Generac 35 kW QT03524KNSN Standby Generator Manual

Serial Number

STANDBY GENERATOR

OWNER'S MANUAL

2.4L

35/45kW

Models

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!

. 0G5407 t No Par

Catalog No. OMASPE035-045-1

This manual should remain with the unit.

v. C 10/07 Cover115 Re

SECTION PAGE

SAFETY RULES ................................................

1-1

INTRODUCTION .....................................................1-3

Read this Manual Thoroughly ...................................1-3

Operation and Maintenance ......................................1-3

How to Obtain Service ..............................................1-3

IDENTIFICATION RECORD .....................................2-1

EQUIPMENT DESCRIPTION ...................................3-1

Equipment Description ................................................3-1

Engine Oil Recommendations ......................................3-1

Coolant Recommendations...........................................3-1

ENGINE PROTECTIVE DEVICES ............................4-1

High Coolant Temperature Switch ............................4-1

Low Coolant Level Sensor .........................................4-1

Low Oil Pressure Switch ...........................................4-1

RPM Sensor Loss Shutdown .....................................4-1

FUEL SYSTEMS .....................................................5-1

Natural Gas Fuel System ..........................................5-1

Propane Vapor Withdrawal Fuel System....................5-1

LP Fuel System .........................................................5-1

SPECIFICATIONS ...................................................6-1

Engine.......................................................................6-1

Cold Weather Kit .......................................................6-2

Reconfiguring the Fuel System ..................................6-2

GENERAL INFORMATION .......................................7-1

Generator AC Lead Connections ..................................7-1

Alternator Power Winding Connections ........................7-1

INSTALLATION .......................................................8-1

Installation ...................................................................8-1

Preparation Before Start-up .........................................8-1

Generator Set Lubrication ........................................8-1

Prior to Initial Start-up .............................................8-1

Standby Generator Sets

Table of Contents

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

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

Maintenance Owner/Operator Can Perform ................10-3

Check Engine Oil Level ...........................................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

Miscellaneous Maintenance ........................................10-4

Cleaning the Generator ...........................................10-4

Initial Inspection for QT Genset Start-up .....................8-1

Start-up Checklist ........................................................8-2

Preparation for Start-up............................................8-2

SERVICE SCHEDULE ...........................................11-1

TROUBLESHOOTING ...........................................12-1

Troubleshooting Guide ...............................................12-1

NOTES

EXPLODED VIEWS & PARTS LISTS

WIRING DIAGRAMS & SCHEMATICS

A 06/07 Content016 Rev.


Important Safety Instructions

 SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators,

 potential operators, and service and repair technicians for this equipment.





WARNING:

The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

WARNING:





This product contains or emits chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit.

The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit are, therefore, not all inclusive. If a procedure, work method or operating technique is used that the manufacturer does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique utilized does not render the generator unsafe.

DANGER



Despite the safe design of this generator, operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to install, operate or maintain this equipment.



Potentially lethal voltages are generated by these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator.



Parts of the generator are rotating and/or hot during operation. Exercise care near running generators.

1-1



GENERAL HAZARDS



• For safety reasons, the manufacturer recommends that this equipment be installed, serviced and repaired by 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.

v. B 08/07 Safety004 Re



• 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.


1-2

• Generators installed with an automatic transfer switch will crank and start automatically when normal (utility) source voltage is removed or is below an acceptable preset level. To prevent such automatic start-up and possible injury to personnel, disable the generator’s automatic start circuit

(battery cables, etc.) before working on or around the unit. Then, place a “Do Not Operate” tag on the generator control panel and on the transfer switch.

• In case of accident caused by electric shock, immediately shut down the source of electrical power.

If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT

WITH THE VICTIM. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help.

• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving components causing injury.



FIRE HAZARDS



• Keep a fire extinguisher near the generator at all times. Do NOT use any carbon tetra-chloride type extinguisher. Its fumes are toxic, and the liquid can deteriorate wiring insulation. Keep the extinguisher properly charged and be familiar with its use. If there are any questions pertaining to fire extinguishers, consult the local fire department.



EXPLOSION HAZARDS



• Properly ventilate any room or building housing the generator to prevent build-up of explosive gas.

• Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or

EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.

• These generator sets may operate using one of several types of fuels. All fuel types are potentially

FLAMMABLE and/or EXPLOSIVE and should be handled with care. Comply with all laws regulating the storage and handling of fuels. Inspect the unit’s fuel system frequently and correct any leaks immediately. Fuel supply lines must be properly installed, purged and leak tested according to applicable fuel-gas codes before placing this equipment into service.

• Diesel fuels are highly FLAMMABLE. Gaseous fluids such as natural gas and liquid propane

(LP) gas are extremely EXPLOSIVE. Natural gas is lighter than air, and LP gas is heavier than air; install leak detectors accordingly.



INTRODUCTION

Thank you for purchasing this model of the standby generator set product line.

Every effort was expended to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written. However, the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any time without prior notice.

READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, contact the nearest Service Dealer for starting, operating and servicing procedures.

Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING,

CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.

Their definitions are as follows:

DANGER

After this heading, read instructions that, if not strictly complied with, will result in serious personal injury, including death, or property damage.

After this heading, read instructions that, if not strictly complied with, may result in personal injury or property damage.

After this heading, read instructions that, if not strictly complied with, could result in damage to equipment and/or property.

NOTE:

After this heading, read explanatory statements that require special emphasis.

These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the service are essential to preventing accidents.

Four commonly used safety symbols accompany the

DANGER, WARNING and CAUTION blocks. The type of information each indicates is as follows:



This symbol points out important safety information that, if not followed, could endanger personal safety and/or property of others.



This symbol points out potential explosion hazard.



This symbol points out potential fire hazard.



This symbol points out potential electrical shock hazard.

The operator is responsible for proper and safe use of the equipment. The manufacturer strongly recommends that the operator read this Owner's Manual and thoroughly understand all instructions before using this equipment. The manufacturer also strongly recommends instructing other users to properly start and operate the unit. This prepares them if they need to operate the equipment in an emergency.

OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment checked periodically by 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.

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.

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.

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.

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.


1-3


General Information

IDENTIFICATION RECORD

DATA LABEL

Every generator set has a DATA LABEL that contains important information pertinent to the generator. The data label, which can be found attached to the generator’s lower connection box, lists the unit’s serial number and its rated voltage, amps, wattage capacity, phase, frequency, rpm, power factor, etc.

NOTE:

For actual information related to this particular model, please refer to the Manual Drawing Listing located at the end of this manual, or to the data label affixed to the unit.

Generator Model and Serial Number

This number is the key to numerous engineering and manufacturing details pertaining to your unit. Always supply this number when requesting service, ordering parts or seeking information.

Data Label

MANUFACTURING INFORMATION

2-1

A 03/07 Identy 005 Rev.


Equipment Description

EQUIPMENT DESCRIPTION

This equipment is a revolving field, alternating current generator set. It is powered by a gaseous fueled engine operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for 2-pole direct drive units and

2300 - 3000 rpm for quiet drive gear units. See the

Specifications section for exact numbers. The unit comes complete with a sound attenuated enclosure, internally mounted muffler, control console, mainline circuit breaker, battery charger, and protective alarms as explained in the following paragraph.

All AC connections, including the power leads from the alternator, 120 volt battery charger input and control connections to the transfer switch are available in the main connection box.

The generator incorporates the following generator features:

• Rotor and Stator insulation is Class H rated as defined by NEMA MG1-32.6, NEMA MG1-1.66.

The generator is self ventilated and drip-proof constructed.

• The voltage waveform deviation, total harmonic content of the AC waveform and telephone influence factor have been evaluated and are acceptable according to NEMA MG1-32.

ENGINE OIL RECOMMENDATIONS

The unit has been filled with 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).



Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in an engine failure.

NOTE:

For temperatures below 32° F, it is strongly recommended to use the optional Cold Weather Start Kit

(part number listed in the Specification Section).

The oil grade for temperatures below 32° F is 5W-

30 synthetic oil.

COOLANT RECOMMENDATIONS

Use a mixture of half low silicate ethylene glycol base anti-freeze and deionized water. Cooling system capacity is listed in the specifications. Use only deionized water and only low silicate anti-freeze. If desired, add a high quality rust inhibitor to the recommended coolant mixture. When adding coolant, always add the recommended 50-50 mixture.



Do not use any chromate base rust inhibitor with ethylene glycol base anti-freeze or chromium hydroxide (“green slime”) forms and will cause overheating. Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base anti-freeze. Using any high silicate anti-freeze boosters or additives will also cause overheating. The manufacturer also recommends that any soluble oil inhibitor is NOT used for this equipment.

DANGER



Do not remove the radiator pressure cap while the engine is hot or serious burns from boiling liquid or steam could result.



Ethylene glycol base antifreeze is poisonous.

Do not use mouth to siphon coolant from the radiator, recovery bottle or any container. Wash hands thoroughly after handling. Never store used antifreeze in an open container because animals are attracted to the smell and taste of antifreeze even though it is poisonous to them.

B 07/08 Equip001 Rev.

3-1


Engine Protective Devices

ENGINE PROTECTIVE DEVICES

The standby generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant temperature, oil pressure or rpm. For that reason, the engine has several devices designed to protect it against potentially damaging conditions by automatically shutting down the unit when the oil pressure is too low, the coolant temperature is too high, the coolant level is too low, or the engine is running too fast.

NOTE:

Engine protective switches and sensors are mentioned here for the reader’s convenience. Also refer to the applicable control panel manual for additional automatic engine shutdown information.

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.

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.

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.

OVERCRANK SHUTDOWN

After a prespecified duration of cranking, this function ends the cranking if the engine has failed to start. The overcrank LED will turn ON. Turn OFF the

AUTO/OFF/MANUAL switch, then turn switch back to

AUTO to reset the generator control board.

NOTE:

If the fault is not corrected, the overcrank feature will continue to activate.

Approximate Crank Cycle Times

• 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.

RPM SENSOR LOSS SHUTDOWN

If the speed signal to the control panel is lost, engine shutdown will occur.

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.)

A 06/08 EngProt001 Rev.

4-1


Fuel Systems

FUEL SYSTEM

FUEL REQUIREMENTS

The standby generator may be equipped with one of the following fuel systems:

• Natural gas fuel system

• Propane vapor (PV) fuel system

The Manual Drawing Listing that is affixed to the unit includes the “Identification Code,” which may be used to identify the type of fuel system installed on the unit.

Recommended fuels should have a Btu content of at least 1,000 Btu's per cubic foot for natural gas; or at least 2,520 Btu's per cubic foot for LP gas. Ask the fuel supplier for the Btu content of the fuel.

Required fuel pressure for natural gas is 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).

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.

NOTE:

It is the responsibility of the installer to make sure that only the correct recommended fuel is supplied to the generator fuel system. Thereafter, the owner/operator must make certain that only the proper fuel is supplied.

NATURAL GAS FUEL SYSTEM

Natural gas is supplied in its vapor state. In most cases, the gas distribution company provides piping from the main gas distribution line to the standby generator site. The following information applies to natural gas fuel systems.

• Gas pressure in a building is usually regulated by national, state and local codes.

• To reduce gas pressure to a safe level before the gas enters a building, a primary regulator is needed. The natural gas supplier may or may not supply such a regulator.

• It is the responsibility of the gas supplier to make sure sufficient gas pressure is available to operate the primary regulator.

• Gas pressure at the inlet to the fuel shutoff solenoid should not exceed approximately 14 inches water column (0.5 psi). Optimum pressure at the fuel shutoff solenoid is 11 inches water column

(0.4 psi).

5-1

PROPANE VAPOR WITHDRAWAL FUEL SYSTEM

This type of system utilizes the vapors formed above the liquid fuel in the supply tank. Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor state. The vapor withdrawal system is generally best suited for smaller engines that require less fuel. The installer should be aware of the following:

• When ambient temperatures are low and engine fuel consumption is high, the vapor withdrawal system may not function efficiently.

• Ambient temperatures around the supply tank must be high enough to sustain adequate vaporization, or the system will not deliver the needed fuel volume.

• In addition to the cooling effects of ambient air, the vaporization process itself provides an additional cooling effect.

LP LIQUID FUEL SYSTEM

LP is supplied as a liquid in pressure tanks. It is usually made up of propane, butane, or a mixture of the two gases. Propane tends to vaporize readily even at temperatures as low as -20° F (-29° C). However, butane reverts to its liquid state when temperatures drop below 32° F (0° C).

LP in a liquid withdrawal system must be converted to its gaseous state before it is introduced into the engine carburetor. A vaporizer-converter is generally used to accomplish this. In such a converter, heated engine coolant is ported through the converter to provide the necessary heat for conversion of the fuel from a liquid to a gaseous state.

A 06/08 FuelSys001 Rev.


Specifications

SPECIFICATIONS

GENERATOR

Type ............................................................................. Synchronous

Rotor Insulation ................................................................... Class H

Stator Insulation .................................................................. Class H

Total Harmonic Distortion ..........................................................<5%

Telephone Interference Factor (TIF) ..........................................< 50

Alternator Output Leads 3-phase ........................................... 4-wire

Bearings .........................................................................Sealed Ball

Coupling .......................................................................Flexible Disc

Load Capacity (Standby Rating) .......................................35/45kW*

*

NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349,

ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural gas.

Excitation System ....................................................................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

277/480V, 3-phase, 0.8 pf

35/45 121/156 150/175

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

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

Engine Parameters

Rated Synchronous RPM ..............................................60 Hz, 3600

HP at rated kW (35/45kW) ...................................................... 55/71

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%

Engine Lubrication System

Type of Oil Pump ...................................................................... Gear

Oil Filter ............................................... Full Flow Spin-on, Cartridge

Crankcase Oil Capacity ....................................................4 U.S. qts.

6-1

COOLING SYSTEM

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 ft 3 /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)

FUEL SYSTEM

Type of Fuel ......................................... Natural Gas, Propane Vapor

Carburetor ...................................................................... Down Draft

Secondary Fuel Regulator .................................................Standard

Fuel Shut-off Solenoid ........................................................Standard

Operating Fuel Pressure ...................... 5 in. - 14 in. Water Column

Fuel Consumption - ft 3 /hr (Natural Gas/LPV)

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

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

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

Controller .................................................R-200

A 04/07 GenSpec039 Rev.


Specifications

Figure 1 — Interconnections

CONTROL PANEL

GENERATOR

CONNECTION

BOX

N1

N2

23

194

183

178

120 Volt +

Neutral

Grd

Battery

Charger

Input

CIRCUIT

BREAKER

GROUND

TO

ALTERNATOR

NEUTRAL

Transfer Switch

4- # 14 GA

WIRES TO

GENERATOR

CONNECTION

BOX

Gen

N1

N2

23

194

186

178

Utility In

NEUTRAL

Load

Out

TO GENERATOR

CONNECTION BOX

To Generator Control Panel

FRAME RAIL

Ground Level

Concrete Slab

STUB-UP AREA

See Install Dwg for

Dimensions

CIRCUIT BREAKER SIZE

KW VOLTS / AMPS LUG SIZE

45 240 1 Ø 200 #6 to 300 mcm

45 208 3 Ø 175 #6 to 300 mcm

45 480 3 Ø 80 #6 to 300 mcm

COLD WEATHER KIT

For cold climates, optional cold weather kit (part number 0F6148) is recommended. The kit includes:

• Battery Warmer

• 4” Junction Box with hardware

• 6 qt. pack 5W-30 synthetic oil (engine)

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:

A 04/07

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.

GenSpec039 Rev.

6-2

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 pipe onto the outlet port of the demand regulator.

10. Reverse steps 1-4 in this procedure to reactivate the demand regulator.

Figure 6.2 — Reconfigure the Fuel System

DANGER



Serious injury or damage may occur if not configured properly. Please consult an Authorized

Dealer with any questions.



GENERATOR AC LEAD CONNECTIONS

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.

Voltage codes apply to the type of stator assembly installed on a particular generator.

ALTERNATOR POWER WINDING

CONNECTIONS

FOUR-LEAD, SINGLE-PHASE STATOR

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

3-PHASE ALTERNATORS ("Y" CONFIGURATION)

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.

The rated voltage between each circuit breaker terminal and the neutral point 00 is either 277V or 120V depending on the model.

Figure 7.2 — Stator Power Winding

Connections - 3-phase, 120/208V (12 Lead)

E1

S7 S1

S10

S12

S4

S5

L - L

E3

S9

S3

S6 S11

S2

E2

L - N

S8



S1

E1

S3

E3

S4

S7

S6

S9

S12

S10

S11

S8

S5

L - N

L - L v. 0 04/06

S2

E2

ACConn005 Re

7-1



S1 E1

INTERNAL

CONNECTIONS

E3 S3

S6 S4

NEUTRAL

S5

L-L

S2 E2

L-N



3-PHASE ALTERNATORS

("DELTA" CONFIGURATION)

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.

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.



v. 0 04/06 ACConn005 Re

7-2


Installation

INSTALLATION

Refer to the separate “Installation Guide” supplied with the unit.

PREPARATION BEFORE START-UP

The instructions in this section assume that the standby generator has been properly installed, serviced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor.

Be sure to read the “Safety Rules”, as well as all other safety information in this manual, before attempting to operate this (and related) equipment.

Before starting the generator for the first time, the installer must complete the following procedures. For follow-up maintenance information and/or service intervals, please refer to the “Maintenance” section and the “Service Schedule”.

TRANSFER SWITCH

If this generator is used to supply power to any electrical system normally powered by an electric utility, the National Electrical Code requires that a transfer switch be installed. The transfer switch prevents electrical backfeed between two different electrical systems. (For additional information, see the applicable transfer switch manual for this unit.) The transfer switch, as well as the generator and other standby components, must be properly located and mounted in strict compliance with applicable codes, standards and regulations.

FUEL SYSTEM

Make sure the fuel supply system to the generator (a) delivers the correct fuel at the correct pressure and (b) is properly purged and leak tested according to code.

No fuel leakage is permitted. See “Specifications” for more information.

GENERATOR SET LUBRICATION

Check the engine crankcase oil level before operating and add oil to the proper level – the dipstick “FULL” mark. Never operate the engine with the oil level below the dipstick “ADD” mark. See “Specifications” and “Engine Oil Recommendations”.

NOTE:

This engine is shipped from the manufacturer with “break-in” oil. This oil should be changed after 30 hours of operation.

8-1

PRIOR TO INITIAL START-UP



Prior to initially starting the generator, it must be properly prepared for use. Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids (oil, coolant, fuel, etc.) may result in an engine failure.

ENGINE COOLANT

Have the engine cooling system properly filled with the recommended coolant mixture. Check the system for leaks and other problems. See “Specifications” and “Coolant” sections.

BELT TENSION

Check-the engine-fan belt tension and condition prior to placing the unit into service and at recommended intervals. Belt tension is correct when a force of approximately 22 pounds (10 kg), applied midway between pulleys, deflects the belt about 3/8- to 5/8inch (10 to 16 mm).

ELECTRICAL SYSTEM

Make sure the generator is properly connected to an approved earth ground.

Make sure the generator battery is fully charged, properly installed and interconnected, and ready for use.

NOTE:

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.

INITIAL INSPECTION FOR GENSET

STARTUP

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.

C 01/07 Install002 Rev.


Installation

• Battery charger connection to 120 VAC.

• Communication wires connected between transfer switch and generator (HTS only).

• Unit secured to pad.

START-UP CHECKLIST



Before working on the generator, ensure the following:

• The AUTO/OFF/MANUAL switch is in the OFF position.

• The 120VAC supply to the battery charger is switched OFF.

PREPARATION FOR START-UP

• Ensure that the 120VAC circuit breaker to the battery charger is open.

• Remove the fuse from the the control panel. Open the front door of the control box and remove the

15 Amp ATO fuse in the lower left-hand corner of the control box.

• Connect the battery cables to the battery. Attach negative battery cable last.

• Close the 120VAC circuit breaker to the battery charger.

• Measure the voltage at the battery before and after the charger is turned on.

• Verify all AC electrical connections are tight at the circuit breaker and transfer switch.

• Visually inspect entire area looking for loose paper, plastic wrappings, leaves, etc.

• Check all hoses clamps fittings for leaks or damage.

• Check all electrical plugs throughout the generator. Ensure each plug is seated correctly and fully inserted into its receptacle.

• Verify the AUTO/OFF/MANUAL switch is in OFF position.

• Open the valve to the engine fuel line.

• Bleed the fuel system of air. (necessary for long fuel lines).

• Open the generator main line circuit breaker.

• Connect a manometer to the gas line and record the static pressure. It must be as listed in the

Specifications.

• Insert the fuse into the control panel.

• Move the AUTO/OFF/MANUAL switch to the 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.

C 01/07 Install002 Rev.

8-2


Operation

GENERATOR CONTROL AND

OPERATION

Refer to the appropriate control panel operator’s manual for this unit.

OPERATING UNIT WITH MANUAL

TRANSFER SWITCH

If the generator was installed in conjunction with a transfer switch capable of manual operation only, the following procedure applies. A manually operated transfer switch is one that will not provide automatic start-up and does not include an intelligence circuit.

ENGINE START-UP AND TRANSFER

For additional information, refer to the applicable control panel manual for this unit, as well as any literature pertaining to the specific transfer switch.

DANGER



The Maintenance Disconnect Switch and the

AUTO/OFF/MANUAL switches (if so equipped) must be set properly, or the generator will crank and start as soon as the utility power to the transfer switch is turned off. Refer to applicable control panel and transfer switch manuals for more information.



Do not proceed until certain that utility source voltage is available to the transfer switch and the transfer switch main contacts are set to

UTILITY.



Do not attempt manual operation until all power supplies to the transfer switch have been positively turned off, or extremely dangerous - possibly lethal - electrical shock will result.



Transfer switch enclosure doors should be kept closed and locked. Only authorized personnel should be allowed access to the transfer switch interior. Extremely high and dangerous voltages are present in the transfer switch.

In order to transfer load from the utility source to the generator, follow these directions:

• Turn OFF or disconnect the utility power circuit to the transfer switch, using the means provided

(such as the utility source main line circuit breaker).

• Set the transfer handle to its UTILITY (NORMAL) position with load circuits connected to the utility power supply.

• Set the standby generator’s main line circuit breaker to its OFF (or OPEN) position.

• Start the generator.

9-1



Do not crank the engine continuously for longer than 30 seconds, or the heat may damage the starter motor.

• Let engine stabilize and warm up.

• Check all applicable instrument and gauge readings. When certain that all readings are correct, move the transfer switch manual handle to its

STANDBY (GENERATOR) position, i.e., load circuits supplied by the generator.

• Set the standby generator’s main line circuit breaker to its ON (or CLOSED) position.

• Load circuits are now powered by the standby generator.

RETRANSFER AND SHUTDOWN

For additional information, refer to the applicable control panel manual for this unit, as well as any literature pertaining to the specific transfer switch.

To transfer the load back to the utility power source and shut down the generator, follow these directions:

• Set the standby generator’s main line circuit breaker to its OFF (or OPEN) position.

• Manually move the transfer switch handle to its

UTILITY (NORMAL) position, i.e., load circuits connected to the utility.

• Turn ON the utility power supply to the transfer switch, using the means provided (such as the utility power source main line circuit breaker).

• Let the generator run at no-load for a few minutes to stabilize internal temperatures.

• Shut down the generator.

OPERATING UNIT WITH AUTOMATIC

TRANSFER SWITCH

If the generator has been installed with an automatic transfer switch, such as an RTS, HTS, or GTS-type transfer switch, the engine may be started and stopped automatically or manually.

NOTE:

Refer to the applicable manual for your transfer switch and to “Transfer Switch Start Signal

Connections”. In addition, please note the dangers under “Engine Start-up and Transfer.”

0 08/05 Oper001 Rev.


Maintenance

MAINTENANCE PERFORMED BY

SERVICE FACILITIES



Before working on the generator, ensure the following:

• The AUTO/OFF/MANUAL switch is in the OFF position.

• The 15A fuse has been removed from the control box.

• The 120VAC supply to the battery charger is switched OFF.

EVERY THREE MONTHS

1. Check battery condition.

2. Inspect and test fuel system.

3. Check transfer switch.

4. Inspect exhaust system.

5. Check engine ignition system.

6. Check fan belts.

ONCE EVERY SIX MONTHS

1. Test Engine Safety Devices (low oil pressure, low coolant level, high coolant temperature).

ONCE ANNUALLY

1. Test engine governor; adjust or repair, if needed.

2. Clean, inspect generator.

3. Flush cooling system.

FIRST 30 OPERATING HOURS

1. Change engine "break-in" oil and filter.

FIRST 100 OPERATING HOURS

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.

EVERY 500 OPERATING HOURS

1. Service air cleaner.

3. Check engine DC alternator.

COOLING SYSTEM

Air intake and outlet openings in the generator compartment must be open and unobstructed for continued proper operation. This includes such obstructions as high grass, weeds, brush, leaves and snow.

Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down. (See the installation diagram.)



The exhaust system parts from this product get extremely hot and remains hot after shutdown.

High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such materials may ignite and burn from the heat of the exhaust system.

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.



If a circuit breaker opens or a fuse element melts, find the cause of the overload before resetting the circuit breaker or replacing the fuse.

CHECKING FLUID LEVELS

CHECK ENGINE OIL

Check engine crankcase oil level (Figure 10.1) at least every 20 hours of operation, or prior to use.

Figure 10.1 - Oil Dipstick and Oil Fill Cap

Oil Fill Cap

Oil

Dipstick

E 07/08 Maint012 Rev.

10-1

E 07/08


Maintenance

• 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.

BATTERY FLUID

Check battery electrolyte fluid based on the

Maintenance Schedule. Fluid should cover separators in all battery cells. If fluid level is low, add distilled water to cover tops of separators. DO NOT USE

TAP WATER IN BATTERY.

ENGINE COOLANT

Check coolant level in coolant recovery bottle. See

Specifications.

• 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.

MAINTENANCE OWNER/

OPERATOR CAN PERFORM

CHECK ENGINE OIL LEVEL

Refer to “Checking Fluid Levels”.

CHECK BATTERY

• See “Checking Fluid Levels”.

• Check battery cables for condition, tightness, corrosion or damage. Clean, tighten or replace as necessary.

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.

INSPECT COOLING SYSTEM

• Inspect engine cooling system. See “Maintenance

Schedule”.

• Check hoses for damage, deterioration, leaks, etc.

Correct any discrepancies found.

• Check hose clamps for tightness.

CHECK ENGINE COOLANT LEVEL

See “Checking Fluid Levels”.

PERFORM VISUAL INSPECTION

Complete a thorough visual inspection of the entire engine-generator monthly. Look for obvious damage, loose, missing or corroded nuts, bolts and other fasteners. Look for fuel, oil or coolant leaks.

INSPECT EXHAUST SYSTEM

Inspect the exhaust system at least once every three months. Check all exhaust system pipes, mufflers, clamps, etc. for condition, tightness, leaks, security, damage.

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.

INSPECT ENGINE GOVERNOR

Visually inspect electronic governor.

DANGER



Do not attempt to adjust the governor. Only qualified service facilities should adjust the governor. Excessively high operating speeds are dangerous and increase the risk of personal injury. Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life. Correct rated frequency and voltage are supplied only at the proper governed speed. Some connected electrical load devices may be damaged by incorrect frequency and/or voltage. Only qualified service technicians should adjust the governed speed.

Maint012 Rev.

10-2


Maintenance

CHANGING ENGINE OIL

Refer to maintenance performed by service facilities for engine oil and filter change frequencies.

Drain the oil while the engine is still warm from running. This means warm up the engine, shut it down and drain immediately as follows:

1. Remove OIL DRAIN HOSE from its retaining clip.

2. Loosen and remove OIL DRAIN HOSE CAP. Drain oil completely into suitable container.

3. When all oil has drained, install and tighten OIL

DRAIN HOSE CAP, and re-install into its retaining clip.

4. Turn OIL FILTER (Figure 10.2) counterclockwise and remove. Properly dispose of old filter.

Figure 10.2 – Oil Filter

Figure 10.3 – Engine Air Cleaner

Air Cleaner

Oil

Filter

(Doors Removed for Clarity)

SPARK PLUGS

Reset the spark plug gap or replace the spark plugs as necessary (Figure 10.4).

1. Clean the area around the base of the spark plugs to keep dirt and debris out of the engine. Clean by scraping or washing using a wire brush and commercial solvent. Do not blast the spark plugs to clean.

2. Remove the spark plugs and check the condition.

Replace the spark plugs if worn or if reuse is questionable. See the “Service Schedule” section for recommended inspection.

3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 1.07-1.17 mm (0.042-

0.046 inch) by carefully bending the ground electrode (Figure 10.4).

Figure 10.4 – Setting the Spark Plug Gap

SET PLUG GAP AT 1.07 - 1.17 mm

(0.042 - 0.046 inch)

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).



After refilling the crankcase with oil, always 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).

See the “Service Schedule,” for air cleaner maintenance.

10-3

Every year, have a service facility drain, flush and refill the cooling system. See “Specifications” for cooling system recommendations.

E 07/08 Maint012 Rev.


Maintenance

MISCELLANEOUS MAINTENANCE

CLEANING THE GENERATOR

Keep the generator as clean and as dry as possible.

Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation resistance.

Periodically clean generator exterior surfaces. A soft brush may be used to loosen caked on dirt. Use a vacuum system or dry, low pressure air to remove any accumulations of dirt. The generator is housed inside an all-weather enclosure, clean the enclosure with a soft, damp cloth or sponge and water.

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:

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.

DANGER



Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing tools or equipment near the battery.



Battery electrolyte fluid is an extremely 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.

• DO NOT use jumper cables and a booster battery to crank or start the generator engine.

• DO NOT recharge a weak battery while it is installed in the generator. Remove battery from generator and recharge in a well-ventilated area, away from fuel vapors, sparks, heat or flames.

• Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns. DO

NOT permit fluid to contact eyes, skin, clothing, painted surfaces, wiring insulation, etc. If any battery fluid is spilled, flush the affected area with clear water immediately.

• Always wear safety glasses, rubber apron and gloves when handling a battery.

• Batteries give off explosive hydrogen gas while charging. The gas can form an explosive mixture around the battery for several hours after charging.

Any spark, heat or flames can ignite the gas and cause an explosion which can shatter the battery, causing blindness or other serious injury.

BATTERY MAINTENANCE

The battery should be inspected per the "Scheduled

Maintenance" section. The following procedure should be followed for inspection:

E 07/08

1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary.

Maint012 Rev.

10-4



Be sure the AUTO/OFF/MANUAL switch is set to the OFF position, before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected.



Be sure the 120VAC power supply to the battery is turned OFF, or sparking may occur at the battery posts as the cables are attached and cause an explosion.

BATTERY REPLACEMENT

Unit DOES NOT include battery.

When supplying or replacing the battery, the recommended number and type of battery is listed in the

Specifications Section.

The BCI number should be located directly on the battery.

REPAIR PARTS

NOTE:

NOTE:

The later portion of this manuals consists of exploded views, parts lists and electrical data pertaining to this generator set.


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.


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.


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.


v. C 06/08 SrvSchd001 Re

11-1



Maintenance Level 1 Level 2 Level 3 Level 4 Level5

Tasks

RecomTask Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.

to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Datemonthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) annually/ Initials)

10 hrs. 30 hrs. 50 hrs. 100 hrs. 250 hrs.

1. Disable the unit from operating per the first page warning.

Check the engine oil level. Adjust as necessary.

Check the engine coolant level.

Adjust as necessary.

4. coolant thermal protection level.

Correct as necessary.

5. gas delivery system for leaks and correct pressure on gas engine driven units. Tighten connections as necessary.

Check the air inlets and outlets for debris. Clean as necessary.

electrolyte level and specific gravity if accessible. Adjust as necessary.

Check the battery posts, cables, and charger for loose connections, corrosion, and proper operation.


wiring for loose connections, corrosion, and damage. Correct as necessary.


11-2




Tasks



250 hrs.

10. Check the engine accessory drive belts and fan coupling device if equipped for correct tension, wear, weather cracking, and damage. Replace as necessary.

11. Check the engine valve clearance/ 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

10 hrs. 30 hrs. 50 hrs. 100 hrs. operating conditions.


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.

v. C 06/08

11-3

SrvSchd001 Re




Tasks



10 hrs. 30 hrs. 50 hrs. 100 hrs. 250 hrs.

18. Start and exercise the unit at full rated load

(use a load bank if the site load is not enough) for at least 2 hours looking for leaks, loose connections or components, and abnormal operating conditions.


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


Troubleshooting

TROUBLESHOOTING GUIDE

PROBLEM CAUSE

Engine won’t crank.

Engine cranks but won't start

Engine starts hard, runs rough.

1. 15 amp fuse blown.

2. Loose or corroded or defective battery cables.

3. Defective starter contactor.

4. Defective starter motor.

5. Dead or Defective Battery.

6. 5 amp fuse blown.

1. Out of fuel.

2. Fuel solenoid (FS) is defective

3. Open Wire #14A from Engine Control circuit board.

4. Spark plugs defective.

5. Door on tank not closed.

1. Flame arrestor (air cleaner) plugged or damaged.

2. Plugged fuel line.

3. Defective spark plugs.

4. Fuel pressure incorrect.

Engine starts then shuts down. 1. Engine oil level is low.

2. Engine is overheated.

3. Defective Low Oil Pressure Switch

4. Defective Coolant Temperature Switch

5. Defective Control Module circuit board.

6. Coolant Level is Low.

7. Defective Low Coolant Level Switch

AUTO/OFF/MANUAL Switch at OFF, 1. Defective AUTO/OFF/MANUAL switch engine continues to run 2. Open/disconnected wire #15A between

AUTO/OFF/MANUAL switch and Control

Module circuit board.

3. Defective Control Module circuit board

No AC output from generator.

CORRECTION

1. Replace fuse.

2. Tighten, clean or replace battery cables as necessary.

3. Replace contactor.*

4. Replace starter motor.*

5. Remove, change or replace battery.

6. Replace fuse.*

1. Replenish fuel.

2. Replace solenoid.*

3. Reconnect wire.

4. Clean, regap or replace plugs.

5. Close door on tank.

1. Clean or replace as needed.

2. Unclog fuel line.

3. Clean, regap or replace plugs.

4. Confirm fuel pressure to regulator is as recommended in SPECIFICATIONS.

1. Check oil and add oil as needed.

2. Check cooling system for leaks.

3. Replace switch.*

4. Replace switch.*

5. Replace board.*

6. Repair leak - Add coolant.

7. Replace Switch.*

1. Replace switch.*

2. Reconnect/close wire.

1. Check main line circuit breaker.

2. Check circuit breaker & fuses.

3. Transfer switch set to NORMAL position

3. Replace board.*

1. Reset to ON or CLOSED.

2. Reset and replace, if necessary.

3. Set to GENERATOR position.

5. Thermal circuit breaker open. 5. Auto-reset - Wait 5 min. and attempt restart.

*Contact the nearest Authorized Dealer for assistance.

0 08/05 lsht001 Rev.

T rb

12-1


Notes


Notes


Notes


Notes

D

E

F

G

H

47

1)

A

C

(3) 39

(4) 40

(4) 41

(4) 42

(4) 43

(4) 44

(4) 45

(4) 46

32

33

34

35

36

37

D

E

F

G

2)

A

C

J

K

L

23

24

(1) 26

27

28

29

30

31

14

(2) 15

(2) 16

17

18

19

20

21

6

7

8

(1) 9

10

11

12

13

4

5

1

2

3

0F6145

0F3328

0D5552

0D5553

0D5554

0D5556

0D9693

0F0492

048927

023897

022152

022158

081008

077043J

051713

0F6156

029289

047411

0G0770

0G5952

036943

023897

022152

022158

0C2454

055934D

0C2454

029289

0F1733

0F3138

0D5572

0D5573

0D5574

0D5575

0D5576

0F0199

081320

022473

022097

057073

0D5466

0A7822

022237

022241

049226

0C2266

0C2454

022473

022097

0D4698

0F4464

025433

024469

067210A

0D6029

0F3137

0F3188

0F3189

023484N

0F6366B

0F6366A

043180

022264

0C3990

057701

022155

0C2428

0F3824

0A9457

-

-

-

1

1

-

1

4

4

4

1

1

1

1

1

1

PAN CB CONN BOX

STAND RH CONTROL

STAND LH CONTROL

BUSHING SNAP SB-2.5-31

XFMR DUAL 120V/16V (FOR 120/240V & 277/480V UNITS)

XFMR DUAL 104V/16V (FOR 120/208V UNITS)

2

2

WASHER FLAT M4

WASHER LOCK #8-M4

2 SCREW PHTT M4-0.7 X 10 ZYC

REF BLOCK TERM 20A 8 X 6 X 1100V

4 WASHER LOCK #6

4

1

1

SCREW PHTT #6-32 X 1/2 ZYC

DECAL UTIL SENSE/CUST CONN

DECAL NEUTRAL

2 JUNCTION BLOCK 3/8-16

REF BUS BAR NEUTRAL BLOCK 390

REF LUG SLDLSS 600/250-1/0 X 1/4-28

2 WASHER LOCK 3/8

2 NUT HEX 3/8-16 STEEL

6

6

8

WASHER LOCK M5

SCREW PHTT M5-0.8 X 16 ZYC

SCREW THF M6-1 X 16 N WA Z/JS

8

4

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

REF BLOCK TERM 20A 6 X 3 X 1100V

1

1

1

1

4

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

2

1

1

1

1

2

4

2

1

1

4

1

1

2

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


CLAMP VINYL 1.06 X .406 Z

1

4

4

4

4

-

-

-

A/R SEAL WEATHER .45"DIA

UL CIRCUIT BREAKER (ED)

1

1

-

COVER ED CB SHORT STND

CB 0050A 3P 480V S ED4 LL





INSULATOR CB S (ED-3P)

SCREW RHM #10-32 X 4-1/2


WASHER LOCK #10


9

1



1 DECAL CUSTOMER CONNECT INSIDE

UL CIRCUIT BREAKER (FD)

COVER CB CONN BOX

CB 0150A 3P 600V S FD6 LL





INSULATOR CB FD FRAME 30MIL

SCREW SHC 1/4-20 X 4.5 G8.8 NZ


WASHER LOCK M6-1/4

J

K

F

G

H

D

E

L

4)

A

C

H

J

K

C

D

E

F

G

L

3)

A

H

J

K

0F1733

0F8135

0E7283

0E7284

0E3664

074908

0F8140

036261

0C2454

029289

0F1733

022127

0C2454

029289

0F1733

0F3329

0D5577

0F2353

022770

022473

022097

022127

0C2454

029289

4

9

1

1

2

4

4

4

4

9

1

NUT HEX 1/4-20 STEEL




UL CIRCUIT BREAKER (JD+LD)

1 COVER JD/LD CB SHRT STAND

CB 0300A 3P 600V S JD6 LL

INSULATOR CIRCUIT BR. JD/LD

SCREW RHM 1/4-20 X 3


WASHER LOCK M6-1/4





UL CIRCUIT BREAKER (QN)

1 COVER QN FRM CB

- CB 0150A 2P 240V S QN2 LL

-

1

2

CB 0175A 2P S QN2 LL 240V

BASE, QN CIRCUIT BREAKER

SCREW HHTT M5-0.8 X 10 BP

1

4

COVER QN CB DISH

RIVET POP .125 X .275 SS

11 SCREW THF M6-1X16 N WA Z/JS

1

1


DECAL CUSTOMER CONNECT INSIDE

(1) ITEM INCLUDED WITH HARNESS

(2) ITEM INCLUDED WITH 0D5464B

(3) ITEM USED WITH EARLY MODEL 208V UNITS ONLY

(4) ITEMS USED ON 4.2L MODELS ONLY.

H

J

K

(2) L

D

E

F

G

(2) V

(1) W

X

7)

A

C

N

P

(2) R

(2) S

(2) T

(2) U

(2) F

(2) G

(2) H

(2) J

K

L

(2) M

(2) W

(2) X

Y

(2) M

N

P

(1) S

T

U

V

D

E

A

B

C

Q

6)

L

M

N

P

H

J

K

D

E

F

G

5)

A

C

0F8843

W/CB

0G3259

0F4187

0F4166$

0F1733

042419

023897

022152

022158

0C2454

029289

052647

053640

038150

022264

022471

029289

0F1733

022129

0F8432

0F8432A

0C2454

0F8451

049897

022145

045771

046526

W/CB

0A7822

W/CB

023334

022097

022473

W/CB

W/CB

0G3259

0F1733

0F4185

058306

0F4165$

0F4143

0F4148

0F4149

0F4151

0G5247$

0G5250

0G4478

0F4186

0F4186AGS0R

036261

0F8137

0E7994

0F8136

036261

022473

022097

022127

0F8139

0C2454

022237

048527

029289

022770

2

2

1

2

2

1

9

UL CIRCUIT BREAKER (QJ-2P)

1

-

COVER QJ 2P FRM CB

CB 0225A 240V 2P S QJ22

1

4

2

2

COVER QJ 2P CB DISH



WASHER LOCK M6-1/4


INSUL CB 2P QJ


WASHER LOCK 3/8

SCREW SHC 3/8-16 X 3/4 G8.8 NZ


SCREW RHM 1/4-20 X 3


UL CIRCUIT BREAKER (225AF) (2P & 3P)

1

3

COVER CB C2-C4 (225AF)

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)

4

COVER CB DISH 225AF (2P)


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


6/9 WASHER LOCK M8-5/16

1

1

INSULATOR CB 225AF (3P)

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

UL CIRCUIT BREAKER (400AF)

1 COVER CB C2-C4 400AF

REF CIRCUIT BREAKERS 400A FRAME

1

4

4

4


SCREW RHM 10-32 X 4


WASHER LOCK #10

4

9



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

6

6

6

TERM COVER CB

SCREW HHC 1/4-28 X 1/2 G5

WASHER LOCK M6-1/4


2/3 SCREW SHC M10-1.5 X 25 G12.9

2/3 WASHER LOCK M10

1 DECAL TERMINAL SHOCK HZD BI

N

H

J

K

L

M

E

F

G

C

D

9)

A

F

G

H

B

C

D

E

8)

A

0A2077

040532

0C3990

0E7890

0E6002

022859

0G0008

023897

022152

022158

0F1733

029289

0C2454

0D5466

039287

022145

022129

045771

045335

083896

0A7822

0G1968

0G1970

NEUTRAL BLOCK 390 / 200-400A

2 BUS BAR NEUTRAL BLOCK 390

1

1

1

1

SCREW HHC M8-1.25 X 45 G8.8 FT


WASHER LOCK M8-5/16

NUT HEX M8-1.25 G8 YEL CHR

2

2

SCREW HHC 1/4-28 X 3/4 G5

WASHER LOCK 1/4-M6 SS

1 LUG SLDLSS 600/250-1/0 X 1/4-28

UL CIRCUIT BREAKER (BQ)

1

-

6

1

1

-

1

-

2

COVER BQ CIR BREAKER CPL 3P

COVER BQ CIR BREAKER CPL 2P

CB 0125A 2P 240V S BQ2 LL

CB 0100A 3P 240V S BQ3 LL

SCREW PHTT M4-0.7 X 10 ZYC

BRKT CB MTG BACK

MTG TRACK BQ SIEMENS CB 3P

SCREW RHM #10-32 X 3/4

BRKT BQ CB STANDOFF

6

6

6

1

1


WASHER LOCK #10



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

26

18

19

20

21

22

23 *

24 *

25

9

10

11

12

13

6

7

8

14

15

16

17

3

4

5

2

1

072879

0F8408

046526

0C3993

022264

047248

070892

0G0588

077043A

0G6567

0H0201

0C9708

SEE ENGINE EV

SEE ENGINE EV

0F5767B

0E5706

0F7874

0G0587

038150

023454

077043E

04576100BU

052646

043123

051779

0A2601

0G0059

0G0183

0G0184

0G1932

0G2098

0G2099

0G2100

0G3736

0G3737

0G3738

0G6104

0G6563

0G6565

0G6566

0F9677

0G0056

0G0959

0G1155

0G1931

0G2101

0G3734

0G6562

0G6564

0F9664

0G0057

0G0058

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

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

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

1

4

1

1

4

1

1

1

4

4

4

1

1

1

REF

REF

REF

STR 390 35JD1 CPL

STR-2390--60JD2 CPL

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



1

1

1

1

4

4

4

4

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

1

* ROTOR REPLACEMENT PARTS

CONDUIT FLEX .38" ID (60”)

COMPONENTS INCLUDED IN 0G3364E

1 0F1823A 1

2 0F3078 1

3 0F2606 1

4

5

036261

0E7358

6

4

RIVET POP .125 X .275 SS

SCREW PPPH HI-LO #4-24 X 3/8

6 052777 3

7

8

10

0G1303D

0F1262

0F1264

1

4

1

ASSY PCB R-200 3600 RPM

HOLDER, FUSE WICKMANN 178.6150

9 0F1263 1 SIDE

ADPTR,LH SIDE WICKMAN 178.6192

11

12 067680 1

13

0F1725C

0E6875A

1

2

ASSY PCB 2AMP 12V UL BATT CHGR

VOLTAGE

RELAY, 12VDC C FORM W/DIODE

14

15

055911

0F5459

1

1

BLOCK TERM 20A 12 X 6 X 1100V

DECAL CPL CONTROL PANEL FUSES

16 0E3161 1 ASSY PCB BOSCH GOV DRIVER

17 0F5090 1

18 0F5462 1

19

20

21

0A5062J

029673

048467

4

1

1

SPACER 9.5H 3.2 ID

DIO BRIDGE 25A 600V

CIRCT BRK 7 X 1 ETA 46-500-P

22 0F1958 1

23 082573 1 SWITCH RKR DPST 125V SPD

SWITCH ON-OFF-ON

27 0F6305A 1

28 0F5886 3

SEAL

29 051713 12

COVER

SCREW HHPM M5-0.8 X 12

30 049226 12

31

32

0F5752F

0F5884

1

2

RES WW 15R 5% 25W QK CONN

SCREW PHTT M3.5-0.6 X 10

33

34

35

36

0F5896

0C2265

0C3990

091526

2

4

2

4

SCREW PHTT M3.5-0.6 X 16

SCREW PHTT M4-0.7 X 12 ZYC


SCREW PPHM M5-0.8 X 12 ZNC

37

38

39

051716

079224

075476

9

2

2

NUT HEX M5-0.8 G8 CLEAR ZINC

SCREW PPHM M5-0.8 X 30 SS

SCREW PPHM M4-0.7 X 16

WASHER

41 022264 2

42

43 043182 7

44

051715

051714

2

7

NUT HEX M4-0.7 G8 YEL CHR

LOCK


45

46

47

A

B

0F3192

0E7403C

0F9785

056739

022287

1

1

1

SUPPORT ANGLE PCB

FUSE ATO TYPE 15 AMP (BLUE)

HARN 3600RPM R200 CONTROL PNL

COMPONENTS INSTALLED PER THIS DRAWING

1

2

RELAY SOLENOID 12VDC PNL MNT

SCREW HHC 1/4-20 X 3/4 G5

D 022097 2

E

G

022127

WASHER

NUT HEX 1/4-20 STEEL

F 0F6145 A/R

0F2627A

2

1

LOCK

WEATHER

COVER CONTROL PANEL SIDE

H

WASHER

K 051713 4

L

091526

0G3545

4

1


FLAT

DANGER HIGH VOLTAGE (SPANISH)

0F9597A

045764

062963

022302

022131

065852

0F9597

022129

026204

022145

045771

0F9596

0F9596A

0F9517

052860

052251

052257

052252

052259

052891

0536210410

042909

047411

055414

022447

022097

022473

049813

022261

21

22

23

24

17

18

19

20

25

26

27

29

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

1

1

4

1

4

4

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

5

1

5

5

5

5

1

4

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


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





SPACER ENGINE MOUNT (2.4L G1)

SPACER LH ENGINE MOUNT (2.4L G2)

14

15

16

17

9

10

11

12

7

8

5

6

3

4

1

2

0F3408B

0F3411

025507

052212

046526

022131

050331A

050331

038805Y

03880400AE

045771

022129

0F3976

0C2454

022145

077483

1

1

REF

REF

1

4

REF

REF

1

1

REF

REF

REF

REF

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


BATTERY POST COVER RED +

BATTERY POST COVER BLACK -

CABLE BATTERY BLACK #1 X 18.00

CABLE BATT RED #1 X 18.00



BOOT CONTACTOR CABLES

SCREW THF M6-1 X 16 N WA Z/JS


BATTERY 12VDC 75-AH 26

0E6586

0E0519A

0C8127

049815

022127

062974

0G0190

037561

(1) 6

7

8

1

2

3

4

5

1

1

1

4

1

1

1

1

GASKET BOSCH 32 & 40

ADAPTER CARBURETOR W/PVC CONN

ELEMENT AIR CLEANER



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).

0D2244M

0F9420

0E9747

0G1472A

0G1476

0G0707

0G0950

0F9583

0G0792

0G0792A

0G1501

0F9501

0G0952

0D3488S

022097

022473

043116

026073A

052243

0A8258

0G0664

0G1502

047290

049340

045757

0G0951

0G3910

0F9965E

0G0788

0G2750

049721

026925

0F2776

052203

0F2776D

0G7313

063076

0G1394

052830

025507

062963

049821

022129

0D6029

0A6751

0E0502

022145

045771

022131

049813

046525

058306

0G0408

046526

039414

0G0149

0E9868A

0F3217

042574

0A8584

0F4612

057772

057765

043790

0C7649

069860E

(1) 53

54

55

56

57

59

(1) 60

47

48

49

50

51

52

(1) 36

37

38

39

(3) 40

(1) 44

45

46

30

31

32

33

34

35

61

62

63

(3) 64

65

(3) 66

67

22

23

25

26

27

28

29

14

15

16

17

18

19

20

21

7

8

9

10

11

12

13

1

2

3

4

5

(2) 6

1

1

3

1

1

2

1

REF

3

1

3

2

15

1

1

7

3

26

3

7

7

2

5

3

1

1

1

1

1

1

1

1

1

1

1

1

3

4

ENGINE 2.4L MITSUBISHI 4G64

WASHER LOCK M10


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


SWITCH HI-TEMP 245D X 3/8 NPT (R-PANEL)

TEMPERATURE SENDER DELPHI (H-PANEL)


NUT HEX M8-1.25 G8 CLEAR ZINC


NUT HEX M6 X 1.0 G8 YEL CHR


SCREW SHC M8-1.25 X 25 G12.9

2

1

1

7

10

4

WASHER LOCK M6-1/4



PLUG STD PIPE 1/4 STEEL SQ HD


SCREW HHC M8-1.25 X 25 G10.9

1(REF) OIL FILTER G2 ENGINE

1 COIL PACK

1

1

1

HOSE 3/8 ID SINGLE BRAID (15” LG)



1(REF) GASKET EXHAUST MANIFOLD

1 EXHAUST MANIFOLD G2 (MACHINE) (25KW, 35KW & 45KW)

1 FLEX PLATE 2 POLE 2.4L G2

2

1

1

ASSY MAGPICKUP(3/8-24 MALE)

ADAPTER ENGINE 2.4L MACHINE

STARTER, 12 VOLT

1 CAM SENSOR PIN ASSY

1(REF) COVER CAM GEAR G2 REWORKED

1 MANIFOLD INTAKE

1(REF) GASKET INTAKE MANIFOLD

1 SPACER 2.4L G2 FLEX PLATE

1 SHIELD HEAT G2

1

1

SHIELD HEAT SML

BRACKET COIL PACK

1 ADAPTER 2.4L CRANKSHAFT MACH

1(REF) POLY V-BELT G2 (3600 RPM)

1 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


BRACKET, SIGNAL CONDITIONER


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

0G68030ST03

0F2608

0F5263

046526

059981

0F2776A

0F5050A

0F2573

0F4011

0G56820ST03

0G2990

7

9

10

11

12

4

(1) 5

6

1

2

3

1

1

1

1

1

5

4

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"

031971

0F4496

042911

0F2872

022304

022195

022196

0F8651

070015

0F9867

0F2461

022145

022129

039414

082774

0G0795

0F2862

0F2560

022131

0E2507

035685

0F2561

0C8145

052250

0C7043

022473

0C8146

022097

076749

048031C

0G0816

049813

052644

0C8566

0C2454

090283

080713

0G4376

0G56830ST03

039253

051698

049820

0G67930ST03

099502

0C8165

029032

36

37

38

39

40

(1) 41

42

43

28

29

(1) 30

31

32

33

34

35

19

20

21

23

(1) 24

25

26

(2) 27

13

14

15

16

17

18

50

51

52

53

54

55

56

57

58

59

44

45

46

47

48

49

16

10

1

1

1

1

1

1

1

1

9

1

1

1

1

2

8

2

12

8

4

16

1

2(REF)

1

2

1

1

1

4

3

1

2

1

1

1

2

1

2

1

16

2

1

1

8

1

SPRING TENSION CPL

PULLEY V-BELT 4" FLANGED


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


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 1/2-13 X 2" G8

WASHER FLAT 1/2 ZINC

WASHER LOCK 1/2


SCREW HHFC M8-1.25 X 20 W/M6

NUT HEX LOCK 5/16-18 NY INS SS

SHAFT FAN DRIVE

RETAINER BEARING


WASHER LOCK M8-5/16


KEY WOODRUFF 4 X 19D

HOSE LOWER RADIATOR G2

HOSE UPPER RADIATOR G2


SPACER .5 X 1.5 X .25 STL/ZINC

SCREW HHFC M6-1.0 X 20 G8.8


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.

20

21

22

23

15

16

17

18

19

9

10

11

13

14

5

6

7

1

2

3

4

32

24

26

27

28

29

30

047527

0D1509

050279

050280

0F2119

0E6586

0E4394

0E4395

040105

057753B

0G4573C

0G4573B

0F7790E

0F7790H

026915

075580

0F6390C

0F6390B

039253

022145

022129

045771

0E8286

026812

0F8379

057823

059057

0E7121

022097

046580

035685

0F6155

047290

057823

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

2

1

2

2

2

2

1

1

1

2

2

2

1

1

1

4

4

NIPPLE CLOSE 3/4 X 1.375

FLANGE FUEL INLET

REGULATOR ASSY 2.4L (25KW)

REGULATOR ASSY 2.4L (35KW & 45KW)



WASHER LOCK M8-5/16


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)


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


CLAMP HOSE #10 .56-1.06

RECONFIGURING THE FUEL SYSTEM

Note: All models are configured to run on natural gas from the factory.



2. Remove the carburetor fuel hose from the outlet port of the demand regulator (See Detail “A”).





7. Remove the LP fuel jet (loosen counter clockwise) from the jet keeper port on the side of the regulator housing.

Note: The jet sizes are stamped on the individual jets. The larger jet size is used for running on NG.

Install this jet into the outlet port in the regulator casting.

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.


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.

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

21

22

23

24

25

17

18

19

20

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

4

4

2

1

1

2

1

1

1

4

2

5

1

2

2

1

2

10

10

1

1

2

2

4

1

* NOT USED ON OPEN SET.

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)


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



BOLT U 5/16-18 X 2.25


WASHER LOCK M8 SS

WASHER FLAT 3/8 SS



PIPE EXHAUST CROSSOVER

PIPE EXHAUST MUFFLER OUT

21

22

23

24

25

26

27

28

15

16

17

18

19

20

6

7

8

9

10 *

11

12

13

14

1

2

3

4

5

35

36

37

38

39

40

29

30

31

32

33

34

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

2

2

10

26

2

1

2

3

1

1

2

2

1

2

21

1

2

2

2

1

1

1

1

54

2

2

4

REAR WRAP C2 CPL


DOOR C2


SCREW TH-FRM M6 W/CAP SHKPRF W

DISCHARGE DUCT LH & RH SIDE C2

FRONT CORNERS C2

DISCHARGE CENTER DUCT C2


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 LOCK M6-1/4


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

4

6

1

2

4

2

INSULATION DUCT

RETAINER INSULATION (820)

INSULATION DUCT SIDES

RETAINER INSULATION (450)

WASHER SELF LOCKING DOME #8-32

INSULATION LOWER SPLITTER

1

1

1

2

2

2


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. MATERIAL COLOR

0XXXXXSN STEEL TAN

0XXXXXAN ALUMINUM TAN

0XXXXXSG STEEL GRAY

0XXXXXAG ALUMINUM 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.

4.)

A

B

C

1.)

A

B

2.)

A

B

3.)

A

B

C2 UNITS

0F9832

0F9832GGS0R

0C2454

C3 UNITS

0F9832B

0F9832KGS0R

0C2454

C4 UNITS

0F9832A

0C2454

C5 UNITS

0F9832C

0F9832D

0F9832EGS0R

0F9832HGS0R

0F9832JGS0R

0F9832FGS0R

0C2464

1

1

1

1

1

1

3

1

3

1

1

3

1

1

4

SHIELD CONN BOX C2

SHIELD CONTROL STAND C2














v. A 04/07 BackPg001 Re

EXPLODED VIEW: EV AIR CLEANER

DRAWING #: 0F9809

ITEM PART# QTY. DESCRIPTION

1

2

3

4

5

(1) 6

0E6586

0E0519A

0C8127

049815

022127

062974

1

1

1

4

1

1



ELEMENT AIR CLEANER



STUD TH 1/4-20 X 4-1/2 G2 ZNC

7

8

9

0G0190

025870

022097

1

1

1


NUT WING 1/4-20

WASHER LOCK M6-1/4

WASHER FLAT 1/4-M6 ZINC 10 022473 1

(1) APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THREADS.

GROUP D

REVISION: J-8527-B

DATE: 5/7/14

Page 2 of 2

0E6586

0E0519A

0C8127

049815

022127

062974

0G0190

037561

(1) 6

7

8

1

2

3

4

5

1

1

1

4

1

1

1

1



ELEMENT AIR CLEANER



STUD TH 1/4-20 X 4-1/2 G2 ZNC


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).

30

31

32

24

25

26

27

29

18

19

20

21

22

23

12

13

14

15

16

17

9

10

11

6

7

8

1

2

3

4

5

022129

026204

022145

045771

0F9596

0F9596A

052212

0C2454

0H5718

0F9517

052860

052251

052257

052252

052259

052891

0536210410

042909

047411

055414

022447

022097

022473

049813

022261

0F9597A

045764

062963

022302

022131

065852

0F9597

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 FLAT M6-1/4 ZINC

NUT HEX M6 -1.0 G8 YEL CHR


SUPPORT LH ENGINE 2.4L


SCREW HHC M10-1.25 X 30 G8.8

WASHER LOCK 7/16


SPRING CLIP HOLDER .37-.62

SUPPORT RH ENGINE 2.4L





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

3

1

1

1

1

1

1

1

5

1

1

1

4

5

1

1

1

1

1

2

1

1

1

4

4

1

1

4

4

4

4

14

15

16

17

9

10

11

12

7

8

5

6

3

4

1

2

0F3408B

0F3411

025507

052212

046526

022131

050331A

050331

038805Y

03880400AE

045771

022129

0F3976

0C2454

022145

077483

1

1

REF

REF

1

4

REF

REF

1

1

REF

REF

REF

REF

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


BATTERY POST COVER RED +

BATTERY POST COVER BLACK -

CABLE BATTERY BLACK #1 X 18.00

CABLE BATT RED #1 X 18.00



BOOT CONTACTOR CABLES



BATTERY 12VDC 75-AH 26

COMPONENTS INCLUDED IN 0G3364E

1 0F1823A 1

2 0F3078 1

3 0F2606 1

4

5

036261

0E7358

6

4

RIVET POP .125 X .275 SS

SCREW PPPH HI-LO #4-24 X 3/8

6 052777 3

7

8

0G1303D

0F1262

1

4

ASSY PCB R-200 3600 RPM

HOLDER, FUSE WICKMANN 178.6150

9 0F1263 1

10 0F1264 1 ADPTR,LH SIDE WICKMAN 178.6192

11

13

14

0F1725C

0E6875A

055911

1

2

1

ASSY PCB 2AMP 12V UL BATT CHGR

12 067680 1 VOLTAGE

RELAY, 12VDC C FORM W/DIODE

BLOCK TERM 20A 12 X 6 X 1100V

31

32

33

34

35

36

37

15

16

0F5459

0E3161

1

1

DECAL CPL CONTROL PANEL FUSES

ASSY PCB BOSCH GOV DRIVER

ASSY

18 0F5462 1

19

20

21

0A5062J

029673

048467

4

1

1

SPACER 9.5H 3.2 ID

DIO BRIDGE 25A 600V

CIRCT BRK 7 X 1 ETA 46-500-P

22 0F1958 1

23 082573 1 SWITCH RKR DPST 125V SPD

24 0E4494 1

DECAL,

26 0F6305 2

ON-OFF-ON

27 0F6305A 1

28 0F5886 3 SCREW HHPM M5-0.8 X 12

WASHER

30 049226 12

0F5752F

0F5884

0F5896

0C2265

0C3990

091526

051716

4

2

4

9

1

2

2

RES WW 15R 5% 25W QK CONN

SCREW PHTT M3.5-0.6 X 10

SCREW PHTT M3.5-0.6 X 16





46

47

A

B

38

39

079224

075476

2

2

SCREW PPHM M5-0.8 X 30 SS

SCREW PPHM M4-0.7 X 16

WASHER

41 022264 2

42

44

45

051715

051714

0F3192

2

7

1


43 043182 7 LOCK


SUPPORT ANGLE PCB

0E7403C

0F9785

056739

022287

1

1

FUSE ATO TYPE 15 AMP (BLUE)

HARN 3600RPM R200 CONTROL PNL

COMPONENTS INSTALLED PER THIS DRAWING

1

2

RELAY SOLENOID 12VDC PNL MNT

SCREW HHC 1/4-20 X 3/4 G5

D 022097 2

E

F 0F6145 A/R

G

022127

0F2627A

2

1


WEATHER

COVER CONTROL PANEL SIDE

H

WASHER

K 051713 4

L

091526

0G3545

4

1


FLAT

DANGER HIGH VOLTAGE (SPANISH)

7

8

5

6

3

4

1

2

0G0045 (XX)

0C2454

0F5849 (XX)

087233

0E3257

0F5852 (XX)

0F9833 (XX)

0F5851 (XX)

2

1

4

2

1

54

2

2

REAR WRAP C2 CPL


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

9

10 *

11

049813

077992

0F9835 (XX)

2

21

1

NUT HEX M6 X 1.0 G8 YEL CHR

NUT HEX LOCK M6-1.0 SS NY INS

ROOF C2

12 0F2786 2

13 0F2785 1

14 0F3364 1

C4

SPLITTER LOWER C4

15 0F4880 2

16 0F5049 2

STINGER

SUPPORT SPLITTER LH C2

TAB

17 0F4487A 1

PULL

ACCESS

WASHER FLAT 1/4-M6 ZINC 18

20

022473

022127

3

19 022097 1

1

LOCK


21 0F3072 10

22 078115 44

24 0F4051A 1

WASHER

23 0F4051 2 DOOR

INSULATION ROOF TOP

25 0F5048D 2 LATCH

GASKET EXTRUDED TRIM (440.64” LG) 26 0E5968 1

27 0F3760K 2

28 0F3760E 2

29 0F4051C 2 DUCT

RETAINER INSULATION (820) 30

32

33

0F3890B

0F3890

0F3890A

10

31 0F4051B 2

4

3

DUCT

RETAINER INSULATION (450)

RETAINER INSULATION (740)

34 0F3760L 1

35

36

37 022447 2

38 0F4051E 1

39

042568

0912970094

0F8869D 1

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. MATERIAL COLOR

2

2

LOWER

SCREW HHC M6-1.0 X 20 G8.8

ASSY WIRE 14 AWG 34.8" GRN/YEL

REAR

KEY VISE-ACTION LATCH SLOT CIR

0XXXXXSN STEEL TAN

0XXXXXAN ALUMINUM TAN

0XXXXXSG STEEL GRAY

0XXXXXAG ALUMINUM 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

DRAWING #: 0G1151

ITEM PART# QTY. DESCRIPTION

GROUP E

13

14

15

18

19

20

21

22

23

24

26

1

2

3

4

5

6

7

9

10

11

G057823

G059057

G047527

0F2119

0E6586

0E4394

0E4395

0K9704

057753B

0G4573C

0G4573B

0F7790E

0F7790H

0E7121

G022097

G026915

G075580

0F6390C

0F6390B

G039253

G022145

G022129

G045771

0E8286

G026812

G035589

1

1

1

4

1

1

1

1

1

1

1

1

2

1

1

2

2

2

2

1

2

2

2

1

1

1

NIPPLE CLOSE 3/4 X 1.375

FLANGE FUEL INLET

REGULATOR ASSY 2.4L (25KW)

REGULATOR ASSY 2.4L (35KW & 45KW)



WASHER LOCK M8-5/16


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


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)


WASHER LOCK M6-1/4

27

28

29

30

32

33

34

35

36

G046580

G035685

0F6155

G047290

G057823

0K2339

0K2340

0K3795

0H3632

4

2

1

1

2

1

1

1

1

SCREW SHC M6-1.0 X 45 G12.9

CLAMP HOSE #28 1.32-2.25

HARNESS CPL FUEL JUMPER


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 37 0L5884 1

RECONFIGURING THE FUEL SYSTEM

Note: All models are configured to run on natural gas from the factory.



2. Remove the carburetor fuel hose from the outlet port of the demand regulator (See Detail “A”).





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.


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

DRAWING #: 0G1141

APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION

GROUP D

28

29

30

31

32

33

34

35

(1) 36

37

38

39

(3) 40

(1) 44

14

15

16

17

18

19

20

21

22

23

25

26

27

1

2

3

4

5

6

7

8

9

10

11

12

13

0H1951

0H1619

G046526

G039414

0G0149

0E9868A

0F3217

G042574

0A8584

0F4612

G057772

0A4707L

G043790

0C7649

069860E

G063076

0G1394

G052830

G025507

G062963

G049821

G022129

0D6029

0A6751

0E0502

G022145

G045771

G022131

G049813

G046525

G058306

G022097

G022473

G043116

026073A

G052243

0A8258

0G0664

0G1502

G047290

G049340

G045757

0G0951

1

1

1

1

1

1

1

1

1

1

1

1

3

4

1

3

3

26

3

7

7

2

5

1

1

7

3

1

3

4

2

1

9

2

7

7

10

1(REF)

1

1

1

1

1(REF)

ENGINE 2.4L G2 4G64 CERT

ENGINE 2.4L G2 CERTIFIED

WASHER LOCK M10


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 3/8NPT X M14-1.5


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


SWITCH HI-TEMP 245D X 3/8 NPT (R-PANEL)

TEMPERATURE SENDER DELPHI (H-PANEL)






SCREW SHC M8-1.25 X 25 G12.9

WASHER LOCK M6-1/4





SCREW HHC M8-1.25 X 25 G10.9

OIL FILTER G2 ENGINE

COIL PACK




GASKET EXHAUST MANIFOLD

57

59

(1) 60

61

62

63

(3) 64

65

(3) 66

67

69

70

45

46

47

48

49

50

51

52

(1) 53

54

55

56

0G3910

0F9965E

0D2244M

G0F9420

0G7461

0G1472A

0G1476

0G0707

0G8488

0G0950

0F9583

0G0792

0G0792A

0G1501

0F9501

0G0952

0D3488S

0G0788

0H8572

G049721

G026925

0F2776

G052203

0F2776D

0G9378

0G10080125

0G3823

1

1

2

1

1

1

1(REF)

1

1

1(REF)

1

1

1

1

1

1(REF)

1

1

1

3

1

1

2

1

1(REF)

1

1

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 MOTOR 12V

CAM SENSOR PIN ASSY

COVER CAM GEAR G2 REWORKED

MANIFOLD INTAKE (USE HOSE 0G0816)

MANIFOLD INTAKE (MACHINED) (USE HOSE 0H1546)

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)



SCREW HHC M6-1.0 X 35 G8.8 BLK


BRACKET, SIGNAL CONDITIONER


BRACKET SIGNAL CONDITONER

DECAL SORE EPA CERTIFICATION

ROD ASSY OIL LEVEL GAUGE

O-RING SIZE 9.0MM X 2.0MM NITR

71

72

73

74

0G10080288

0G10080289

0G10080290

0G10080291

1

1

1

1

1(REF)

CABLE, SPARK PLUG, NO.1




PLUG TAPER (2) 75 0G9520

(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

12

13

14

(2) 15

(2) 16

17

18

19

20

21

23

24

(1) 26

(1) 9

10

11

4

5

6

7

8

1

2

3

(3) 39

(4) 40

(4) 41

(4) 42

(4) 43

(4) 44

(4) 45

(4) 46

47

1)

A

C

27

28

29

30

31

32

33

34

35

36

37

2)

A

G

H

J

K

L

C

D

E

F

G

D

E

F

0F3824

0A9457

057073

0D5466

0A7822

022237

022241

049226

0C2266

0C2454

022473

022097

0D4698

0F3137

0F3188

0F3189

023484N

0F6366B

0F6366A

043180

022264

0C3990

057701

022155

0C2428

0F4464

025433

024469

067210A

0D6029

081008

077043J

051713

0F6156

029289

047411

0G0770

0H0348

036943

023897

022152

022158

0C2454

055934D

0F6145

0F3328

0D5552

0D5553

0D5554

0D5556

0D9693

0F0492

048927

023897

022152

022158

0C2454

029289

0F1733

0F3138

0D5572

0D5573

0D5574

0D5575

0D5576

0F0199

081320

022473

022097

1

1

1

2

2

2

1

1

1

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


REF BLOCK TERM 20A 8 X 6 X 1100V

4 WASHER LO CK #6

4 SCREW PHTT #6- 32 X 1/2 ZYC

1

1

2

DECAL UT IL SENSE/CUST CONN

DECAL NEUTRAL

JUNCTION BLOCK 3/8-16

REF BUS BAR NEUTRAL BLOCK 390

REF LUG SLDLSS 600/250-1/0 X 1/4-28

2

2

6

WASHER LO CK 3/8


WASHER LO CK M5

6

8



8

4

WASHER FL AT 1/4-M6 ZINC

WASHER LO CK M6- 1/4

REF BLOCK TERM 20A 6 X 3 X 1100V

4

2

2

1

1

2

1

4

1

1

1

1

1

2

1

1

4

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 W IRE 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

1

1


CLAMP VINYL 1.06 X .406 Z

A/R SEAL W EATHER .45" DIA

UL CIRCUIT BREAKER (ED)

1

1

-

COVER ED CB SHO RT STND

CB 0050A 3P 480V S ED4 LL

CB 0060A 3P 480V S ED4 LL

1

4

4

4

-

-

-

1

4

4

-

-

-

CB 0070A 3P 480V S ED4 LL

CB 0090A 3P 480V S ED4 LL

CB 0125A 3P 480V S ED4 LL

INSULATOR CB S (ED-3P)

SCREW RHM #10-32 X 4- 1/2

WASHER FL AT #10 ZINC

9

1

4

4

WASHER LO CK #10



TAPE ELEC 1/2 FO AM (AS REQ’D)

1

UL CIRCUIT BREAKER (F D)

1

DECAL CUSTOMER CONNECT INSIDE

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

INSULATOR CB FD FRAME 30MIL

SCREW SHC 1/4-20 X 4.5 G8.8 NZ

WASHER FL AT 1/4-M6 ZINC

WASHER LO CK M6- 1/4

F

G

H

4)

A

C

J

K

L

D

E

F

G

H

L

3)

A

C

D

E

H

J

K

J

K

0C2454

029289

0F1733

0F8135

0E7283

0E7284

0E3664

074908

0F8140

036261

0C2454

022127

0C2454

029289

0F1733

0F3329

0D5577

0F2353

022770

022473

022097

022127

029289

0F1733

4

9

1


SCREW THF M6- 1 X 16 N W A Z/JS

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

2

4

CB 0300A 3P 600V S JD6 LL

INSULATOR CIRCUIT BR. JD/LD

SCREW RHM 1/4- 20 X 3

4

4

4

W ASHER FLAT 1/4-M6 ZINC

W ASHER LOCK M6-1/4


1

-

-

1

2

9

1

SCREW THF M6- 1 X 16 N W A Z/JS



UL CIRCUIT BREAKER (QN)

COVER QN FRM CB

CB 0150A 2P 240V S QN2 LL

CB 0175A 2P S QN2 LL 240V

BASE, QN CIRCUIT BREAKER


1

4

11

COVER QN CB DISH

RIVET POP .125 X .275 SS

SCREW THF M6- 1X16 N WA Z/JS

1

1



(1) ITEM INCL UDED W IT H HARNESS

(2) ITEM INCL UDED W IT H 0D5464B

(3) ITEM USED W IT H EARLY MO DEL 208V UNITS ONLY

(4) ITEMS USED ON 4.2L MO DELS O NL Y.

H

J

K

(2) L

D

E

F

G

(2) V

(1) W

X

7)

A

C

N

P

(2) R

(2) S

(2) T

(2) U

(2) F

(2) G

(2) H

(2) J

K

L

(2) M

(2) W

(2) X

Y

(2) M

N

P

(1) S

T

U

V

D

E

A

B

C

Q

6)

L

M

N

P

H

J

K

D

E

F

G

5)

A

C

0F8843

W/CB

0G3259

0F4187

0F4166$

0F1733

042419

023897

022152

022158

0C2454

029289

052647

053640

038150

022264

022471

029289

0F1733

022129

0F8432

0F8432A

0C2454

0F8451

049897

022145

045771

046526

W/CB

0A7822

W/CB

023334

022097

022473

W/CB

W/CB

0G3259

0F1733

0F4185

058306

0F4165$

0F4143

0F4148

0F4149

0F4151

0G5247$

0G5250

0G4478

0F4186

0F4186AGS0R

036261

0F8137

0E7994

0F8136

036261

022473

022097

022127

0F8139

0C2454

022237

048527

029289

022770

2

2

1

2

2

1

9

UL CIRCUIT BREAKER (QJ-2P)

1

-

COVER QJ 2P FRM CB

CB 0225A 240V 2P S QJ22

1

4

2

2

COVER QJ 2P CB DISH

RIVET POP .125 X .275 SS




INSUL CB 2P QJ


WASHER LOCK 3/8

SCREW SHC 3/8-16 X 3/4 G8.8 NZ


SCREW RHM 1/4-20 X 3


UL CIRCUIT BREAKER (225AF) (2P & 3P)

1

3

COVER CB C2-C4 (225AF)

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)

4

COVER CB DISH 225AF (2P)

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


6/9 WASHER LOCK M8-5/16

1

1

INSULATOR CB 225AF (3P)

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

UL CIRCUIT BREAKER (400AF)

1 COVER CB C2-C4 400AF

REF CIRCUIT BREAKERS 400A FRAME

1

4

4

4


SCREW RHM 10-32 X 4

WASHER FLAT #10 ZINC

WASHER LOCK #10

4

9



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

6

6

6

TERM COVER CB

SCREW HHC 1/4-28 X 1/2 G5



2/3 SCREW SHC M10-1.5 X 25 G12.9

2/3 WASHER LOCK M10

1 DECAL TERMINAL SHOCK HZD BI

N

H

J

K

L

M

E

F

G

C

D

9)

A

F

G

H

B

C

D

E

8)

A

0A2077

040532

0C3990

0E7890

0E6002

022859

0G0008

023897

022152

022158

0F1733

029289

0C2454

0D5466

039287

022145

022129

045771

045335

083896

0A7822

0G1968

0G1970

NEUTRAL BLOCK 390 / 200-400A

2 BUS BAR NEUTRAL BLOCK 390

1

1

1

1

SCREW HHC M8-1.25 X 45 G8.8 FT




2

2

SCREW HHC 1/4-28 X 3/4 G5

WASHER LOCK 1/4-M6 SS

1 LUG SLDLSS 600/250-1/0 X 1/4-28

UL CIRCUIT BREAKER (BQ)

1

-

6

1

1

-

1

-

2

COVER BQ CIR BREAKER CPL 3P

COVER BQ CIR BREAKER CPL 2P

CB 0125A 2P 240V S BQ2 LL

CB 0100A 3P 240V S BQ3 LL


BRKT CB MTG BACK

MTG TRACK BQ SIEMENS CB 3P

SCREW RHM #10-32 X 3/4

BRKT BQ CB STANDOFF

6

6

6

1

1


WASHER LOCK #10



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

18

19

20

21

22

23 *

24 *

12

13

14

15

16

17

8

9

10

11

5

6

7

3

4

25

26

27

2

1

0H1299

0H1300

0H1301

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

0G0059

0G0183

0G0184

0G1932

0G2098

0G2099

0G2100

0G3736

0G3737

0G3738

0G6104

0G6563

0G6565

0G6566

0G6567

0H0201

0F9677

0G0056

0G0959

0G1155

0G1931

0G2101

0G3734

0G6562

0G6564

0F9664

0G0057

0G0058

4

4

1

1

1

4

4

4

4

1

1

4

4

REF

1

1

1

1

1

4

1

1

1

1

REF

REF

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

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

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 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 36JD1 CPL

ASSY STR 390 36 GD1 CPL

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


KEY WOODRUFF #E

CONDUIT FLEX 1.0" ID (35” LG)

STUD M14-2.0 570 G5 ZINC

WASHER FLAT M14

WASHER LOCK M14


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


WASHER LOCK #8-M4

BALL BEARING-45 MM

SLIP RING MACHINED

1

1

1

GUARD REAR BEARING CARRIER

CONDUIT FLEX .38" ID (60”)

TRIM VINYL BLACK 1/8GP (16.5”LG)

* ROTOR REPLACEMENT PARTS

4.)

A

B

C

1.)

A

B

2.)

A

B

3.)

A

B

C2 UNITS

0F9832

0F9832GGS0R

0C2454

C3 UNITS

0F9832B

0F9832KGS0R

0C2454

C4 UNITS

0F9832A

0C2454

C5 UNITS

0F9832C

0F9832D

0F9832EGS0R

0F9832HGS0R

0F9832JGS0R

0F9832FGS0R

0C2464

1

1

1

1

1

1

3

1

3

1

1

3

1

1

4

SHIELD CONN BOX C2

SHIELD CONTROL STAND C2














0G68030ST03

0F2608

0F5263

046526

059981

0F2776A

0F5050A

0F2573

0F4011

0G56820ST03

0G2990

7

9

10

11

12

1

2

3

4

(1) 5

6

1

1

1

1

1

5

4

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"

0F2862

0F2560

022131

0E2507

0H1827

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

035685

0F2561

0C8145

052250

0C7043

022473

0C8146

022097

076749

048031C

031971

0F4496

042911

0F2872

022304

022195

022196

0F8651

13

14

15

16

46

47

48

49

50

51

36

37

38

39

40

(1) 41

42

43

44A

44B

45

52

53

54

55

56

57

58

59

(3) 60

(3) 61

23

(1) 24

25

26

(2) 27

28

29

(1) 30

31

32

33

34

35

17

18

19

20

21

1

1

4

1

1

1

1

1

1

16

2

1

1

1

16

10

1

1

1

1

1

8

1

2

1

3

1

2

2

1

9

1

2

1

8

2

12

8

4

16

1

2(REF)

1

1

1

1

2

1

1

9

SPRING TENSION CPL

PULL EY V-BELT 4" FLANGED


PRO BE COOLANT LEVEL 3/8 NPTF (USE W ITH

HARNESS P/N 0G 4882)

PRO BE COOLANT LEVEL 3/8- 18NPTF ( USE W ITH

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


SCREW HHC 5/16-24 X 1.124


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


SCREW HHFC M8-1.25 X 20 W /M6

NUT HEX LO CK 5/16-18 NY INS SS

SHAFT FAN DRIVE

RETAINER BEARING



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


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 W RAP 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.

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

21

22

23

24

25

17

18

19

20

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

4

4

2

1

1

2

1

1

1

4

2

5

1

2

2

1

2

10

10

1

1

2

2

4

1

* NOT USED ON OPEN SET.

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)


PIPE EXHAUST G2

DIFFUSER EXHAUST WELDMENT

GASKET EXHAUST RING


SCREW HHC 3/8-16 X 1-3/4 SS

EXHAUST FLANGE 2" PIPE

SCREW HHC M6-1.0 X 35 G8.8 BLK



BOLT U 5/16-18 X 2.25


WASHER LOCK M8 SS

WASHER FLAT 3/8 SS



PIPE EXHAUST CROSSOVER

PIPE EXHAUST MUFFLER OUT

Generac 35 kW QT03524KNSN Standby Generator Manual

Serial Number

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!

WARNING:

WARNING:

GENERAL HAZARDS

ELECTRICAL HAZARDS

FIRE HAZARDS

EXPLOSION HAZARDS

INTRODUCTION

READ THIS MANUAL THOROUGHLY

OPERATION AND MAINTENANCE

HOW TO OBTAIN SERVICE

IDENTIFICATION RECORD

DATA LABEL

Generator Model and Serial Number

Data Label

EQUIPMENT DESCRIPTION

ENGINE OIL RECOMMENDATIONS

COOLANT RECOMMENDATIONS

ENGINE PROTECTIVE DEVICES

HIGH COOLANT TEMPERATURE SWITCH

LOW COOLANT LEVEL SENSOR

LOW OIL PRESSURE SWITCH

OVERCRANK SHUTDOWN

Approximate Crank Cycle Times

OVERSPEED SHUTDOWN

RPM SENSOR LOSS SHUTDOWN

DC FUSES

FUEL SYSTEM

FUEL REQUIREMENTS

NATURAL GAS FUEL SYSTEM

PROPANE VAPOR WITHDRAWAL FUEL SYSTEM

LP LIQUID FUEL SYSTEM

SPECIFICATIONS

GENERATOR

ENGINE

COOLING SYSTEM

FUEL SYSTEM

ELECTRICAL SYSTEM

Figure 1 — Interconnections

COLD WEATHER KIT

RECONFIGURING THE FUEL SYSTEM

Figure 6.2 — Reconfigure the Fuel System

GENERATOR AC LEAD CONNECTIONS

ALTERNATOR POWER WINDING

CONNECTIONS

FOUR-LEAD, SINGLE-PHASE STATOR

Figure 7.1 — Four-lead, Single-phase Stator

3-PHASE ALTERNATORS ("Y" CONFIGURATION)

Figure 7.2 — Stator Power Winding

Connections - 3-phase, 120/208V (12 Lead)

Figure 7.3 — Stator Power Winding

Connections - 3-phase, 277/480V (12 Lead)

Figure 7.1 — Stator Power Winding

Connections - 3-phase, 346/600V (6 Lead)

3-PHASE ALTERNATORS

("DELTA" CONFIGURATION)

Figure 7.5 — Stator Power Winding

Connections - 3-phase, 120/240V (12 Lead)

INSTALLATION

PREPARATION BEFORE START-UP

TRANSFER SWITCH

FUEL SYSTEM

GENERATOR SET LUBRICATION

PRIOR TO INITIAL START-UP

ENGINE COOLANT

BELT TENSION

ELECTRICAL SYSTEM

INITIAL INSPECTION FOR GENSET

STARTUP

START-UP CHECKLIST