELDMENT FRAME 2.4L C2
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 ENGINE MOUNT (2.4L G1)
SPACER LH ENGINE MOUNT (2.4L G2)
1
2
3
4
5
6
7
8
9
10
11
12
14
15
16
17
0F3408B
0F3411
025507
052212
046526
022131
050331A
050331
038805Y
03880400AE
045771
022129
0F3976
0C2454
022145
077483
1
1
REF
REF
REF
REF
REF
REF
1
1
REF
REF
1
4
REF
REF
BATTERY TRAY C1 CPL
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
BOOT CONTACTOR CABLES
SCREW THF M6-1 X 16 N WA Z/JS
WASHER FLAT 5/16-M8 ZINC
BATTERY 12VDC 75-AH 26
1
2
3
4
5
(1) 6
7
8
0E6586
0E0519A
0C8127
049815
022127
062974
0G0190
037561
1
1
1
4
1
1
1
1
GASKET BOSCH 32 & 40
ADAPTER CARBURETOR W/PVC CONN
ELEMENT AIR CLEANER
SCREW HHC M5-0.8 X 16 G8.8
NUT HEX 1/4-20 STEEL
STUD TH 1/4-20 X 4-1/2 G2 ZNC
PLATE, AIR CLEANER TOP 2.4L
NUT WING 1/4-20 NYLK
(1) APPLY MEDIUM STRENGTH BLUE TREAD LOCKING FLUID TO THREADS ON
ONE END OF I/N 6 (STUD) THAT SCREWS INTO I/N 2 (CARB ADAPTER).
1
2
3
4
5
(2) 6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
25
26
27
28
29
30
31
32
33
34
35
(1) 36
37
38
39
(3) 40
(1) 44
45
46
47
48
49
50
51
52
(1) 53
54
55
56
57
59
(1) 60
61
62
63
(3) 64
65
(3) 66
67
0G0408
046526
039414
0G0149
0E9868A
0F3217
042574
0A8584
0F4612
057772
057765
043790
0C7649
069860E
063076
0G1394
052830
025507
062963
049821
022129
0D6029
0A6751
0E0502
022145
045771
022131
049813
046525
058306
022097
022473
043116
026073A
052243
0A8258
0G0664
0G1502
047290
049340
045757
0G0951
0G3910
0F9965E
0D2244M
0F9420
0E9747
0G1472A
0G1476
0G0707
0G0950
0F9583
0G0792
0G0792A
0G1501
0F9501
0G0952
0D3488S
0G0788
0G2750
049721
026925
0F2776
052203
0F2776D
0G7313
1
3
4
1
1
1
1
1
1
1
1
1
1
1
7
7
2
5
3
3
26
3
1
1
7
3
1
3
2
15
7
10
4
2
1
1
1(REF)
1
1
1
1
1(REF)
1
1
2
1
1
1
1(REF)
1
1(REF)
1
1
1
1
1
1(REF)
1
1
1
3
1
1
2
1
REF
ENGINE 2.4L MITSUBISHI 4G64
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
ADAPTOR 1/8 NPTF TO 1/8 BSPT
SWITCH OIL PRESSURE 10 PSI 2 POL (R-PANEL)
SENDER OIL PRESSURE 1/8" NPT (H-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
SCREW THF M6-1 X 16 N WA Z/JS
SWITCH HI-TEMP 245D X 3/8 NPT (R-PANEL)
TEMPERATURE SENDER DELPHI (H-PANEL)
WASHER FLAT 5/16-M8 ZINC
NUT HEX M8-1.25 G8 CLEAR ZINC
WASHER FLAT 3/8-M10 ZINC
NUT HEX M6 X 1.0 G8 YEL CHR
NUT HEX M10-1.25 G8 YEL CHR
SCREW SHC M8-1.25 X 25 G12.9
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
SCREW HHC M6-1.0 X 12 G8.8
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
OIL FILTER G2 ENGINE
COIL PACK
HOSE 3/8 ID SINGLE BRAID (15” LG)
BARBED EL 90 1/4 NPT X 3/8
SCREW HHC M6-1.0 X 25 G8.8
GASKET EXHAUST MANIFOLD
EXHAUST MANIFOLD G2 (MACHINE) (25KW, 35KW & 45KW)
FLEX PLATE 2 POLE 2.4L G2
ASSY MAGPICKUP(3/8-24 MALE)
ADAPTER ENGINE 2.4L MACHINE
STARTER, 12 VOLT
CAM SENSOR PIN ASSY
COVER CAM GEAR G2 REWORKED
MANIFOLD INTAKE
GASKET INTAKE MANIFOLD
SPACER 2.4L G2 FLEX PLATE
SHIELD HEAT G2
SHIELD HEAT SML
BRACKET COIL PACK
ADAPTER 2.4L CRANKSHAFT MACH
POLY V-BELT G2 (3600 RPM)
BELT SERPENTINE 37.0" (1800 RPM)
PULLEY DC ALTERNATOR (3600 RPM)
PULLEY 69 OD DC ALTERNATOR (1800 RPM)
SCREW HHC M6-1.0 X 35 G8.8 BLK
PLUG STD PIPE 3/8 STEEL SQ HD
BRACKET, SIGNAL CONDITIONER
SCREW HHC M8-1.25 X 70 G8.8
BRACKET SIGNAL CONDITONER
DECAL EMISSION CTRL INFO 2.4L
(1) SUPPLIED WITH ENGINE.
(2) NOT USED ON 1800 RPM UNITS.
(3) USED WITH H-PANEL ONLY
1
2
3
4
(1) 5
6
0G68030ST03
0F2608
0F5263
046526
059981
0F2776A
1
1
1
5
4
1
7
9
10
11
12
0F5050A
0F2573
0F4011
0G56820ST03
0G2990
1
1
1
1
1
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
BRACKET, SIGNAL CONDITIONER (USED ONLY
WITH QTA PRODUCT)
SHIELD RADIATOR C4
PULLEY FAN V-GROOVE 9"
FAN COOL 22" DIA 10 BLADE LH
FLAT TENSIONER ARM
SHOULDER BOLT 3/8 X 1/2"
13
14
15
16
17
18
19
20
21
23
(1) 24
25
26
(2) 27
28
29
(1) 30
31
32
33
34
35
36
37
38
39
40
(1) 41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
0F2862
0F2560
022131
0E2507
035685
0F2561
0C8145
052250
0C7043
022473
0C8146
022097
076749
048031C
031971
0F4496
042911
0F2872
022304
022195
022196
0F8651
070015
0F9867
0F2461
022145
022129
039414
082774
0G0795
0G0816
049813
052644
0C8566
0C2454
090283
080713
0G4376
0G56830ST03
039253
051698
049820
0G67930ST03
099502
0C8165
029032
1
1
4
1
2
1
8
2
12
8
4
16
1
2(REF)
1
1
1
1
2
1
1
9
1
1
1
16
10
1
1
1
1
8
1
16
2
1
1
1
1
2
1
3
1
2
2
1
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
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 4.5" DIA MACHINED
SCREW HHC M10-1.5 X 30 G8.8
SCREW HHC 1/2-13 X 2" G8
WASHER FLAT 1/2 ZINC
WASHER LOCK 1/2
NUT HEX 1/2-13 STEEL
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 35 G8.8
KEY WOODRUFF 4 X 19D
HOSE LOWER 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 (27”LG)
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.
1
2
3
4
5
6
7
9
10
11
13
14
15
16
17
18
19
20
21
22
23
24
26
27
28
29
30
32
026915
075580
0F6390C
0F6390B
039253
022145
022129
045771
0E8286
026812
0F8379
057823
059057
047527
0D1509
050279
050280
0F2119
0E6586
0E4394
0E4395
040105
057753B
0G4573C
0G4573B
0F7790E
0F7790H
0E7121
022097
046580
035685
0F6155
047290
057823
2
1
1
1
2
2
2
2
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
2
1
1
2
NIPPLE CLOSE 3/4 X 1.375
FLANGE FUEL INLET
REGULATOR ASSY 2.4L (25KW)
REGULATOR ASSY 2.4L (35KW & 45KW)
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 CLEAR ZINC
STREET EL 45D 1/2 NPT BRASS
ELBOW 90D 3/4 NPT
NIPPLE PIPE 3/4 NPT X 7
CLAMP HOSE #10 .56 - 1.06
HOSE 3/4 ID SAE-30R2 (18” LG)
BARBED STR 1/2 NPT X 3/4
DECAL INLET PRESSURE
DECAL FUEL INLET NG (NATURAL GAS APPLICATION)
DECAL FUEL INLET LPG (LP VAPOR APPLICATION)
O-RING 45.63 ID X 2.62 WIDTH
GASKET BOSCH 32
ACTUATOR BOSCH 40 GOVERNOR (45KW)
ACTUATOR BOSCH 32 GOVERNOR (25 & 35KW)
HOSE COOL 2 IN ID 20R4 (45KW)
HOSE 1.5 ID X 2 LG 20R4 (35KW)
MIXER ACTUATOR 32MM MACHINED (25KW)
MIXER ACTUATOR 40MM MACHINED (35 & 45KW)
VENTURI THROTTLE 26MM (35 & 45KW)
VENTURI THROTTLE 19MM (25KW)
O-RING 47.625 ID X 2.38 WIDTH
WASHER LOCK M6-1/4
SCREW SHC M6-1.0 X 45 G12.9
CLAMP HOSE #28 1.32-2.25
HARNESS CPL FUEL JUMPER
HOSE 3/8 ID SINGLE BRAID (18” LG)
CLAMP HOSE #10 .56-1.06
RECONFIGURING THE FUEL SYSTEM
Note: All models are configured to run on natural gas from the factory.
To reconfigure the fuel system from NG to LP, follow these steps:
1. Turn the main gas supply off.
2. Remove the carburetor fuel hose from the outlet port of the demand regulator (See Detail “A”).
3. Disconnect the power wires from the fuel solenoid located on top of the regulator assembly.
4. Loosen the spring clamp on the small fuel enrichment line and remove the hose from the hose barb.
5. Remove the black pipe assembly from the outlet port of the demand regulator.
6. Remove the NG fuel jet (loosen counter clockwise) from the outlet port.
7. Remove the LP fuel jet (loosen counter clockwise) from the jet keeper port on the side of the regulator housing.
Install this jet into the outlet port in the regulator casting.
Note: The jet sizes are stamped on the individual jets. The larger jet size is used for running on NG.
8. Install the previously removed NG jet into the jet keeper port on the side of the regulator housing.
9. Install the previously removed black iron pipe onto the outlet port of the demand regulator.
10. Reverse steps 1-4 in this procedure to reactivate the demand regulator.
11. For LP vapor application substitute LPG fuel inlet decal p/n 050280 for NG fuel inlet decal p/n 050279 (Item 17).
12. When switching fuel types, the proper dip switch settings must be made to the control panel. See owners
manual, fuel section, for more details.
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
0F9794
0G0113
0G1007
0F2830
0F2962
080762
0E0170A
0C2454
0G0776
0G0007
044149
085917
0D2611
0E8816
049721
022097
022473
036797
022259
070006
088775
022241
085917
0F2809
0F2808B
2
1
1
2
2
5
1
4
1
1
1
2
2
1
4
4
4
1
2
2
2
10
10
1
1
MUFFLER 7" X 9" X 18-1/2" 2" IN/OUT
EXHAUST ELBOW 2 1/4 OD 2 1/2OD
BRACKET MUFFLER
MUFFLER BRACKET STIFFENER
MUFFLER STRAP
BOLT U 3/8-16 X 2.62
EXHAUST BLANKET 988MM (C2)
SCREW THF M6-1 X 16 N WA Z/JS
PIPE EXHAUST G2
DIFFUSER EXHAUST WELDMENT
GASKET EXHAUST RING
WASHER LOCK 3/8 SS
SCREW HHC 3/8-16 X 1-3/4 SS
EXHAUST FLANGE 2" PIPE
SCREW HHC M6-1.0 X 35 G8.8 BLK
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
BOLT U 5/16-18 X 2.25
NUT HEX 5/16-18 STEEL
WASHER LOCK M8 SS
WASHER FLAT 3/8 SS
NUT HEX 3/8-16 STEEL
WASHER LOCK 3/8 SS
PIPE EXHAUST CROSSOVER
PIPE EXHAUST MUFFLER OUT
* NOT USED ON OPEN SET.
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
0G0045 (XX)
0C2454
0F5849 (XX)
087233
0E3257
0F5852 (XX)
0F9833 (XX)
0F5851 (XX)
049813
077992
0F9835 (XX)
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
0G5892B
0F8869D
0E5298L
1
54
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
REAR WRAP C2 CPL
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
DISCHARGE DUCT LH & RH SIDE C2
FRONT CORNERS C2
DISCHARGE CENTER DUCT 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
INSULATION REAR WRAP
KEY VISE-ACTION LATCH SLOT CIR
FOAM 300 X 300 THERMAL ACO (APPLIES TO 4.2L UNITS ONLY)
OPTIONAL COMPARTMENT MATERIALS:
ALL P/N’S WITH AN (XX) SUFFIX INDICATE A MULTIPLE MATERIAL AND COLOR OPTION.
USE THE FOLLOWING LEGEND TO IDENTIFY THE CORRECT PART NUMBER:
PART NO.
0XXXXXSN
0XXXXXAN
0XXXXXSG
0XXXXXAG
MATERIAL
STEEL
ALUMINUM
STEEL
ALUMINUM
COLOR
TAN
TAN
GRAY
GRAY
* 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.
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
EXPLODED VIEW: EV AIR CLEANER
GROUP D
DRAWING #: 0F9809
ITEM
PART#
QTY.
0E6586
0E0519A
0C8127
049815
022127
062974
0G0190
025870
022097
022473
1
1
1
4
1
1
1
1
1
1
1
2
3
4
5
(1) 6
7
8
9
10
DESCRIPTION
GASKET BOSCH 32 & 40
ADAPTER CARBURETOR W/PVC CONN
ELEMENT AIR CLEANER
SCREW HHC M5-0.8 X 16 G8.8
NUT HEX 1/4-20 STEEL
STUD TH 1/4-20 X 4-1/2 G2 ZNC
PLATE, AIR CLEANER TOP 2.4L
NUT WING 1/4-20
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
(1) APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THREADS.
REVISION: J-8527-B
DATE: 5/7/14
Page 2 of 2
1
2
3
4
5
(1) 6
7
8
0E6586
0E0519A
0C8127
049815
022127
062974
0G0190
037561
1
1
1
4
1
1
1
1
GASKET BOSCH 32 & 40
ADAPTER CARBURETOR W/PVC CONN
ELEMENT AIR CLEANER
SCREW HHC M5-0.8 X 16 G8.8
NUT HEX 1/4-20 STEEL
STUD TH 1/4-20 X 4-1/2 G2 ZNC
PLATE, AIR CLEANER TOP 2.4L
NUT WING 1/4-20 NYLK
(1) APPLY MEDIUM STRENGTH BLUE TREAD LOCKING FLUID TO THREADS ON
ONE END OF I/N 6 (STUD) THAT SCREWS INTO I/N 2 (CARB ADAPTER).
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
31
32
0F9517
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
0F9596
0F9596A
052212
0C2454
0H5718
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
1
3
1
WELDMENT FRAME 2.4L C2
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 ENGINE MOUNT (2.4L G1)
SPACER LH ENGINE MOUNT (2.4L G2)
SCREW HHC M10-1.25 X 25 C8.8
SCREW HWHT M6-1 X 16 N WA Z/JS
HEAT SHIELD 2.4L G2
1
2
3
4
5
6
7
8
9
10
11
12
14
15
16
17
0F3408B
0F3411
025507
052212
046526
022131
050331A
050331
038805Y
03880400AE
045771
022129
0F3976
0C2454
022145
077483
1
1
REF
REF
REF
REF
REF
REF
1
1
REF
REF
1
4
REF
REF
BATTERY TRAY C1 CPL
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
BOOT CONTACTOR CABLES
SCREW THF M6-1 X 16 N WA Z/JS
WASHER FLAT 5/16-M8 ZINC
BATTERY 12VDC 75-AH 26
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
44
45
46
47
0F1823A
0F3078
0F2606
036261
0E7358
052777
0G1303D
0F1262
0F1263
0F1264
0F1725C
067680
0E6875A
055911
0F5459
0E3161
0F5090
0F5462
0A5062J
029673
048467
0F1958
082573
0E4494
0F3215
0F6305
0F6305A
0F5886
051713
049226
0F5752F
0F5884
0F5896
0C2265
0C3990
091526
051716
079224
075476
043180
022264
051715
043182
051714
0F3192
0E7403C
0F9785
COMPONENTS INCLUDED IN 0G3364E
1
ENCL HSB CONTROL PANEL
1
COVER CONTROL PANEL
1
HINGE CONTINUOUS H-PANEL
6
RIVET POP .125 X .275 SS
4
SCREW PPPH HI-LO #4-24 X 3/8
3
WASHER FLAT M3
1
ASSY PCB R-200 3600 RPM
4
HOLDER, FUSE WICKMANN 178.6150
1
ADPTR,RH SIDE WICKMAN 178.6191
1
ADPTR,LH SIDE WICKMAN 178.6192
1
ASSY PCB 2AMP 12V UL BATT CHGR
1
ASSY VOLTAGE REGULATOR 60HZ
2
RELAY, 12VDC C FORM W/DIODE
1
BLOCK TERM 20A 12 X 6 X 1100V
1
DECAL CPL CONTROL PANEL FUSES
1
ASSY PCB BOSCH GOV DRIVER
1
ASSY PCB SCR BRIDGE
1
DECAL CPL 3.9L TB1
4
SPACER 9.5H 3.2 ID
1
DIO BRIDGE 25A 600V
1
CIRCT BRK 7 X 1 ETA 46-500-P
1
PLATE,HARNESS CLAMP
1
SWITCH RKR DPST 125V SPD
1
SWITCH RKR DPDT ON-OFF-ON
1
DECAL, CONTROL HSB
2
SEAL COVER 3.18X12.7X382
1
SEAL COVER 3.18X12.7X283
3
SCREW HHPM M5-0.8 X 12
12
WASHER FLAT M5
12
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
4
SCREW PHTT M4-0.7 X 12 ZYC
2
SCREW PHTT M4-0.7 X 10 ZYC
4
SCREW PPHM M5-0.8 X 12 ZNC
9
NUT HEX M5-0.8 G8 CLEAR ZINC
2
SCREW PPHM M5-0.8 X 30 SS
2
SCREW PPHM M4-0.7 X 16
2
WASHER FLAT M4
2
WASHER LOCK #8-M4
2
NUT HEX M4-0.7 G8 YEL CHR
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 3600RPM R200 CONTROL PNL
A
B
C
D
E
F
G
H
J
K
L
056739
022287
022473
022097
022127
0F6145
0F2627A
091526
049226
051713
0G3545
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
DANGER HIGH VOLTAGE (SPANISH)
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
0G0045 (XX)
0C2454
0F5849 (XX)
087233
0E3257
0F5852 (XX)
0F9833 (XX)
0F5851 (XX)
049813
077992
0F9835 (XX)
0F2786
0F2785
0F3364
0F4880
0F5049
0F4487A
022473
022097
022127
0F3072
078115
0F4051
0F4051A
0F5048D
0E5968
0F3760K
0F3760E
0F4051C
0F3890B
0F4051B
0F3890
0F3890A
0F3760L
042568
0912970094
022447
0F4051E
0F8869D
1
54
2
2
4
2
2
1
2
21
1
2
1
1
2
2
1
3
1
1
10
44
2
1
2
1
2
2
2
10
2
4
3
1
2
2
2
1
1
REAR WRAP C2 CPL
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
DISCHARGE DUCT LH & RH SIDE C2
FRONT CORNERS C2
DISCHARGE CENTER DUCT 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
ASSY ACCESS COVER
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX 1/4-20 STEEL
INSULATION RETAINMENT HANGER
WASHER SELF LOCKING DOME
INSULATION DOOR C2
INSULATION ROOF TOP
VISE-ACTION LATCH SLOTTED CIR
GASKET EXTRUDED TRIM (440.64” LG)
INSULATION SPLITTER
INSULATION SPLITTER
INSULATION DUCT
RETAINER INSULATION (820)
INSULATION DUCT SIDES
RETAINER INSULATION (450)
RETAINER INSULATION (740)
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
INSULATION REAR WRAP
KEY VISE-ACTION LATCH SLOT CIR
OPTIONAL COMPARTMENT MATERIALS:
ALL P/N’S WITH AN (XX) SUFFIX INDICATE A MULTIPLE MATERIAL AND COLOR OPTION.
USE THE FOLLOWING LEGEND TO IDENTIFY THE CORRECT PART NUMBER:
PART NO.
0XXXXXSN
0XXXXXAN
0XXXXXSG
0XXXXXAG
MATERIAL
STEEL
ALUMINUM
STEEL
ALUMINUM
COLOR
TAN
TAN
GRAY
GRAY
* ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO
THE BASE FRAME MUST BE SECURED USING ITEM 2 & 5 THREAD FORMING
FASTENER AND ITEM 39 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.
EXPLODED VIEW: EV FUEL SYSTEM 2.4L G2
GROUP E
DRAWING #: 0G1151
ITEM
1
2
3
4
5
6
7
9
10
11
13
14
15
18
19
20
21
22
23
24
26
27
28
29
30
32
33
34
35
36
37
PART#
QTY.
G026915
G075580
0F6390C
0F6390B
G039253
G022145
G022129
G045771
0E8286
G026812
G035589
G057823
G059057
G047527
0F2119
0E6586
0E4394
0E4395
0K9704
057753B
0G4573C
0G4573B
0F7790E
0F7790H
0E7121
G022097
G046580
G035685
0F6155
G047290
G057823
0K2339
0K2340
0K3795
0H3632
0L5884
2
1
1
1
2
2
2
2
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
2
1
1
2
1
1
1
1
1
DESCRIPTION
NIPPLE CLOSE 3/4 X 1.375
FLANGE FUEL INLET
REGULATOR ASSY 2.4L (25KW)
REGULATOR ASSY 2.4L (35KW & 45KW)
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 CLEAR ZINC
STREET EL 45D 1/2 NPT BRASS
ELBOW 90D 3/4 NPT
NIPPLE PIPE 3/4 NPT X 3-1/2
CLAMP HOSE #10 .56 - 1.06
HOSE 3/4 ID SAE-30R2 (18” LG)
BARBED STR 1/2 NPT X 3/4
O-RING 45.63 ID X 2.62 WIDTH
GASKET BOSCH 32
ACTUATOR BOSCH 40 GOVERNOR (45KW)
ACTUATOR BOSCH 32 GOVERNOR (25 & 35KW)
HOSE COOLING 2IN ID 20R4 (2IN) (45KW)
HOSE 1.5 ID X 2 LG 20R4 (35KW)
MIXER ACTUATOR 32MM MACHINED (25KW)
MIXER ACTUATOR 40MM MACHINED (35 & 45KW)
VENTURI THROTTLE 26MM (35 & 45KW)
VENTURI THROTTLE 19MM (25KW)
O-RING 47.625 ID X 2.38 WIDTH
WASHER LOCK M6-1/4
SCREW SHC M6-1.0 X 45 G12.9
CLAMP HOSE #28 1.32-2.25
HARNESS CPL FUEL JUMPER
HOSE 3/8 ID SINGLE BRAID (18” LG)
CLAMP HOSE #10 .56-1.06
REDUCING TEE, 3/4 X 1/4 X 3/4
PLUG, PRESSURE GAUGE, 1/4" NPT
HANG TAG FUEL PRESS TEST POINT
TIE WRAP UL 5.6 X .10 BLACK
LUG PLASTIC 0.75 TAPERED CAP
RECONFIGURING THE FUEL SYSTEM
Note: All models are configured to run on natural gas from the factory.
To reconfigure the fuel system from NG to LP, follow these steps:
1. Turn the main gas supply off.
2. Remove the carburetor fuel hose from the outlet port of the demand regulator (See Detail “A”).
3. Disconnect the power wires from the fuel solenoid located on top of the regulator assembly.
4. Loosen the spring clamp on the small fuel enrichment line and remove the hose from the hose barb.
5. Remove the black pipe assembly from the outlet port of the demand regulator.
6. Remove the NG fuel jet (loosen counter clockwise) from the outlet port.
7. Remove the LP fuel jet (loosen counter clockwise) from the jet keeper port on the side of the regulator housing. Install this jet into the outlet port in the regulator casting.
Note: The jet sizes are stamped on the individual jets. The larger jet size is used for running on NG.
8. Install the previously removed NG jet into the jet keeper port on the side of the regulator housing.
9. Install the previously removed black iron pipe onto the outlet port of the demand regulator.
10. Reverse steps 1-4 in this procedure to reactivate the demand regulator.
11. For LP vapor application substitute LPG fuel inlet decal p/n 050280 for NG fuel inlet decal p/n 050279 (Item 17).
12. When switching fuel types, the proper dip switch settings must be made to the control panel. See owners manual, fuel section, for more details.
REVISION: CN-0026967-L
DATE: 5/31/19
Page 2 of 2
EXPLODED VIEW: EV ENGCOMPRT 2.4L G2
GROUP D
DRAWING #: 0G1141
APPLICABLE TO:
ITEM
PART#
QTY.
DESCRIPTION
1
0H1951
1
ENGINE 2.4L G2 4G64 CERT
0H1619
1
ENGINE 2.4L G2 CERTIFIED
2
G046526
3
WASHER LOCK M10
3
G039414
4
SCREW HHC M8-1.25 X 35 G8.8
4
0G0149
1
SCREW SHC M14-1.5 X 35 G10.9
5
0E9868A
1
ALTERNATOR DC W/OUT PULLEY
6
0F3217
1
SPACER DC ALTERNATOR PULLEY
7
G042574
1
ADAPTOR 1/8 NPTF TO 1/8 BSPT
8
0A8584
1
SWITCH OIL PRESSURE 10 PSI 2 POL (R-PANEL)
0F4612
1
SENDER OIL PRESSURE 1/8" NPT (H-PANEL)
9
G057772
1
WASHER NYLON .565
10
0A4707L
1
ADAPTER 3/8NPT X M14-1.5
11
G043790
1
BARBED EL 90 3/8 NPT X 3/8
12
0C7649
1
CLAMP HOSE .38-.87
13
069860E
1
HOSE DRAIN ASSY 28"
14
G063076
7
WASHER FLAT .531 ID X 1.062 OD
15
0G1394
7
SCREW HHC M12-1.25 X 20 G10.9
16
G052830
2
SCREW HHC M10-1.25 X 45 G8.8
17
G025507
5
WASHER SHAKEPROOF EXT 7/16 STL
18
G062963
3
SCREW HHC M10-1.25 X 30 G8.8
19
G049821
3
SCREW SHC M8-1.25 X 30 G12.9
20
G022129
26
WASHER LOCK M8-5/16
21
0D6029
3
SCREW THF M6-1 X 16 N WA Z/JS
22
0A6751
1
SWITCH HI-TEMP 245D X 3/8 NPT (R-PANEL)
0E0502
1
TEMPERATURE SENDER DELPHI (H-PANEL)
23
G022145
7
WASHER FLAT 5/16-M8 ZINC
25
G045771
3
NUT HEX M8-1.25 G8 CLEAR ZINC
26
G022131
1
WASHER FLAT 3/8-M10 ZINC
27
G049813
3
NUT HEX M6 X 1.0 G8 YEL CHR
28
G046525
2
NUT HEX M10-1.25 G8 YEL CHR
29
G058306
7
SCREW SHC M8-1.25 X 25 G12.9
30
G022097
7
WASHER LOCK M6-1/4
31
G022473
10
WASHER FLAT 1/4-M6 ZINC
32
G043116
4
SCREW HHC M6-1.0 X 12 G8.8
33
026073A
2
PLUG STD PIPE 1/4 STEEL SQ HD
34
G052243
1
SCREW HHC M10-1.5 X 60 G8.8
35
0A8258
9
SCREW HHC M8-1.25 X 25 G10.9
(1) 36
0G0664
1(REF)
OIL FILTER G2 ENGINE
37
0G1502
1
COIL PACK
38
G047290
1
HOSE 3/8 ID SINGLE BRAID (15” LG)
39
G049340
1
BARBED EL 90 1/4 NPT X 3/8
(3) 40
G045757
1
SCREW HHC M6-1.0 X 25 G8.8
(1) 44
0G0951
1(REF)
GASKET EXHAUST MANIFOLD
45
0G3910
1
EXHAUST MANIFOLD G2 (MACHINE) (25KW, 35KW & 45KW)
46
0F9965E
1
FLEX PLATE 2 POLE 2.4L G2
47
0D2244M
2
ASSY MAGPICKUP(3/8-24 MALE)
48
G0F9420
1
ADAPTER ENGINE 2.4L MACHINE
49
0G7461
1
STARTER MOTOR 12V
50
0G1472A
1
CAM SENSOR PIN ASSY
51
0G1476
1(REF)
COVER CAM GEAR G2 REWORKED
52
0G0707
1
MANIFOLD INTAKE (USE HOSE 0G0816)
0G8488
1
MANIFOLD INTAKE (MACHINED) (USE HOSE 0H1546)
(1) 53
0G0950
1(REF)
GASKET INTAKE MANIFOLD
54
0F9583
1
SPACER 2.4L G2 FLEX PLATE
55
0G0792
1
SHIELD HEAT G2
56
0G0792A
1
SHIELD HEAT SML
57
0G1501
1
BRACKET COIL PACK
59
0F9501
1
ADAPTER 2.4L CRANKSHAFT MACH
(1) 60
0G0952
1(REF)
POLY V-BELT G2 (3600 RPM)
0D3488S
1
BELT SERPENTINE 37.0" (1800 RPM)
61
0G0788
1
PULLEY DC ALTERNATOR (3600 RPM)
0H8572
1
PULLEY DC ALTERNATOR (1800 RPM)
62
G049721
3
SCREW HHC M6-1.0 X 35 G8.8 BLK
63
G026925
1
PLUG STD PIPE 3/8 STEEL SQ HD
(3) 64
0F2776
1
BRACKET, SIGNAL CONDITIONER
65
G052203
2
SCREW HHC M8-1.25 X 70 G8.8
(3) 66
0F2776D
1
BRACKET SIGNAL CONDITONER
67
0G9378
1(REF)
DECAL SORE EPA CERTIFICATION
69
0G10080125
1
ROD ASSY OIL LEVEL GAUGE
70
0G3823
1
O-RING SIZE 9.0MM X 2.0MM NITR
71
0G10080288
1
CABLE, SPARK PLUG, NO.1
72
0G10080289
1
CABLE, SPARK PLUG, NO.2
73
0G10080290
1
CABLE, SPARK PLUG, NO.3
74
0G10080291
1
CABLE, SPARK PLUG, NO.4
(2) 75
0G9520
1(REF)
PLUG TAPER
(1) SUPPLIED WITH ENGINE.
(2) APPLY LOCTITE 620 BEARING RETAINMENT COMPOUND TO I/N 75.
(3) USED WITH H-PANEL ONLY
REVISION: CN-0008970-W
DATE: 9/5/17
Page 2 of 2
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
(4) 41
(4) 42
(4) 43
(4) 44
(4) 45
(4) 46
47
1)
A
C
D
E
F
G
H
J
K
L
2)
A
C
D
E
F
G
0F3137
0F3188
0F3189
023484N
0F6366B
0F6366A
043180
022264
0C3990
057701
022155
0C2428
0F3824
0A9457
057073
0D5466
0A7822
022237
022241
049226
0C2266
0C2454
022473
022097
0D4698
0F4464
025433
024469
067210A
0D6029
081008
077043J
051713
0F6156
029289
047411
0G0770
0H0348
036943
023897
022152
022158
0C2454
055934D
0F6145
1
1
1
1
1
1
2
2
2
REF
4
4
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
PAN CB CONN BOX
STAND RH CONTROL
STAND LH CONTROL
BUSHING SNAP SB-2.5-31
XFMR DUAL 120V/16V (F OR 120/240V & 277/480V UNITS)
XFMR DUAL 104V/16V (F OR 120/208V UNITS)
WASHER FL AT M4
WASHER LO CK #8-M4
SCREW PHTT M4-0.7 X 10 ZYC
BLOCK TERM 20A 8 X 6 X 1100V
WASHER LO CK #6
SCREW PHTT #6- 32 X 1/2 ZYC
DECAL UT IL SENSE/CUST CONN
DECAL NEUTRAL
JUNCTION BLOCK 3/8-16
BUS BAR NEUTRAL BLOCK 390
LUG SLDLSS 600/250-1/0 X 1/4-28
WASHER LO CK 3/8
NUT HEX 3/8-16 STEEL
WASHER LO CK M5
SCREW PHTT M5-0.8 X 16 ZYC
SCREW THF M6-1 X 16 N WA Z/JS
WASHER FL AT 1/4-M6 ZINC
WASHER LO CK M6- 1/4
BLOCK TERM 20A 6 X 3 X 1100V
DECAL CUST CO NN 120V UTILITY
LUG SLDLSS #6- 14 X 13/64 CU
SCREW HHTT #10-32 X 3/8 CZ
DECAL GROUND LUG
SCREW HHTT M6-1.0 X 16 Z YC
GROMMET 1.25 X .25 X .75
CONDUIT FLEX 2.0" ID (36” LG)
WASHER FL AT M5
PLATE WIRE SNGL G ALV
TAPE ELEC 1/2 FO AM (AS REQ’D)
SCREW HHC M6-1.0 X 16 G8.8
HARNESS, TRANSFO RMER ADAPTER
ASSY ENCLOSURE PCB 4.2L IGN MD
SCREW PPHM #10/32 X 2
WASHER FL AT #10 ZINC
WASHER LO CK #10
NUT HEX #10-32 STEEL
SCREW THF M6-1 X 16 N WA Z/JS
CLAMP VINYL 1.06 X .406 Z
SEAL W EATHER .45" DIA
0F3328
0D5552
0D5553
0D5554
0D5556
0D9693
0F0492
048927
023897
022152
022158
0C2454
029289
0F1733
UL CIRCUIT BREAKER (ED)
1
COVER ED CB SHO RT 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 FL AT #10 ZINC
4
WASHER LO CK #10
4
NUT HEX #10-32 STEEL
9
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FO AM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
0F3138
0D5572
0D5573
0D5574
0D5575
0D5576
0F0199
081320
022473
022097
UL CIRCUIT BREAKER (F D)
1
COVER CB CONN BO X
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
1
INSULATOR CB FD FRAME 30MIL
4
SCREW SHC 1/4-20 X 4.5 G8.8 NZ
4
WASHER FL AT 1/4-M6 ZINC
4
WASHER LO CK M6- 1/4
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
022127
0C2454
029289
0F1733
0F3329
0D5577
0F2353
022770
022473
022097
022127
0C2454
029289
0F1733
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+L D)
1
COVER JD/L D 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
W ASHER FLAT 1/4-M6 ZINC
4
W ASHER 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
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
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)
(2)
(3)
(4)
ITEM INCL UDED WIT H HARNESS
ITEM INCL UDED WIT H 0D5464B
ITEM USED WIT H EARLY MO DEL 208V UNITS ONLY
ITEMS USED ON 4.2L MO DELS O NL Y.
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
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)
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
6)
A
B
C
D
E
(2) F
(2) G
(2) H
(2) J
K
L
(2) M
N
8)
A
B
C
D
E
F
G
H
9)
A
C
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
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
1
2
3
4
(1) 5
6
0G68030ST03
0F2608
0F5263
046526
059981
0F2776A
1
1
1
5
4
1
7
9
10
11
12
0F5050A
0F2573
0F4011
0G56820ST03
0G2990
1
1
1
1
1
WELDMENT RADIATO R SUPPO RT 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
BRACKET, SIGNAL CONDITIONER (USED O NLY
WITH QTA PRODUCT)
SHIELD RADIATOR C4
PULLEY FAN V-GROO VE 9"
FAN COOL 22" DIA 10 BLADE LH
FLAT TENSIONER ARM
SHOULDER BOLT 3/8 X 1/2"
13
14
15
16
17
18
19
20
21
23
(1) 24
25
26
(2) 27
28
29
(1) 30
31
32
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
(3) 60
(3) 61
0F2862
0F2560
022131
0E2507
1
1
4
1
0H1827
1
035685
0F2561
0C8145
052250
0C7043
022473
0C8146
022097
076749
048031C
031971
0F4496
042911
0F2872
022304
022195
022196
0F8651
070015
0F9867
0F2461
022145
022129
039287
082774
0G0795
0G0816
0H1546
049813
052644
0C8566
0C2454
090283
080713
0G4376
0G 56830ST03
039253
051698
049820
0G 67930ST03
099502
0C8165
029032
029333A
0H1851
2
1
8
2
12
8
4
16
1
2(REF)
1
1
1
1
2
1
1
9
1
1
1
16
10
1
1
1
1
1
8
1
16
2
1
1
1
1
2
1
3
1
2
2
1
9
1
SPRING TENSION CPL
PULL EY V-BELT 4" FLANGED
WASHER FLAT 3/8-M10 ZINC
PRO BE COOLANT LEVEL 3/8 NPTF (USE W ITH
HARNESS P/N 0G 4882)
PRO BE COOLANT LEVEL 3/8- 18NPTF ( USE WITH
HARNESS P/N 0H3069)
CLAMP HOSE #28 1.32- 2.25
HUB FL EX PLATE
WASHER FLEX (THIN)
TAPE FOAM 1 X 1 (26.75” LG)
DISK FLEX
WASHER FLAT 1/4-M6 ZINC
SCREW HHC 5/16-24 X 1.124
WASHER LOCK M6-1/4
TANK CO OLANT RECOVERY
CLAMP HOSE BAND 1/4
BEARING #6205 2NSE C3 E SRI2 S
PULL EY 4.5" DIA MACHINED
SCREW HHC M10-1.5 X 30 G 8.8
SCREW HHC 1/2- 13 X 2" G8
WASHER FLAT 1/2 ZINC
WASHER LOCK 1/2
NUT HEX 1/2-13 STEEL
SCREW HHFC M8-1.25 X 20 W /M6
NUT HEX LO CK 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 RADIATO R 13 PSI
BRACKET CO OLANT TANK
WASHER BELLEVILLE .75X.38X.028
TENSIONER ARM SUPPO RT BENT 90
SCREW HHC M8- 1.25 X 20 C8.8
SCREW HHC M8- 1.25 X 75 C8.8
NUT HEX LO CK M8- 1.25 NY INS
BRACKET TENSIO NER SPRING
CLAMP HOSE #24 B1.06-2.00
NUT HEX LO CK 5/16-24 NY INS
HOSE 9/32 ID (27”LG )
TIE WRAP UL 7.4” X .19” BLK (NO T SHOWN)
ASSY PCB LCL SENSOR (USE WITH I/N 16, P/N
0H1827 O NLY)
BEARING PRESS NOTE:
APPLY LO CTITE 620 BEARING RETAINMENT
COMPOUND TO BEARING SURFACE ON IT EM 37
PRIOR TO PRESSING ITEM 28 ONTO ITEM 37.
ALSO APPLY LOCTITE 620 BEARING RETAINMENT
COMPOUND TO THE OUTSIDE OF 28 PRIO R TO
INSTALLING ITEM 28 INTO ITEM 38.
(1) APPLY MEDIUM STRENGTH BLUE THREAD
LOCKING FLUID TO T HREADS.
(2) INCLUDED W ITH I/N 26.
(3) USE WITH R- PANEL ONLY.
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
0F9794
0G0113
0G1007
0F2830
0F2962
080762
0E0170A
0C2454
0G0776
0G0007
044149
085917
0D2611
0E8816
049721
022097
022473
036797
022259
070006
088775
022241
085917
0F2809
0F2808B
2
1
1
2
2
5
1
4
1
1
1
2
2
1
4
4
4
1
2
2
2
10
10
1
1
MUFFLER 7" X 9" X 18-1/2" 2" IN/OUT
EXHAUST ELBOW 2 1/4 OD 2 1/2OD
BRACKET MUFFLER
MUFFLER BRACKET STIFFENER
MUFFLER STRAP
BOLT U 3/8-16 X 2.62
EXHAUST BLANKET 988MM (C2)
SCREW THF M6-1 X 16 N WA Z/JS
PIPE EXHAUST G2
DIFFUSER EXHAUST WELDMENT
GASKET EXHAUST RING
WASHER LOCK 3/8 SS
SCREW HHC 3/8-16 X 1-3/4 SS
EXHAUST FLANGE 2" PIPE
SCREW HHC M6-1.0 X 35 G8.8 BLK
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
BOLT U 5/16-18 X 2.25
NUT HEX 5/16-18 STEEL
WASHER LOCK M8 SS
WASHER FLAT 3/8 SS
NUT HEX 3/8-16 STEEL
WASHER LOCK 3/8 SS
PIPE EXHAUST CROSSOVER
PIPE EXHAUST MUFFLER OUT
* NOT USED ON OPEN SET.
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