Generac 35 kW QT03524ANSNR Standby Generator Manual

Generac 35 kW QT03524ANSNR Standby Generator Manual

Serial Number STATIONARY EMERGENCY GENERATOR OWNER'S MANUAL 2.4L

35/45kW Models EPA Certified

A new standard of reliability

 

Not intended for use in critical life support applications.

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CAUTION

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ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!

. 0H1631 t No Par Catalog No. OMASPE035-045-1 This manual should remain with the unit.

v. A 01/09 Cover164 Re

Stationary Emergency Generator Table of Contents

SECTION PAGE SAFETY RULES

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1-1

INTRODUCTION .....................................................1-3 Read this Manual Thoroughly ...................................1-3 Operation and Maintenance ......................................1-3 How to Obtain Service ..............................................1-3 IDENTIFICATION RECORD .....................................2-1 EQUIPMENT DESCRIPTION ...................................3-1 Equipment Description ................................................3-1 Engine Oil Recommendations ......................................3-1 Coolant Recommendations...........................................3-1 ENGINE PROTECTIVE DEVICES ............................4-1 High Coolant Temperature Switch ............................4-1 Low Coolant Level Sensor .........................................4-1 Low Oil Pressure Switch ...........................................4-1 RPM Sensor Loss Shutdown .....................................4-1 FUEL SYSTEMS .....................................................5-1 Natural Gas Fuel System ..........................................5-1 Propane Vapor Withdrawal Fuel System....................5-1 LP Fuel System .........................................................5-1 SPECIFICATIONS ...................................................6-1 Engine.......................................................................6-1 Cold Weather Kit .......................................................6-2 Reconfiguring the Fuel System ..................................6-2 GENERAL INFORMATION .......................................7-1 Generator AC Lead Connections ..................................7-1 Four-lead, Single-phase Stator ..................................7-1 Alternator Power Winding Connections ........................7-1 INSTALLATION .......................................................8-1 Installation ...................................................................8-1 Preparation Before Start-up .........................................8-1 Generator Set Lubrication ........................................8-1 Prior to Initial Start-up .............................................8-1 Initial Inspection for QT Genset Start-up .....................8-1 Start-up Checklist ........................................................8-2 Preparation for Start-up............................................8-2 OPERATION ...........................................................9-1 Generator Control and Operation ................................9-1 Operating Unit with Manual Transfer Switch ...............9-1 Engine Start-up and Transfer ...................................9-1 Retransfer and Shutdown .........................................9-1 Operating Unit with Automatic Transfer Switch ...........9-1 MAINTENANCE .....................................................10-1 Maintenance Performed by Authorized Service Facilities .....................................................10-1 Every Three Months ...............................................10-1 Once Every Six Months ...........................................10-1 First 100 Operating Hours ......................................10-1 Every 500 Operating Hours ....................................10-1 Every 800 Operating Hours ....................................10-1 Exhaust Manifold Procedure ......................................10-1 Intake Manifold Procedure .........................................10-1 Cylinder Head Procedure ...........................................10-1 Cooling System ..........................................................10-2 Overload Protection for Engine DC Electrical System ....................................................10-2 Checking Fluid Levels ................................................10-2 Check Engine Oil ....................................................10-2 Maintenance Owner/Operator Can Perform ................10-3 Check Engine Oil Level ...........................................10-3 Inspect Cooling System ...........................................10-3 Check Engine Coolant Level....................................10-3 Perform Visual Inspection .......................................10-3 Inspect Exhaust System ..........................................10-3 Check Fan Belt ........................................................10-3 Inspect Engine Governor ........................................10-3 Changing Engine Oil ...............................................10-3 Changing the Engine Air Cleaner ............................10-3 Miscellaneous Maintenance ........................................10-4 Cleaning the Generator ...........................................10-4 SERVICE SCHEDULE ...........................................11-1 TROUBLESHOOTING ...........................................12-1 Troubleshooting Guide ...............................................12-1 EMISSIONS WARRANTY .......................................13-1 NOTES EXPLODED VIEWS & PARTS LISTS WIRING DIAGRAMS & SCHEMATICS A 11/08 Content031 Rev.

Standby Emergency Generator Important Safety Instructions

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

INTRODUCTION

Thank you for purchasing this model of the stationary emergency generator product line.

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

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READ THIS MANUAL THOROUGHLY

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

Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service or operation that may be hazardous if performed incor rectly or carelessly. Observe them carefully. Their definitions are as follows: 

This symbol points out potential fire hazard.

This symbol points out potential electrical shock hazard.

The operator is responsible for proper and safe use of the equip ment. The manufacturer strongly recommends that the operator read this Owner's Manual and thoroughly understand all instruc tions 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.

For safety reasons, the manufacturer recommends that this equipment be installed, serviced and repaired by a Service Dealer or other competent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations. The operator also must comply with all such codes, standards and regulations.

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

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

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

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

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

Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of information each indicates is as follows: 

This symbol points out important safety informa tion that, if not followed, could endanger per sonal safety and/or property of others.

This symbol points out potential explosion hazard.

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OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment checked periodically by a Service Dealer. Normal maintenance service and replacement of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage con tribute to the need for maintenance service.

Proper maintenance and care of the generator ensure a minimum number of problems and keep operating expenses at a minimum. See a Service Dealer for service aids and accessories.

Operating instructions presented in this manual assume that the generator electric system has been installed by a Service Dealer or other competent, qualified contractor. Installation of this equipment is not a “do-it-yourself” project.

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HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs, simply contact a Service Dealer for assistance. Service technicians are factory trained and are capable of handling all service needs.

When contacting a 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.

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1-1

Standby Emergency Generator Important Safety Instructions

WARNING:

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

 

WARNING:

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

Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely, effi ciently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

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

DANGER

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

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

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

• • • • • • • • • • 

GENERAL HAZARDS

 For safety reasons, the manufacturer recommends that this equipment be installed, serviced and repaired by a Service Dealer or other competent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations. The operator also must comply with all such codes, standards and regulations.

Installation, operation, servicing and repair of this (and related) equipment must always comply with applicable codes, stan dards, 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, operat ed and serviced in accordance with the manufacturer’s instruc tions and recommendations. Following installation, do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes, standards, laws and regulations.

The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. For that reason, adequate ventilation must be provided. This should be considered prior to installing the generator. The unit should be positioned to direct exhaust gasses safely away from any building where people, animals, etc., will not be harmed. Any exhaust stacks that ship loose with the unit must be installed properly per the manufacturer's instruction, and in strict compli ance with applicable codes and standards.

Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.

Adequate, unobstructed flow of cooling and ventilating air is critical in any room or building housing the generator to prevent buildup of explosive gases and to ensure correct generator operation. Do not alter the installation or permit even partial blockage of ventilation provisions, as this can seriously affect safe operation of the generator.

Keep the area around the generator clean and uncluttered. Remove any materials that could become hazardous.

When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued.

Inspect the generator regularly, and promptly repair or replace all worn, damaged or defective parts using only factory approved parts.

Before performing any maintenance on the generator, discon nect 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 dan gerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

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Standby Emergency Generator Important Safety Instructions

• • • • • • • • • • 

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 dan gerous 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 stand ing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT.

If personnel must stand on metal or concrete while installing, operating, servicing, adjusting or repairing this equipment, place insulative mats over a dry wooden platform. Work on the equipment only while standing on such insulative mats.

The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be con nected 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 (ampac ity) 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 pos sibly 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 cir cuit (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 pos sible, 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.

1-3

• 

FIRE HAZARDS

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

• • • • 

EXPLOSION HAZARDS

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

Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.

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

Diesel fuels are highly FLAMMABLE. Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE. Natural gas is lighter than air, and LP gas is heavier than air; install leak detectors accordingly.

. E 08/09 Safety004 Rev

Stationary Emergency Generator General Information

IDENTIFICATION RECORD

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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.

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.

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Stationary Emergency Generator Model and Serial Number

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

Data Label

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. C 05/09 Identy005 Rev

Stationary Emergency Generator Equipment Description

EQUIPMENT DESCRIPTION

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, bat tery charger, and protective alarms as explained in the following paragraph.

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

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 evalu ated and are acceptable according to NEMA MG1-32.

ENGINE OIL RECOMMENDATIONS

The unit has been filled with 5W-20 engine oil at the factory. Use a high-quality detergent oil classified “For Service SJ or SH.” Detergent oils keep the engine cleaner and reduce carbon deposits. When changing the engine oil, be sure to use 5W-30 engine oil.

Any attempt to crank or start the engine before it has been properly serviced with the recom mended 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.

COOLANT RECOMMENDATIONS

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

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

DANGER

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

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

. F 06/09 Equip001 Rev 3-1

Stationary Emergency Generator Engine Protective Devices

ENGINE PROTECTIVE DEVICES

The Stationary Emergency Generator may be required to operate for long periods of time without an opera tor 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 run ning too fast.

NOTE: Engine protective switches and sensors are men tioned here for the reader’s convenience. Also refer to the applicable control panel manual for additional automatic engine shutdown informa tion.

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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.

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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.

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LOW OIL PRESSURE SWITCH

This switch has normally closed contacts that are held open by engine oil pressure during cranking and operating. Should oil pressure drop below the 8 psi range, switch contacts close, and the engine shuts down. The unit should not be restarted until oil is added, and the AUTO/OFF/MANUAL switch must be turned to OFF and then back to AUTO.

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OVERCRANK SHUTDOWN

After a prespecified duration of cranking, this func tion ends the cranking if the engine has failed to start. The overcrank LED will turn ON. Turn OFF the AUTO/OFF/MANUAL switch, then turn switch back to AUTO to reset the generator control board.

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

Approximate Crank Cycle Times

• 15 seconds ON • 7 seconds OFF • 7 seconds ON • 7 seconds OFF • Repeat for 45 seconds Approximately 90 seconds total.

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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.

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RPM SENSOR LOSS SHUTDOWN

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

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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 har ness adjacent to the DC alternator. It is used to pre vent 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 replace ment part number.) B 09/08 EngProt001 Rev.

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Stationary Emergency Generator Fuel Systems

FUEL SYSTEM

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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.

Required fuel pressure for natural gas is 5 inches to 14 inches

water column (0.18 to 0.5 psi); and for liquid propane, 5 inches to 14 inches of water column (0.18 to 0.5 psi).

NOTE: Any piping used to connect the generator to the fuel supply should be of adequate size to ensure the fuel pressure NEVER drops below five inches water column for natural gas or 5 inches water column for propane vapor for all load ranges. 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.

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.

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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 distribu tion 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).

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PROPANE VAPOR WITHDRAWAL FUEL SYSTEM

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

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LP LIQUID FUEL SYSTEM

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

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

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D 07/09 ev.

FuelSys001 R

Stationary Emergency Generator Specifications

SPECIFICATIONS

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STATIONARY EMERGENCY GENERATOR

Type ............................................................................. Synchronous Rotor Insulation ................................................................... Class H Stator Insulation .................................................................. Class H Total Harmonic Distortion ..........................................................<5% Telephone Interference Factor (TIF) ..........................................< 50 Alternator Output Leads 3-phase ........................................... 4-wire Bearings .........................................................................Sealed Ball Coupling .......................................................................Flexible Disc Load Capacity (Standby Rating) .......................................35/45kW* * NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349, ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural gas.

Excitation System ....................................................................Direct

Generator Output Voltage/kW - 60 Hz kW Amp CB Size 120/240V, 1-phase, 1.0 pf 35/45 146/188 175/200 120/208V, 3-phase, 0.8 pf 120/240V, 3-phase, 0.8 pf 35/45 35/45 121/156 150/175 105/135 125/150 277/480V, 3-phase, 0.8 pf 35/45 53/68 60/80 Generator Locked Rotor KVA Available @ Voltage Dip of 35% Single-phase or 208, 3-phase (35/45kW) ..................... 69/80 KVA 480V, 3-phase (35/45kW) ............................................ 76/100 KVA ‹

ENGINE

Make ................................................................................... Generac Model ..................................................................................... In Line Cylinders and Arrangement ............................................................ 4 Displacement ....................................................................... 2.4 Liter Bore ...................................................................................... 3.41 in.

Stroke ................................................................................... 3.94 in.

Compression Ratio ...............................................................8.5-to-1 Air Intake System ...............................................Naturally Aspirated Valve Seats ....................................................................... Hardened Lifter Type .......................................................................... Hydraulic

Engine Parameters

Rated Synchronous RPM ..............................................60 Hz, 3600 HP at rated kW (35/45kW) ...................................................... 55/71

Exhaust System

Exhaust Flow at Rated Output 60 Hz (35/45kW) ......... 360/429 cfm Exhaust Temp. at Rated Output (35/45kW) ............1050° F/1150° F

Combustion Air Requirements (Natural Gas)

Flow at rated power, 60 Hz (35/45kW) ......................... 129/144 cfm

Governor

Type .................................................................................. Electronic Frequency Regulation ...................................................Isochronous

Steady State Regulation ......................................................± 0.25% 6-1

Engine Lubrication System

Type of Oil Pump ...................................................................... Gear Oil Filter ............................................... Full Flow Spin-on, Cartridge Crankcase Oil Capacity ....................................................4 U.S. qts.

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COOLING SYSTEM

Type ...................................................Pressurized Closed Recovery Water Pump .................................................................... Belt Driven Fan Speed .........................................................................2150 rpm Fan Diameter .....................................................................22 inches Fan Mode ................................................................................ Puller Air Flow (inlet air including alternator and combustion air) ...........................................................4500 ft 3 /min.

Coolant Capacity ........................................................ (3.0 U.S. gal.) Heat Rejection to Coolant (35/45kW) ...........134,000/173,000 Btu/h Maximum Operating Air Temp. on Radiator ..............60° C (150° F) Maximum Ambient Temperature ................................50° C (140° F) ‹

FUEL SYSTEM

Type of Fuel ......................................... Natural Gas, Propane Vapor Carburetor ...................................................................... Down Draft Secondary Fuel Regulator .................................................Standard

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

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

Fuel Consumption - ft

3

/hr (Natural Gas/LPV)

Exercise Cycle Load

35kW 87/34.5 150/59.6 291/115.7 405/160.8 560/222.3

45kW 102/40.4 194/77.1 373/148 520/206.3 720/286 ‹

ELECTRICAL SYSTEM

Battery Charge Alternator ............................................12V, 30 Amp Static Battery Charger ............................................................2 Amp Recommended Battery ...................................... Group 26, 525CCA System Voltage .....................................................................12 Volts

Voltage Regulator

Type .................................................................................. Electronic Sensing ........................................................................ Single-phase Regulation ................................................................................± 1% Features ................................................. V/F Adjustable, Adjustable Voltage and Gain LED Indicators

Power Adjustment for Ambient Conditions

Temperature Deration 3% for every 10° C above °C (35/45kW) .............................. 40/25 1.65% for every 10° above °F (35/45kW) ........................... 104/77 Altitude Deration 1% for every 100 m above m (35/45kW) .......................... 915/183 3% for every 1000 ft. above ft. (35/45kW) ....................... 3000/600

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

C 12/08 GenSpec039 Rev.

Stationary Emergency Generator Specifications

Figure 1 — Interconnections

CONTROL PANEL ALTERNATOR CONNECTION BOX N1 N2 23 194 183 178 120 Volt + Neutral Grd Battery Charger Input CIRCUIT BREAKER GROUND TO ALTERNATOR NEUTRAL

Transfer Switch

Utility In NEUTRAL 4- # 14 GA WIRES TO ALTERNATOR CONNECTION BOX Gen N1 N2 23 194 186 178 Load Out TO ALTERNATOR CONNECTION BOX To Generator Control Panel FRAME RAIL Ground Level Concrete Slab STUB-UP AREA See Install Dwg for Dimensions ‹

COLD WEATHER KIT

For cold climates, optional cold weather kit (part number 0F6148) is recommended. The kit includes: • Battery Warmer • 4” Junction Box with hardware • 6 qt. pack 5W-30 synthetic oil (engine) ‹

RECONFIGURING THE FUEL SYSTEM

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

To reconfigure the fuel system from NG to LP, follow these steps: C 12/08 1. Turn the main gas supply off.

2. Remove the carburetor fuel hose from the outlet port of the demand regulator (see Figure 6.2).

3. Disconnect the power wires from the fuel sole noid located on top of the regulator assembly.

4. Loosen the spring clamp on the small fuel enrich ment 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 clock wise) from the outlet port. 7. Remove the LP fuel jet (loosen counter clockwise) from the jet keeper port on the side of the regula tor housing. Install this jet into the outlet port in the regulator casting.

GenSpec039 Rev.

6-2

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

8. Install the previously removed NG jet into the jet keeper port on the side of the regulator housing. 9. Install the previously removed black pipe onto the outlet port of the demand regulator. 10. Reverse steps 1-4 in this procedure to reactivate the demand regulator.

Figure 6.2 — Reconfigure the Fuel System

DANGER

Serious injury or damage may occur if not con figured properly. Please consult an Authorized Dealer with any questions.

Stationary Emergency Generator General Information

GENERATOR AC LEAD CONNECTIONS

See “Voltage Codes”. This Stationary Emergency Generator may be rated at any one of five voltages, either single-phase or three-phase. The electrical wires in the unit’s AC connection (lower) panel should be installed according to the number of leads and the voltage/phase required for the application. If there are any questions regarding lead connection, refer to the wiring diagrams at the back of this manual.

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

ALTERNATOR POWER WINDING CONNECTIONS

‹

FOUR-LEAD, SINGLE-PHASE STATOR

Four-lead generators are built to supply electrical loads with voltage code "A" (240V, 1-phase, 60Hz). Electrical power is produced in the stator power windings. These windings were connected at the fac tory to the main circuit breaker as shown in Figure 7.1.

The rated voltage between each circuit breaker ter minal is 240V. The rated voltage between each circuit breaker terminal and the neutral point 00 is 120V.

Figure 7.1 — Four-lead, Single-phase Stator

‹

3-PHASE ALTERNATORS ("Y" CONFIGURATION)

The Stationary Emergency Generator is designed to supply 3-phase electrical loads. Electric power is produced in the alternator power windings. These windings were connected at the factory to the main circuit breaker with a “Y” configuration as shown in Figures 7.2, 7.3, and 7.4.

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 termi nal and the neutral point 00 is either 277V or 120V depending on the model.

Figure 7.2 — Stator Power Winding Connections - 3-phase, 120/208V (12 Lead)

E1 S7 S1 S10 S12 L - L S4 S5 E3 S9 S3 S6 S11 S2 E2 L - N S8

Figure 7.3 — Stator Power Winding Connections - 3-phase, 277/480V (12 Lead)

S1 E1 S3 E3 S4 S7 S6 S9 S12 S10 S11 S8 S5 L - N L - L

v. A 09/08

S2 E2

ACConn005 Re 7-1

Stationary Emergency Generator General Information

Figure 7.1 — Stator Power Winding Connections - 3-phase, 346/600V (6 Lead)

S1 E1 INTERNAL CONNECTIONS E3 S3 S6 S4 NEUTRAL S5 L-L S2 E2 L-N ‹

3-PHASE ALTERNATORS ("DELTA" CONFIGURATION)

The Stationary Emergency Generator is designed to supply 3-phase electrical loads. Electric power is produced in the alternator power windings. These windings were connected at the factory to the main circuit breaker with a “Delta” configuration as shown in Figures 7.5.

The rated voltage between circuit breaker terminals E1-E2, E1-E3 and E2-E3 is 208V.

The rated voltage between E1 or E3 and the neutral point 00 is 120V.

Figure 7.5 — Stator Power Winding Connections - 3-phase, 120/240V (12 Lead)

E2 E1 E

v. A 09/08 ACConn005 Re 7-2

Stationary Emergency Generator Installation

INSTALLATION

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

For safety reasons, the manufacturer recommends that this equip ment be installed, serviced and repaired by a Service Dealer or other competent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations. The operator also must comply with all such codes, standards and regulations.

PREPARATION BEFORE START-UP

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.

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

‹

TRANSFER SWITCH

If this generator is used to supply power to any electrical system normally powered by an electric utility, the National Electrical Code requires that a transfer switch be installed. The transfer switch pre vents 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.

‹

FUEL SYSTEM

Make sure the fuel supply system to the generator (a) delivers the correct fuel at the correct pressure and (b) is properly purged and leak tested according to code. No fuel leakage is permitted. See “Specifications” for more information.

‹

GENERATOR SET LUBRICATION

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

Check the oil level in the generator gearbox (if so equipped) prior to initial use and at the intervals indicated by the “Service Schedule.” The recommended oil is SAE 90 gear lubricant.

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

‹

PRIOR TO INITIAL START-UP

8-1

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

‹

ENGINE COOLANT

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

‹

BELT TENSION

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

‹

ELECTRICAL SYSTEM

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

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

NOTE: Battery charger must be connected to 120 VAC, 15 amp circuit to operate.

Check to ensure that there are no loose electrical connections. Restrain any loose wires to keep them clear of any moving genera tor set components.

INITIAL INSPECTION FOR GENSET STARTUP

Inspect for the following.

• Freight Damage.

• Manuals present.

• Fluid Levels (Oil, coolant, battery, Gear Drive).

• Correct fuel piping.

• Correct muffler installation for external applications (open units only).

• Adequate air flow, clearances and ventilation per installation drawings and applicable codes.

• Correct AC and DC wire size, connections and grounding. Control and communication wiring to/from the transfer switch must be run in a separate conduit from the AC power leads.

• Battery charger connection to 120 VAC.

• Unit secured to pad.

. F 08/09 Install002 Rev

Stationary Emergency Generator Installation

START-UP CHECKLIST

Before working on the Stationary Emergency Generator, ensure the following: • The AUTO/OFF/MANUAL switch is in the OFF position.

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

‹

PREPARATION FOR START-UP

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

• Remove the fuse from the the control panel. Open the front door of the control box and remove the 15 Amp ATO fuse in the lower left-hand corner of the control box.

• Connect the battery cables to the battery. Attach negative bat tery 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 pres sure. It must be as listed in the Specifications.

• Insert the fuse into the control panel.

• Move the AUTO/OFF/MANUAL switch to the manual position. The engine should now crank and start.

• Check voltage at the generator terminals.

• For 3-phase units, check phase rotation at the transfer switch terminals. The generator phase rotation must match the utility phase rotation.

• Check for coolant, fuel, oil, and exhaust leaks.

• Close the generators main line circuit breaker.

• Turn the generator set off.

• Connect the UTILITY supply to the transfer switch.

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

• Disconnect utility power before the transfer switch.

Engine should start, transfer to load.

Run at least 15 minutes on generator power. Make certain all 3-phase loads are functioning correctly (correct phase rota tion).

• 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.

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8-2

Stationary Emergency Generator Operation

STATIONARY EMERGENCY GENERATOR CONTROL AND OPERATION

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

OPERATING UNIT WITH MANUAL TRANSFER SWITCH

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

‹

ENGINE START-UP AND TRANSFER

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

DANGER

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

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

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

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

In order to transfer load from the utility source to the generator, follow these directions: • • • • Turn OFF or disconnect the utility power circuit to the transfer switch, using the means provided (such as the utility source main line circuit breaker).

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

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

Start the generator.

9-1

 •

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

Let engine stabilize and warm up.

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

‹

RETRANSFER AND SHUTDOWN

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

To transfer the load back to the utility power source and shut down the generator, follow these directions: • • • • • Set the generator’s main line circuit breaker to its OFF (or OPEN) position.

Manually move the transfer switch handle to its UTILITY (NORMAL) position, i.e., load circuits connected to the utility.

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

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

Shut down the generator.

OPERATING UNIT WITH AUTOMATIC TRANSFER SWITCH

If the Stationary Emergency Generator has been installed with an automatic transfer switch, the engine may be started and stopped automatically or manually.

NOTE: Refer to the applicable manual for your transfer switch and to “Transfer Switch Start Signal Connections”. In addition, please note the dangers under “Engine Start-up and Transfer.”

. C 08/09 Oper001 Rev

Stationary Emergency Generator Maintenance

MAINTENANCE PERFORMED BY SERVICE DEALERS/CONTRACTORS

Before working on the Stationary Emergency Generator, ensure the following: • The AUTO/OFF/MANUAL switch is in the OFF position.

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

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

‹

EVERY THREE MONTHS

1. Check battery condition.

2. Inspect and test fuel system.

3. Check transfer switch.

4. Inspect exhaust system.

5. Check engine ignition system.

6. Check fan belts.

‹

ONCE EVERY SIX MONTHS

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

‹

ONCE ANNUALLY

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

2. Clean, inspect generator.

3. Flush cooling system.

4. Clean/re-gap spark plugs or replace as necessary.

‹

FIRST 30 OPERATING HOURS

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

‹

FIRST 100 OPERATING HOURS

1. Change engine oil and oil filter. After initial change, service engine oil and filter at 100 operating hours or six months, whichever comes first.

2. Retorque intake and exhaust manifold.

‹

EVERY 500 OPERATING HOURS

1. Service air cleaner.

2. Check 3. Check engine DC alternator.

COOLING SYSTEM

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

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

OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM

Engine cranking, start up and running are controlled by a solid state Engine Controller circuit board. Battery voltage is delivered to that circuit board via a 15 amp fuse. These overcurrent protection devices will open if the circuit is overloaded.

The exhaust system parts from this product get extremely hot and remains hot after shutdown. High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such materials may ignite and burn from the heat of the exhaust system.

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

CHECKING FLUID LEVELS

‹

CHECK ENGINE OIL

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

Figure 10.1 - Oil Dipstick and Oil Fill Cap

Oil Fill Cap Oil Dipstick

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.

. H 06/09 Maint012 Rev

Stationary Emergency Generator Maintenance

‹

BATTERY FLUID

Check battery electrolyte fluid based on the Maintenance Schedule. Fluid should cover separators in all battery cells. If fluid level is low, add distilled water to cover tops of separators. DO NOT USE TAP WATER IN BATTERY.

‹

ENGINE COOLANT

Check coolant level in coolant recovery bottle. See Specifications.

• Add recommended coolant mixture as necessary.

• Periodically remove radiator pressure cap (only when engine has cooled down) to make sure the coolant recovery system is functioning properly. Coolant should be at bottom of radia tor filler neck. If coolant level is low, inspect gasket in radiator pressure cap. Replace cap, if necessary. To have pressure cap tested, contact a Service Dealer. Inspect cooling system and coolant recovery system for leaks.

MAINTENANCE OWNER/ OPERATOR CAN PERFORM

Before working on the generator, ensure the fol lowing: • The AUTO/OFF/MANUAL switch is in the OFF position.

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

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

‹

CHECK ENGINE OIL LEVEL

Refer to “Checking Fluid Levels”.

‹

PERFORM VISUAL INSPECTION

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

‹

INSPECT EXHAUST SYSTEM

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

‹

CHECK FAN BELT

• Inspect fan belts every three months. Replace any damaged, deteriorated, worn or otherwise defective belt.

• Check fan belt tension. Thumb pressure, exerted midway between pulleys, should deflect about 3/8 to 5/8 of an inch. Adjust belt tension as required.

• Check fan belt alignment.

‹

INSPECT ENGINE GOVERNOR

Visually inspect electronic governor.

DANGER

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

‹

CHANGING ENGINE OIL

‹

CHECK BATTERY

• See “Checking Fluid Levels”.

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

‹

EXERCISE SYSTEM

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.

‹

INSPECT COOLING SYSTEM

• Inspect engine cooling system. See “Maintenance Schedule”.

• Check hoses for damage, deterioration, leaks, etc. Correct any discrepancies found.

• Check hose clamps for tightness.

‹

CHECK ENGINE COOLANT LEVEL

See “Checking Fluid Levels”.

. H 06/09 Maint012 Rev

10-2

Hot oil may cause burns. Allow engine to cool before draining oil. Avoid prolonged or repeated 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.

Drain the oil while the engine is still warm from running. This means warm up the engine, shut it down and drain immediately as follows: 1. Remove OIL DRAIN HOSE from its retaining clip.

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

3. When all oil has drained, install and tighten OIL DRAIN HOSE CAP, and re-install into its retaining clip.

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

Stationary Emergency Generator Maintenance

Figure 10.2 – Oil Filter

Oil Filter 5. Apply light coating of new engine oil to seal of new oil filter.-Install FILTER and tighten by hand only. DO NOT OVER TIGHTEN.

6. Remove OIL FILL CAP and add recommended oil. Crankcase oil capacity is listed in the "Specifications" section.

After refilling the crankcase with oil, always check oil level on dipstick. NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK “ADD” MARK.

7. Start engine and check for oil leaks.

8. Shut OFF engine and wait 10 minutes for the oil to settle down into the oil pan. Recheck oil level on dipstick. DO NOT fill above the dipstick "FULL" mark.

9. Dispose of used oil at a proper collection center.

‹

CHANGING THE ENGINE AIR CLEANER

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).

Figure 10.3 – Engine Air Cleaner

Air Cleaner ‹

SPARK PLUGS

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

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

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

3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 1.07-1.17 mm (0.042-0.046 inch) by carefully bend ing the ground electrode (Figure 10.4).

Figure 10.4 – Setting the Spark Plug Gap

SET PLUG GAP AT 1.07 - 1.17 mm (0.042 - 0.046 inch)

‹

COOLANT CHANGE

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

MISCELLANEOUS MAINTENANCE

‹

CLEANING THE STATIONARY EMERGENCY GENERATOR

Keep the generator as clean and as dry as possible. Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation resistance.

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

Once each year have the generator cleaned and inspected by a Service Dealer. That dealer will use dry, low pressure air to clean internal windings. Parts inside the control console should be cleaned and inspected at this time as well.

Finally, have the insulation resistance of stator and rotor windings checked. If insulation resistances are excessively low, the genera tor may require drying.

(Doors Removed for Clarity) See the “Service Schedule,” for air cleaner maintenance.

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10-3

Stationary Emergency Generator Maintenance

‹

BATTERY

All lead-acid storage batteries discharge when not in use. Refer to specific instructions and warnings that accompany the battery. If such information is not available, observe the following precau tions when handling a battery: • DO NOT use jumper cables and a booster battery to crank or start the generator engine.

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

• Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns. DO NOT permit fluid to contact eyes, skin, clothing, painted surfaces, wiring insulation, etc. If any battery fluid is spilled, flush the affected area with clear water immediately.

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

• Batteries give off explosive hydrogen gas while charging. The gas can form an explosive mixture around the battery for sev eral hours after charging. Any spark, heat or flames can ignite the gas and cause an explosion which can shatter the battery, causing blindness or other serious injury.

‹

BATTERY MAINTENANCE

The battery should be inspected per the "Scheduled Maintenance" section. The following procedure should be followed for inspec tion: 1. Inspect the battery posts and cables for tightness and corro sion. Tighten and clean as necessary.

2. Check the battery fluid level of unsealed batteries and, if necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP WATER IN BATTERIES.

3. Have the state of charge and condition checked. This should be done with an automotive-type battery hydrometer.

DANGER

Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charg ing. 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 smok ing, open flame, sparks or any spark producing tools or equipment near the battery.

Battery electrolyte fluid is an extremely corro sive sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If fluid is spilled, flush the affected area immediately with clear water.

Do not use any jumper cables or booster battery to crank and start the generator engine. If the battery has completely discharged, remove it from the generator for recharging.

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

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

‹

BATTERY REPLACEMENT

NOTE: Unit DOES NOT include battery.

When supplying or replacing the battery, the recommended num ber and type of battery is listed in the Specifications Section.

NOTE: The BCI number should be located directly on the battery.

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10-4

Stationary Emergency Generator 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: • 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 opera tion 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.

11-1

. F 07/09 SrvSchd001 Rev

Stationary Emergency Generator Service Schedule Maintenance Level 1 Tasks

1. from operating per the first page warning.

2. oil level. Adjust as necessary.

3. 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.

Level 2 Level 3 Level 4 Level 5

Recom mended 10 hrs. Task Required Task Required Task Comp. to be done Comp. to be done Comp. Task Required Task Required Comp. to be done Comp.

to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Date monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) annually/ Initials) 30 hrs. 50 hrs. 100 hrs. 250 hrs.

. F 07/09 SrvSchd001 Rev

11-2

Stationary Emergency Generator Service Schedule Maintenance Level 1 Tasks

Recom mended to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Date monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) annually/ Initials) 10 hrs. Task Required Task Required Task Comp. to be done Comp. to be done Comp.

Level 2

30 hrs.

Level 3

50 hrs.

Level 4

Task Required Task Required Comp. to be done Comp.

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

11. Check the engine valve clearance/ lash. Adjust as necessary.** 12. Visually inspect the unit looking for leaks, wear or damage, loose connections or components, and corrosion. Correct as necessary.

13. Test the engine and transfer switch safety devices. Correct and/or adjust as necessary.

14. Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks, loose connections or components, and abnormal 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.

Level5

250 hrs.

11-3

. F 07/09 SrvSchd001 Rev

Stationary Emergency Generator Service Schedule Maintenance Level 1 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 2 Level 3 Level 4 Level5

Recom mended 10 hrs. Task Required Task Required Task Comp. to be done Comp. to be done Comp. Task Required Task Required Comp. to be done Comp.

to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Date monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) annually/ Initials) 30 hrs. 50 hrs. 100 hrs. 250 hrs.

. F 07/09 SrvSchd001 Rev

11-4

Stationary Emergency Generator Troubleshooting

TROUBLESHOOTING GUIDE PROBLEM CAUSE

Engine won’t crank. Engine cranks but won't start Engine starts hard, runs rough. 1. 15 amp fuse blown. 2. Loose or corroded or defective battery cables. 3. Defective starter contactor. 4. Defective starter motor. 5. Dead or Defective Battery. 6. 5 amp fuse blown. 1. Out of fuel. 2. Fuel solenoid (FS) is defective 3. Open Wire #14A from Engine Control circuit board.

4. Spark plugs defective. 5. Door on tank not closed. 1. Flame arrestor (air cleaner) plugged or damaged.

2. Plugged fuel line. 3. Defective spark plugs. 4. Fuel pressure incorrect. Engine starts then shuts down. AUTO/OFF/MANUAL Switch at OFF, engine continues to run 1. Engine oil level is low. 2. Engine is overheated. 3. Defective Low Oil Pressure Switch 4. Defective Coolant Temperature Switch 5. Defective Control Module circuit board. 6. Coolant Level is Low. 7. Defective Low Coolant Level Switch 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 No AC output from generator. 1. Check main line circuit breaker. 2. Check circuit breaker & fuses. 3. Transfer switch set to NORMAL position 4. Generator internal failure. 5. Thermal circuit breaker open.

CORRECTION

1. Replace fuse.

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

3. Replace contactor.* 4. Replace starter motor.* 5. Remove, change or replace battery.

6. Replace fuse.* 1. Replenish fuel.

2. Replace solenoid.* 3. Reconnect wire.

4. Clean, regap or replace plugs.

5. Close door on tank.

1. Clean or replace as needed. 2. Unclog fuel line.

3. Clean, regap or replace plugs.

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

1. Check oil and add oil as needed.

2. Check cooling system for leaks.

3. Replace switch.* 4. Replace switch.* 5. Replace board.* 6. Repair leak - Add coolant.

7. Replace Switch.* 1. Replace switch.* 2. Reconnect/close wire. 3. Replace board.* 1. Reset to ON or CLOSED.

2. Reset and replace, if necessary.

3. Set to GENERATOR position.

4. * 5. Auto-reset - Wait 5 min. and attempt restart.

*Contact the nearest Authorized Dealer for assistance.

A 10/08 lsht001 Rev.

T rb 12-1

Stationary Emergency Generator Warranty

United States Environmental Protection Agency Warranty Statement Warranty Rights, Obligations and Coverage

The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system or component on your engine is found defective in materials or workmanship Generac will repair your engine at no cost to you for diagnosis, replacement parts and labor provided it be done by an Authorized Warranty Service Facility. Your emission control system may include parts such as the fuel metering, ignition, and exhaust systems and other related emission related components listed below. Generac will warrant the emissions control systems on your 2009 and later model year engines provided there has been no abuse, neglect, unapproved modification or improper main tenance of your engine. For engines less than 130 HP the warranty period is two years from the date of sale to the ultimate purchaser. For engines greater than or equal to 130 HP the warranty period is three year from the date of the engine being placed into service.

Purchaser’s/Owner’s Warranty Responsibilities

As the engine purchaser/owner you are responsible for the following. 1.) The engine must be installed and configured in accordance to the installation specifications. 2.) The completion of all maintenance requirements listed in your Owner’s Manual. 3.) Any engine setting adjustment must be done in accordance and consistent with the instructions in the Owner’s Manual. 4.) Any emission control system or component must be maintained and operated appropriately in order to ensure proper operation of the engine and control system to minimize emissions at all times. Generac may deny any, or all Emission Control System Warranty coverage or responsibility of the engine, or an emission control system or component on your engine thereof, if it has failed due to abuse, neglect, unapproved modification or improper maintenance, or the use of counterfeit and/or ‘gray market’ parts not made, supplied or approved by Generac. Warranty service/scheduled maintenance can be arranged by contacting your selling dealer or an Authorized Warranty Service dealer. The purchaser/owner shall be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the inspection or repair facilities. The purchaser/owner shall be responsible for any and/ or all damages or losses incurred while the engine is being transported/shipped for inspection or warranty repairs.

Emission Related Parts Include the Following (if so equipped)

1) Fuel Metering System 1.1) Gasoline Carburetor assembly and internal components a) Fuel filter, b) Carburetor, c) Fuel Pump 1.2) Carburetion assembly and its components a) Fuel controller, b) Carburetor and its gaskets, c) Mixer and it gaskets, d) Primary gas regulator e) Liquid vaporizer 1.3) Fuel Regulator 2) Air Induction System including a) Intake pipe/manifold, b) Air cleaner 3) Ignition System including a) Spark plug, b) Ignition module, c) ignition coil, d) Spark plug wirers 4) Exhaust system a) Catalyst assembly, b) Exhaust manifold, c) Muffler, d) Exhaust pipe, e) Muffler gasket 5) Crankcase Breather Assembly including a) Breather connection tube, b) PCV valve 6) Oxygen Sensor 7) Diagnostic Emission-Control System B 06/09 ev.

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13-1

Stationary Emergency Generator Warranty

United States Environmental Protection Agency Compliance Requirements Purchaser’s/Owner’s Recordkeeping Responsibilities

The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac), are pleased to explain your recordkeeping requirements for compliance with Subpart JJJJ – Standards of Performance for Stationary Spark Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60. As the engine purchaser/owner who operates and maintains their certified emergency stationary engine and emission control system according to applicable emission related guidelines as specified in this Owner’s Manual you are required to meet the fol lowing notification and recordkeeping requirements to demonstrate compliance. 1.) Maintain documentation that the engine is certified to meet emission standards. 2.) Recordkeeping of maintenance conducted. 3.) Recordkeeping of the provision allowing natural gas engines to operate using propane for a maximum of 100 hours per year as an alternate fuel solely dur ing emergency operations provided the engine is not certified to operate on propane. 4.) Meet all compliance notifications submitted to the purchaser/owner and maintain all supporting documentation. 5.) Recordkeeping of hours of operation, including what classified the operation as emergency and how many hours are spent for non-emergency operation. For emergency engines greater than or equal to 130 HP, recordkeeping of hours of operation begins January 1, 2011. For emer gency engines less than 130 HP, recordkeeping of hours of operation begins January 1, 2009; Engines are equipped with non-resettable hour meters to facilitate recordkeeping. Specific Air Quality Management or Air Pollution Control Districts may have different and additional record keeping/ reporting requirements. Your permit to construct and/or operate the engine may be contingent upon compliance with those require ments. Check with your local Air Quality Management or Air Pollution Control District for specific requirements. Emergency stationary internal combustion engines (ICE) may be operated for the purpose of maintenance checks and readi ness testing, provided that the tests are recommended by Federal, State or local government, Generac, or the insurance com pany associated with the engine. Maintenance checks and readiness testing of such units is limited to 100 hours per year. There is no time limit on the use of emergency stationary ICE in emergency situations. The purchaser/owner may petition the Administrator for approval of additional hours to be used for maintenance checks and readiness testing, but a petition is not required if the owner maintains records indicating that Federal, State, or local standards require maintenance and testing of emergency ICE beyond 100 hours per year. Emergency stationary ICE may operate up to 50 hours per year in non-emergen cy situations, but those 50 hours are counted towards the 100 hours per year provided for maintenance and testing. The 50 hours per year for non-emergency situations cannot be used for peak shaving or to generate income for a facility to supply power to an electric grid or otherwise supply power as part of a financial arrangement with another entity. For purchaser/ owner of emergency engines, any operation other than emergency operation, maintenance and testing, and operation in non emergency situations for 50 hours per year, as permitted in this section is prohibited. If you operate and maintain your certified emergency stationary SI internal combustion engine and emissions control sys tems in accordance with the specifications and guidelines in the Owner’s Manual, EPA will not require engine performance testing. If not, your engine will be considered non-certified and you must demonstrate compliance according to Subpart JJJJ – Standards of Performance for Stationary Spark Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60.

Emission-Related Installation Instructions

B 06/09 Your certified emergency stationary engine has pre-set emission control systems or components that require no adjustment. Inspection and replacement of an emissions related component is required to be done in accordance with the requirements cited in the United States Environmental Protection Agency Warranty Statement or can be arranged by contacting your sell ing dealer or an Authorized Warranty Service dealer. Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates federal law 40 CFR 1068.105 (b), subject to fines or penalties as described in the Clean Air Act. ev.

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13-2

Stationary Emergency Generator Notes

Stationary Emergency Generator Notes

Stationary Emergency Generator Notes

Stationary Emergency Generator Notes

D E F D E F G G H J K L 2) A C (3) 39 (4) 40 (4) 41 (4) 42 (4) 43 (4) 44 (4) 45 (4) 46 47 1) A C 33 34 35 36 37 27 28 29 30 31 32 1 2 3 6 7 8 4 5 (1) 9 10 11 12 13 14 (2) 15 (2) 16 17 18 19 20 21 23 24 (1) 26 0D5554 0D5556 0D9693 0F0492 048927 023897 022152 022158 0C2454 029289 0F1733 0F3138 0D5572 0D5573 0D5574 0D5575 0D5576 0F0199 081320 022473 022097 0F4464 025433 024469 067210A 0D6029 081008 077043J 051713 0F6156 029289 047411 0G0770 0H0348 036943 023897 022152 022158 0C2454 055934D 0F6145 0F3328 0D5552 0D5553 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 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 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 1 2 1 1 4 1 1 1 1 4 1 1 1 2 4 2 2 DECAL CUST CO NN 120V UTILITY LUG SLDLSS #6- 14 X 13/64 CU SCREW HHTT #10-32 X 3/8 CZ DECAL GROUND LUG SCREW HHTT M6-1.0 X 16 Z YC GROMMET 1.25 X .25 X .75 CONDUIT FLEX 2.0" ID (36” LG) WASHER FL AT M5 PLATE W IRE SNGL G ALV TAPE ELEC 1/2 FO AM (AS REQ’D) SCREW HHC M6-1.0 X 16 G8.8 HARNESS, TRANSFO RMER ADAPTER ASSY ENCLOSURE PCB 4.2L IGN MD SCREW PPHM #10/32 X 2 WASHER FL AT #10 ZINC WASHER LO CK #10 NUT HEX #10-32 STEEL 1 1 A/R SCREW THF M6-1 X 16 N WA Z/JS CLAMP VINYL 1.06 X .406 Z SEAL W EATHER .45" DIA UL CIRCUIT BREAKER (ED) 1 1 - COVER ED CB SHO RT STND CB 0050A 3P 480V S ED4 LL CB 0060A 3P 480V S ED4 LL - - - 1 4 4 - - - 1 4 4 4 CB 0070A 3P 480V S ED4 LL CB 0090A 3P 480V S ED4 LL CB 0125A 3P 480V S ED4 LL INSULATOR CB S (ED-3P) SCREW RHM #10-32 X 4- 1/2 WASHER FL AT #10 ZINC 4 4 9 1 WASHER LO CK #10 NUT HEX #10-32 STEEL SCREW THF M6-1 X 16 N WA Z/JS TAPE ELEC 1/2 FO AM (AS REQ’D) 1 UL CIRCUIT BREAKER (F D) 1 DECAL CUSTOMER CONNECT INSIDE COVER CB CONN BO X 1 - CB 0150A 3P 600V S FD6 LL CB 0175A 3P 600V S FD6 LL CB 0200A 3P 600V S FD6 LL CB 0225A 3P 600V S FD6 LL CB 0250A 3P 600V S FD6 LL INSULATOR CB FD FRAME 30MIL SCREW SHC 1/4-20 X 4.5 G8.8 NZ WASHER FL AT 1/4-M6 ZINC WASHER LO CK M6- 1/4 J K H J K L 3) A C D E F G H J K L 4) A C D E F G H 029289 0F1733 022127 0C2454 029289 0F1733 0F3329 0D5577 0F2353 022770 022473 022097 022127 0C2454 029289 0F1733 0F8135 0E7283 0E7284 0E3664 074908 0F8140 036261 0C2454 4 9 1 1 DECAL CUSTOMER CONNECT INSIDE UL CIRCUIT BREAKER (JD+L D) 1 COVER JD/L D CB SHRT STAND 1 2 4 NUT HEX 1/4-20 STEEL SCREW THF M6- 1 X 16 N W A Z/JS TAPE ELEC 1/2 FOAM (AS REQ’D) CB 0300A 3P 600V S JD6 LL INSULATOR CIRCUIT BR. JD/LD SCREW RHM 1/4- 20 X 3 4 4 4 W ASHER FLAT 1/4-M6 ZINC W ASHER LOCK M6-1/4 NUT HEX 1/4-20 STEEL 9 1 SCREW THF M6- 1 X 16 N W A Z/JS TAPE ELEC 1/2 FOAM (AS REQ’D) 1 DECAL CUSTOMER CONNECT INSIDE UL CIRCUIT BREAKER (QN) 1 - - 1 2 COVER QN FRM CB CB 0150A 2P 240V S QN2 LL CB 0175A 2P S QN2 LL 240V BASE, QN CIRCUIT BREAKER SCREW HHTT M5-0.8 X 10 BP 1 4 11 COVER QN CB DISH RIVET POP .125 X .275 SS SCREW THF M6- 1X16 N WA Z/JS 1 1 TAPE ELEC 1/2 FOAM (AS REQ’D) DECAL CUSTOMER CONNECT INSIDE (1) ITEM INCL UDED W IT H HARNESS (2) ITEM INCL UDED W IT H 0D5464B (3) ITEM USED W IT H EARLY MO DEL 208V UNITS ONLY (4) ITEMS USED ON 4.2L MO DELS O NL Y.

5) A C D E F G H J K L M N P Q 6) A B C D E (2) M N P (1) S T U V (2) W (2) X Y (2) F (2) G (2) H (2) J K L (2) M N P (2) R (2) S (2) T (2) U (2) V (1) W X 7) A C H J K (2) L D E F G 0F8137 0E7994 0F8136 036261 022473 022097 022127 0F8139 0C2454 022237 048527 029289 022770 0F1733 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 0F4187 0F4166$ 0F1733 042419 023897 022152 022158 0C2454 029289 052647 046526 W/CB 0A7822 W/CB 023334 022097 022473 W/CB W/CB 0G3259 2/3 3 3 2 6 6 6 2/3 2/3 1 2 1 9 2 2 1 2 UL CIRCUIT BREAKER (QJ-2P) 1 - COVER QJ 2P FRM CB CB 0225A 240V 2P S QJ22 1 4 2 2 COVER QJ 2P CB DISH RIVET POP .125 X .275 SS WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 NUT HEX 1/4-20 STEEL INSUL CB 2P QJ SCREW THF M6-1 X 16 N WA Z/JS WASHER LOCK 3/8 SCREW SHC 3/8-16 X 3/4 G8.8 NZ TAPE ELEC 1/2 FOAM (AS REQ’D) SCREW RHM 1/4-20 X 3 1 DECAL CUSTOMER CONNECT INSIDE UL CIRCUIT BREAKER (225AF) (2P & 3P) 1 3 REF REF COVER CB C2-C4 (225AF) SCREW SHC M8-1.25 X 25 G12.9 CIRCUIT BREAKERS 200A FRAME (3P) CB 0040A 3P 480V 225AF (3P) REF REF REF REF REF REF 1 4 CB 0125A 3P 480V G 225AF CB 0150A 3P 480V G 225AF CB 0200A 3P 480V G 225AF CB 200A FRAME G 240V (2P) CB 175A 2 POLE 240V 225AF (2P) CB 200A 2 POLE 240V 225AF (2P) COVER CB DISH 225AF (3P) COVER CB DISH 225AF (2P) RIVET POP .125 X .275 SS 2/4 2/4 2/4 2/4 2 1 6/9 1 1 11 2/3 4/6 4/6 2/3 SCREW RHM #8-32 X 3-1/4 WASHER FLAT #8 ZINC WASHER LOCK #8-M4 NUT HEX #8-32 STEEL TAPE ELEC 1/2 FOAM DECAL CUSTOMER CONNECT INSIDE WASHER LOCK M8-5/16 INSULATOR CB 225AF (3P) INSULATOR CB 225AF (2P) SCREW THF M6-1 X 16 N WA Z/JS LUG SLDLSS 300 MCM-6 AL/CU SCREW SHC M8-1.25 X 20 G8 WASHER FLAT 5/16-M8 ZINC NUT HEX M8-1.25 G8 CLEAR ZINC 2/3 2 1 BUS BAR 200A LUG ADAPTOR TERMINAL COVER CB DECAL TERMINAL SHOCK HZD BI UL CIRCUIT BREAKER (400AF) 1 COVER CB C2-C4 400AF REF CIRCUIT BREAKERS 400A FRAME 1 4 4 4 4 9 1 2/3 DECAL CUSTOMER CONNECT INSIDE SCREW RHM 10-32 X 4 WASHER FLAT #10 ZINC WASHER LOCK #10 NUT HEX #10-32 STEEL SCREW THF M6-1 X 16 N WA Z/JS TAPE ELEC 1/2 FOAM SCREW SHC M10-1.5 X 25 G12.9 WASHER LOCK M10 BUS BAR CB ADAPTER 225-400 A LUG SLDLSS 600/250-1/0 X 1/4-28 TERM COVER CB SCREW HHC 1/4-28 X 1/2 G5 WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC SCREW SHC M10-1.5 X 25 G12.9 WASHER LOCK M10 DECAL TERMINAL SHOCK HZD BI 8) A B C D E F G H 9) A C D E F G N H J K L M 0D5466 039287 022145 022129 045771 045335 083896 0A7822 0G1968 0G1970 0A2077 040532 0C3990 0E7890 0E6002 022859 0G0008 023897 022152 022158 0F1733 029289 0C2454 NEUTRAL BLOCK 390 / 200-400A 2 BUS BAR NEUTRAL BLOCK 390 1 1 1 1 SCREW HHC M8-1.25 X 45 G8.8 FT WASHER FLAT 5/16-M8 ZINC WASHER LOCK M8-5/16 NUT HEX M8-1.25 G8 YEL CHR 2 2 SCREW HHC 1/4-28 X 3/4 G5 WASHER LOCK 1/4-M6 SS 1 LUG SLDLSS 600/250-1/0 X 1/4-28 UL CIRCUIT BREAKER (BQ) 1 - 1 - 2 1 - 6 1 COVER BQ CIR BREAKER CPL 3P COVER BQ CIR BREAKER CPL 2P CB 0125A 2P 240V S BQ2 LL CB 0100A 3P 240V S BQ3 LL SCREW PHTT M4-0.7 X 10 ZYC BRKT CB MTG BACK MTG TRACK BQ SIEMENS CB 3P SCREW RHM #10-32 X 3/4 BRKT BQ CB STANDOFF 6 6 6 1 1 WASHER FLAT #10 ZINC WASHER LOCK #10 NUT HEX #10-32 STEEL DECAL CUSTOMER CONNECT INSIDE TAPE ELEC 1/2 FOAM 11 SCREW THF M6-1 X 16 N WA Z/JS (1) HARDWARE FOR MTG. CB TERMINAL COVERS IS SUPPLIED WITH CIRCUIT BREAKERS. (2) QTY. REQ’D FOR “2POLE / 3POLE” BREAKER

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 * 24 * 25 26 27 0F9677 0G0056 0G0959 0G1155 0G1931 0G2101 0G3734 0G6562 0G6564 0F9664 0G0057 0G0058 0G0059 0G0183 0G0184 0G1932 0G2098 0G2099 0G2100 0G3736 0G3737 0G3738 0G6104 0G6563 0G6565 0G6566 0G6567 0H0201 0H1299 0H1300 0H1301 0C9708 SEE ENGINE EV SEE ENGINE EV 0F5767B 0E5706 0F7874 0G0587 038150 023454 077043E 04576100BU 052646 043123 051779 0A2601 072879 0F8408 046526 0C3992 022264 047248 070892 0G0588 077043A 056326 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ROTOR-2390-45KD1 CPL ROTOR-2390-35KD1 CPL ROTOR-2390-45KD1 CPL (G2) ROTOR-2390-35KD1 CPL (G2) ROTOR 25KW 3PH DIRECT 390 1800 ROTOR 25KW 1PH DIRECT 390 1800 RTR-2390-60KD2 CPL RTR 390 35AD1 CPL RTR 390 35KD1 CPL STATOR-390 45K 2P 1PH DIRECT STATOR-2390-35AD1 CPL STATOR-2390-35KD1 CPL STATOR-2390-35GD1 CPL STATOR-2309-45KW 2P 3PH 208V STATOR-2309-45-KD1 CPL ASSY STR 390 25GD3 CPL ASSY STR 390 25AD1 CPL ASSY STR 390 25KD3 CPL ASSY STR 390 25JD3 CPL ASSY STR 2390 60AD2 CPL ASSY STR 390 60KW 2P 3PH 208V ASSY STR 390 60KW 2P 3PH 480V STR-2390--45JD1 CPL STR 390 35AD1 CPL STR 390 35GD1 CPL STR 390 35KD1 CPL STR 390 35JD1 CPL STR-2390--60JD2 CPL ASSY STR 390 36AD1 CPL ASSY STR 390 36JD1 CPL ASSY STR 390 36 GD1 CPL REF REF REF 1 1 1 1 4 1 1 4 4 4 4 1 1 INSTR HYPOT TEST (NOT SHOWN) ENGINE ADAPTER FLEXPLATE ASSY FLYWHEEL CPL W/40MM FAN B REAR BEARING CARRIER 390/DRCT ASSY BRUSH HOLDER 390/HSB GUARD REAR BEARING CARRIER WASHER FLAT #8 ZINC KEY WOODRUFF #E CONDUIT FLEX 1.0" ID (35” LG) STUD M14-2.0 570 G5 ZINC WASHER FLAT M14 WASHER LOCK M14 NUT HEX M14-2.0 G8 YEL CHR SCREW HHC M16-2.0 X 45 G8.8 SPACER .69 X 2.75 X .37 ST/ZNC 4 4 4 4 1 1 1 1 1 TRIM VINYL BLACK 1/8GP (16.5”LG) * ROTOR REPLACEMENT PARTS 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”)

COMPONENTS INCLUDED IN 0G3364E ENCL 2 0F3078 1 3 0F2606 1 4 5 7 8 10 036261 0E7358 6 052777 3 0G1303D 0F1262 0F1264 6 4 1 4 1 RIVET POP .125 X .275 SS SCREW PPPH HI-LO #4-24 X 3/8 FLAT ASSY PCB R-200 3600 RPM HOLDER, FUSE WICKMANN 178.6150 9 0F1263 1 WICKMAN ADPTR,LH SIDE WICKMAN 178.6192 11 0F1725C 1 ASSY PCB 2AMP 12V UL BATT CHGR 12 067680 1 13 0E6875A 2 VOLTAGE RELAY, 12VDC C FORM W/DIODE 14 15 16 055911 0F5459 0E3161 1 1 1 BLOCK TERM 20A 12 X 6 X 1100V DECAL CPL CONTROL PANEL FUSES ASSY PCB BOSCH GOV DRIVER 17 0F5090 1 18 0F5462 1 19 20 21 23 0A5062J 029673 048467 082573 4 1 1 SPACER 9.5H 3.2 ID DIO BRIDGE 25A 600V CIRCT BRK 7 X 1 ETA 46-500-P 22 0F1958 1 1 SWITCH RKR DPST 125V SPD 24 0E4494 1 CLAMP ON-OFF-ON 28 0F5886 3 SEAL 27 0F6305A 1 COVER SCREW HHPM M5-0.8 X 12 29 051713 12 30 049226 12 31 32 0F5752F 0F5884 1 2 RES WW 15R 5% 25W QK CONN SCREW PHTT M3.5-0.6 X 10 33 34 35 36 0F5896 0C2265 0C3990 091526 2 4 2 4 SCREW PHTT M3.5-0.6 X 16 SCREW PHTT M4-0.7 X 12 ZYC SCREW PHTT M4-0.7 X 10 ZYC SCREW PPHM M5-0.8 X 12 ZNC 37 38 39 051716 079224 075476 9 2 2 NUT HEX M5-0.8 G8 CLEAR ZINC SCREW PPHM M5-0.8 X 30 SS SCREW PPHM M4-0.7 X 16 WASHER 41 022264 2 42 051715 2 NUT HEX M4-0.7 G8 YEL CHR 43 043182 7 44 051714 7 LOCK NUT HEX M3-0.5 G8 YEL CHR 45 46 47 0F3192 0E7403C 0F9785 1 1 1 SUPPORT ANGLE PCB FUSE ATO TYPE 15 AMP (BLUE) HARN 3600RPM R200 CONTROL PNL A B E G 056739 022287 022127 0F2627A COMPONENTS INSTALLED PER THIS DRAWING 1 2 2 1 RELAY SOLENOID 12VDC PNL MNT SCREW HHC 1/4-20 X 3/4 G5 C 022473 4 D 022097 2 NUT HEX 1/4-20 STEEL F 0F6145 A/R LOCK WEATHER COVER CONTROL PANEL SIDE H J 049226 4 L 091526 0G3545 4 1 SCREW PPHM M5-0.8 X 12 ZNC WASHER K 051713 4 FLAT DANGER HIGH VOLTAGE (SPANISH)

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 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 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 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

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) 6 7 8 1 2 3 4 5 0E6586 0E0519A 0C8127 049815 022127 062974 0G0190 037561 1 1 1 1 1 1 4 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 0G 0149 0E9868A 0F3217 042574 0A8584 0F4612 057772 057765 043790 0C7649 069860E 063076 0G 1394 052830 025507 062963 049821 022129 1 1 3 4 1 1 1 1 1 7 7 1 1 1 1 1 1 2 5 3 3 26 ENGINE 2.4L G 2 4G64 CERT ENGINE 2.4L G 2 CERTIFIED WASHER LO CK M10 SCREW HHC M8-1.25 X 35 G8.8 SCREW SHC M14-1.5 X 35 G 10.9 ALTERNATOR DC W /O UT PULLEY SPACER DC ALTERNATOR PULLEY ADAPTOR 1/8 NPTF TO 1/8 BSPT SW ITCH OIL PRESSURE 10 PSI 2 POL (R-PANEL) SENDER O IL 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 FL AT .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 G 12.9 WASHER LO CK 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 70 71 72 73 74 (4) 75 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 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 0G 1472A 0G1476 0G0707 0G8488 0G0950 0F9583 0G0792 0G 0792A 0G1501 0F9501 0G0952 0D3488S 0G0788 0G2750 049721 026925 0F2776 052203 0F2776D 0G7313 0G 10080125 0G3823 0G 10080288 0G 10080289 0G 10080290 0G 10080291 0G9520 3 1 1 7 3 1 3 2 15 7 10 4 2 1 1 1(REF) 1 1 1 1 1(REF) 1 1 1 1 1 1 1(REF) 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 SCREW THF M6- 1 X 16 N W A Z/JS SWITCH HI-TEMP 245D X 3/8 NPT ( R-PANEL) TEMPERATURE SENDER DELPHI (H-PANEL) W ASHER FLAT 5/16-M8 ZINC NUT HEX M8-1.25 G8 CLEAR ZINC W ASHER 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 W ASHER LOCK M6-1/4 W ASHER 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 G 8.8 SCREW HHC M8-1.25 X 25 G 10.9 O IL FILTER G2 ENGINE COIL PACK HOSE 3/8 ID SINGLE BRAID (15” L G) BARBED EL 90 1/4 NPT X 3/8 SCREW HHC M6-1.0 X 25 G8.8 G ASKET EXHAUST MANIFOLD EXHAUST MANIFO LD G2 (MACHINE) (25KW, 35KW & 45KW ) FLEX PLATE 2 POLE 2.4L G2 ASSY MAGPICKUP(3/8-24 MALE) ADAPTER ENGINE 2.4L MACHINE STARTER MOT OR 12V CAM SENSOR PIN ASSY COVER CAM GEAR G2 REW ORKED MANIFO LD INTAKE (USE HOSE 0G0816) MANIFO LD INTAKE (MACHINED) (USE HOSE 0H1546) G ASKET INTAKE MANIFOLD SPACER 2.4L G2 FLEX PL ATE SHIELD HEAT G2 SHIELD HEAT SML BRACKET COIL PACK ADAPTER 2.4L CRANKSHAFT MACH POLY V-BELT G 2 (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 CONDITIO NER SCREW HHC M8-1.25 X 70 G 8.8 BRACKET SIGNAL CONDIT ONER DECAL EMISSION CTRL INFO 2.4L ROD ASSY OIL LEVEL GAUG E 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) SUPPL IED WITH ENGINE. ( 2) NOT USED ON 1800 RPM UNITS. ( 3) USED WITH H- PANEL O NLY ( 4) APPLY L OCTIT E 620 BEARING RETAINMENT COMPO UND TO I/N 75.

1 2 3 4 (1) 5 6 7 9 10 11 12 0G68030ST03 0F2608 0F5263 046526 059981 0F2776A 0F5050A 0F2573 0F4011 0G56820ST03 0G2990 1 1 1 5 4 1 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 0H1827 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 1 1 4 1 1 2 1 8 2 12 8 4 16 1 2(REF) 1 1 1 1 2 1 1 9 1 2 1 3 1 2 2 1 9 1 1 1 1 1 8 1 1 1 16 10 1 1 16 2 1 1 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 W ITH HARNESS P/N 0H3069) CLAMP HOSE #28 1.32- 2.25 HUB FL EX PLATE WASHER FLEX (THIN) TAPE FOAM 1 X 1 (26.75” LG) DISK FLEX 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 W RAP UL 7.4” X .19” BLK (NO T SHOWN) ASSY PCB LCL SENSOR (USE WITH I/N 16, P/N 0H1827 O NLY) BEARING PRESS NOTE: APPLY LO CTITE 620 BEARING RETAINMENT COMPOUND TO BEARING SURFACE ON IT EM 37 PRIOR TO PRESSING ITEM 28 ONTO ITEM 37. ALSO APPLY LOCTITE 620 BEARING RETAINMENT COMPOUND TO THE OUTSIDE OF 28 PRIO R TO INSTALLING ITEM 28 INTO ITEM 38. (1) APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO T HREADS. (2) INCLUDED W ITH I/N 26. (3) USE WITH R- PANEL ONLY.

1 2 3 4 5 6 7 9 10 11 13 14 15 16 17 18 19 20 21 22 23 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 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 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) 24 26 27 28 29 30 0E7121 022097 046580 035685 0F6155 047290 1 4 4 2 1 1 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) 32 057823 2 CLAMP HOSE #10 .56-1.06 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.

9. Install the previously removed black iron pipe onto the outlet port of the demand regulator. Install the previously removed NG jet into the jet keeper port on the side of the regulator housing. 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.

17 18 19 20 21 22 23 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0F9794 0G0113 0G1007 0F2830 0F2962 080762 0E0170A 0C2454 0G0776 0G0007 044149 085917 0D2611 0E8816 049721 022097 022473 036797 022259 070006 088775 022241 085917 0F2809 0F2808B 4 1 2 2 2 10 10 1 1 2 1 1 2 2 5 1 4 1 1 1 2 2 1 4 4 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.

28 29 30 31 32 33 34 35 36 37 38 39 40 41 (2) 1 2 (2) 3 4 5 (2) 6 (2) 7 (2) 8 9 (1) 10 (3) 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 0G0045 0C2454 0F5849 087233 0E3257 0F5852 0F9833 0F5851 049813 077992 0F9835 0F2786 0F2785 0F3364 0F4880 0F5049 0F4487A 022473 022097 022127 0F3072 078115 0G5892 0G5892A 0F5048D 0E5968 0G5892D 1 54 2 2 4 2 2 1 2 21 1 2 1 1 2 2 1 3 1 1 10 26 2 1 2 1 2 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 0G5892C 0F4051C 0F3890B 0F4051B 0F3890 078115A 0G5892E 042568 0912970094 022447 0G5892B 0F8869D 0E5298L 066760 2 2 4 2 4 6 1 2 2 2 1 1 1 1 INSULATION SPLITTER INSULATION DUCT RETAINER INSULATION (820) INSULATION DUCT SIDES RETAINER INSULATION (450) WASHER SELF LOCKING DOME #8-32 INSULATION LOWER SPLITTER SCREW HHC M6-1.0 X 20 G8.8 ASSY WIRE 14 AWG 34.8" GRN/YEL WASHER SHAKEPROOF INT 1/4 INSULATION REAR WRAP KEY VISE-ACTION LATCH SLOT CIR FOAM 300 X 300 THERMAL ACO (APPLIES TO 4.2L UNITS ONLY) STRIP SEALANT 1/8 X 1 (44.52”LG) (1) ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE SECURED USING ITEM 2 & 5 THREAD FORMING FASTENER AND I/N 10 LOCK NUT. LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS. ALL ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER. (2) NOTE: PART NUMBER SHOWN IS FOR TAN / STEEL. REFER TO THE SAMPLE GUIDE BELOW FOR AVAILABLE COLOR AND/OR ALUMINUM PART NUMBER FORMAT. 0FXXXXSN = TAN / STEEL 0FXXXX0ST13 = BISQUE / STEEL 0FXXXXAN = TAN / ALUMINUM 0FXXXXALT13 = BISQUE / ALUMINUM 0FXXXXSG = T- GRAY / STEEL 0FXXXX0ST14 = GRAY / STEEL 0FXXXXNG = T- GRAY / ALUMINUM 0FXXXXALT14 = GRAY / ALUMINUM 0FXXXX0ST05 = WHITE / STEEL 0FXXXX0AL05 = WHITE / ALUMINUM (3) PART NUMBER SHOWN IS FOR TAN. SEE GUIDE BELOW FOR AVAILABLE COLOR AND PART NUMBER FORMAT. 0FXXXXAN = T- GRAY / ALUMINUM 0FXXXXALT13 = BISQUE / ALUMINUM 0FXXXX0AL05 = WHITE / ALUMINUM 0FXXXXALT14 = GRAY / ALUMINUM

1.) A B 2.) A B 3.) A B 4.) A B C C2 UNITS 0F9832 0F9832GGS0R 0C2454 C3 UNITS 0F9832B 0F9832KGS0R 0C2454 C4 UNITS 0F9832A 0C2454 C5 UNITS 0F9832C 0F9832D 0F9832EGS0R 0F9832HGS0R 0F9832JGS0R 0F9832FGS0R 0C2464 1 1 4 1 1 3 1 3 1 1 3 1 1 1 1 SHIELD CONN BOX C2 SHIELD CONTROL STAND C2 SCREW THF M6-1 X 16 N WA Z/JS SHIELD CONTROL STAND C3 SHIELD CONTROL STAND C3 SCREW THF M6-1 X 16 N WA Z/JS SHIELD CONTROL STAND C4 SCREW THF M6-1 X 16 N WA Z/JS 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

v. A 04/07 BackPg001 Re

United States Environmental Protection Agency Warranty Statement (Stationary Emergency Spark-Ignited Generators)

Warranty Rights, Obligations and Coverage

The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system or compo nent on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diagnosis, replace ment parts and labor provided it be done by a Generac Authorized Warranty Service Facility. Your emission control system may include parts such as the fuel metering, ignition, and exhaust systems and other related emission related components listed below. Generac will warrant the emissions control systems on your 2009 and later model year engines provided there has been no abuse, neglect, unapproved modifica tion, or improper maintenance of your engine. For engines less than 130 HP the warranty period is two years from the date of sale to the ulti mate purchaser. For engines greater than or equal to 130 HP the warranty period is three years or 2500 hours of operation, whichever comes first, from the date of the engine being placed into service. For high-cost warranted components, the Emission Control System war ranty is valid for 5 years or 3500 hours of operation, whichever comes first.

Purchaser's/Owner's Warranty Responsibilities

As the engine purchaser/owner you are responsible for the following: 1) The engine must be installed and configured in accordance to Gen erac's installation specifications. 2) The completion of all maintenance requirements listed in your Owner's Manual. 3) Any engine setting adjustment must be done in accordance and consistent with the instructions in the Owner's Manual. 4) Any emission control system or com ponent must be maintained and operated appropriately in order to ensure proper operation of the engine and control system to minimize emissions at all times.

Generac may deny any/or all Emission Control System Warranty coverage or responsibility of the engine, or an emission control system or component on your engine thereof, if it has failed due to abuse, neglect, unapproved modification or improper maintenance, or the use of counterfeit and/or “gray market” parts not made, supplied or approved by Generac. Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. The purchaser/owner shall be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the inspection or repair facilities. The purchaser/owner shall be responsible for any and/or all damages or losses incurred while the engine is being trans ported/shipped for inspection or warranty repairs. Contact Generac Power Systems Inc. for additional Emission Control System Warranty related information, Generac Power Systems, Inc., PO. Box 8, Waukesha, WI 53187, or call 1-800-333-1322 or www.generac.com.

Important Note

This warranty statement explains your rights and obligations under the Emission Control System Warranty, which is provided to you by Gen erac pursuant to federal law. Note that this warranty shall not apply to 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). 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 you.

Emission Related Parts Include the Following (if so equipped)

1) Fuel Metering System 1.1) Gasoline Carburetor Assembly and Internal Components A) Fuel Filter, B) Carburetor, C) Fuel Pump 1.2) Carburetion Assembly and Its Components A) Fuel Controller, B) Carburetor and Its Gaskets, C) Mixer and Its Gaskets, D) Primary Gas Regulator, E) Liquid Vaporizer 1.3) Fuel Regulator 2) Air Induction System Including A) Intake Pipe/Manifold, B) Air Cleaner 3) Ignition System Including A) Spark Plug, B) Ignition Module, C) Ignition Coil, D) Spark Plug Wires 4) Exhaust System A) Catalyst Assembly*, B) Exhaust Manifold, C) Muffler, D) Exhaust Pipe, E) Muffler Gasket 5) Crankcase Breather Assembly Including A) Breather Connection Tube, B) PCV Valve 6) Oxygen Sensor 7) Diagnostic Emission-Control System *High-Cost Warranted Component EmsnWrnty001 Revision F (04/15)

United States Environmental Protection Agency Compliance Requirements (Stationary Emergency Spark-Ignited Generators)

Purchaser's/Owner's Record Keeping Responsibilities

The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain your record keeping requirements for compliance with Subpart JJJJ- Standards of Performance for Stationary Spark Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60. As the engine purchaser/owner who operates and maintains their certified emergency stationary engine and emission control system according to applicable emission related guidelines as specified in this Owner's Manual, you are required to meet the following notification and record keeping requirements to demonstrate compliance: 1) Maintain documentation that the engine is certified to meet emission standards. 2) Record keeping of maintenance conducted. 3) Record keeping of the provision allowing natural gas engines to operate using propane for a maximum of 100 hours per year as an alternate fuel solely during emergency operations provided the engine is not certified to operate on propane. 4) Meet all compliance notifications submitted to the purchaser/owner and maintain all supporting documentation. 5) Record keeping of hours of operation, including what classified the operation as emergency and how many hours are spent for non-emergency operation. For emergency engines greater than or equal to 130 HP, record keeping of hours of operation begins January 1, 2011. For emergency engines less than 130 HP, record keeping of hours of oper ation begins January 1, 2009; engines are equipped with non-resettable hour meters to facilitate record keeping.

Specific Air Quality Management or Air Pollution Control Districts may have different and additional record keeping/reporting requirements. Your permit to construct and/or operate the engine may be contingent upon compliance with those requirements. Check with your local Air Quality Management or Air Pollution Control District for specific requirements.

Emergency stationary internal combustion engines (ICE) may be operated for the purpose of maintenance checks and readiness testing, provided that the tests are recommended by Federal, State or local government, Generac, or the insurance company associated with the engine. Maintenance checks and readiness testing of such units is limited to 100 hours per year. There is no time limit on the use of emer gency stationary ICE in emergency situations. The purchaser/owner may petition the Administrator for approval of additional hours to be used for maintenance checks and readiness testing, but a petition is not required if the owner maintains records indicating that Federal, State, or local standards require maintenance and testing of emergency ICE beyond 100 hours per year. Emergency stationary ICE may operate up to 50 hours per year in non emergency situations, but those 50 hours are counted towards the 100 hours per year provided for maintenance and testing.

The 50 hours per year for non-emergency situations cannot be used for peak shaving or to generate income for a facility to supply power to an electric grid or otherwise supply power as part of a financial arrangement with another entity. For purchaser/owner of emergency engines, any operation other than emergency operation, maintenance and testing, and operation in non-emergency situations for 50 hours per year, as permitted in this section is prohibited.

If you operate and maintain your certified emergency stationary SI internal combustion engine and emissions control systems in accordance to the specifications and guidelines in this Owner’s Manual, EPA will not require engine performance testing. If not, your engine will be con sidered non-certified and you must demonstrate compliance according to Subpart JJJJ - Standards of Performance for Stationary Spark Igni tion Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60.

Emission-Related Installation Instructions

Your certified emergency stationary engine has pre-set emission control systems or components that require no adjustment. Inspection and replacement of an emissions related component is required to be done so in accordance with the requirements cited in the United States Environmental Protection Agency Warranty Statement or can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. Failing to follow these instructions when installing a certified engine in a piece of non-road equipment violates federal law 40 CFR 1068.105 (b), subject to fines or penalties as described in the Clean Air Act.

EmsnWrnty001 Revision F (04/15)

EXPLODED VIEW: EV AIR CLEANER DRAWING #: 0F9809 ITEM PART# QTY. DESCRIPTION

1 2 3 4 0E6586 0E0519A 0C8127 049815 1 1 1 4 GASKET BOSCH 32 & 40 ADAPTER CARBURETOR W/PVC CONN ELEMENT AIR CLEANER SCREW HHC M5-0.8 X 16 G8.8 5 (1) 6 7 8 9 022127 062974 0G0190 025870 022097 1 1 1 1 1 NUT HEX 1/4-20 STEEL STUD TH 1/4-20 X 4-1/2 G2 ZNC PLATE, AIR CLEANER TOP 2.4L NUT WING 1/4-20 WASHER LOCK M6-1/4 10 022473 1 WASHER FLAT 1/4-M6 ZINC (1) APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THREADS.

GROUP D

REVISION: J-8527-B DATE: 5/7/14 Page 2 of 2

(1) 6 7 8 1 2 3 4 5 0E6586 0E0519A 0C8127 049815 022127 062974 0G0190 037561 1 1 1 1 1 1 4 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).

EXPLODED VIEW: EV ENGCOMPRT 2.4L G2 DRAWING #: 0G1141 APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION

GROUP D

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 34 35 (1) 36 37 38 39 (3) 40 (1) 44 0H1951 0H1619 G046526 G039414 0G0149 0E9868A 0F3217 G042574 0A8584 0F4612 G057772 0A4707L G043790 0C7649 069860E G063076 0G1394 G052830 G025507 G062963 G049821 G022129 0D6029 0A6751 0E0502 G022145 G045771 G022131 G049813 G046525 G058306 G022097 G022473 G043116 026073A G052243 0A8258 0G0664 0G1502 G047290 G049340 G045757 0G0951 1 1 3 4 1 1 1 1 1 1 1 1 1 1 1 7 7 2 5 3 3 26 3 1 1 7 3 1 3 2 7 7 10 4 2 1 9 1(REF) 1 1 1 1 1(REF) 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 3/8NPT X M14-1.5 BARBED EL 90 3/8 NPT X 3/8 CLAMP HOSE .38-.87 HOSE DRAIN ASSY 28" WASHER FLAT .531 ID X 1.062 OD SCREW HHC M12-1.25 X 20 G10.9 SCREW HHC M10-1.25 X 45 G8.8 WASHER SHAKEPROOF EXT 7/16 STL SCREW HHC M10-1.25 X 30 G8.8 SCREW SHC M8-1.25 X 30 G12.9 WASHER LOCK M8-5/16 SCREW THF M6-1 X 16 N WA Z/JS SWITCH HI-TEMP 245D X 3/8 NPT (R-PANEL) TEMPERATURE SENDER DELPHI (H-PANEL) WASHER FLAT 5/16-M8 ZINC NUT HEX M8-1.25 G8 CLEAR ZINC WASHER FLAT 3/8-M10 ZINC NUT HEX M6 X 1.0 G8 YEL CHR NUT HEX M10-1.25 G8 YEL CHR SCREW SHC M8-1.25 X 25 G12.9 WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC SCREW HHC M6-1.0 X 12 G8.8 PLUG STD PIPE 1/4 STEEL SQ HD SCREW HHC M10-1.5 X 60 G8.8 SCREW HHC M8-1.25 X 25 G10.9 OIL FILTER G2 ENGINE COIL PACK HOSE 3/8 ID SINGLE BRAID (15” LG) BARBED EL 90 1/4 NPT X 3/8 SCREW HHC M6-1.0 X 25 G8.8 GASKET EXHAUST MANIFOLD 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 0G3910 0F9965E 0D2244M G0F9420 0G7461 0G1472A 0G1476 0G0707 0G8488 0G0950 0F9583 0G0792 0G0792A 0G1501 0F9501 0G0952 0D3488S 0G0788 0H8572 G049721 G026925 0F2776 G052203 0F2776D 0G9378 0G10080125 0G3823 1 1 2 1 1 1 1(REF) 1 1 1(REF) 1 1 1 1 1 1(REF) 1 1 1 3 1 1 2 1 1(REF) 1 1 EXHAUST MANIFOLD G2 (MACHINE) (25KW, 35KW & 45KW) FLEX PLATE 2 POLE 2.4L G2 ASSY MAGPICKUP(3/8-24 MALE) ADAPTER ENGINE 2.4L MACHINE STARTER MOTOR 12V CAM SENSOR PIN ASSY COVER CAM GEAR G2 REWORKED MANIFOLD INTAKE (USE HOSE 0G0816) MANIFOLD INTAKE (MACHINED) (USE HOSE 0H1546) GASKET INTAKE MANIFOLD SPACER 2.4L G2 FLEX PLATE SHIELD HEAT G2 SHIELD HEAT SML BRACKET COIL PACK ADAPTER 2.4L CRANKSHAFT MACH POLY V-BELT G2 (3600 RPM) BELT SERPENTINE 37.0" (1800 RPM) PULLEY DC ALTERNATOR (3600 RPM) PULLEY 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 SORE EPA CERTIFICATION ROD ASSY OIL LEVEL GAUGE O-RING SIZE 9.0MM X 2.0MM NITR 71 72 73 74 0G10080288 0G10080289 0G10080290 0G10080291 1 1 1 1 CABLE, SPARK PLUG, NO.1 CABLE, SPARK PLUG, NO.2 CABLE, SPARK PLUG, NO.3 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

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