Generac 35 kW QT03524AVANR Standby Generator Manual

Generac 35 kW QT03524AVANR Standby Generator Manual
Serial Number
QT
2.4L
35kW
Models
STANDBY GENERATOR
OWNER'S MANUAL
A new standard of reliability
This manual should remain with the unit.
Cover055 Rev. 0 04/06
Part No. 0G1144
Standby Generator Sets
Table of Contents
INTRODUCTION .....................................................1-3
Read this Manual Thoroughly ...................................1-3
Operation and Maintenance ......................................1-3
How to Obtain Service ..............................................1-3
IDENTIFICATION RECORD .....................................2-1
Data Label ................................................................2-1
EQUIPMENT DESCRIPTION ...................................3-1
Equipment Description ................................................3-1
Engine Oil Recommendations ......................................3-1
Coolant Recommendations...........................................3-1
ENGINE PROTECTIVE DEVICES ............................4-1
High Coolant Temperature Switch ............................4-1
Low Coolant Level Sensor.........................................4-1
Low Oil Pressure Switch ...........................................4-1
Overcrank Shutdown ................................................4-1
Overspeed Shutdown ................................................4-1
RPM Sensor Loss Shutdown.....................................4-1
DC Fuse ....................................................................4-1
FUEL SYSTEMS .....................................................5-1
Fuel Requirements ....................................................5-1
Natural Gas Fuel System ..........................................5-1
Propane Vapor Withdrawal Fuel System....................5-1
LP Fuel System .........................................................5-1
SPECIFICATIONS ...................................................6-1
Generator .................................................................6-1
Engine.......................................................................6-1
Cooling System .........................................................6-1
Fuel System ..............................................................6-1
Electrical System ......................................................6-1
Cold Weather Kit .......................................................6-2
Reconfiguring the Fuel System ..................................6-2
GENERAL INFORMATION.......................................7-1
Generator AC Lead Connections ..................................7-1
Four-lead, Single-phase Stator ..................................7-1
Alternator Power Winding Connections ........................7-1
3-phase Alternators ..................................................7-1
INSTALLATION.......................................................8-1
Installation ...................................................................8-1
Preparation Before Start-up .........................................8-1
Transfer Switch ........................................................8-1
Fuel System ..............................................................8-1
Generator Set Lubrication ........................................8-1
Prior to Initial Start-up .............................................8-1
Engine Coolant .........................................................8-1
Belt Tension ..............................................................8-1
Electrical System ......................................................8-1
Initial Inspection for QT Genset Start-up .....................8-1
Start-up Checklist ........................................................8-2
Preparation for Start-up............................................8-2
Start-up Inspection ...................................................8-2
OPERATION ...........................................................9-1
Generator Control and Operation ................................9-1
Operating Unit with Manual Transfer Switch ...............9-1
Engine Start-up and Transfer ...................................9-1
Retransfer and Shutdown .........................................9-1
Operating Unit with Automatic Transfer Switch ...........9-1
MAINTENANCE.....................................................10-1
Maintenance Performed by Authorized
Service Facilities .....................................................10-1
Every Three Months ...............................................10-1
Once Every Six Months ...........................................10-1
Once Annually.........................................................10-1
First 100 Operating Hours ......................................10-1
Every 500 Operating Hours ....................................10-1
Every 800 Operating Hours ....................................10-1
Exhaust Manifold Procedure ......................................10-1
Intake Manifold Procedure .........................................10-1
Cylinder Head Procedure ...........................................10-1
Cooling System ..........................................................10-2
Overload Protection for Engine DC
Electrical System ....................................................10-2
Checking Fluid Levels ................................................10-2
Check Engine Oil ....................................................10-2
Battery Fluid ...........................................................10-2
Engine Coolant .......................................................10-2
Maintenance Owner/Operator Can Perform ................10-3
Check Engine Oil Level ...........................................10-3
Check Battery .........................................................10-3
Exercise System ......................................................10-3
Inspect Cooling System ...........................................10-3
Check Engine Coolant Level....................................10-3
Perform Visual Inspection .......................................10-3
Inspect Exhaust System ..........................................10-3
Check Fan Belt........................................................10-3
Inspect Engine Governor ........................................10-3
Changing Engine Oil ...............................................10-3
Changing the Engine Air Cleaner ............................10-3
Spark Plugs ............................................................10-4
Coolant Change .......................................................10-4
Miscellaneous Maintenance ........................................10-4
Cleaning the Generator ...........................................10-4
Battery ....................................................................10-4
Battery Maintenance ...............................................10-4
Battery Replacement ...............................................10-5
SERVICE SCHEDULE ...........................................11-1
TROUBLESHOOTING ...........................................12-1
Troubleshooting Guide...............................................12-1
NOTES
EXPLODED VIEWS & PARTS LISTS
WIRING DIAGRAMS & SCHEMATICS
WARRANTY
Content004 Rev. 0 09/05
SECTION
PAGE
SAFETY RULES ................................................ 1-1
Safety Rules
INTRODUCTION
shock hazard.
This symbol points out potential electrical
Thank you for purchasing this model of the Stationary Emergency
Generator set product line.
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.
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
OPERATION AND MAINTENANCE
If any portion of this manual is not understood, contact the nearest Authorized Service Dealer for starting, operating and servicing
procedures.
It is the operator's responsibility to perform all safety checks, to
make sure that all maintenance for safe operation is performed
promptly, and to have the equipment checked periodically by
an Authorized Service Dealer. Normal maintenance service and
replacement of parts are the responsibility of the owner/operator
and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits
and usage contribute to the need for maintenance service.
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:
Proper maintenance and care of the generator ensure a minimum
number of problems and keep operating expenses at a minimum.
See an Authorized Service Dealer for service aids and accessories.
INDICATES A HAZARDOUS SITUATION OR
ACTION WHICH, IF NOT AVOIDED, WILL RESULT
IN DEATH OR SERIOUS INJURY.
Operating instructions presented in this manual assume that the
generator electric system has been installed by an Authorized
Service Dealer or other competent, qualified contractor. Installation
of this equipment is not a “do-it-yourself” project.
Indicates a hazardous situation or action which,
if not avoided, could result in death or serious
injury.
HOW TO OBTAIN SERVICE
Indicates a hazardous situation or action which,
if not avoided, could result in minor or moderate
injury.
NOTE:
When contacting a dealer about parts and service, always supply
the complete Model Number, Serial Number and Type Code (where
applicable) from the DATA LABEL that is affixed to the unit.
When the generator requires servicing or repairs, simply contact
an Authorized Service Dealer for assistance. Service technicians
are factory-trained and are capable of handling all service needs.
Notes contain additional information important to a procedure
and will be found within the regular text body of this manual.
These safety warnings cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the special
instructions while performing the action or 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:
AUTHORIZED SERVICE DEALER LOCATION
To locate the nearest AUTHORIZED
SERVICE DEALER, please call this number:
This symbol points out important safety
information that, if not followed, could
n
endanger personal safety and/or property of
1-800-333-1322
or locate us on the web at:
others.
www.generac.com
1-1
Safety 001 Rev. d 06/10

This symbol points out potential fire hazard.

This symbol points out potential explosion
hazard.
Safety Rules
Save These Instructions – The manufacturer suggests that these rules for safe operation be copied
n
and posted in potential hazard areas. Safety should be stressed to all operators, potential operators,
and service and repair technicians for this equipment.
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 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 factoryapproved parts.
• 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.
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.
Despite the safe design of this generator,
operating this equipment imprudently,
n
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.
these machines. Ensure all steps are taken to
Potentially lethal voltages are generated by
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 runn
ning generators.
GENERAL HAZARDS
• For safety reasons, the manufacturer recommends that this
equipment be installed, serviced and repaired by an Authorized
Service Dealer or other competent, qualified electrician or installation technician who is familiar with applicable codes, standards
and regulations. The operator also must comply with all such
codes, standards and regulations.
• Installation, operation, servicing and repair of this (and related)
equipment must always comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and
national electrical and building codes. Comply with regulations
the Occupational Safety and Health Administration (OSHA) has
established. Also, ensure that the generator is installed, operated and serviced in accordance with the manufacturer’s instructions and recommendations. Following installation, do nothing
that might render the unit unsafe or in noncompliance with the
aforementioned codes, standards, laws and regulations.
ELECTRICAL HAZARDS
• All Stationary Emergency Generators covered by this manual
produce dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely high and dangerous voltages to the transfer switch as well as the generator.
Avoid contact with bare wires, terminals, connections, etc.,
on the generator as well as the transfer switch, if applicable.
Ensure all appropriate covers, guards and barriers are in place
before operating the generator. If work must be done around
an operating unit, stand on an insulated, dry surface to reduce
shock hazard.
• Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
1-2
Safety 001 Rev. d 06/10
Safety Rules
FIRE HAZARDS
• If personnel must stand on metal or concrete while installing,
operating, servicing, adjusting or repairing this equipment,
place insulative mats over a dry wooden platform. Work on the
equipment only while standing on such insulative mats.
• The National Electrical Code (NEC) requires the frame and
external electrically conductive parts of the generator to be connected to an approved earth ground. This grounding will help
prevent dangerous electrical shock that might be caused by a
ground fault condition in the generator or by static electricity.
Never disconnect the ground wire.
• Wire gauge sizes of electrical wiring, cables and cord sets must
be adequate to handle the maximum electrical current (ampacity) to which they will be subjected.
• Before installing or servicing this (and related) equipment, make
sure that all power voltage supplies are positively turned off at
their source. Failure to do so will result in hazardous and possibly fatal electrical shock.
• Connecting this unit to an electrical system normally supplied
by an electric utility shall be by means of a transfer switch so as
to isolate the generator electric system from the electric utility
distribution system when the generator is operating. Failure to
isolate the two electric system power sources from each other
by such means will result in damage to the generator and may
also result in injury or death to utility power workers due to
backfeed of electrical energy.
• Stationary Emergency Generators installed with an automatic
transfer switch will crank and start automatically when normal
(utility) source voltage is removed or is below an acceptable
preset level. To prevent such automatic start-up and possible
injury to personnel, disable the generator’s automatic start circuit (battery cables, etc.) before working on or around the unit.
Then, place a “Do Not Operate” tag on the generator control
panel and on the transfer switch.
• In case of accident caused by electric shock, immediately
shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID
DIRECT CONTACT WITH THE VICTIM. Use a nonconducting
implement, such as a dry rope or board, to free the victim from
the live conductor. If the victim is unconscious, apply first aid
and get immediate medical help.
• Never wear jewelry when working on this equipment. Jewelry
can conduct electricity resulting in electric shock, or may get
caught in moving components causing injury.
• Keep a fire extinguisher near the generator at all times. Do NOT
use any carbon tetra-chloride type extinguisher. Its fumes are
toxic, and the liquid can deteriorate wiring insulation. Keep the
extinguisher properly charged and be familiar with its use. If
there are any questions pertaining to fire extinguishers, consult
the local fire department.
EXPLOSION HAZARDS
• Properly ventilate any room or building housing the generator to
prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any fuel or oil
spills immediately. Ensure that no combustible materials are left
in the generator compartment, or on or near the generator, as
FIRE or EXPLOSION may result. Keep the area surrounding the
generator clean and free from debris.
• These generators may operate using one of several types
of fuels. All fuel types are potentially FLAMMABLE and/or
EXPLOSIVE and should be handled with care. Comply with all
laws regulating the storage and handling of fuels. Inspect the
unit’s fuel system frequently and correct any leaks immediately.
Fuel supply lines must be properly installed, purged and leak
tested according to applicable fuel-gas codes before placing
this equipment into service.
• Diesel fuels are highly FLAMMABLE. Gaseous fluids such
as natural gas and liquid propane (LP) gas are extremely
EXPLOSIVE. Natural gas is lighter than air, and LP gas is heavier
than air; install leak detectors accordingly.
CALIFORNIA PROPOSITION 65 WARNING
Engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects
and other reproductive harm.
CALIFORNIA PROPOSITION 65 WARNING
This product contains or emits chemicals known to the
State of California to cause cancer, birth defects and
other reproductive harm.
Safety 001 Rev. d 06/10
1-3
General Information
IDENTIFICATION RECORD
Identification Code
Use this code to obtain important information about the generator.
For example, if the code is:
DATA LABEL
Every generator set has a DATA LABEL that contains important
information pertinent to the generator. The data label, which can be
found attached to the generator’s lower connection box, lists the
unit’s serial number and its rated voltage, amps, wattage capacity,
phase, frequency, rpm, power factor, production date, etc.
M Q
QT
100
5.4
A
MADE IN USA
SERIAL
MODEL
RATED KVA
RATED KW
POWER FACTOR
PHASE
RATED AMPS
RATED VOLTAGE
HERTZ
ALT RPM
PRODUCTION DATE
ENGINE RPM
ALTERNATOR SUBTRANSIENT REACTANCE
N —
S —
ALTERNATOR TRANSIENT REACTANCE
CLASS
—
—
—
—
ROTOR
STATOR WINDING INSULATION AT 25°C AMBIENT
GENERAC POWER SYSTEMS, INC.
N —
WAUKESHA, WI
A —
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.
T
1
0
0
5
4
A
N
S
N A
able for this configuration.
Quiet Test Generator Series
kw Rating
Engine Size in Liters
Voltage Code: A = 120/240, Single-phase; G =
120/208, Three-phase; K = 277/480, Three-phase; J
= 120/240, Three-phase;
L = 346/600, Three-phase
Fuel: N = Natural Gas; V = Vapor Propane
Enclosure Material: A = Aluminum; S = Steel
(Corrosion Resistant Aluminum Enclosure Material,
Steel is Standard)
Emission Equipment: N = No Equipment; Y =
Catalytic Converter and Air/Fuel Ratio Controller
Industrial Dealer Product
Voltage Codes
The identification code letter following the unit’s engine size is the
generator’s “voltage code.”
Stationary Emergency Generator Model and Serial
Number
Groups and Assembly Numbers
The manual drawing listing lists the groups and corresponding
assembly numbers for each unit. The assembly numbers refer to
exploded view drawing numbers that are applicable to the specific
generator model. These drawings are located in the back half of
this manual.
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.
2-1
Identy001 Rev. E 06/10
GENERATOR SET DATA
M — Designates generators capable of paralleling. NOTE:
Only 100kW and 150kW, 6.8L units are currently avail-
Equipment Description
EQUIPMENT DESCRIPTION
COOLANT RECOMMENDATIONS
This equipment is a revolving field, alternating current Stationary
Emergency Generator. It is powered by a gaseous fueled engine
operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for
2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear
units. See the Specifications section for exact numbers. The unit
comes complete with a sound attenuated enclosure, internally
mounted muffler, control console, mainline circuit breaker, battery charger, and protective alarms as explained in the following
paragraph.
Use a mixture of half low silicate ethylene glycol base anti-freeze
and deionized water. Cooling system capacity is listed in the
specifications. Use only deionized water and only low silicate
anti-freeze. If desired, add a high quality rust inhibitor to the recommended coolant mixture. When adding coolant, always add the
recommended 50-50 mixture.
not use any chromate base rust inhibitor
nDo
with ethylene glycol base anti-freeze or chromium hydroxide (“green slime”) forms and will
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.
cause overheating. Engines that have been
operated with a chromate base rust inhibitor
must be chemically cleaned before adding ethylene glycol base anti-freeze. Using any high
silicate anti-freeze boosters or additives will
also cause overheating. The manufacturer also
recommends that any soluble oil inhibitor is
NOT used for this equipment.
The Stationary Emergency Generator incorporates the following
alternator features:
• Rotor and Stator insulation class is rated as defined by NEMA
MG1-32.6, NEMA MG1-1.66. The generator is self ventilated
and drip-proof constructed. Refer to the Specifications section
or the data label for the class ratings.
• The voltage waveform deviation, total harmonic content of the
AC waveform and telephone influence factor have been evaluated and are acceptable according to NEMA MG1-32.
not remove the radiator pressure cap while
nDo
the engine is hot or serious burns from boiling
liquid or steam could result.
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.
glycol base antifreeze is poisonous.
nEthylene
Do not use mouth to siphon coolant from the
radiator, recovery bottle or any container. Wash
hands thoroughly after handling. Never store
used antifreeze in an open container because
animals are attracted to the smell and taste of
antifreeze even though it is poisonous to them.
attempt to crank or start the engine before
nAny
it has been properly serviced with the recommended oil may result in an engine failure.
NOTE:
If not already equipped, it is strongly recommended to use the
optional Cold Weather Start Kit for temperatures below 32° F.
The part number for the Cold Weather Start Kit can be found
in the Specifications section or by contacting an authorized
dealer. The oil grade for temperatures below 32° F is 5W-30
synthetic oil.
Equip001 Rev. G 05/10
3-1
Engine Protective Devices
ENGINE PROTECTIVE DEVICES
OVERCRANK SHUTDOWN
The Stationary Emergency Generator may be required to operate
for long periods of time without an operator on hand to monitor
such engine conditions as coolant temperature, oil pressure or
rpm. For that reason, the engine has several devices designed to
protect it against potentially damaging conditions by automatically
shutting down the unit when the oil pressure is too low, the coolant
temperature is too high, the coolant level is too low, or the engine
is running too fast.
After a prespecified duration of cranking, this function ends the
cranking if the engine has failed to start. The overcrank LED will
turn ON. Turn OFF the AUTO/OFF/MANUAL switch, then turn switch
back to AUTO to reset the generator control board.
NOTE:
If the fault is not corrected, the overcrank feature will continue
to activate.
NOTE:
Approximate Crank Cycle Times
Engine protective switches and sensors are mentioned here for
the reader’s convenience. Also refer to the applicable control
panel manual for additional automatic engine shutdown information.
•
•
•
•
•
HIGH COOLANT TEMPERATURE SWITCH
The switch will close if the temperature should exceed approximately 140° C (284° F), initiating an engine shutdown. The generator will automatically restart and the LED will reset once the
temperature has returned to a safe operating level.
15 seconds ON
7 seconds OFF
7 seconds ON
7 seconds OFF
Repeat for 45 seconds
Approximately 90 seconds total.
OVERSPEED SHUTDOWN
A speed circuit controls engine cranking, start-up, operation and
shutdown. Engine speed signals are delivered to the circuit board
whenever the unit is running. Should the engine overspeed above
a safe, preset value, the circuit board initiates an automatic engine
shutdown. Contact the nearest Authorized Dealer if this failure
occurs.
LOW COOLANT LEVEL SENSOR
To prevent overheating, the engine has a low coolant level sensor.
If the level of engine coolant drops below the level of the low coolant level sensor, the engine automatically shuts down.
RPM SENSOR LOSS SHUTDOWN
LOW OIL PRESSURE SWITCH
If the speed signal to the control panel is lost, engine shutdown
will occur.
This switch has normally closed contacts that are held open by
engine oil pressure during cranking and operating. Should oil pressure drop below the 8 psi range, switch contacts close, and the
engine shuts down. The unit should not be restarted until oil is
added, and the AUTO/OFF/MANUAL switch must be turned to OFF
and then back to AUTO.
DC FUSES
Fuse F1 (15 amp) is located inside of the control panel. It protects
the panel wiring and components from damaging overload. Always
remove this fuse before commencing work on the generator. The
unit will not start or crank if the fuse is blown.
Fuse F2 (25 amp) is located in the engine wire harness adjacent
to the DC alternator. It is used to prevent circuit failure due to DC
alternator falure. If this fuse is blown, battery charging will not
occur while the engine is running. Replace these fuses with the
same size, type, and rating. (See the exploded views and parts
lists at the end of this manual for replacement part number.)
EngProt001 Rev. C 06/10
4-1
Fuel System
FUEL SYSTEM
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:
FUEL REQUIREMENTS
The Stationary Emergency Generator may be equipped with one of
the following fuel systems:
• Natural gas fuel system
• Propane vapor (PV) fuel system
• Liquid propane (LP) fuel system
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.
• 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.
Required fuel pressure for natural gas is 5 inches to 14 inches
water column (0.18 to 0.5 psi); and for liquid propane, 5 inches
to 14 inches of water column (0.18 to 0.5 psi).
LP LIQUID FUEL SYSTEM
NOTE:
Any piping used to connect the generator to the fuel supply
should be of adequate size to ensure the fuel pressure NEVER
drops below five inches water column for natural gas or 5
inches water column for propane vapor for all load ranges. The
fuel supply piping shall be sized according to the installation
manual using the fuel consumption requirements identified in
the Specifications section of the Owner's Manual.
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 vaporizerconverter 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.
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).
FuelSys001 Rev. E 05/10
5-1
Standby Generator Sets
Specifications
SPECIFICATIONS
‹ COOLING SYSTEM
‹ GENERATOR
Type ...................................................Pressurized Closed Recovery
Water Pump.................................................................... Belt Driven
Fan Speed .........................................................................2150 rpm
Fan Diameter .....................................................................22 inches
Fan Mode ................................................................................Puller
Air Flow (inlet air including alternator and
combustion air) ...........................................................4500 ft3/min.
Coolant Capacity ........................................................ (3.0 U.S. gal.)
Heat Rejection to Coolant ..........................................134,000 Btu/h
Maximum Operating Air Temp. on Radiator ..............60° C (150° F)
Maximum Ambient Temperature................................50° C (140° F)
Type ............................................................................. Synchronous
Rotor Insulation ................................................................... Class H
Stator Insulation .................................................................. Class H
Total Harmonic Distortion ......................................................< 3.5%
Telephone Interference Factor (TIF) ..........................................< 50
Alternator Output Leads 3-phase ........................................... 4-wire
Bearings .........................................................................Sealed Ball
Coupling .......................................................................Flexible Disc
Load Capacity (Standby Rating) ............................................35kW*
* NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349,
‹ FUEL SYSTEM
ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural
gas.
Type of Fuel .........................................Natural Gas, Propane Vapor
Carburetor ...................................................................... Down Draft
Secondary Fuel Regulator .................................................Standard
Fuel Shut-off Solenoid ........................................................Standard
Operating Fuel Pressure ...................... 5 in. - 14 in. Water Column
Excitation System ....................................................................Direct
Generator Output Voltage/kW - 60 Hz
kW
Amp CB Size
120/240V, 1-phase, 1.0 pf
35
146
175
120/208V, 3-phase, 0.8 pf
35
121
150
277/480V, 3-phase, 0.8 pf
35
53
60
Generator Locked Rotor KVA Available @ Voltage Dip of 35%
Single-phase or 208, 3-phase ............................................ 69 KVA
480V, 3-phase .................................................................... 76 KVA
Fuel Consumption - ft3/hr (Natural Gas/LPV)
Exercise
25%
50%
75%
100%
Cycle
Load
Load
Load
Load
87/34.5
150/59.6 291/115.7 405/160.8 560/222.3
‹ ENGINE
Make ................................................................................... Generac
Model ..................................................................................... In Line
Cylinders and Arrangement............................................................ 4
Displacement ....................................................................... 2.4 Liter
Bore ...................................................................................... 3.41 in.
Stroke ................................................................................... 3.94 in.
Compression Ratio ...............................................................8.5-to-1
Air Intake System ...............................................Naturally Aspirated
Valve Seats....................................................................... Hardened
Lifter Type .......................................................................... Hydraulic
‹ ELECTRICAL SYSTEM
Battery Charge Alternator ............................................12V, 30 Amp
Static Battery Charger ............................................................2 Amp
Recommended Battery...................................... Group 26, 525CCA
System Voltage .....................................................................12 Volts
Voltage Regulator
Type .................................................................................. Electronic
Sensing........................................................................ Single-phase
Regulation ................................................................................± 1%
Features ................................................. V/F Adjustable, Adjustable
Voltage and Gain LED Indicators
Engine Parameters
Rated Synchronous RPM ..............................................60 Hz, 3600
HP at rated kW ..................................................................60 Hz, 55
Power Adjustment for Ambient Conditions
Temperature Deration
3% for every 10° C above °C ..................................................... 40
1.65% for every 10° above °F .................................................. 104
Altitude Deration
1% for every 100 m above m ................................................... 915
3% for every 1000 ft. above ft. ............................................... 3000
Exhaust System
Exhaust Flow at Rated Output 60 Hz.................................. 360 cfm
Exhaust Temperature at Rated Output ................................ 1050° F
Combustion Air Requirements (Natural Gas)
Flow at rated power, 60 Hz ................................................. 129 cfm
Controller .................................................R-200
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.
GenSpec019 Rev. B 05/06
6-1
Standby Generator Sets
Specifications
Figure 1 — Interconnections
Utility In
Transfer Switch
CONTROL PANEL
NEUTRAL
TO
ALTERNATOR
Gen
N1
N2
23
194
GENERATOR
CONNECTION
BOX
183
178
NEUTRAL
N1
N2
23
194
4- # 14 GA
WIRES TO
GENERATOR
CONNECTION
BOX
CIRCUIT
BREAKER
Battery
Charger
Input
186
178
Load
Out
TO GENERATOR
CONNECTION BOX
GROUND
120 Volt +
Neutral
Grd
To Generator Control Panel
FRAME RAIL
Ground Level
Concrete Slab
KW
35
35
35
STUB-UP AREA
See Install Dwg for
Dimensions
‹ COLD WEATHER KIT
CIRCUIT BREAKER SIZE
VOLTS / AMPS
LUG SIZE
240 1 Ø
175
#6 to 300 mcm
208 3 Ø
150
#6 to 300 mcm
480 3 Ø
60
#6 to 300 mcm
10. Reverse the procedure to convert back to natural
gas.
11. The Dip switch inside the control panel must be
in the LP or NG position when switching to different fuels.
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)
Figure 6.2 — Reconfigure the Fuel System
‹ RECONFIGURING THE FUEL SYSTEM
NOTE:
All models are configured for natural gas or LP
vapor from the factory.
To reconfigure the fuel system from NG to LP, follow
these steps:
1. Turn the main gas supply off.
2. Remove the carburetor fuel hose from the outlet
port (Port 1) of the demand regulator (Figure
6.2).
3. Remove the brass hose fitting from the outlet port
(Port 1) of the demand regulator.
4. Remove the brass hose fitting with solenoid from
Port 2.
5. Install brass hose fitting into Port 2.
6. Install the brass hose fitting with solenoid into
Port 1.
7. Connect carburetor gas hose to brass fitting.
8. Tighten all clamps and plugs.
9. Make sure fuel supply is of the proper pressure
and type for configuration.
NOTE:
Port 1 is for NG only and Port 2 is for LP vapor
only. No provision for dual fuel has been made.
DANGER
injury or damage may occur if not con Serious
figured properly. Please consult an Authorized
Service Dealer with any questions.
6-2
GenSpec019 Rev. B 05/06
General Information
ALTERNATOR AC LEAD
CONNECTIONS
ALTERNATOR POWER WINDING
CONNECTIONS
See “Voltage Codes”. This Stationary Emergency Generator may
be rated at any one of three voltages, either single-phase or 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.
3-PHASE ALTERNATORS
The Stationary Emergency Generator is designed to supply
3-phase electrical loads. Electric power is produced in the alternator power windings. These windings were connected at the factory
to the main circuit breaker with a “Y” configuration as shown in
Figures 7.2 and 7.3.
Voltage codes apply to the type of stator assembly installed on a
particular generator.
The rated voltage between circuit breaker terminals E1-E2, E1-E3
and E2-E3 is 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.
FOUR-LEAD, SINGLE-PHASE STATOR
Four-lead alternators (see Figure 7.1) are designed to supply electrical loads with voltage code “A” (240V, 1-phase, 60 Hz). Electrical
power is produced in the stator power windings. These windings
were connected at the factory to the main circuit breaker as shown
in Figure 7.1.
Figure 7.2 — Stator Power Winding
Connections - 3-phase, 277/480V (6 Lead)
S1 E1
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.
INTERNAL
CONNECTIONS
Figure 7.1 — Four-lead, Single-phase Stator
L-L
S6
S4
NEUTRAL
S5
E3 S3
S2
E2
L-N
Figure 7.3 — Stator Power Winding
Connections - 3-phase, 120/208V (6 Lead)
E1
S1
S1
S6
S3
E3
L-L
S4
S4
S5
00 (NEUTRAL)
S2
S6 S5
S3
S2
E2
L-N
ACConn001 Rev. B 06/10
7-1
Installation
INSTALLATION
PRIOR TO INITIAL START-UP
Refer to the separate “Installation Guide QT Product Line” supplied
with the unit.
Prior to initially starting the generator, it
n
must be properly prepared for use. Any
PREPARATION BEFORE START-UP
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.
The instructions in this section assume that the Stationary
Emergency Generator has been properly installed, serviced, tested,
adjusted and otherwise prepared for use by a competent, qualified
installation contractor. Be sure to read the “Safety Rules”, as well
as all other safety information in this manual, before attempting to
operate this (and related) equipment.
ENGINE COOLANT
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”.
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.
TRANSFER SWITCH
BELT TENSION
If this generator is used to supply power to any electrical system
normally powered by an electric utility, the National Electrical Code
requires that a transfer switch be installed. The transfer switch prevents electrical backfeed between two different electrical systems.
(For additional information, see the applicable transfer switch
manual for this unit.) The transfer switch, as well as the generator
and other electrical components, must be properly located and
mounted in strict compliance with applicable codes, standards
and regulations.
Check-the engine-fan belt tension and condition prior to placing
the unit into service and at recommended intervals. Belt tension is
correct when a force of approximately 22 pounds (10 kg), applied
midway between pulleys, deflects the belt about 3/8- to 5/8-inch
(10 to 16 mm).
FUEL SYSTEM
Make sure the generator battery is fully charged, properly installed
and interconnected, and ready for use.
ELECTRICAL SYSTEM
Make sure the generator is properly connected to an approved
earth ground.
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.
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.
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”.
INITIAL INSPECTION FOR QT
GENSET STARTUP
NOTE:
This engine is shipped from the manufacturer with “break-in”
oil. This oil should be changed after 30 hours of operation.
Inspect for the following.
Check the oil level in the generator gearbox (if so equipped) prior to
initial use and at the intervals indicated by the “Service Schedule.”
The recommended oil is SAE 90 gear lubricant.
Also, if the engine is equipped with a mechanical governor, make
sure the governor is properly lubricated with clean engine oil.
•
•
•
•
8-1
Freight Damage.
Manuals present.
Fluid Levels (Oil, coolant, battery, Gear Drive).
Correct fuel piping.
Correct muffler installation for external application.
Adequate air flow, clearances and ventilation per installation
drawings and applicable codes.
Correct AC and DC wire size, connections and grounding.
Control and communication wiring to/from the transfer switch
must be run in a separate conduit from the AC power leads.
Battery charger connection to 120 VAC.
Communication wires connected between transfer switch and
generator (HTS only).
Unit secured to pad.
Install001 Rev. F 06/10
•
•
•
•
•
•
Installation
START-UP CHECKLIST
• 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.
Before working on the Stationary Emergency
Generator, ensure the following:
n
• The AUTO/OFF/MANUAL switch is in the OFF position.
• The 120VAC supply to the battery charger is switched OFF.
PREPARATION FOR START-UP
• Ensure that the 120VAC circuit breaker to the battery charger is
open.
• Remove the fuse from the the control panel. For the H-100 and
R-series: Open the front door of the control box and remove the
15 Amp ATO fuse in the lower left-hand corner of the control
box.
• Connect the battery cables to the battery. Attach negative battery cable last.
• Close the 120VAC circuit breaker to the battery charger.
• Measure the voltage at the battery before and after the charger
is turned on.
• Verify all AC electrical connections are tight at the circuit breaker
and transfer switch.
• Visually inspect entire area looking for loose paper, plastic
wrappings, leaves, etc.
• Check all hoses clamps fittings for leaks or damage.
• Check all electrical plugs throughout the generator. Ensure each
plug is seated correctly and fully inserted into its receptacle.
• Verify the AUTO/OFF/MANUAL switch is in OFF position.
• Open the valve to the engine fuel line.
• Bleed the fuel system of air. (necessary for long fuel lines).
• Open the generator main line circuit breaker.
• Connect a manometer to the gas line and record the static pressure. It must be as listed in the Specifications.
• Insert the fuse into the control panel.
• Move the AUTO/OFF/MANUAL switch to the MANUAL position.
The engine should now crank and start.
START-UP INSPECTION
When a start-up is performed by an Authorized Service Dealer, a
standard three-part form titled “Start-up Inspection for Standby
Power Systems” (part no. 067377), should be completed by the
installation technician or engineer. See page 1-3 for information on
locating the nearest Authorized Service Dealer. The installer should
complete the form and disseminate copies as follows:
• White copy: Mail to Generac Warranty Department, P.O. Box
340, 211 Murphy Dr., Eagle, WI 53119-2062.
• Pink Copy: For service file of installing dealer.
• Yellow Copy: For the customer’s records.
8-2
Install001 Rev. F 06/10
Operation
STATIONARY EMERGENCY
GENERATOR CONTROL AND
OPERATION
not crank the engine continuously for longer than 30 seconds, or the heat may
nDo
damage the starter motor.
Refer to the appropriate control panel operator’s manual for this
unit.
• Let engine stabilize and warm up.
• Check all applicable instrument and gauge readings. When
certain that all readings are correct, move the transfer switch
manual handle to the STANDBY (or EMERGENCY STANDBY)
position, i.e., load circuits supplied by the generator.
• Set the generator’s main line circuit breaker to its ON (or
CLOSED) position.
• Load circuits are now powered by the generator.
OPERATING UNIT WITH MANUAL
TRANSFER SWITCH
If the Stationary Emergency Generator was installed in conjunction
with a transfer switch capable of manual operation only, the following procedure applies. A manually operated transfer switch is
one that will not provide automatic start-up and does not include
an intelligence circuit.
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.
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.
To transfer the load back to the utility power source and shut down
the generator, follow these directions:
• Set the generator’s main line circuit breaker to its OFF (or OPEN)
position.
• Manually move the transfer switch handle to its UTILITY
(NORMAL) position, i.e., load circuits connected to the utility.
• Turn ON the utility power supply to the transfer switch, using
the means provided (such as the utility power source main line
circuit breaker).
• Let the generator run at no-load for a few minutes to stabilize
internal temperatures.
• Shut down the generator.
Maintenance Disconnect Switch and the
nThe
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.
not proceed until certain that utility source
nDo
voltage is available to the transfer switch and
the transfer switch main contacts are set to
OPERATING UNIT WITH AUTOMATIC
TRANSFER SWITCH
UTILITY.
power supplies to the transfer switch have been
If the Stationary Emergency Generator has been installed with an
automatic transfer switch, the engine may be started and stopped
automatically or manually.
Do not attempt manual operation until all
positively turned off, or extremely dangerous possibly lethal - electrical shock will result.
NOTE:

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:
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.”
• Turn OFF or disconnect the utility power circuit to the transfer
switch, using the means provided (such as the utility source
main line circuit breaker).
• Set the transfer handle to its UTILITY (NORMAL) position with
load circuits connected to the utility power supply.
• Set the generator’s main line circuit breaker to its OFF (or OPEN)
position.
• Start the generator.
Oper001 Rev. D 05/10
9-1
Stationary Emergency Generator
Maintenance
MAINTENANCE PERFORMED BY
SERVICE DEALERS/CONTRACTORS
exhaust system parts from this product get
 The
extremely hot and remains hot after shutdown.
High grass, weeds, brush, leaves, etc. must
remain clear of the exhaust. Such materials may
ignite and burn from the heat of the exhaust
system.
working on the Stationary Emergency
 Before
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.
OVERLOAD PROTECTION FOR
ENGINE DC ELECTRICAL SYSTEM
‹ EVERY THREE MONTHS
1.
2.
3.
4.
5.
6.
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.
Check battery condition.
Inspect and test fuel system.
Check transfer switch.
Inspect exhaust system.
Check engine ignition system.
Check fan belts.
a circuit breaker opens or a fuse element
 Ifmelts,
find the cause of the overload before
‹ ONCE EVERY SIX MONTHS
1.
resetting the circuit breaker or replacing the
fuse.
Test Engine Safety Devices (low oil pressure, low coolant
level, high coolant temperature).
CHECKING FLUID LEVELS
‹ ONCE ANNUALLY
1.
2.
3.
4.
Test engine governor; adjust or repair, if needed.
Clean, inspect generator.
Flush cooling system.
Clean/re-gap spark plugs or replace as necessary.
‹ 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
‹ FIRST 30 OPERATING HOURS
1.
Change engine "break-in" oil and filter.
Oil Fill Cap
‹ FIRST 100 OPERATING HOURS
1.
2.
Change engine oil and oil filter. After initial change, service
engine oil and filter at 100 operating hours or six months,
whichever comes first.
Retorque intake and exhaust manifold.
Oil
Dipstick
‹ EVERY 500 OPERATING HOURS
1.
2.
3.
Service air cleaner.
Check starter.
Check engine DC alternator.
COOLING SYSTEM
•
•
•
•
Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down. (See the
installation diagram.)
10-1
Remove oil dipstick and wipe dry with a clean, lint-free 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
Recommen-dations” for recommended oils.
Maint012 Rev. H 06/09
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.
Stationary Emergency Generator
Maintenance
‹ BATTERY FLUID
‹ PERFORM VISUAL INSPECTION
Check battery electrolyte fluid based on the Maintenance Schedule.
Fluid should cover separators in all battery cells. If fluid level is low,
add distilled water to cover tops of separators. DO NOT USE TAP
WATER IN BATTERY.
Complete a thorough visual inspection of the entire engine-generator monthly. Look for obvious damage, loose, missing or corroded
nuts, bolts and other fasteners. Look for fuel, oil or coolant leaks.
‹ INSPECT EXHAUST SYSTEM
‹ ENGINE COOLANT
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 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.
‹ CHECK FAN BELT
• Inspect fan belts every three months. Replace any damaged,
deteriorated, worn or otherwise defective belt.
• Check fan belt tension. Thumb pressure, exerted midway
between pulleys, should deflect about 3/8 to 5/8 of an inch.
Adjust belt tension as required.
• Check fan belt alignment.
MAINTENANCE OWNER/
OPERATOR CAN PERFORM
‹ INSPECT ENGINE GOVERNOR
Visually inspect electronic governor.
DANGER

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.
not attempt to adjust the governor. Only quali Do
fied 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.
‹ 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.
‹ CHANGING ENGINE OIL
‹ EXERCISE SYSTEM
oil may cause burns. Allow engine to cool
 Hot
before draining oil. Avoid prolonged or repeated
Start the Stationary Emergency 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.
skin exposure with used oil. Thoroughly wash
exposed areas with soap.
Refer to maintenance performed by service facilities for engine oil
and filter change frequencies.
‹ INSPECT COOLING SYSTEM
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:
• Inspect engine cooling system. See “Maintenance Schedule”.
• Check hoses for damage, deterioration, leaks, etc. Correct any
discrepancies found.
• Check hose clamps for tightness.
1.
2.
‹ CHECK ENGINE COOLANT LEVEL
3.
See “Checking Fluid Levels”.
4.
10-2
Remove OIL DRAIN HOSE from its retaining clip.
Loosen and remove OIL DRAIN HOSE CAP. Drain oil completely into suitable container.
When all oil has drained, install and tighten OIL DRAIN HOSE
CAP, and re-install into its retaining clip.
Turn OIL FILTER (Figure 10.2) counterclockwise and remove.
Properly dispose of old filter.
Maint012 Rev. H 06/09
Stationary Emergency Generator
Maintenance
‹ SPARK PLUGS
Figure 10.2 – Oil Filter
Reset the spark plug gap or replace the spark plugs as necessary
(Figure 10.4).
1.
2.
Oil
Filter
5.
6.
3.
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.
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.
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
Apply light coating of new engine oil to seal of new oil
filter.-Install FILTER and tighten by hand only. DO NOT OVER
TIGHTEN.
Remove OIL FILL CAP and add recommended oil. Crankcase
oil capacity is listed in the "Specifications" section.
SET PLUG GAP AT 1.07 - 1.17 mm
(0.042 - 0.046 inch)
refilling the crankcase with oil, always
 After
check oil level on dipstick. NEVER OPERATE
7.
8.
9.
ENGINE WITH OIL BELOW THE DIPSTICK
“ADD” MARK.
Start engine and check for oil leaks.
Shut OFF engine and wait 10 minutes for the oil to settle down
into the oil pan. Recheck oil level on dipstick. DO NOT fill
above the dipstick "FULL" mark.
Dispose of used oil at a proper collection center.
‹ COOLANT CHANGE
Every year, have a service facility drain, flush and refill the cooling
system. See “Specifications” for cooling system recommendations.
‹ CHANGING THE ENGINE AIR CLEANER
MISCELLANEOUS MAINTENANCE
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).
‹ CLEANING THE STATIONARY EMERGENCY
GENERATOR
Figure 10.3 – Engine Air Cleaner
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.
Air Cleaner
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.
(Doors Removed for Clarity)
See the “Service Schedule,” for air cleaner maintenance.
Maint012 Rev. H 06/09
10-3
Stationary Emergency Generator
Maintenance
‹ BATTERY
electrolyte fluid is an extremely corro Battery
sive sulfuric acid solution that can cause severe
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:
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 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 wellventilated 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.
not use any jumper cables or booster battery
 Do
to crank and start the generator engine. If the
battery has completely discharged, remove it
from the generator for recharging.
sure the AUTO/OFF/MANUAL switch is set to
 Be
the OFF position, before connecting the battery
cables. If the switch is set to AUTO or MANUAL,
the generator can crank and start as soon as
the battery cables are connected.
sure the 120VAC power supply to the battery
 Be
is turned OFF, or sparking may occur at the battery posts as the cables are attached and cause
an explosion.
‹ BATTERY MAINTENANCE
‹ BATTERY REPLACEMENT
The battery should be inspected per the "Scheduled Maintenance"
section. The following procedure should be followed for inspection:
1.
2.
3.
NOTE:
Unit DOES NOT include battery.
Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary.
Check the battery fluid level of unsealed batteries and, if
necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP
WATER IN BATTERIES.
Have the state of charge and condition checked. This should
be done with an automotive-type battery hydrometer.
When supplying or replacing the battery, the recommended number and type of battery is listed in the Specifications Section.
NOTE:
The BCI number should be located directly on the battery.
DANGER
batteries give off explosive hydrogen
 Storage
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.
10-4
Maint012 Rev. H 06/09
Service Schedule
SERVICE SCHEDULE
22 KW - 150 KW GASEOUS STATIONARY EMERGENCY GENERATOR
The following is a recommended maintenance schedule for Gaseous Stationary Emergency Generator sets from 22kW to 150 kW in size. The
established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need
to be decreased (performed more frequently) if the unit is used in a severe application. Use calendar time, from the previous maintenance
interval to determine the next required maintenance interval.
Service Maintenance Interval Information:
The various service maintenance intervals are designated by interval numbers as follows:
1 An early inspection of the generator set to insure it is ready to operate when required and to identify any potential problem areas.
This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting
automatically without warning:
To prevent injury, perform the following steps in the order indicated before starting any maintenance:
• Disable the generator set from starting and/or connecting to the load by setting the control panel Auto/Off/Manual switch to the
“OFF” position.
• Remove the 15 amp control panel fuse.
• Turn off the battery charger.*
• Remove the negative battery cable.
* The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition from burning out
sensitive control panel components and circuits.
Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal operation when required.
2 A wear-in service inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any
potential problem areas.
Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be
performed only by a Service Dealer.
3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential
problem areas.
Performed semi-annually or following each 50 hours of operation of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be
performed only by a Service Dealer.
4 A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential
problem areas.
Performed annually or following each 100 hours of operation of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be
performed only by a Service Dealer.
5 A comprehensive inspection of the generator set to insure it is properly serviced and ready to operate and carry the load when required,
and to identify any potential problem areas.
Performed annually or following each 250 hours of operation of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be
performed only by a Service Dealer.
SrvSchd001 Rev. G 06/10
11-1
Service Schedule
Maintenance
Tasks
Level 1
Recommended
to be done
monthly/
10 hrs.
Level 2
Task
Comp.
(DateInitials)
Required
to be done
3 months/
Break-in
30 hrs.
Level 3
Task
Comp.
(DateInitials)
Required
to be done
Semiannually/
50 hrs.
1. Disable the unit
from operating
per the first page
warning.
2. Check the engine
oil level. Adjust
as necessary.
3. Check the engine
coolant level.
Adjust as
necessary.
4. Check the engine
coolant thermal
protection level.
Correct as
necessary.
5. Check the natural
gas delivery
system for leaks
and correct
pressure on gas
engine driven
units. Tighten
connections as
necessary.
6. Check the air
inlets and outlets
of the enclosure
and radiator for
debris. Clean
as necessary.
7. Check the battery
electrolyte level
and specific
gravity if
accessible. Adjust
as necessary.
8. Check the battery
posts, cables,
and charger for
loose connections,
corrosion, and
proper operation.
Correct as
necessary.
9. Check the unit
wiring for loose
connections,
corrosion, and
damage. Correct
as necessary.
11-2
Level 4
Task
Comp.
(DateInitials)
Required
to be done
Annually/
100 hrs.
Level 5
Task
Comp.
(DateInitials)
Required
to be done
Biannually/
250 hrs.
Task
Comp.
(DateInitials)
SrvSchd001 Rev. G 06/10
Service Schedule
Level 1
Recommended
to be done
monthly/
10 hrs.
Level 2
Level 3
Task
Required
Task
Required
Comp. to be done Comp. to be done
(Date- 3 months/ (DateSemiInitials) Break-in Initials) annually/
30 hrs.
50 hrs.
Level 4
Task
Comp.
(DateInitials)
Required
to be done
Annually/
100 hrs.
Level5
Task
Comp.
(DateInitials)
10. Check the engine
accessory drive
belts and fan
coupling device
if equipped for
correct tension,
wear, weather
cracking, and
damage. Replace
as necessary.
11. Check the engine
valve clearance/
lash. Adjust as
necessary.**
12. Visually inspect
the unit looking
for leaks, wear or
damage, loose
connections or
components, and
corrosion. Correct
as necessary.
13. Test the engine
and transfer
switch safety
devices. Correct
and/or adjust as
necessary.
14. Initiate an
automatic start
and transfer of
the unit to site
load and exercise
it for at least 1
hour looking for
leaks, loose
connections or
components, and
abnormal
operating
conditions.
Correct as
necessary.
15. Replace the
engine
accessory
drive belts.
16. Check gearbox
oil level (if
equipped).
17. Change gearbox
oil (if equipped).
** Not required for engines equipped with hydraulic lifters. See the "Specification" section for lifter type.
11-3
Required
to be done
Biannually/
250 hrs.
Task
Comp.
(DateInitials)
SrvSchd001 Rev. G 06/10
Maintenance
Tasks
Service Schedule
Maintenance
Tasks
18. Start and
exercise the unit
at full rated load
(use a load bank
if the site load is
not enough) for
at least 2 hours
looking for leaks,
loose
connections or
components, and
abnormal
operating
conditions.
Correct as
necessary.
19. Perform an
engine oil
analysis (send a
sample to a lab
for results).
Change the
engine oil and
filters if the
analysis results
indicate this is
required.
20. Change the
engine oil.
21. Replace the
engine oil filter(s).
22. Replace engine
spark plugs.
Clean and re-gap
or replace as
necessary.
23. Replace the
engine air
filter(s).
24. Perform a 5
minute no-load
operational run
of the unit
looking for any
post service
problems.
25. Return the unit
to standby setup
for operation
when required.
Level 1
Recommended
to be done
monthly/
10 hrs.
Level 2
Level 3
Task
Required
Task
Required
Comp. to be done Comp. to be done
(Date- 3 months/ (DateSemiInitials) Break-in Initials) annually/
30 hrs.
50 hrs.
11-4
Level 4
Task
Comp.
(DateInitials)
Required
to be done
Annually/
100 hrs.
Level5
Task
Comp.
(DateInitials)
Required
to be done
Biannually/
250 hrs.
Task
Comp.
(DateInitials)
SrvSchd001 Rev. G 06/10
Troubleshooting
TROUBLESHOOTING GUIDE
PROBLEM
CAUSE
CORRECTION
Engine won’t crank.
1. 15 amp fuse blown.
2. Loose or corroded or defective
battery cables.
3. Defective starter contactor.
4. Defective starter motor.
5. Dead or Defective Battery.
6. 5 amp fuse blown.
1. Replace fuse.
2. Tighten, clean or replace
battery cables as necessary.
3. Replace contactor.*
4. Replace starter motor.*
5. Remove, change or replace battery.
6. Replace fuse.*
Engine cranks but won't start
1. Out of fuel.
2. Fuel solenoid (FS) is defective
3. Open Wire #14A from Engine Control
circuit board.
4. Spark plugs defective.
5. Door on tank not closed.
1. Replenish fuel.
2. Replace solenoid.*
3. Reconnect wire.
1. Flame arrestor (air cleaner) plugged or
damaged.
2. Plugged fuel line.
3. Defective spark plugs.
4. Fuel pressure incorrect.
1. Clean or replace as needed.
Engine starts then shuts down.
1.
2.
3.
4.
5.
6.
7.
1.
2.
3.
4.
5.
6.
7.
AUTO/OFF/MANUAL Switch at OFF,
engine continues to run
1. Defective AUTO/OFF/MANUAL switch
2. Open/disconnected wire #15A between
AUTO/OFF/MANUAL switch and Control
Module circuit board.
3. Defective Control Module circuit board
1. Replace switch.*
2. Reconnect/close wire.
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
No AC output from generator.
Engine oil level is low.
Engine is overheated.
Defective Low Oil Pressure Switch
Defective Coolant Temperature Switch
Defective Control Module circuit board.
Coolant Level is Low.
Defective Low Coolant Level Switch
Check main line circuit breaker.
Check circuit breaker & fuses.
Transfer switch set to NORMAL position
Generator internal failure.
Thermal circuit breaker open.
2. Unclog fuel line.
3. Clean, regap or replace plugs.
4. Confirm fuel pressure to regulator is as
recommended in SPECIFICATIONS.
Check oil and add oil as needed.
Check cooling system for leaks.
Replace switch.*
Replace switch.*
Replace board.*
Repair leak - Add coolant.
Replace Switch.*
3. Replace board.*
Reset to ON or CLOSED.
Reset and replace, if necessary.
Set to GENERATOR position.
*
Auto-reset - Wait 5 min. and attempt restart.
*Contact the nearest Authorized Dealer for assistance.
12-1
Trblsht001 Rev. B 06/10
Engine starts hard, runs rough.
4. Clean, regap or replace plugs.
5. Close door on tank.
Notes
1
2
3
4
5
6
7
8
(1) 9
10
11
12
13
14
(2) 15
(2) 16
17
18
19
20
21
23
24
(1) 26
27
28
29
30
31
32
33
34
35
36
37
(3) 39
(4) 40
(4) 41
(4) 42
(4) 43
(4) 44
(4) 45
(4) 46
47
1)
A
C
D
E
F
G
H
J
K
L
2)
A
C
D
E
F
G
0F3137
0F3188
0F3189
023484N
0F6366B
0F6366A
043180
022264
0C3990
057701
022155
0C2428
0F3824
0A9457
057073
0D5466
0A7822
022237
022241
049226
0C2266
0C2454
022473
022097
0D4698
0F4464
025433
024469
067210A
0D6029
081008
077043J
051713
0F6156
029289
047411
0G0770
0H0348
036943
023897
022152
022158
0C2454
055934D
0F6145
1
1
1
1
1
1
2
2
2
REF
4
4
1
1
2
REF
REF
2
2
6
6
8
8
4
REF
1
1
1
1
4
1
1
2
1
1
4
1
1
2
4
2
2
1
1
A/R
PAN CB CONN BOX
STAND RH CONTROL
STAND LH CONTROL
BUSHING SNAP SB-2.5-31
XFMR DUAL 120V/16V (F OR 120/240V & 277/480V UNITS)
XFMR DUAL 104V/16V (F OR 120/208V UNITS)
WASHER FL AT M4
WASHER LO CK #8-M4
SCREW PHTT M4-0.7 X 10 ZYC
BLOCK TERM 20A 8 X 6 X 1100V
WASHER LO CK #6
SCREW PHTT #6- 32 X 1/2 ZYC
DECAL UT IL SENSE/CUST CONN
DECAL NEUTRAL
JUNCTION BLOCK 3/8-16
BUS BAR NEUTRAL BLOCK 390
LUG SLDLSS 600/250-1/0 X 1/4-28
WASHER LO CK 3/8
NUT HEX 3/8-16 STEEL
WASHER LO CK M5
SCREW PHTT M5-0.8 X 16 ZYC
SCREW THF M6-1 X 16 N WA Z/JS
WASHER FL AT 1/4-M6 ZINC
WASHER LO CK M6- 1/4
BLOCK TERM 20A 6 X 3 X 1100V
DECAL CUST CO NN 120V UTILITY
LUG SLDLSS #6- 14 X 13/64 CU
SCREW HHTT #10-32 X 3/8 CZ
DECAL GROUND LUG
SCREW HHTT M6-1.0 X 16 Z YC
GROMMET 1.25 X .25 X .75
CONDUIT FLEX 2.0" ID (36” LG)
WASHER FL AT M5
PLATE WIRE SNGL G ALV
TAPE ELEC 1/2 FO AM (AS REQ’D)
SCREW HHC M6-1.0 X 16 G8.8
HARNESS, TRANSFO RMER ADAPTER
ASSY ENCLOSURE PCB 4.2L IGN MD
SCREW PPHM #10/32 X 2
WASHER FL AT #10 ZINC
WASHER LO CK #10
NUT HEX #10-32 STEEL
SCREW THF M6-1 X 16 N WA Z/JS
CLAMP VINYL 1.06 X .406 Z
SEAL W EATHER .45" DIA
0F3328
0D5552
0D5553
0D5554
0D5556
0D9693
0F0492
048927
023897
022152
022158
0C2454
029289
0F1733
UL CIRCUIT BREAKER (ED)
1
COVER ED CB SHO RT STND
1
CB 0050A 3P 480V S ED4 LL
CB 0060A 3P 480V S ED4 LL
CB 0070A 3P 480V S ED4 LL
CB 0090A 3P 480V S ED4 LL
CB 0125A 3P 480V S ED4 LL
1
INSULATOR CB S (ED-3P)
4
SCREW RHM #10-32 X 4- 1/2
4
WASHER FL AT #10 ZINC
4
WASHER LO CK #10
4
NUT HEX #10-32 STEEL
9
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FO AM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
0F3138
0D5572
0D5573
0D5574
0D5575
0D5576
0F0199
081320
022473
022097
UL CIRCUIT BREAKER (F D)
1
COVER CB CONN BO X
1
CB 0150A 3P 600V S FD6 LL
CB 0175A 3P 600V S FD6 LL
CB 0200A 3P 600V S FD6 LL
CB 0225A 3P 600V S FD6 LL
CB 0250A 3P 600V S FD6 LL
1
INSULATOR CB FD FRAME 30MIL
4
SCREW SHC 1/4-20 X 4.5 G8.8 NZ
4
WASHER FL AT 1/4-M6 ZINC
4
WASHER LO CK M6- 1/4
H
J
K
L
3)
A
C
D
E
F
G
H
J
K
L
4)
A
C
D
E
F
G
H
J
K
022127
0C2454
029289
0F1733
0F3329
0D5577
0F2353
022770
022473
022097
022127
0C2454
029289
0F1733
4
NUT HEX 1/4-20 STEEL
9
SCREW THF M6- 1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
UL CIRCUIT BREAKER (JD+L D)
1
COVER JD/L D CB SHRT STAND
1
CB 0300A 3P 600V S JD6 LL
2
INSULATOR CIRCUIT BR. JD/LD
4
SCREW RHM 1/4- 20 X 3
4
W ASHER FLAT 1/4-M6 ZINC
4
W ASHER LOCK M6-1/4
4
NUT HEX 1/4-20 STEEL
9
SCREW THF M6- 1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
0F8135
0E7283
0E7284
0E3664
074908
0F8140
036261
0C2454
029289
0F1733
UL CIRCUIT BREAKER (QN)
1
COVER QN FRM CB
CB 0150A 2P 240V S QN2 LL
CB 0175A 2P S QN2 LL 240V
1
BASE, QN CIRCUIT BREAKER
2
SCREW HHTT M5-0.8 X 10 BP
1
COVER QN CB DISH
4
RIVET POP .125 X .275 SS
11
SCREW THF M6- 1X16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
(1)
(2)
(3)
(4)
ITEM INCL UDED WIT H HARNESS
ITEM INCL UDED WIT H 0D5464B
ITEM USED WIT H EARLY MO DEL 208V UNITS ONLY
ITEMS USED ON 4.2L MO DELS O NL Y.
5)
A
C
D
E
F
G
H
J
K
L
M
N
P
Q
0F8137
0E7994
0F8136
036261
022473
022097
022127
0F8139
0C2454
022237
048527
029289
022770
0F1733
UL CIRCUIT BREAKER (QJ-2P)
1
COVER QJ 2P FRM CB
CB 0225A 240V 2P S QJ22
1
COVER QJ 2P CB DISH
4
RIVET POP .125 X .275 SS
2
WASHER FLAT 1/4-M6 ZINC
2
WASHER LOCK M6-1/4
2
NUT HEX 1/4-20 STEEL
1
INSUL CB 2P QJ
9
SCREW THF M6-1 X 16 N WA Z/JS
2
WASHER LOCK 3/8
2
SCREW SHC 3/8-16 X 3/4 G8.8 NZ
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
2
SCREW RHM 1/4-20 X 3
1
DECAL CUSTOMER CONNECT INSIDE
P
(2) R
(2) S
(2) T
(2) U
(2) V
(1) W
X
0F4185
058306
0F4165$
0F4143
0F4148
0F4149
0F4151
0G5247$
0G5250
0G4478
0F4186
0F4186AGS0R
036261
053640
038150
022264
022471
029289
0F1733
022129
0F8432
0F8432A
0C2454
0F8451
049897
022145
045771
0F8843
W/CB
0G3259
UL CIRCUIT BREAKER (225AF) (2P & 3P)
1
COVER CB C2-C4 (225AF)
3
SCREW SHC M8-1.25 X 25 G12.9
REF
CIRCUIT BREAKERS 200A FRAME (3P)
REF
CB 0040A 3P 480V 225AF (3P)
REF
CB 0125A 3P 480V G 225AF
REF
CB 0150A 3P 480V G 225AF
REF
CB 0200A 3P 480V G 225AF
REF
CB 200A FRAME G 240V (2P)
REF
CB 175A 2 POLE 240V 225AF (2P)
REF
CB 200A 2 POLE 240V 225AF (2P)
1
COVER CB DISH 225AF (3P)
COVER CB DISH 225AF (2P)
4
RIVET POP .125 X .275 SS
2/4
SCREW RHM #8-32 X 3-1/4
2/4
WASHER FLAT #8 ZINC
2/4
WASHER LOCK #8-M4
2/4
NUT HEX #8-32 STEEL
2
TAPE ELEC 1/2 FOAM
1
DECAL CUSTOMER CONNECT INSIDE
6/9
WASHER LOCK M8-5/16
1
INSULATOR CB 225AF (3P)
1
INSULATOR CB 225AF (2P)
11
SCREW THF M6-1 X 16 N WA Z/JS
2/3
LUG SLDLSS 300 MCM-6 AL/CU
4/6
SCREW SHC M8-1.25 X 20 G8
4/6
WASHER FLAT 5/16-M8 ZINC
2/3
NUT HEX M8-1.25 G8 CLEAR ZINC
2/3
BUS BAR 200A LUG ADAPTOR
2
TERMINAL COVER CB
1
DECAL TERMINAL SHOCK HZD BI
7)
A
C
D
E
F
G
H
J
K
(2) L
(2) M
N
P
(1) S
T
U
V
(2) W
(2) X
Y
0F4187
0F4166$
0F1733
042419
023897
022152
022158
0C2454
029289
052647
046526
W/CB
0A7822
W/CB
023334
022097
022473
W/CB
W/CB
0G3259
UL CIRCUIT BREAKER (400AF)
1
COVER CB C2-C4 400AF
REF
CIRCUIT BREAKERS 400A FRAME
1
DECAL CUSTOMER CONNECT INSIDE
4
SCREW RHM 10-32 X 4
4
WASHER FLAT #10 ZINC
4
WASHER LOCK #10
4
NUT HEX #10-32 STEEL
9
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM
2/3
SCREW SHC M10-1.5 X 25 G12.9
2/3
WASHER LOCK M10
3
BUS BAR CB ADAPTER 225-400 A
3
LUG SLDLSS 600/250-1/0 X 1/4-28
2
TERM COVER CB
6
SCREW HHC 1/4-28 X 1/2 G5
6
WASHER LOCK M6-1/4
6
WASHER FLAT 1/4-M6 ZINC
2/3
SCREW SHC M10-1.5 X 25 G12.9
2/3
WASHER LOCK M10
1
DECAL TERMINAL SHOCK HZD BI
6)
A
B
C
D
E
(2) F
(2) G
(2) H
(2) J
K
L
(2) M
N
8)
A
B
C
D
E
F
G
H
9)
A
C
D
E
F
G
H
J
K
L
M
N
0D5466
039287
022145
022129
045771
045335
083896
0A7822
NEUTRAL BLOCK 390 / 200-400A
2
BUS BAR NEUTRAL BLOCK 390
1
SCREW HHC M8-1.25 X 45 G8.8 FT
1
WASHER FLAT 5/16-M8 ZINC
1
WASHER LOCK M8-5/16
1
NUT HEX M8-1.25 G8 YEL CHR
2
SCREW HHC 1/4-28 X 3/4 G5
2
WASHER LOCK 1/4-M6 SS
1
LUG SLDLSS 600/250-1/0 X 1/4-28
0G1968
0G1970
0A2077
040532
0C3990
0E7890
0E6002
022859
0G0008
023897
022152
022158
0F1733
029289
0C2454
UL CIRCUIT BREAKER (BQ)
1
COVER BQ CIR BREAKER CPL 3P
COVER BQ CIR BREAKER CPL 2P
1
CB 0125A 2P 240V S BQ2 LL
CB 0100A 3P 240V S BQ3 LL
2
SCREW PHTT M4-0.7 X 10 ZYC
1
BRKT CB MTG BACK
MTG TRACK BQ SIEMENS CB 3P
6
SCREW RHM #10-32 X 3/4
1
BRKT BQ CB STANDOFF
6
WASHER FLAT #10 ZINC
6
WASHER LOCK #10
6
NUT HEX #10-32 STEEL
1
DECAL CUSTOMER CONNECT INSIDE
1
TAPE ELEC 1/2 FOAM
11
SCREW THF M6-1 X 16 N WA Z/JS
(1) HARDWARE FOR MTG. CB TERMINAL COVERS IS
SUPPLIED WITH CIRCUIT BREAKERS.
(2) QTY. REQ’D FOR “2POLE / 3POLE” BREAKER
1
0F9677
0G0056
0G0959
0G1155
0G1931
0G2101
0G3734
0G6562
0G6564
1
1
1
1
1
1
1
1
1
ROTOR-2390-45KD1 CPL
ROTOR-2390-35KD1 CPL
ROTOR-2390-45KD1 CPL (G2)
ROTOR-2390-35KD1 CPL (G2)
ROTOR 25KW 3PH DIRECT 390 1800
ROTOR 25KW 1PH DIRECT 390 1800
RTR-2390-60KD2 CPL
RTR 390 35AD1 CPL
RTR 390 35KD1 CPL
2
0F9664
0G0057
0G0058
0G0059
0G0183
0G0184
0G1932
0G2098
0G2099
0G2100
0G3736
0G3737
0G3738
0G6104
0G6563
0G6565
0G6566
0G6567
0H0201
0H1299
0H1300
0H1301
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
STATOR-390 45K 2P 1PH DIRECT
STATOR-2390-35AD1 CPL
STATOR-2390-35KD1 CPL
STATOR-2390-35GD1 CPL
STATOR-2309-45KW 2P 3PH 208V
STATOR-2309-45-KD1 CPL
ASSY STR 390 25GD3 CPL
ASSY STR 390 25AD1 CPL
ASSY STR 390 25KD3 CPL
ASSY STR 390 25JD3 CPL
ASSY STR 2390 60AD2 CPL
ASSY STR 390 60KW 2P 3PH 208V
ASSY STR 390 60KW 2P 3PH 480V
STR-2390--45JD1 CPL
STR 390 35AD1 CPL
STR 390 35GD1 CPL
STR 390 35KD1 CPL
STR 390 35JD1 CPL
STR-2390--60JD2 CPL
ASSY STR 390 36AD1 CPL
ASSY STR 390 36JD1 CPL
ASSY STR 390 36 GD1 CPL
3
4
5
6
7
8
0C9708
SEE ENGINE EV
SEE ENGINE EV
0F5767B
0E5706
0F7874
0F7874A
0G0587
038150
023454
077043E
04576100BU
052646
043123
051779
0A2601
072879
0F8408
046526
0C3992
022264
047248
070892
0G0588
077043A
056326
REF
REF
REF
1
1
1
1
1
4
1
1
4
4
4
4
1
1
4
4
4
4
1
1
1
1
1
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23 *
24 *
25
26
27
INSTR HYPOT TEST (NOT SHOWN)
ENGINE ADAPTER
FLEXPLATE
ASSY FLYWHEEL CPL W/40MM FAN B
REAR BEARING CARRIER 390/DRCT
ASSY BRUSH HOLDER 390/HSB
ASSY BRUSH HOLDER 390/HSB
GUARD REAR BEARING CARRIER
WASHER FLAT #8 ZINC
KEY WOODRUFF #E
CONDUIT FLEX 1.0" ID (35” LG)
STUD M14-2.0 570 G5 ZINC
WASHER FLAT M14
WASHER LOCK M14
NUT HEX M14-2.0 G8 YEL CHR
SCREW HHC M16-2.0 X 45 G8.8
SPACER .69 X 2.75 X .37 ST/ZNC
SCREW HHC M10-1.50 X 16 G10.9
WASHER LOCK M10
SCREW HHTT M4-0.7 X 16 BP
WASHER LOCK #8-M4
BALL BEARING-45 MM
SLIP RING MACHINED
GUARD REAR BEARING CARRIER
CONDUIT FLEX .38" ID (60”)
TRIM VINYL BLACK 1/8GP (16.5”LG)
* ROTOR REPLACEMENT PARTS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
0F1823A
0F3078
0F2606
036261
0E7358
052777
0G1303D
0F1262
0F1263
0F1264
0F1725C
067680
0E6875A
055911
0F5459
0E3161
0F5090
0F5462
0A5062J
029673
048467
0F1958
082573
0E4494
0F3215
0F6305
0F6305A
0F5886
051713
049226
0F5752F
0F5884
0F5896
0C2265
0C3990
091526
051716
079224
075476
043180
022264
051715
043182
051714
0F3192
0E7403C
0F9785
COMPONENTS INCLUDED IN 0G3364E
1
ENCL HSB CONTROL PANEL
1
COVER CONTROL PANEL
1
HINGE CONTINUOUS H-PANEL
6
RIVET POP .125 X .275 SS
4
SCREW PPPH HI-LO #4-24 X 3/8
3
WASHER FLAT M3
1
ASSY PCB R-200 3600 RPM
4
HOLDER, FUSE WICKMANN 178.6150
1
ADPTR,RH SIDE WICKMAN 178.6191
1
ADPTR,LH SIDE WICKMAN 178.6192
1
ASSY PCB 2AMP 12V UL BATT CHGR
1
ASSY VOLTAGE REGULATOR 60HZ
2
RELAY, 12VDC C FORM W/DIODE
1
BLOCK TERM 20A 12 X 6 X 1100V
1
DECAL CPL CONTROL PANEL FUSES
1
ASSY PCB BOSCH GOV DRIVER
1
ASSY PCB SCR BRIDGE
1
DECAL CPL 3.9L TB1
4
SPACER 9.5H 3.2 ID
1
DIO BRIDGE 25A 600V
1
CIRCT BRK 7 X 1 ETA 46-500-P
1
PLATE,HARNESS CLAMP
1
SWITCH RKR DPST 125V SPD
1
SWITCH RKR DPDT ON-OFF-ON
1
DECAL, CONTROL HSB
2
SEAL COVER 3.18X12.7X382
1
SEAL COVER 3.18X12.7X283
3
SCREW HHPM M5-0.8 X 12
12
WASHER FLAT M5
12
WASHER LOCK M5
1
RES WW 15R 5% 25W QK CONN
2
SCREW PHTT M3.5-0.6 X 10
2
SCREW PHTT M3.5-0.6 X 16
4
SCREW PHTT M4-0.7 X 12 ZYC
2
SCREW PHTT M4-0.7 X 10 ZYC
4
SCREW PPHM M5-0.8 X 12 ZNC
9
NUT HEX M5-0.8 G8 CLEAR ZINC
2
SCREW PPHM M5-0.8 X 30 SS
2
SCREW PPHM M4-0.7 X 16
2
WASHER FLAT M4
2
WASHER LOCK #8-M4
2
NUT HEX M4-0.7 G8 YEL CHR
7
WASHER LOCK M3
7
NUT HEX M3-0.5 G8 YEL CHR
1
SUPPORT ANGLE PCB
1
FUSE ATO TYPE 15 AMP (BLUE)
1
HARN 3600RPM R200 CONTROL PNL
A
B
C
D
E
F
G
H
J
K
L
056739
022287
022473
022097
022127
0F6145
0F2627A
091526
049226
051713
0G3545
COMPONENTS INSTALLED PER THIS DRAWING
1
RELAY SOLENOID 12VDC PNL MNT
2
SCREW HHC 1/4-20 X 3/4 G5
4
WASHER FLAT 1/4-M6 ZINC
2
WASHER LOCK M6-1/4
2
NUT HEX 1/4-20 STEEL
A/R
SEAL WEATHER .45"DIA
1
COVER CONTROL PANEL SIDE
4
SCREW PPHM M5-0.8 X 12 ZNC
4
WASHER LOCK M5
4
WASHER FLAT M5
1
DANGER HIGH VOLTAGE (SPANISH)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
29
30
31
32
0F9517
052860
052251
052257
052252
052259
052891
0536210410
042909
047411
055414
022447
022097
022473
049813
022261
0F9597A
045764
062963
022302
022131
065852
0F9597
022129
026204
022145
045771
0F9596
0F9596A
052212
0C2454
0H5718
1
4
4
4
4
4
4
1
1
1
1
1
1
2
1
1
1
1
4
5
5
1
1
1
1
1
1
1
1
1
3
1
WELDMENT FRAME 2.4L C2
NUT FLANGED HEX M12-1.75
DAMPENER VIBRATION 40 BLUE
SPACER .49 X .62 X 1.87 PWDR/ZNC
DAMPENER VIBRATION
WASHER FLAT M12
SCREW HHC M12-1.75 X 80 G8.8
ASSY WIRE 14.00"
SCREW HHC M8-1.25 X 30 G8.8
SCREW HHC M6-1.0 X 16 G8.8
LUG SLDLSS #2-#8 X 17/64 CU
WASHER SHAKEPROOF INT 1/4
WASHER LOCK M6-1/4
WASHER FLAT M6-1/4 ZINC
NUT HEX M6 -1.0 G8 YEL CHR
WASHER SHAKEPROOF INT 3/8
SUPPORT LH ENGINE 2.4L
SCREW HHTT M4-0.7 X 8 BP
SCREW HHC M10-1.25 X 30 G8.8
WASHER LOCK 7/16
WASHER FLAT 3/8-M10 ZINC
SPRING CLIP HOLDER .37-.62
SUPPORT RH ENGINE 2.4L
WASHER LOCK M8-5/16
WASHER SHAKEPROOF INT 5/16
WASHER FLAT 5/16-M8 ZINC
NUT HEX M8-1.25 G8 CLEAR ZINC
SPACER ENGINE MOUNT (2.4L G1)
SPACER LH ENGINE MOUNT (2.4L G2)
SCREW HHC M10-1.25 X 25 C8.8
SCREW HWHT M6-1 X 16 N WA Z/JS
HEAT SHIELD 2.4L G2
1
2
3
4
5
6
7
8
9
10
11
12
14
15
16
17
0F3408B
0F3411
025507
052212
046526
022131
050331A
050331
038805Y
03880400AE
045771
022129
0F3976
0C2454
022145
077483
1
1
REF
REF
REF
REF
REF
REF
1
1
REF
REF
1
4
REF
REF
BATTERY TRAY C1 CPL
STRAP BATTERY RETAINMENT
WASHER SHAKEPROOF EXT 7/16 STL
SCREW HHC M10-1.25 X 25 G8.8
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
BATTERY POST COVER RED +
BATTERY POST COVER BLACK CABLE BATTERY BLACK #1 X 18.00
CABLE BATT RED #1 X 18.00
NUT HEX M8-1.25 G8 YEL CHR
WASHER LOCK M8-5/16
BOOT CONTACTOR CABLES
SCREW THF M6-1 X 16 N WA Z/JS
WASHER FLAT 5/16-M8 ZINC
BATTERY 12VDC 75-AH 26
1
2
3
4
5
(1) 6
7
8
0E6586
0E0519A
0C8127
049815
022127
062974
0G0190
037561
1
1
1
4
1
1
1
1
GASKET BOSCH 32 & 40
ADAPTER CARBURETOR W/PVC CONN
ELEMENT AIR CLEANER
SCREW HHC M5-0.8 X 16 G8.8
NUT HEX 1/4-20 STEEL
STUD TH 1/4-20 X 4-1/2 G2 ZNC
PLATE, AIR CLEANER TOP 2.4L
NUT WING 1/4-20 NYLK
(1) APPLY MEDIUM STRENGTH BLUE TREAD LOCKING FLUID TO THREADS ON
ONE END OF I/N 6 (STUD) THAT SCREWS INTO I/N 2 (CARB ADAPTER).
1
2
3
4
5
(2) 6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
0H1951
0H1619
046526
039414
0G0149
0E9868A
0F3217
042574
0A8584
0F4612
057772
057765
043790
0C7649
069860E
063076
0G1394
052830
025507
062963
049821
022129
1
1
3
4
1
1
1
1
1
1
1
1
1
1
1
7
7
2
5
3
3
26
ENGINE 2.4L G2 4G64 CERT
ENGINE 2.4L G2 CERTIFIED
WASHER LOCK M10
SCREW HHC M8-1.25 X 35 G8.8
SCREW SHC M14-1.5 X 35 G10.9
ALTERNATOR DC W/OUT PULLEY
SPACER DC ALTERNATOR PULLEY
ADAPTOR 1/8 NPTF TO 1/8 BSPT
SWITCH OIL PRESSURE 10 PSI 2 POL (R-PANEL)
SENDER OIL PRESSURE 1/8" NPT (H-PANEL)
WASHER NYLON .565
ADAPTER M14-1.50 X 3/8 NPT
BARBED EL 90 3/8 NPT X 3/8
CLAMP HOSE .38-.87
HOSE DRAIN ASSY 28"
WASHER FLAT .531 ID X 1.062 OD
SCREW HHC M12-1.25 X 20 G10.9
SCREW HHC M10-1.25 X 45 G8.8
WASHER SHAKEPROOF EXT 7/16 STL
SCREW HHC M10-1.25 X 30 G8.8
SCREW SHC M8-1.25 X 30 G12.9
WASHER LOCK M8-5/16
21
22
23
25
26
27
28
29
30
31
32
33
34
35
(1) 36
37
38
39
(3) 40
(1) 44
45
46
47
48
49
50
51
52
(1) 53
54
55
56
57
59
(1) 60
61
62
63
(3) 64
65
(3) 66
67
69
70
71
72
73
74
(4) 75
0D6029
0A6751
0E0502
022145
045771
022131
049813
046525
058306
022097
022473
043116
026073A
052243
0A8258
0G0664
0G1502
047290
049340
045757
0G0951
0G3910
0G6093E
0D2244M
0F9420
0G7461
0G1472A
0G1476
0G0707
0G8488
0G0950
0F9583
0G0792
0G0792A
0G1501
0F9501
0G0952
0D3488S
0G0788
0G2750
049721
026925
0F2776
052203
0F2776D
0G7313
0G10080125
0G3823
0G10080288
0G10080289
0G10080290
0G10080291
0G9520
3
1
1
7
3
1
3
2
7
7
10
4
2
1
9
1(REF)
1
1
1
1
1(REF)
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
1
1
1
1
1(REF)
SCREW THF M6-1 X 16 N WA Z/JS
SWITCH HI-TEMP 245D X 3/8 NPT (R-PANEL)
TEMPERATURE SENDER DELPHI (H-PANEL)
WASHER FLAT 5/16-M8 ZINC
NUT HEX M8-1.25 G8 CLEAR ZINC
WASHER FLAT 3/8-M10 ZINC
NUT HEX M6 X 1.0 G8 YEL CHR
NUT HEX M10-1.25 G8 YEL CHR
SCREW SHC M8-1.25 X 25 G12.9
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
SCREW HHC M6-1.0 X 12 G8.8
PLUG STD PIPE 1/4 STEEL SQ HD
SCREW HHC M10-1.5 X 60 G8.8
SCREW HHC M8-1.25 X 25 G10.9
OIL FILTER G2 ENGINE
COIL PACK
HOSE 3/8 ID SINGLE BRAID (15” LG)
BARBED EL 90 1/4 NPT X 3/8
SCREW HHC M6-1.0 X 25 G8.8
GASKET EXHAUST MANIFOLD
EXHAUST MANIFOLD G2 (MACHINE) (25KW, 35KW & 45KW)
FLEX PLATE 2 POLE 2.4L G2
ASSY MAGPICKUP(3/8-24 MALE)
ADAPTER ENGINE 2.4L MACHINE
STARTER 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)
PULLEY DC ALTERNATOR (3600 RPM)
PULLEY 69 OD DC ALTERNATOR (1800 RPM)
SCREW HHC M6-1.0 X 35 G8.8 BLK
PLUG STD PIPE 3/8 STEEL SQ HD
BRACKET, SIGNAL CONDITIONER
SCREW HHC M8-1.25 X 70 G8.8
BRACKET SIGNAL CONDITONER
DECAL EMISSION CTRL INFO 2.4L
ROD ASSY OIL LEVEL GAUGE
O-RING SIZE 9.0MM X 2.0MM NITR
CABLE, SPARK PLUG, NO.1
CABLE, SPARK PLUG, NO.2
CABLE, SPARK PLUG, NO.3
CABLE, SPARK PLUG, NO.4
PLUG TAPER
(1) SUPPLIED WITH ENGINE.
(2) NOT USED ON 1800 RPM UNITS.
(3) USED WITH H-PANEL ONLY
(4) APPLY LOCTITE 620 BEARING RETAINMENT
COMPOUND TO I/N 75.
1
2
3
4
(1) 5
6
0G68030ST03
0F2608
0F5263
046526
059981
0F2776A
1
1
1
5
4
1
7
9
10
11
12
0F5050A
0F2573
0F4011
0G56820ST03
0G2990
1
1
1
1
1
WELDMENT RADIATO R SUPPO RT C2
RADIATOR 598 X 568 X 49 CPL RH
V-BELT 31/64" X 57-3/8"
WASHER LOCK M10
SCREW HHC M10-1.5 X 30 G10.9
BRACKET, SIGNAL CONDITIONER (USED O NLY
WITH QTA PRODUCT)
SHIELD RADIATOR C4
PULLEY FAN V-GROO VE 9"
FAN COOL 22" DIA 10 BLADE LH
FLAT TENSIONER ARM
SHOULDER BOLT 3/8 X 1/2"
13
14
15
16
17
18
19
20
21
23
(1) 24
25
26
(2) 27
28
29
(1) 30
31
32
33
34
35
36
37
38
39
40
(1) 41
42
43
44A
44B
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
(3) 60
(3) 61
0F2862
0F2560
022131
0E2507
1
1
4
1
0H1827
1
035685
0F2561
0C8145
052250
0C7043
022473
0C8146
022097
076749
048031C
031971
0F4496
042911
0F2872
022304
022195
022196
0F8651
070015
0F9867
0F2461
022145
022129
039287
082774
0G0795
0G0816
0H1546
049813
052644
0C8566
0C2454
090283
080713
0G4376
0G 56830ST03
039253
051698
049820
0G 67930ST03
099502
0C8165
029032
029333A
0H1851
2
1
8
2
12
8
4
16
1
2(REF)
1
1
1
1
2
1
1
9
1
1
1
16
10
1
1
1
1
1
8
1
16
2
1
1
1
1
2
1
3
1
2
2
1
9
1
SPRING TENSION CPL
PULL EY V-BELT 4" FLANGED
WASHER FLAT 3/8-M10 ZINC
PRO BE COOLANT LEVEL 3/8 NPTF (USE W ITH
HARNESS P/N 0G 4882)
PRO BE COOLANT LEVEL 3/8- 18NPTF ( USE WITH
HARNESS P/N 0H3069)
CLAMP HOSE #28 1.32- 2.25
HUB FL EX PLATE
WASHER FLEX (THIN)
TAPE FOAM 1 X 1 (26.75” LG)
DISK FLEX
WASHER FLAT 1/4-M6 ZINC
SCREW HHC 5/16-24 X 1.124
WASHER LOCK M6-1/4
TANK CO OLANT RECOVERY
CLAMP HOSE BAND 1/4
BEARING #6205 2NSE C3 E SRI2 S
PULL EY 4.5" DIA MACHINED
SCREW HHC M10-1.5 X 30 G 8.8
SCREW HHC 1/2- 13 X 2" G8
WASHER FLAT 1/2 ZINC
WASHER LOCK 1/2
NUT HEX 1/2-13 STEEL
SCREW HHFC M8-1.25 X 20 W /M6
NUT HEX LO CK 5/16-18 NY INS SS
SHAFT FAN DRIVE
RETAINER BEARING
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
SCREW HHC M8- 1.25 X 45 C8.8
KEY WOODRUFF 4 X 19D
HOSE LOWER RADIATOR G2
HOSE UPPER RADIATOR G2
HOSE UPPER RADIATOR G2
NUT HEX M6 X 1.0 G8 YEL CHR
SPACER .5 X 1.5 X .25 STL/ZINC
SCREW HHFC M6-1.0 X 20 G8.8
SCREW THF M6-1 X 16 N WA Z/JS
CAP RADIATO R 13 PSI
BRACKET CO OLANT TANK
WASHER BELLEVILLE .75X.38X.028
TENSIONER ARM SUPPO RT BENT 90
SCREW HHC M8- 1.25 X 20 C8.8
SCREW HHC M8- 1.25 X 75 C8.8
NUT HEX LO CK M8- 1.25 NY INS
BRACKET TENSIO NER SPRING
CLAMP HOSE #24 B1.06-2.00
NUT HEX LO CK 5/16-24 NY INS
HOSE 9/32 ID (27”LG )
TIE WRAP UL 7.4” X .19” BLK (NO T SHOWN)
ASSY PCB LCL SENSOR (USE WITH I/N 16, P/N
0H1827 O NLY)
BEARING PRESS NOTE:
APPLY LO CTITE 620 BEARING RETAINMENT
COMPOUND TO BEARING SURFACE ON IT EM 37
PRIOR TO PRESSING ITEM 28 ONTO ITEM 37.
ALSO APPLY LOCTITE 620 BEARING RETAINMENT
COMPOUND TO THE OUTSIDE OF 28 PRIO R TO
INSTALLING ITEM 28 INTO ITEM 38.
(1) APPLY MEDIUM STRENGTH BLUE THREAD
LOCKING FLUID TO T HREADS.
(2) INCLUDED W ITH I/N 26.
(3) USE WITH R- PANEL ONLY.
1
2
3
4
5
6
7
9
10
11
13
14
15
16
17
18
19
20
21
22
23
24
26
27
28
29
30
32
026915
075580
0F6390C
0F6390B
039253
022145
022129
045771
0E8286
026812
0F8379
057823
059057
047527
0D1509
050279
050280
0F2119
0E6586
0E4394
0E4395
040105
057753B
0G4573C
0G4573B
0F7790E
0F7790H
0E7121
022097
046580
035685
0F6155
047290
057823
2
1
1
1
2
2
2
2
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
2
1
1
2
NIPPLE CLOSE 3/4 X 1.375
FLANGE FUEL INLET
REGULATOR ASSY 2.4L (25KW)
REGULATOR ASSY 2.4L (35KW & 45KW)
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 CLEAR ZINC
STREET EL 45D 1/2 NPT BRASS
ELBOW 90D 3/4 NPT
NIPPLE PIPE 3/4 NPT X 7
CLAMP HOSE #10 .56 - 1.06
HOSE 3/4 ID SAE-30R2 (18” LG)
BARBED STR 1/2 NPT X 3/4
DECAL INLET PRESSURE
DECAL FUEL INLET NG (NATURAL GAS APPLICATION)
DECAL FUEL INLET LPG (LP VAPOR APPLICATION)
O-RING 45.63 ID X 2.62 WIDTH
GASKET BOSCH 32
ACTUATOR BOSCH 40 GOVERNOR (45KW)
ACTUATOR BOSCH 32 GOVERNOR (25 & 35KW)
HOSE COOL 2 IN ID 20R4 (45KW)
HOSE 1.5 ID X 2 LG 20R4 (35KW)
MIXER ACTUATOR 32MM MACHINED (25KW)
MIXER ACTUATOR 40MM MACHINED (35 & 45KW)
VENTURI THROTTLE 26MM (35 & 45KW)
VENTURI THROTTLE 19MM (25KW)
O-RING 47.625 ID X 2.38 WIDTH
WASHER LOCK M6-1/4
SCREW SHC M6-1.0 X 45 G12.9
CLAMP HOSE #28 1.32-2.25
HARNESS CPL FUEL JUMPER
HOSE 3/8 ID SINGLE BRAID (18” LG)
CLAMP HOSE #10 .56-1.06
RECONFIGURING THE FUEL SYSTEM
Note: All models are configured to run on natural gas from the factory.
To reconfigure the fuel system from NG to LP, follow these steps:
1. Turn the main gas supply off.
2. Remove the carburetor fuel hose from the outlet port of the demand regulator (See Detail “A”).
3. Disconnect the power wires from the fuel solenoid located on top of the regulator assembly.
4. Loosen the spring clamp on the small fuel enrichment line and remove the hose from the hose barb.
5. Remove the black pipe assembly from the outlet port of the demand regulator.
6. Remove the NG fuel jet (loosen counter clockwise) from the outlet port.
7. Remove the LP fuel jet (loosen counter clockwise) from the jet keeper port on the side of the regulator housing.
Install this jet into the outlet port in the regulator casting.
Note: The jet sizes are stamped on the individual jets. The larger jet size is used for running on NG.
8. Install the previously removed NG jet into the jet keeper port on the side of the regulator housing.
9. Install the previously removed black iron pipe onto the outlet port of the demand regulator.
10. Reverse steps 1-4 in this procedure to reactivate the demand regulator.
11. For LP vapor application substitute LPG fuel inlet decal p/n 050280 for NG fuel inlet decal p/n 050279 (Item 17).
12. When switching fuel types, the proper dip switch settings must be made to the control panel. See owners
manual, fuel section, for more details.
1
2
3
4
5
6
7
8
9
10 *
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
0G0045 (XX)
0C2454
0F5849 (XX)
087233
0E3257
0F5852 (XX)
0F9833 (XX)
0F5851 (XX)
049813
077992
0F9835 (XX)
0F2786
0F2785
0F3364
0F4880
0F5049
0C2634A
022473
022097
022127
0F3072
078115
0F4051
0F4051A
0F5048D
0E5968
0F3760K
0F3760E
0F4051C
0F3890B
0F4051B
0F3890
0F3890A
0F3760L
042568
0912970094
022447
0F4051E
0F8869D
078115A
1
54
2
2
4
2
2
1
2
21
1
2
1
1
2
2
1
3
1
1
10
38
2
1
2
1
2
2
2
10
2
4
3
1
2
2
2
1
1
6
REAR WRAP C2 CPL
SCREW THF M6-1 X 16 N WA Z/JS
DOOR C2
RIVET POP .1875 X .450 SS
SCREW TH-FRM M6 W/CAP SHKPRF W
DISCHARGE DUCT LH & RH SIDE C2
FRONT CORNERS C2
DISCHARGE CENTER DUCT C2
NUT HEX M6 X 1.0 G8 YEL CHR
NUT HEX LOCK M6-1.0 SS NY INS
ROOF C2
SLITTER C4
SPLITTER LOWER C4
SPLITTER STINGER C2
SUPPORT SPLITTER LH C2
TAB PULL
ASSEMBLY COVER ACCESS
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX 1/4-20 STEEL
INSULATION RETAINMENT HANGER
WASHER SELF LOCKING DOME #4-40
INSULATION DOOR C2
INSULATION ROOF TOP
VISE-ACTION LATCH SLOTTED CIR
GASKET EXTRUDED TRIM (328” LG)
INSULATION SPLITTER
INSULATION SPLITTER
INSULATION DUCT
RETAINER INSULATION (820)
INSULATION DUCT SIDES
RETAINER INSULATION (450)
RETAINER INSULATION (740)
INSULATION LOWER SPLITTER
SCREW HHC M6-1.0 X 20 G8.8
ASSY WIRE 14 AWG 34.8" GRN/YEL
WASHER SHAKEPROOF INT 1/4
INSULATION REAR WRAP
KEY VISE-ACTION LATCH SLOT CIR
WASHER SELF LOCKING DOME #8-32
OPTIONAL COMPARTMENT MATERIALS:
ALL P/N’S WITH AN (XX) SUFFIX INDICATE A MULTIPLE MATERIAL AND COLOR OPTION.
USE THE FOLLOWING LEGEND TO IDENTIFY THE CORRECT PART NUMBER:
PART NO.
0XXXXXSN
0XXXXXAN
0XXXXXSG
0XXXXXAG
MATERIAL
STEEL
ALUMINUM
STEEL
ALUMINUM
COLOR
TAN
TAN
GRAY
GRAY
* ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO
THE BASE FRAME MUST BE SECURED USING ITEM 2 & 5 THREAD FORMING
FASTENER AND ITEM 39 LOCK NUT. LOCK NUT IS TO BE INSTALLED AFTER THREAD
FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN
ENCLOSURE PANELS. ALL ROOF PANELS ARE TO BE SECURED IN THE SAME
MANNER.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
0F9794
0G0113
0G1007
0F2830
0F2962
080762
0E0170A
0C2454
0G0776
0G0007
044149
085917
0D2611
0E8816
049721
022097
022473
036797
022259
070006
088775
022241
085917
0F2809
0F2808B
2
1
1
2
2
5
1
4
1
1
1
2
2
1
4
4
4
1
2
2
2
10
10
1
1
MUFFLER 7" X 9" X 18-1/2" 2" IN/OUT
EXHAUST ELBOW 2 1/4 OD 2 1/2OD
BRACKET MUFFLER
MUFFLER BRACKET STIFFENER
MUFFLER STRAP
BOLT U 3/8-16 X 2.62
EXHAUST BLANKET 988MM (C2)
SCREW THF M6-1 X 16 N WA Z/JS
PIPE EXHAUST G2
DIFFUSER EXHAUST WELDMENT
GASKET EXHAUST RING
WASHER LOCK 3/8 SS
SCREW HHC 3/8-16 X 1-3/4 SS
EXHAUST FLANGE 2" PIPE
SCREW HHC M6-1.0 X 35 G8.8 BLK
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
BOLT U 5/16-18 X 2.25
NUT HEX 5/16-18 STEEL
WASHER LOCK M8 SS
WASHER FLAT 3/8 SS
NUT HEX 3/8-16 STEEL
WASHER LOCK 3/8 SS
PIPE EXHAUST CROSSOVER
PIPE EXHAUST MUFFLER OUT
* NOT USED ON OPEN SET.
1.)
A
C2 UNITS
0F9832
0F9832GGS0R
0C2454
1
1
4
SHIELD CONN BOX C2
SHIELD CONTROL STAND C2
SCREW THF M6-1 X 16 N WA Z/JS
B
C3 UNITS
0F9832B
0F9832KGS0R
0C2454
1
1
3
SHIELD CONTROL STAND C3
SHIELD CONTROL STAND C3
SCREW THF M6-1 X 16 N WA Z/JS
3.)
A
B
C4 UNITS
0F9832A
0C2454
1
3
SHIELD CONTROL STAND C4
SCREW THF M6-1 X 16 N WA Z/JS
4.)
A
C5 UNITS
0F9832C
0F9832D
0F9832EGS0R
0F9832HGS0R
0F9832JGS0R
0F9832FGS0R
0C2464
1
1
1
1
1
1
3
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SCREW THF M6-1 X 16 N WA Z/JS
B
2.)
A
B
C
Notes
Notes
Warranty
GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR
HOME STANDBY/LIGHT COMMERCIAL STATIONARY EMERGENCY PRODUCT BELOW 50kW
For a period of two (2) years from the date of sale, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part(s) which, upon
examination, inspection, and testing by Generac or an Authorized/Certified Generac Dealer, or branch thereof, is found to be defective under normal use and
service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be examined by
the nearest Authorized/ Certified Generac Dealer, or branch thereof. This warranty applies only to Generac generators used in "Stationary Emergency" applications, as Generac has defined Stationary Emergency, provided said generator has been properly installed and inspected on-site by appropriate personnel.
It is highly recommended that scheduled maintenance, as outlined by the generator Owner's Manual, be performed by an Authorized/Certified Generac
Servie Dealer, or branch thereof. This will verify service has been performed on the unit throughout the warranty period.
*** This warranty only applies to units sold for use in the US and Canada.***
WARRANTY SCHEDULE
YEARS ONE and TWO — Limited comprehensive coverage on mileage, labor, and parts listed.
• - ALL COMPONENTS
*Start-up and/or On-line Activation, or Registration Card, along with Proof of Purchase, must be performed and/or sent in.
GUIDELINES:
• Any and all warranty repairs and/or concerns, must be performed and/or addressed by an Authorized/Certified Generac Service Dealer, or branch thereof.
• A Generac Transfer Switch is highly recommended to be used in conjunction with the genset. If a Non - Generac Transfer Switch is substituted for use and directly causes
damage to the genset, no warranty coverage shall apply.
• All warranty expense allowances are subject to the conditions defined in Generac's General Service Policy Manual.
• Units that have been resold are not covered under the Generac Warranty, as this Warranty is not transferable except with change of ownership of original structure.
• Unit enclosure is only covered against rust or corrosion the first year of the warranty provision.
• Use of Non-Generac replacement part(s) will void the warranty in its entirety.
• Engine coolant heaters (block-heaters), heater controls and circulating pumps are only covered during the first year of the warranty provision (If applicable).
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Any unit built/manufactured prior to January 1, 2005.
Costs of normal maintenance (i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up).
Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze.
Units sold, rated or used for "Prime Power", "Trailer Mounted" or "Rental Unit" applications as Generac has defined Prime Power, Trailer Mounted or Rental Unit. Contact a
Generac Dealer for Prime Power, Trailer Mounted or Rental Unit definition.
Units used for prime power in place of existing utility power where utility is present or in place of utility power where utility power service does not normally exist.
Failures caused by any act of God and other force majeure events beyond the manufacture's control.
Products that are modified or altered in a manner not authorized by Generac in writing.
Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing.
Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the defective part(s).
Failure due to misapplication, misrepresentation, or bi-fuel conversion.
Telephone, facsimile, cell phone, satellite, internet, or any other communication expenses.
Rental equipment used while warranty repairs are being performed (i.e. rental generators, cranes, etc.).
Overtime, holiday, or emergency labor.
Planes, ferries, railroad, busses, helicopters, snowmobiles, snow-cats, off-road vehicle or any other mode of transportation deemed abnormal.
Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct cause of the problem.
Starting batteries, fuses, light bulbs, engine fluids, and overnight freight cost for replacement part(s).
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES AS
TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Any implied warranties which are allowed by law, shall be limited in duration to
the terms of the express warranty provided herein. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may
not apply to purchaser/owner.
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC BE LIABLE FOR
ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC'S NEGLIGENCE.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/ owner.
Purchaser/owner agrees to make no claims against Generac based on negligence. This warranty gives purchaser/owner specific legal rights. Purchaser/
owner also may have other rights that vary from state to state.
Generac Power Systems, Inc. • P.O. Box 8 • Waukesha, WI 53187
Ph: (262) 544-4811 • Fax: (262) 544-4851
1-888-GENERAC (1-888-436-3722)
Bulletin 0171360SVE / Rev. D 06.10 / Printed in U.S.A.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
29
30
31
32
0F9517
052860
052251
052257
052252
052259
052891
0536210410
042909
047411
055414
022447
022097
022473
049813
022261
0F9597A
045764
062963
022302
022131
065852
0F9597
022129
026204
022145
045771
0F9596
0F9596A
052212
0C2454
0H5718
1
4
4
4
4
4
4
1
1
1
1
1
1
2
1
1
1
1
4
5
5
1
1
1
1
1
1
1
1
1
3
1
WELDMENT FRAME 2.4L C2
NUT FLANGED HEX M12-1.75
DAMPENER VIBRATION 40 BLUE
SPACER .49 X .62 X 1.87 PWDR/ZNC
DAMPENER VIBRATION
WASHER FLAT M12
SCREW HHC M12-1.75 X 80 G8.8
ASSY WIRE 14.00"
SCREW HHC M8-1.25 X 30 G8.8
SCREW HHC M6-1.0 X 16 G8.8
LUG SLDLSS #2-#8 X 17/64 CU
WASHER SHAKEPROOF INT 1/4
WASHER LOCK M6-1/4
WASHER FLAT M6-1/4 ZINC
NUT HEX M6 -1.0 G8 YEL CHR
WASHER SHAKEPROOF INT 3/8
SUPPORT LH ENGINE 2.4L
SCREW HHTT M4-0.7 X 8 BP
SCREW HHC M10-1.25 X 30 G8.8
WASHER LOCK 7/16
WASHER FLAT 3/8-M10 ZINC
SPRING CLIP HOLDER .37-.62
SUPPORT RH ENGINE 2.4L
WASHER LOCK M8-5/16
WASHER SHAKEPROOF INT 5/16
WASHER FLAT 5/16-M8 ZINC
NUT HEX M8-1.25 G8 CLEAR ZINC
SPACER ENGINE MOUNT (2.4L G1)
SPACER LH ENGINE MOUNT (2.4L G2)
SCREW HHC M10-1.25 X 25 C8.8
SCREW HWHT M6-1 X 16 N WA Z/JS
HEAT SHIELD 2.4L G2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
0F1823A
0F3078
0F2606
036261
0E7358
052777
0G1303D
0F1262
0F1263
0F1264
0F1725C
067680
0E6875A
055911
0F5459
0E3161
0F5090
0F5462
0A5062J
029673
048467
0F1958
082573
0E4494
0F3215
0F6305
0F6305A
0F5886
051713
049226
0F5752F
0F5884
0F5896
0C2265
0C3990
091526
051716
079224
075476
043180
022264
051715
043182
051714
0F3192
0E7403C
0F9785
COMPONENTS INCLUDED IN 0G3364E
1
ENCL HSB CONTROL PANEL
1
COVER CONTROL PANEL
1
HINGE CONTINUOUS H-PANEL
6
RIVET POP .125 X .275 SS
4
SCREW PPPH HI-LO #4-24 X 3/8
3
WASHER FLAT M3
1
ASSY PCB R-200 3600 RPM
4
HOLDER, FUSE WICKMANN 178.6150
1
ADPTR,RH SIDE WICKMAN 178.6191
1
ADPTR,LH SIDE WICKMAN 178.6192
1
ASSY PCB 2AMP 12V UL BATT CHGR
1
ASSY VOLTAGE REGULATOR 60HZ
2
RELAY, 12VDC C FORM W/DIODE
1
BLOCK TERM 20A 12 X 6 X 1100V
1
DECAL CPL CONTROL PANEL FUSES
1
ASSY PCB BOSCH GOV DRIVER
1
ASSY PCB SCR BRIDGE
1
DECAL CPL 3.9L TB1
4
SPACER 9.5H 3.2 ID
1
DIO BRIDGE 25A 600V
1
CIRCT BRK 7 X 1 ETA 46-500-P
1
PLATE,HARNESS CLAMP
1
SWITCH RKR DPST 125V SPD
1
SWITCH RKR DPDT ON-OFF-ON
1
DECAL, CONTROL HSB
2
SEAL COVER 3.18X12.7X382
1
SEAL COVER 3.18X12.7X283
3
SCREW HHPM M5-0.8 X 12
12
WASHER FLAT M5
12
WASHER LOCK M5
1
RES WW 15R 5% 25W QK CONN
2
SCREW PHTT M3.5-0.6 X 10
2
SCREW PHTT M3.5-0.6 X 16
4
SCREW PHTT M4-0.7 X 12 ZYC
2
SCREW PHTT M4-0.7 X 10 ZYC
4
SCREW PPHM M5-0.8 X 12 ZNC
9
NUT HEX M5-0.8 G8 CLEAR ZINC
2
SCREW PPHM M5-0.8 X 30 SS
2
SCREW PPHM M4-0.7 X 16
2
WASHER FLAT M4
2
WASHER LOCK #8-M4
2
NUT HEX M4-0.7 G8 YEL CHR
7
WASHER LOCK M3
7
NUT HEX M3-0.5 G8 YEL CHR
1
SUPPORT ANGLE PCB
1
FUSE ATO TYPE 15 AMP (BLUE)
1
HARN 3600RPM R200 CONTROL PNL
A
B
C
D
E
F
G
H
J
K
L
056739
022287
022473
022097
022127
0F6145
0F2627A
091526
049226
051713
0G3545
COMPONENTS INSTALLED PER THIS DRAWING
1
RELAY SOLENOID 12VDC PNL MNT
2
SCREW HHC 1/4-20 X 3/4 G5
4
WASHER FLAT 1/4-M6 ZINC
2
WASHER LOCK M6-1/4
2
NUT HEX 1/4-20 STEEL
A/R
SEAL WEATHER .45"DIA
1
COVER CONTROL PANEL SIDE
4
SCREW PPHM M5-0.8 X 12 ZNC
4
WASHER LOCK M5
4
WASHER FLAT M5
1
DANGER HIGH VOLTAGE (SPANISH)
1
2
3
4
5
6
7
8
9
10 *
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
0G0045 (XX)
0C2454
0F5849 (XX)
087233
0E3257
0F5852 (XX)
0F9833 (XX)
0F5851 (XX)
049813
077992
0F9835 (XX)
0F2786
0F2785
0F3364
0F4880
0F5049
0C2634A
022473
022097
022127
0F3072
078115
0F4051
0F4051A
0F5048D
0E5968
0F3760K
0F3760E
0F4051C
0F3890B
0F4051B
0F3890
0F3890A
0F3760L
042568
0912970094
022447
0F4051E
0F8869D
1
54
2
2
4
2
2
1
2
21
1
2
1
1
2
2
1
3
1
1
10
44
2
1
2
1
2
2
2
10
2
4
3
1
2
2
2
1
1
REAR WRAP C2 CPL
SCREW THF M6-1 X 16 N WA Z/JS
DOOR C2
RIVET POP .1875 X .450 SS
SCREW TH-FRM M6 W/CAP SHKPRF W
DISCHARGE DUCT LH & RH SIDE C2
FRONT CORNERS C2
DISCHARGE CENTER DUCT C2
NUT HEX M6 X 1.0 G8 YEL CHR
NUT HEX LOCK M6-1.0 SS NY INS
ROOF C2
SLITTER C4
SPLITTER LOWER C4
SPLITTER STINGER C2
SUPPORT SPLITTER LH C2
TAB PULL
ASSEMBLY COVER ACCESS
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX 1/4-20 STEEL
INSULATION RETAINMENT HANGER
WASHER SELF LOCKING DOME
INSULATION DOOR C2
INSULATION ROOF TOP
VISE-ACTION LATCH SLOTTED CIR
GASKET EXTRUDED TRIM (440.64” LG)
INSULATION SPLITTER
INSULATION SPLITTER
INSULATION DUCT
RETAINER INSULATION (820)
INSULATION DUCT SIDES
RETAINER INSULATION (450)
RETAINER INSULATION (740)
INSULATION LOWER SPLITTER
SCREW HHC M6-1.0 X 20 G8.8
ASSY WIRE 14 AWG 34.8" GRN/YEL
WASHER SHAKEPROOF INT 1/4
INSULATION REAR WRAP
KEY VISE-ACTION LATCH SLOT CIR
OPTIONAL COMPARTMENT MATERIALS:
ALL P/N’S WITH AN (XX) SUFFIX INDICATE A MULTIPLE MATERIAL AND COLOR OPTION.
USE THE FOLLOWING LEGEND TO IDENTIFY THE CORRECT PART NUMBER:
PART NO.
0XXXXXSN
0XXXXXAN
0XXXXXSG
0XXXXXAG
MATERIAL
STEEL
ALUMINUM
STEEL
ALUMINUM
COLOR
TAN
TAN
GRAY
GRAY
* ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO
THE BASE FRAME MUST BE SECURED USING ITEM 2 & 5 THREAD FORMING
FASTENER AND ITEM 39 LOCK NUT. LOCK NUT IS TO BE INSTALLED AFTER THREAD
FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN
ENCLOSURE PANELS. ALL ROOF PANELS ARE TO BE SECURED IN THE SAME
MANNER.
EXPLODED VIEW: EV FUEL SYSTEM 2.4L G2
GROUP E
DRAWING #: 0G1151
ITEM
1
2
3
4
5
6
7
9
10
11
13
14
15
18
19
20
21
22
23
24
26
27
28
29
30
32
33
34
35
36
37
PART#
QTY.
G026915
G075580
0F6390C
0F6390B
G039253
G022145
G022129
G045771
0E8286
G026812
G035589
G057823
G059057
G047527
0F2119
0E6586
0E4394
0E4395
0K9704
057753B
0G4573C
0G4573B
0F7790E
0F7790H
0E7121
G022097
G046580
G035685
0F6155
G047290
G057823
0K2339
0K2340
0K3795
0H3632
0L5884
2
1
1
1
2
2
2
2
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
2
1
1
2
1
1
1
1
1
DESCRIPTION
NIPPLE CLOSE 3/4 X 1.375
FLANGE FUEL INLET
REGULATOR ASSY 2.4L (25KW)
REGULATOR ASSY 2.4L (35KW & 45KW)
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 CLEAR ZINC
STREET EL 45D 1/2 NPT BRASS
ELBOW 90D 3/4 NPT
NIPPLE PIPE 3/4 NPT X 3-1/2
CLAMP HOSE #10 .56 - 1.06
HOSE 3/4 ID SAE-30R2 (18” LG)
BARBED STR 1/2 NPT X 3/4
O-RING 45.63 ID X 2.62 WIDTH
GASKET BOSCH 32
ACTUATOR BOSCH 40 GOVERNOR (45KW)
ACTUATOR BOSCH 32 GOVERNOR (25 & 35KW)
HOSE COOLING 2IN ID 20R4 (2IN) (45KW)
HOSE 1.5 ID X 2 LG 20R4 (35KW)
MIXER ACTUATOR 32MM MACHINED (25KW)
MIXER ACTUATOR 40MM MACHINED (35 & 45KW)
VENTURI THROTTLE 26MM (35 & 45KW)
VENTURI THROTTLE 19MM (25KW)
O-RING 47.625 ID X 2.38 WIDTH
WASHER LOCK M6-1/4
SCREW SHC M6-1.0 X 45 G12.9
CLAMP HOSE #28 1.32-2.25
HARNESS CPL FUEL JUMPER
HOSE 3/8 ID SINGLE BRAID (18” LG)
CLAMP HOSE #10 .56-1.06
REDUCING TEE, 3/4 X 1/4 X 3/4
PLUG, PRESSURE GAUGE, 1/4" NPT
HANG TAG FUEL PRESS TEST POINT
TIE WRAP UL 5.6 X .10 BLACK
LUG PLASTIC 0.75 TAPERED CAP
RECONFIGURING THE FUEL SYSTEM
Note: All models are configured to run on natural gas from the factory.
To reconfigure the fuel system from NG to LP, follow these steps:
1. Turn the main gas supply off.
2. Remove the carburetor fuel hose from the outlet port of the demand regulator (See Detail “A”).
3. Disconnect the power wires from the fuel solenoid located on top of the regulator assembly.
4. Loosen the spring clamp on the small fuel enrichment line and remove the hose from the hose barb.
5. Remove the black pipe assembly from the outlet port of the demand regulator.
6. Remove the NG fuel jet (loosen counter clockwise) from the outlet port.
7. Remove the LP fuel jet (loosen counter clockwise) from the jet keeper port on the side of the regulator housing. Install this jet into the outlet port in the regulator casting.
Note: The jet sizes are stamped on the individual jets. The larger jet size is used for running on NG.
8. Install the previously removed NG jet into the jet keeper port on the side of the regulator housing.
9. Install the previously removed black iron pipe onto the outlet port of the demand regulator.
10. Reverse steps 1-4 in this procedure to reactivate the demand regulator.
11. For LP vapor application substitute LPG fuel inlet decal p/n 050280 for NG fuel inlet decal p/n 050279 (Item 17).
12. When switching fuel types, the proper dip switch settings must be made to the control panel. See owners manual, fuel section, for more details.
REVISION: CN-0026967-L
DATE: 5/31/19
Page 2 of 2
EXPLODED VIEW: EV ENGCOMPRT 2.4L G2
GROUP D
DRAWING #: 0G1141
APPLICABLE TO:
ITEM
PART#
QTY.
DESCRIPTION
1
0H1951
1
ENGINE 2.4L G2 4G64 CERT
0H1619
1
ENGINE 2.4L G2 CERTIFIED
2
G046526
3
WASHER LOCK M10
3
G039414
4
SCREW HHC M8-1.25 X 35 G8.8
4
0G0149
1
SCREW SHC M14-1.5 X 35 G10.9
5
0E9868A
1
ALTERNATOR DC W/OUT PULLEY
6
0F3217
1
SPACER DC ALTERNATOR PULLEY
7
G042574
1
ADAPTOR 1/8 NPTF TO 1/8 BSPT
8
0A8584
1
SWITCH OIL PRESSURE 10 PSI 2 POL (R-PANEL)
0F4612
1
SENDER OIL PRESSURE 1/8" NPT (H-PANEL)
9
G057772
1
WASHER NYLON .565
10
0A4707L
1
ADAPTER 3/8NPT X M14-1.5
11
G043790
1
BARBED EL 90 3/8 NPT X 3/8
12
0C7649
1
CLAMP HOSE .38-.87
13
069860E
1
HOSE DRAIN ASSY 28"
14
G063076
7
WASHER FLAT .531 ID X 1.062 OD
15
0G1394
7
SCREW HHC M12-1.25 X 20 G10.9
16
G052830
2
SCREW HHC M10-1.25 X 45 G8.8
17
G025507
5
WASHER SHAKEPROOF EXT 7/16 STL
18
G062963
3
SCREW HHC M10-1.25 X 30 G8.8
19
G049821
3
SCREW SHC M8-1.25 X 30 G12.9
20
G022129
26
WASHER LOCK M8-5/16
21
0D6029
3
SCREW THF M6-1 X 16 N WA Z/JS
22
0A6751
1
SWITCH HI-TEMP 245D X 3/8 NPT (R-PANEL)
0E0502
1
TEMPERATURE SENDER DELPHI (H-PANEL)
23
G022145
7
WASHER FLAT 5/16-M8 ZINC
25
G045771
3
NUT HEX M8-1.25 G8 CLEAR ZINC
26
G022131
1
WASHER FLAT 3/8-M10 ZINC
27
G049813
3
NUT HEX M6 X 1.0 G8 YEL CHR
28
G046525
2
NUT HEX M10-1.25 G8 YEL CHR
29
G058306
7
SCREW SHC M8-1.25 X 25 G12.9
30
G022097
7
WASHER LOCK M6-1/4
31
G022473
10
WASHER FLAT 1/4-M6 ZINC
32
G043116
4
SCREW HHC M6-1.0 X 12 G8.8
33
026073A
2
PLUG STD PIPE 1/4 STEEL SQ HD
34
G052243
1
SCREW HHC M10-1.5 X 60 G8.8
35
0A8258
9
SCREW HHC M8-1.25 X 25 G10.9
(1) 36
0G0664
1(REF)
OIL FILTER G2 ENGINE
37
0G1502
1
COIL PACK
38
G047290
1
HOSE 3/8 ID SINGLE BRAID (15” LG)
39
G049340
1
BARBED EL 90 1/4 NPT X 3/8
(3) 40
G045757
1
SCREW HHC M6-1.0 X 25 G8.8
(1) 44
0G0951
1(REF)
GASKET EXHAUST MANIFOLD
45
0G3910
1
EXHAUST MANIFOLD G2 (MACHINE) (25KW, 35KW & 45KW)
46
0F9965E
1
FLEX PLATE 2 POLE 2.4L G2
47
0D2244M
2
ASSY MAGPICKUP(3/8-24 MALE)
48
G0F9420
1
ADAPTER ENGINE 2.4L MACHINE
49
0G7461
1
STARTER MOTOR 12V
50
0G1472A
1
CAM SENSOR PIN ASSY
51
0G1476
1(REF)
COVER CAM GEAR G2 REWORKED
52
0G0707
1
MANIFOLD INTAKE (USE HOSE 0G0816)
0G8488
1
MANIFOLD INTAKE (MACHINED) (USE HOSE 0H1546)
(1) 53
0G0950
1(REF)
GASKET INTAKE MANIFOLD
54
0F9583
1
SPACER 2.4L G2 FLEX PLATE
55
0G0792
1
SHIELD HEAT G2
56
0G0792A
1
SHIELD HEAT SML
57
0G1501
1
BRACKET COIL PACK
59
0F9501
1
ADAPTER 2.4L CRANKSHAFT MACH
(1) 60
0G0952
1(REF)
POLY V-BELT G2 (3600 RPM)
0D3488S
1
BELT SERPENTINE 37.0" (1800 RPM)
61
0G0788
1
PULLEY DC ALTERNATOR (3600 RPM)
0H8572
1
PULLEY DC ALTERNATOR (1800 RPM)
62
G049721
3
SCREW HHC M6-1.0 X 35 G8.8 BLK
63
G026925
1
PLUG STD PIPE 3/8 STEEL SQ HD
(3) 64
0F2776
1
BRACKET, SIGNAL CONDITIONER
65
G052203
2
SCREW HHC M8-1.25 X 70 G8.8
(3) 66
0F2776D
1
BRACKET SIGNAL CONDITONER
67
0G9378
1(REF)
DECAL SORE EPA CERTIFICATION
69
0G10080125
1
ROD ASSY OIL LEVEL GAUGE
70
0G3823
1
O-RING SIZE 9.0MM X 2.0MM NITR
71
0G10080288
1
CABLE, SPARK PLUG, NO.1
72
0G10080289
1
CABLE, SPARK PLUG, NO.2
73
0G10080290
1
CABLE, SPARK PLUG, NO.3
74
0G10080291
1
CABLE, SPARK PLUG, NO.4
(2) 75
0G9520
1(REF)
PLUG TAPER
(1) SUPPLIED WITH ENGINE.
(2) APPLY LOCTITE 620 BEARING RETAINMENT COMPOUND TO I/N 75.
(3) USED WITH H-PANEL ONLY
REVISION: CN-0008970-W
DATE: 9/5/17
Page 2 of 2
1
2
3
4
5
6
7
8
(1) 9
10
11
12
13
14
(2) 15
(2) 16
17
18
19
20
21
23
24
(1) 26
27
28
29
30
31
32
33
34
35
36
37
(3) 39
(4) 40
(4) 41
(4) 42
(4) 43
(4) 44
(4) 45
(4) 46
47
1)
A
C
D
E
F
G
H
J
K
L
2)
A
C
D
E
F
G
0F3137
0F3188
0F3189
023484N
0F6366B
0F6366A
043180
022264
0C3990
057701
022155
0C2428
0F3824
0A9457
057073
0D5466
0A7822
022237
022241
049226
0C2266
0C2454
022473
022097
0D4698
0F4464
025433
024469
067210A
0D6029
081008
077043J
051713
0F6156
029289
047411
0G0770
0H0348
036943
023897
022152
022158
0C2454
055934D
0F6145
1
1
1
1
1
1
2
2
2
REF
4
4
1
1
2
REF
REF
2
2
6
6
8
8
4
REF
1
1
1
1
4
1
1
2
1
1
4
1
1
2
4
2
2
1
1
A/R
PAN CB CONN BOX
STAND RH CONTROL
STAND LH CONTROL
BUSHING SNAP SB-2.5-31
XFMR DUAL 120V/16V (F OR 120/240V & 277/480V UNITS)
XFMR DUAL 104V/16V (F OR 120/208V UNITS)
WASHER FL AT M4
WASHER LO CK #8-M4
SCREW PHTT M4-0.7 X 10 ZYC
BLOCK TERM 20A 8 X 6 X 1100V
WASHER LO CK #6
SCREW PHTT #6- 32 X 1/2 ZYC
DECAL UT IL SENSE/CUST CONN
DECAL NEUTRAL
JUNCTION BLOCK 3/8-16
BUS BAR NEUTRAL BLOCK 390
LUG SLDLSS 600/250-1/0 X 1/4-28
WASHER LO CK 3/8
NUT HEX 3/8-16 STEEL
WASHER LO CK M5
SCREW PHTT M5-0.8 X 16 ZYC
SCREW THF M6-1 X 16 N WA Z/JS
WASHER FL AT 1/4-M6 ZINC
WASHER LO CK M6- 1/4
BLOCK TERM 20A 6 X 3 X 1100V
DECAL CUST CO NN 120V UTILITY
LUG SLDLSS #6- 14 X 13/64 CU
SCREW HHTT #10-32 X 3/8 CZ
DECAL GROUND LUG
SCREW HHTT M6-1.0 X 16 Z YC
GROMMET 1.25 X .25 X .75
CONDUIT FLEX 2.0" ID (36” LG)
WASHER FL AT M5
PLATE WIRE SNGL G ALV
TAPE ELEC 1/2 FO AM (AS REQ’D)
SCREW HHC M6-1.0 X 16 G8.8
HARNESS, TRANSFO RMER ADAPTER
ASSY ENCLOSURE PCB 4.2L IGN MD
SCREW PPHM #10/32 X 2
WASHER FL AT #10 ZINC
WASHER LO CK #10
NUT HEX #10-32 STEEL
SCREW THF M6-1 X 16 N WA Z/JS
CLAMP VINYL 1.06 X .406 Z
SEAL W EATHER .45" DIA
0F3328
0D5552
0D5553
0D5554
0D5556
0D9693
0F0492
048927
023897
022152
022158
0C2454
029289
0F1733
UL CIRCUIT BREAKER (ED)
1
COVER ED CB SHO RT STND
1
CB 0050A 3P 480V S ED4 LL
CB 0060A 3P 480V S ED4 LL
CB 0070A 3P 480V S ED4 LL
CB 0090A 3P 480V S ED4 LL
CB 0125A 3P 480V S ED4 LL
1
INSULATOR CB S (ED-3P)
4
SCREW RHM #10-32 X 4- 1/2
4
WASHER FL AT #10 ZINC
4
WASHER LO CK #10
4
NUT HEX #10-32 STEEL
9
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FO AM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
0F3138
0D5572
0D5573
0D5574
0D5575
0D5576
0F0199
081320
022473
022097
UL CIRCUIT BREAKER (F D)
1
COVER CB CONN BO X
1
CB 0150A 3P 600V S FD6 LL
CB 0175A 3P 600V S FD6 LL
CB 0200A 3P 600V S FD6 LL
CB 0225A 3P 600V S FD6 LL
CB 0250A 3P 600V S FD6 LL
1
INSULATOR CB FD FRAME 30MIL
4
SCREW SHC 1/4-20 X 4.5 G8.8 NZ
4
WASHER FL AT 1/4-M6 ZINC
4
WASHER LO CK M6- 1/4
H
J
K
L
3)
A
C
D
E
F
G
H
J
K
L
4)
A
C
D
E
F
G
H
J
K
022127
0C2454
029289
0F1733
0F3329
0D5577
0F2353
022770
022473
022097
022127
0C2454
029289
0F1733
4
NUT HEX 1/4-20 STEEL
9
SCREW THF M6- 1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
UL CIRCUIT BREAKER (JD+L D)
1
COVER JD/L D CB SHRT STAND
1
CB 0300A 3P 600V S JD6 LL
2
INSULATOR CIRCUIT BR. JD/LD
4
SCREW RHM 1/4- 20 X 3
4
W ASHER FLAT 1/4-M6 ZINC
4
W ASHER LOCK M6-1/4
4
NUT HEX 1/4-20 STEEL
9
SCREW THF M6- 1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
0F8135
0E7283
0E7284
0E3664
074908
0F8140
036261
0C2454
029289
0F1733
UL CIRCUIT BREAKER (QN)
1
COVER QN FRM CB
CB 0150A 2P 240V S QN2 LL
CB 0175A 2P S QN2 LL 240V
1
BASE, QN CIRCUIT BREAKER
2
SCREW HHTT M5-0.8 X 10 BP
1
COVER QN CB DISH
4
RIVET POP .125 X .275 SS
11
SCREW THF M6- 1X16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
(1)
(2)
(3)
(4)
ITEM INCL UDED WIT H HARNESS
ITEM INCL UDED WIT H 0D5464B
ITEM USED WIT H EARLY MO DEL 208V UNITS ONLY
ITEMS USED ON 4.2L MO DELS O NL Y.
5)
A
C
D
E
F
G
H
J
K
L
M
N
P
Q
0F8137
0E7994
0F8136
036261
022473
022097
022127
0F8139
0C2454
022237
048527
029289
022770
0F1733
UL CIRCUIT BREAKER (QJ-2P)
1
COVER QJ 2P FRM CB
CB 0225A 240V 2P S QJ22
1
COVER QJ 2P CB DISH
4
RIVET POP .125 X .275 SS
2
WASHER FLAT 1/4-M6 ZINC
2
WASHER LOCK M6-1/4
2
NUT HEX 1/4-20 STEEL
1
INSUL CB 2P QJ
9
SCREW THF M6-1 X 16 N WA Z/JS
2
WASHER LOCK 3/8
2
SCREW SHC 3/8-16 X 3/4 G8.8 NZ
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
2
SCREW RHM 1/4-20 X 3
1
DECAL CUSTOMER CONNECT INSIDE
P
(2) R
(2) S
(2) T
(2) U
(2) V
(1) W
X
0F4185
058306
0F4165$
0F4143
0F4148
0F4149
0F4151
0G5247$
0G5250
0G4478
0F4186
0F4186AGS0R
036261
053640
038150
022264
022471
029289
0F1733
022129
0F8432
0F8432A
0C2454
0F8451
049897
022145
045771
0F8843
W/CB
0G3259
UL CIRCUIT BREAKER (225AF) (2P & 3P)
1
COVER CB C2-C4 (225AF)
3
SCREW SHC M8-1.25 X 25 G12.9
REF
CIRCUIT BREAKERS 200A FRAME (3P)
REF
CB 0040A 3P 480V 225AF (3P)
REF
CB 0125A 3P 480V G 225AF
REF
CB 0150A 3P 480V G 225AF
REF
CB 0200A 3P 480V G 225AF
REF
CB 200A FRAME G 240V (2P)
REF
CB 175A 2 POLE 240V 225AF (2P)
REF
CB 200A 2 POLE 240V 225AF (2P)
1
COVER CB DISH 225AF (3P)
COVER CB DISH 225AF (2P)
4
RIVET POP .125 X .275 SS
2/4
SCREW RHM #8-32 X 3-1/4
2/4
WASHER FLAT #8 ZINC
2/4
WASHER LOCK #8-M4
2/4
NUT HEX #8-32 STEEL
2
TAPE ELEC 1/2 FOAM
1
DECAL CUSTOMER CONNECT INSIDE
6/9
WASHER LOCK M8-5/16
1
INSULATOR CB 225AF (3P)
1
INSULATOR CB 225AF (2P)
11
SCREW THF M6-1 X 16 N WA Z/JS
2/3
LUG SLDLSS 300 MCM-6 AL/CU
4/6
SCREW SHC M8-1.25 X 20 G8
4/6
WASHER FLAT 5/16-M8 ZINC
2/3
NUT HEX M8-1.25 G8 CLEAR ZINC
2/3
BUS BAR 200A LUG ADAPTOR
2
TERMINAL COVER CB
1
DECAL TERMINAL SHOCK HZD BI
7)
A
C
D
E
F
G
H
J
K
(2) L
(2) M
N
P
(1) S
T
U
V
(2) W
(2) X
Y
0F4187
0F4166$
0F1733
042419
023897
022152
022158
0C2454
029289
052647
046526
W/CB
0A7822
W/CB
023334
022097
022473
W/CB
W/CB
0G3259
UL CIRCUIT BREAKER (400AF)
1
COVER CB C2-C4 400AF
REF
CIRCUIT BREAKERS 400A FRAME
1
DECAL CUSTOMER CONNECT INSIDE
4
SCREW RHM 10-32 X 4
4
WASHER FLAT #10 ZINC
4
WASHER LOCK #10
4
NUT HEX #10-32 STEEL
9
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM
2/3
SCREW SHC M10-1.5 X 25 G12.9
2/3
WASHER LOCK M10
3
BUS BAR CB ADAPTER 225-400 A
3
LUG SLDLSS 600/250-1/0 X 1/4-28
2
TERM COVER CB
6
SCREW HHC 1/4-28 X 1/2 G5
6
WASHER LOCK M6-1/4
6
WASHER FLAT 1/4-M6 ZINC
2/3
SCREW SHC M10-1.5 X 25 G12.9
2/3
WASHER LOCK M10
1
DECAL TERMINAL SHOCK HZD BI
6)
A
B
C
D
E
(2) F
(2) G
(2) H
(2) J
K
L
(2) M
N
8)
A
B
C
D
E
F
G
H
9)
A
C
D
E
F
G
H
J
K
L
M
N
0D5466
039287
022145
022129
045771
045335
083896
0A7822
NEUTRAL BLOCK 390 / 200-400A
2
BUS BAR NEUTRAL BLOCK 390
1
SCREW HHC M8-1.25 X 45 G8.8 FT
1
WASHER FLAT 5/16-M8 ZINC
1
WASHER LOCK M8-5/16
1
NUT HEX M8-1.25 G8 YEL CHR
2
SCREW HHC 1/4-28 X 3/4 G5
2
WASHER LOCK 1/4-M6 SS
1
LUG SLDLSS 600/250-1/0 X 1/4-28
0G1968
0G1970
0A2077
040532
0C3990
0E7890
0E6002
022859
0G0008
023897
022152
022158
0F1733
029289
0C2454
UL CIRCUIT BREAKER (BQ)
1
COVER BQ CIR BREAKER CPL 3P
COVER BQ CIR BREAKER CPL 2P
1
CB 0125A 2P 240V S BQ2 LL
CB 0100A 3P 240V S BQ3 LL
2
SCREW PHTT M4-0.7 X 10 ZYC
1
BRKT CB MTG BACK
MTG TRACK BQ SIEMENS CB 3P
6
SCREW RHM #10-32 X 3/4
1
BRKT BQ CB STANDOFF
6
WASHER FLAT #10 ZINC
6
WASHER LOCK #10
6
NUT HEX #10-32 STEEL
1
DECAL CUSTOMER CONNECT INSIDE
1
TAPE ELEC 1/2 FOAM
11
SCREW THF M6-1 X 16 N WA Z/JS
(1) HARDWARE FOR MTG. CB TERMINAL COVERS IS
SUPPLIED WITH CIRCUIT BREAKERS.
(2) QTY. REQ’D FOR “2POLE / 3POLE” BREAKER
1
2
3
4
(1) 5
6
0G68030ST03
0F2608
0F5263
046526
059981
0F2776A
1
1
1
5
4
1
7
9
10
11
12
0F5050A
0F2573
0F4011
0G56820ST03
0G2990
1
1
1
1
1
WELDMENT RADIATO R SUPPO RT C2
RADIATOR 598 X 568 X 49 CPL RH
V-BELT 31/64" X 57-3/8"
WASHER LOCK M10
SCREW HHC M10-1.5 X 30 G10.9
BRACKET, SIGNAL CONDITIONER (USED O NLY
WITH QTA PRODUCT)
SHIELD RADIATOR C4
PULLEY FAN V-GROO VE 9"
FAN COOL 22" DIA 10 BLADE LH
FLAT TENSIONER ARM
SHOULDER BOLT 3/8 X 1/2"
13
14
15
16
17
18
19
20
21
23
(1) 24
25
26
(2) 27
28
29
(1) 30
31
32
33
34
35
36
37
38
39
40
(1) 41
42
43
44A
44B
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
(3) 60
(3) 61
0F2862
0F2560
022131
0E2507
1
1
4
1
0H1827
1
035685
0F2561
0C8145
052250
0C7043
022473
0C8146
022097
076749
048031C
031971
0F4496
042911
0F2872
022304
022195
022196
0F8651
070015
0F9867
0F2461
022145
022129
039287
082774
0G0795
0G0816
0H1546
049813
052644
0C8566
0C2454
090283
080713
0G4376
0G 56830ST03
039253
051698
049820
0G 67930ST03
099502
0C8165
029032
029333A
0H1851
2
1
8
2
12
8
4
16
1
2(REF)
1
1
1
1
2
1
1
9
1
1
1
16
10
1
1
1
1
1
8
1
16
2
1
1
1
1
2
1
3
1
2
2
1
9
1
SPRING TENSION CPL
PULL EY V-BELT 4" FLANGED
WASHER FLAT 3/8-M10 ZINC
PRO BE COOLANT LEVEL 3/8 NPTF (USE W ITH
HARNESS P/N 0G 4882)
PRO BE COOLANT LEVEL 3/8- 18NPTF ( USE WITH
HARNESS P/N 0H3069)
CLAMP HOSE #28 1.32- 2.25
HUB FL EX PLATE
WASHER FLEX (THIN)
TAPE FOAM 1 X 1 (26.75” LG)
DISK FLEX
WASHER FLAT 1/4-M6 ZINC
SCREW HHC 5/16-24 X 1.124
WASHER LOCK M6-1/4
TANK CO OLANT RECOVERY
CLAMP HOSE BAND 1/4
BEARING #6205 2NSE C3 E SRI2 S
PULL EY 4.5" DIA MACHINED
SCREW HHC M10-1.5 X 30 G 8.8
SCREW HHC 1/2- 13 X 2" G8
WASHER FLAT 1/2 ZINC
WASHER LOCK 1/2
NUT HEX 1/2-13 STEEL
SCREW HHFC M8-1.25 X 20 W /M6
NUT HEX LO CK 5/16-18 NY INS SS
SHAFT FAN DRIVE
RETAINER BEARING
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
SCREW HHC M8- 1.25 X 45 C8.8
KEY WOODRUFF 4 X 19D
HOSE LOWER RADIATOR G2
HOSE UPPER RADIATOR G2
HOSE UPPER RADIATOR G2
NUT HEX M6 X 1.0 G8 YEL CHR
SPACER .5 X 1.5 X .25 STL/ZINC
SCREW HHFC M6-1.0 X 20 G8.8
SCREW THF M6-1 X 16 N WA Z/JS
CAP RADIATO R 13 PSI
BRACKET CO OLANT TANK
WASHER BELLEVILLE .75X.38X.028
TENSIONER ARM SUPPO RT BENT 90
SCREW HHC M8- 1.25 X 20 C8.8
SCREW HHC M8- 1.25 X 75 C8.8
NUT HEX LO CK M8- 1.25 NY INS
BRACKET TENSIO NER SPRING
CLAMP HOSE #24 B1.06-2.00
NUT HEX LO CK 5/16-24 NY INS
HOSE 9/32 ID (27”LG )
TIE WRAP UL 7.4” X .19” BLK (NO T SHOWN)
ASSY PCB LCL SENSOR (USE WITH I/N 16, P/N
0H1827 O NLY)
BEARING PRESS NOTE:
APPLY LO CTITE 620 BEARING RETAINMENT
COMPOUND TO BEARING SURFACE ON IT EM 37
PRIOR TO PRESSING ITEM 28 ONTO ITEM 37.
ALSO APPLY LOCTITE 620 BEARING RETAINMENT
COMPOUND TO THE OUTSIDE OF 28 PRIO R TO
INSTALLING ITEM 28 INTO ITEM 38.
(1) APPLY MEDIUM STRENGTH BLUE THREAD
LOCKING FLUID TO T HREADS.
(2) INCLUDED W ITH I/N 26.
(3) USE WITH R- PANEL ONLY.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
0F9794
0G0113
0G1007
0F2830
0F2962
080762
0E0170A
0C2454
0G0776
0G0007
044149
085917
0D2611
0E8816
049721
022097
022473
036797
022259
070006
088775
022241
085917
0F2809
0F2808B
2
1
1
2
2
5
1
4
1
1
1
2
2
1
4
4
4
1
2
2
2
10
10
1
1
MUFFLER 7" X 9" X 18-1/2" 2" IN/OUT
EXHAUST ELBOW 2 1/4 OD 2 1/2OD
BRACKET MUFFLER
MUFFLER BRACKET STIFFENER
MUFFLER STRAP
BOLT U 3/8-16 X 2.62
EXHAUST BLANKET 988MM (C2)
SCREW THF M6-1 X 16 N WA Z/JS
PIPE EXHAUST G2
DIFFUSER EXHAUST WELDMENT
GASKET EXHAUST RING
WASHER LOCK 3/8 SS
SCREW HHC 3/8-16 X 1-3/4 SS
EXHAUST FLANGE 2" PIPE
SCREW HHC M6-1.0 X 35 G8.8 BLK
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
BOLT U 5/16-18 X 2.25
NUT HEX 5/16-18 STEEL
WASHER LOCK M8 SS
WASHER FLAT 3/8 SS
NUT HEX 3/8-16 STEEL
WASHER LOCK 3/8 SS
PIPE EXHAUST CROSSOVER
PIPE EXHAUST MUFFLER OUT
* NOT USED ON OPEN SET.
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