Generac 55 kW QT05554ANNNA Standby Generator Manual

Serial Number
Industrial QT
5.4L
55kW
Models
STANDBY GENERATOR
OWNER'S MANUAL
A new standard of reliability
This manual should remain with the unit.
Cover047 Rev. 0 04/06
Part No. 0G1213
Standby Generator Sets
Table of Contents
INTRODUCTION .....................................................1-3
Read this Manual Thoroughly ...................................1-3
Operation and Maintenance ......................................1-3
How to Obtain Service ..............................................1-3
IDENTIFICATION RECORD .....................................2-1
Data Label ................................................................2-1
EQUIPMENT DESCRIPTION ...................................3-1
Equipment Description ................................................3-1
Engine Oil Recommendations ......................................3-1
Coolant Recommendations...........................................3-1
ENGINE PROTECTIVE DEVICES ............................4-1
Coolant Temperature Sensing ...................................4-1
Low Coolant Level.....................................................4-1
Oil Pressure Sensing .................................................4-1
Overcrank Shutdown ................................................4-1
Overspeed Shutdown ................................................4-1
RPM Sensor Loss Shutdown.....................................4-1
DC Fuse ....................................................................4-1
FUEL SYSTEMS .....................................................5-1
Fuel Requirements ....................................................5-1
Natural Gas Fuel System ..........................................5-1
Propane Vapor Withdrawal Fuel System....................5-1
LP Fuel System .........................................................5-1
SPECIFICATIONS ...................................................6-1
Generator .................................................................6-1
Engine.......................................................................6-1
Cooling System .........................................................6-1
Fuel System ..............................................................6-1
Electrical System ......................................................6-1
5.4L & 6.8L Ignition Description .................................6-3
Ignition Power-up Input (“56 Line Input”) .................6-3
Ignition Enable (“14 Line Input”) ..............................6-3
Ignition Shutdown on Loss of Crank
or CAM Signals .........................................................6-3
Diagnostic Blink Patterns (Red LED Located
on the Ignition Control Board ...................................6-3
GENERAL INFORMATION.......................................7-1
Generator AC Lead Connections ..................................7-1
Alternator Power Winding Connections ........................7-1
Four-lead, Single-phase Stator ..................................7-1
3-phase Alternators ("Y" Configuration) ....................7-1
3-phase Alternators ("Delta" Configuration) ..............7-2
INSTALLATION.......................................................8-1
Installation ...................................................................8-1
Preparation Before Start-up .........................................8-1
Transfer Switch ........................................................8-1
Fuel System ..............................................................8-1
Generator Set Lubrication ........................................8-1
Prior to Initial Start-up .............................................8-1
Engine Coolant .........................................................8-1
Belt Tension ..............................................................8-1
Electrical System ......................................................8-1
Initial Inspection for QT Genset Start-up .....................8-1
Start-up Checklist ........................................................8-2
Preparation for Start-up............................................8-2
Start-up Inspection ...................................................8-2
OPERATION ...........................................................9-1
Generator Control and Operation ................................9-1
Operating Unit with Manual Transfer Switch ...............9-1
Engine Start-up and Transfer ...................................9-1
Retransfer and Shutdown .........................................9-1
Operating Unit with Automatic Transfer Switch ...........9-1
MAINTENANCE.....................................................10-1
Maintenance Performed by Authorized
Service Facilities .....................................................10-1
Every Three Months ...............................................10-1
Once Every Six Months ...........................................10-1
Once Annually.........................................................10-1
First 100 Operating Hours ......................................10-1
Every 500 Operating Hours ....................................10-1
Cooling System ..........................................................10-1
Checking Fluid Levels ................................................10-1
Check Engine Oil ....................................................10-1
Battery Fluid ...........................................................10-1
Engine Coolant .......................................................10-2
Maintenance Owner/Operator Can Perform ................10-2
Check Engine Oil Level ...........................................10-2
Check Battery .........................................................10-2
Exercise System ......................................................10-2
Inspect Cooling System ...........................................10-2
Check Engine Coolant Level....................................10-2
Perform Visual Inspection .......................................10-2
Inspect Exhaust System ..........................................10-2
Check Fan Belt........................................................10-2
Inspect Engine Governor ........................................10-2
Changing Engine Oil ...............................................10-2
Changing the Engine Air Cleaner ............................10-3
Spark Plugs ............................................................10-3
Coolant Change .......................................................10-3
Miscellaneous Maintenance ........................................10-3
Cleaning the Generator ...........................................10-3
Battery ....................................................................10-4
Battery Maintenance ...............................................10-4
Battery Replacement ...............................................10-4
SERVICE SCHEDULE ...........................................11-1
30 kW - 150 kW Standby Gas Engine
Driven Generator Sets ............................................11-1
TROUBLESHOOTING ...........................................12-1
Troubleshooting Guide...............................................12-1
NOTES
EXPLODED VIEWS & PARTS LISTS
WIRING DIAGRAMS & SCHEMATICS
WARRANTY
Content010 Rev. 0 04/06
SECTION
PAGE
SAFETY RULES ................................................ 1-1
Stationary Emergency Generator
Important Safety Instructions
INTRODUCTION
 This symbol points out potential fire hazard.
symbol points out potential electrical shock
 This
hazard.
Thank you for purchasing this model of the Stationary
Emergency Generator set product line.
Every effort was expended to make sure that the
information and instructions in this manual were
both accurate and current at the time the manual was
written. However, the manufacturer reserves the right
to change, alter or otherwise improve this product(s)
at any time without prior notice.
The operator is responsible for proper and safe use
of the equipment. The manufacturer strongly recommends that the operator read this Owner's Manual
and thoroughly understand all instructions before
using this equipment. The manufacturer also strongly recommends instructing other users to properly
start and operate the unit. This prepares them if they
need to operate the equipment in an emergency.
‹ READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest Authorized Service Dealer for starting, operating and servicing procedures.
‹ 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 an Authorized
Service Dealer. Normal maintenance service and
replacement of parts are the responsibility of the
owner/operator and, as such, are not considered
defects in materials or workmanship within the terms
of the warranty. Individual operating habits and usage
contribute to the need for maintenance service.
Throughout this publication, and on tags and decals
affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service
or operation that may be hazardous if performed
incorrectly or carelessly. Observe them carefully.
Their definitions are as follows:
DANGER
After this heading, read instructions that, if not
strictly complied with, will result in serious personal injury, including death, or property damage.
Proper maintenance and care of the generator ensure
a minimum number of problems and keep operating
expenses at a minimum. See an Authorized Service
Dealer for service aids and accessories.
Operating instructions presented in this manual
assume that the generator electric system has been
installed by an Authorized Service Dealer or other
competent, qualified contractor. Installation of this
equipment is not a “do-it-yourself” project.
After this heading, read instructions that, if not
strictly complied with, may result in personal
injury or property damage.
‹ HOW TO OBTAIN SERVICE
After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:
When the generator requires servicing or repairs,
simply contact an Authorized Service Dealer for
assistance. Service technicians are factory-trained
and are capable of handling all service needs.
After this heading, read explanatory statements
that require special emphasis.
When contacting an Authorized Service Dealer or the
factory about parts and service, always supply the
complete model number of the unit as given on the
front cover of this manual or on the DATA LABEL
affixed to the unit.
These safety warnings cannot eliminate the hazards
that they indicate. Common sense and strict compliance with the special instructions while performing
the service are essential to preventing accidents.
Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type
of information each indicates is as follows:
To locate the nearest AUTHORIZED
SERVICE DEALER, please call this number:
This symbol points out important safety information that, if not followed, could endanger
personal safety and/or property of others.
1-800-333-1322
symbol points out potential explosion
 This
hazard.
or locate us on the web at:
www.generac.com
1-1
Safety 001 Rev. B 10/08

AUTHORIZED SERVICE DEALER LOCATION
Stationary 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.


WARNING:
 GENERAL HAZARDS 
• For safety reasons, the manufacturer recommends
that this equipment be installed, serviced and
repaired by an Authorized Service Dealer or other
competent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations. The operator also must
comply with all such codes, standards and regulations.
• Installation, operation, servicing and repair of this
(and related) equipment must always comply with
applicable codes, standards, laws and regulations.
Adhere strictly to local, state and national electrical and building codes. Comply with regulations
the Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the
generator is installed, operated and serviced in
accordance with the manufacturer’s instructions
and recommendations. Following installation, do
nothing that might render the unit unsafe or in
noncompliance with the aforementioned codes,
standards, laws and regulations.
• The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous
gas, if breathed in sufficient concentrations, can
cause unconsciousness or even death. For that
reason, adequate ventilation must be provided.
This should be considered prior to installing the
generator. The unit should be positioned to direct
exhaust gasses safely away from any building
where people, animals, etc., will not be harmed.
Any exhaust stacks that ship loose with the unit
must be installed properly per the manufacturer's
instruction, and in strict compliance with applicable codes and standards.
• Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit
is operating.
• Adequate, unobstructed flow of cooling and ventilating air is critical in any room or building housing the generator to prevent buildup of explosive
gases and to ensure correct generator operation.
Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seriously affect safe operation of the generator.
• Keep the area around the generator clean and
uncluttered. Remove any materials that could
become hazardous.
• When working on this equipment, remain alert
at all times. Never work on the equipment when
physically or mentally fatigued.
• Inspect the generator regularly, and promptly
repair or replace all worn, damaged or defective
parts using only factory-approved parts.
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.

WARNING:


This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become
familiar with this Owner’s Manual and with the unit.
The generator can operate safely, efficiently and reliably only if it is properly installed, operated and
maintained. Many accidents are caused by failing to
follow simple and fundamental rules or precautions.
The manufacturer cannot anticipate every possible
circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed
to the unit are, therefore, not all inclusive. If a procedure, work method or operating technique is used
that the manufacturer does not specifically recommend, ensure that it is safe for others. Also make
sure the procedure, work method or operating technique utilized does not render the generator unsafe.
DANGER
the safe design of this generator,
 Despite
operating this equipment imprudently, neglecting its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to install, operate or maintain this equipment.
lethal voltages are generated by
 Potentially
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
of the generator are rotating and/or hot
 Parts
during operation. Exercise care near running
generators.
1-2
Safety 001 Rev. B 10/08
Stationary Emergency Generator
Important Safety Instructions
• Before performing any maintenance on the generator, disconnect its battery cables to prevent
accidental start-up. Disconnect the cable from the
battery post indicated by a NEGATIVE, NEG or (–)
first. Reconnect that cable last.
• Never use the generator or any of its parts as a
step. Stepping on the unit can stress and break
parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.
• Stationary Emergency Generators installed with
an automatic transfer switch will crank and start
automatically when normal (utility) source voltage is removed or is below an acceptable preset
level. To prevent such automatic start-up and possible injury to personnel, disable the generator’s
automatic start circuit (battery cables, etc.) before
working on or around the unit. Then, place a “Do
Not Operate” tag on the generator control panel
and on the transfer switch.
• In case of accident caused by electric shock, immediately shut down the source of electrical power.
If this is not possible, attempt to free the victim
from the live conductor. AVOID DIRECT CONTACT
WITH THE VICTIM. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical
help.
• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving components causing injury.
 ELECTRICAL HAZARDS 
• All Stationary Emergency Generators covered by
this manual produce dangerous electrical voltages
and can cause fatal electrical shock. Utility power
delivers extremely high and dangerous voltages
to the transfer switch as well as the generator.
Avoid contact with bare wires, terminals, connections, etc., on the generator as well as the transfer
switch, if applicable. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If work must be done around an
operating unit, stand on an insulated, dry surface
to reduce shock hazard.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
• If personnel must stand on metal or concrete while
installing, operating, servicing, adjusting or repairing this equipment, place insulative mats over a
dry wooden platform. Work on the equipment only
while standing on such insulative mats.
• The National Electrical Code (NEC) requires the
frame and external electrically conductive parts of
the generator to be connected to an approved earth
ground. This grounding will help prevent dangerous electrical shock that might be caused by a
ground fault condition in the generator or by static
electricity. Never disconnect the ground wire.
• Wire gauge sizes of electrical wiring, cables and
cord sets must be adequate to handle the maximum electrical current (ampacity) to which they
will be subjected.
• Before installing or servicing this (and related)
equipment, make sure that all power voltage
supplies are positively turned off at their source.
Failure to do so will result in hazardous and possibly fatal electrical shock.
• Connecting this unit to an electrical system normally supplied by an electric utility shall be by
means of a transfer switch so as to isolate the
generator electric system from the electric utility
distribution system when the generator is operating. Failure to isolate the two electric system power
sources from each other by such means will result
in damage to the generator and may also result
in injury or death to utility power workers due to
backfeed of electrical energy.
 FIRE HAZARDS 
• Keep a fire extinguisher near the generator at all
times. Do NOT use any carbon tetra-chloride type
extinguisher. Its fumes are toxic, and the liquid
can deteriorate wiring insulation. Keep the extinguisher properly charged and be familiar with its
use. If there are any questions pertaining to fire
extinguishers, consult the local fire department.
 EXPLOSION HAZARDS 
• Properly ventilate any room or building housing
the generator to prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any
fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.
• These generators may operate using one of several types of fuels. All fuel types are potentially
FLAMMABLE and/or EXPLOSIVE and should be
handled with care. Comply with all laws regulating the storage and handling of fuels. Inspect the
unit’s fuel system frequently and correct any leaks
immediately. Fuel supply lines must be properly installed, purged and leak tested according to
applicable fuel-gas codes before placing this equipment into service.
• Diesel fuels are highly FLAMMABLE. Gaseous
fluids such as natural gas and liquid propane
(LP) gas are extremely EXPLOSIVE. Natural gas
is lighter than air, and LP gas is heavier than air;
install leak detectors accordingly.
Safety 001 Rev. B 10/08
1-3
Stationary Emergency Generator
General Information
IDENTIFICATION RECORD
 Identification Code
‹ DATA LABEL
Use this code to obtain important information about
the generator. For example, if the code is:
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.
MADE IN USA
RATED KVA
RATED KW
POWER FACTOR
PHASE
RATED AMPS
RATED VOLTAGE
HERTZ
ALT RPM
PRODUCTION DATE
ENGINE RPM
ALTERNATOR SUBTRANSIENT REACTANCE
ALTERNATOR TRANSIENT REACTANCE
CLASS
ROTOR
0
5
4
A N S N A
M — Designates generators capable of paralleling.
NOTE: Only 100kW and 150kW, 6.8L units
are currently available for this configuration.
QT — Quiet Test Generator Series
100 — kw Rating
5.4 — Engine Size in Liters
A — Voltage Code: A = 120/240, Single-phase;
G = 120/208, Three-phase; K = 277/480,
Three-phase; J = 120/240, Three-phase;
L = 346/600, Three-phase
N — Fuel: N = Natural Gas; V = Vapor Propane
S — Enclosure Material: A = Aluminum; S
= Steel (Corrosion Resistant Aluminum
Enclosure Material, Steel is Standard)
N — Emission Equipment: N = No Equipment;
Y = Catalytic Converter and Air/Fuel Ratio
Controller
A — Industrial Dealer Product
SERIAL
MODEL
0
STATOR WINDING INSULATION AT 25°C AMBIENT
GENERAC POWER SYSTEMS, INC.
WAUKESHA, WI
 Voltage Codes
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.
The identification code letter following the unit’s
engine size is the generator’s “voltage code.”
 Groups and Assembly Numbers
The manual drawing listing lists the groups and corresponding assembly numbers for each unit. The
assembly numbers refer to exploded view drawing
numbers that are applicable to the specific generator
model. These drawings are located in the back half
of this manual.
 Stationary Emergency Generator Model and
Serial Number
This number is the key to numerous engineering and
manufacturing details pertaining to your unit. Always
supply this number when requesting service, ordering parts or seeking information.
2-1
Identy001 Rev. D 10/08
GENERATOR SET DATA
M Q T 1
Stationary Emergency Generator
Equipment Description
EQUIPMENT DESCRIPTION
COOLANT RECOMMENDATIONS
This equipment is a revolving field, alternating current Stationary Emergency Generator. It is powered
by a gaseous fueled engine operating at 1800 rpm for
4-pole direct drive units, 3600 rpm for 2-pole direct
drive units and 2300 - 3000 rpm for quiet drive gear
units. See the Specifications section for exact numbers. The unit comes complete with a sound attenuated enclosure, internally mounted muffler, control
console, mainline circuit breaker, battery charger,
and protective alarms as explained in the following
paragraph.
Use a mixture of half low silicate ethylene glycol
base anti-freeze and deionized water. Cooling system
capacity is listed in the specifications. Use only deionized water and only low silicate anti-freeze. If desired,
add a high quality rust inhibitor to the recommended
coolant mixture. When adding coolant, always add
the recommended 50-50 mixture.
The Stationary Emergency Generator incorporates
the following alternator features:
mium hydroxide (“green slime”) forms and will
cause overheating. Engines that have been operated with a chromate base rust inhibitor must
be chemically cleaned before adding ethylene
glycol base anti-freeze. Using any high silicate
anti-freeze boosters or additives will also cause
overheating. The manufacturer also recommends
that any soluble oil inhibitor is NOT used for this
equipment.
not use any chromate base rust inhibitor
 Do
with ethylene glycol base anti-freeze or chro-
• Rotor and Stator insulation is Class H rated as
defined by NEMA MG1-32.6, NEMA MG1-1.66.
The generator is self ventilated and drip-proof constructed.
• The voltage waveform deviation, total harmonic
content of the AC waveform and telephone influence factor have been evaluated and are acceptable
according to NEMA MG1-32.
DANGER
ENGINE OIL RECOMMENDATIONS
not remove the radiator pressure cap while
 Do
the engine is hot or serious burns from boiling
The unit has been filled with 15W-40 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. Use oil
having the following SAE viscosity rating, based on
the ambient temperature range anticipated before the
next oil change:
Temperature
Above 80° F (27° C)
32° to 80° F (0° to 27° C)
Below 32° F (0° C)
liquid or steam could result.
glycol base antifreeze is poisonous.
 Ethylene
Do not use mouth to siphon coolant from the
radiator, recovery bottle or any container. Wash
hands thoroughly after handling. Never store
used antifreeze in an open container because
animals are attracted to the smell and taste of
antifreeze even though it is poisonous to them.
Oil Grade (Recommended)
SAE 30W or 15W-40
SAE 20W-20 or 15W-40
See Note
attempt to crank or start the engine before
 Any
it has been properly serviced with the recommended oil may result in an engine failure.
NOTE:
For temperatures below 32° F, it is strongly recommended to use the optional Cold Weather Start Kit
(part number listed in the Specification Section).
The oil grade for temperatures below 32° F is 5W30 synthetic oil.
Equip005 Rev. B 10/08
3-1
Stationary Emergency Generator
Engine Protective Devices
ENGINE PROTECTIVE DEVICES
‹ OIL PRESSURE SENSING
The Stationary Emergency Generator may be required
to operate for long periods of time without an operator on hand to monitor such engine conditions as
coolant temperature, oil pressure or rpm. For that
reason, the engine has several devices designed to
protect it against potentially damaging conditions by
automatically shutting down the unit when the oil
pressure is too low, the coolant temperature is too
high, the coolant level is too low, or the engine is running too fast.
An analog Oil Pressure Sender (OPS) is used for
monitoring the engine oil pressure. This sender
allows the control panel to measure and display the
Engine oil pressure.
The OPS is a resistive device, whose resistance
changes based on engine oil pressure. The resistance
of the sender results in a voltage being developed
across the sender. As the oil pressure increases,
the resistance will decrease, causing the voltage to
decrease. This changing voltage is converted to 420mA signal by a signal conditioner module. The
corresponding 4-20mA signal is read by the control
panel and displayed as the oil pressure.
NOTE:
Engine protective switches and sensors are mentioned here for the reader's convenience. Also refer
to the applicable control panel manual for additional automatic engine shutdown information.
The control panel will monitor and display oil pressure anytime the DC input to the control panel is
present.
‹ COOLANT TEMPERATURE SENSING
Should the oil pressure drop below the 8 psi range,
the engine shutdown is initiated. The unit should not
be restarted until oil is added. Turn the AUTO/OFF/
MANUAL switch to the OFF position, then back to
AUTO to restart.
An analog Water Temperature Sender (WTS) is located in the engine's cooling system. This sender is connected to the panel and allows the panel to monitor
and display the temperature of the coolant system.
The WTS is a resistive device whose resistance changes based on coolant temperature. The resistance of
the sender results in a voltage being developed across
the sender. As the Coolant temperature increases,
the resistance will decrease, causing the voltage to
decrease. This changing voltage is converted to 420mA signal by a signal conditioner module. The
corresponding 4-20mA signal is read by the control
panel and displayed as the coolant temperature.
‹ OVERCRANK SHUTDOWN
When the control panel receives a start signal, it initiates the programmed starting sequence. The start
sequence consists of the number of crank attempts,
the length of each crank attempt, and the rest time
between each crank attempt. If the engine has not
started by the end of the final crank attempt, an
Overcrank alarm is generated, the control panel will
sound the alarm and display the message "Failed to
start".
The control panel will monitor and display the coolant temperature anytime the DC input to the control
panel is present.
‹ OVERSPEED SHUTDOWN
If the temperature exceeds approximately 140° C
(284° F), the engine shutdown will be initiated. The
generator will automatically restart and the display
will reset once the temperature has returned to an
operating level.
A speed circuit controls engine cranking, start-up,
operation and shutdown. Engine speed signals are
delivered to the circuit board whenever the unit is
running. Should the engine over speed above a safe,
preset value, the circuit board initiates an automatic
engine shutdown. Contact the nearest Authorized
Dealer if this failure occurs.
‹ LOW COOLANT LEVEL
A Low Coolant Level (LCL) sensor is placed in the
generators coolant system. This sensor allows the
panel to detect a Low Coolant Level condition.
‹ RPM SENSOR LOSS SHUTDOWN
The LCL is a resistive device whose resistance changes
rapidly based on the presence or absence of coolant.
If the speed signal to the control panel is lost, engine
shutdown will occur.
The resistance of the LCL results in a voltage being
developed across the LCL. This voltage changes as
the resistance changes. This changing voltage is converted to 4-20mA signal by a signal conditioner module. The corresponding 4-20mA signal is read by the
control panel and displayed as the low coolant level.
‹ DC FUSE
This fuse 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. Replace the
fuse with one of the same size, type, and rating. (See
the exploded views and parts lists at the end of this
manual for replacement part number.)
4-1
EngProt002 Rev. C 10/08
If the level of the engine coolant drops below the level
of the low coolant level sensor, the engine shutdown
will be initiated.
Stationary Emergency Generator
Fuel Systems
FUEL SYSTEM
‹ PROPANE VAPOR WITHDRAWAL FUEL SYSTEM
This type of system utilizes the vapors formed above the liquid
fuel in the supply tank. Approximately 10 to 20 percent of the tank
capacity is needed for fuel expansion from the liquid to the vapor
state. The vapor withdrawal system is generally best suited for
smaller engines that require less fuel. The installer should be aware
of the following:
‹ FUEL REQUIREMENTS
The Stationary Emergency Generator may be equipped with one of
the following fuel systems:
• Natural gas fuel system
• Propane vapor (PV) fuel system
• Liquid propane (LP) fuel system
• When ambient temperatures are low and engine fuel consumption is high, the vapor withdrawal system may not function
efficiently.
• Ambient temperatures around the supply tank must be high
enough to sustain adequate vaporization, or the system will not
deliver the needed fuel volume.
• In addition to the cooling effects of ambient air, the vaporization
process itself provides an additional cooling effect.
The Manual Drawing Listing that is affixed to the unit includes the
“Identification Code,” which may be used to identify the type of
fuel system installed on the unit.
Recommended fuels should have a Btu content of at least 1,000
Btu's per cubic foot for natural gas; or at least 2,520 Btu's per
cubic foot for LP gas. Ask the fuel supplier for the Btu content of
the fuel.
‹ LP LIQUID FUEL SYSTEM
Required fuel pressure for natural gas is 5 inches to 14 inches
water column (0.18 to 0.5 psi); and for liquid propane, 5 inches
to 14 inches of water column (0.18 to 0.5 psi).
LP is supplied as a liquid in pressure tanks. It is usually made up
of propane, butane, or a mixture of the two gases. Propane tends
to vaporize readily even at temperatures as low as -20° F (-29° C).
However, butane reverts to its liquid state when temperatures drop
below 32° F (0° C).
NOTE:
Any piping used to connect the generator to the fuel supply
should be of adequate size to ensure the fuel pressure NEVER
drops below five inches water column for natural gas or 5
inches water column for propane vapor for all load ranges. The
fuel supply piping shall be sized according to the installation
manual using the fuel consumption requirements identified in
the Specifications section of the Owner's Manual.
LP in a liquid withdrawal system must be converted to its gaseous
state before it is introduced into the engine carburetor. A vaporizerconverter is generally used to accomplish this. In such a converter,
heated engine coolant is ported through the converter to provide
the necessary heat for conversion of the fuel from a liquid to a
gaseous state.
NOTE:
It is the responsibility of the installer to make sure that only
the correct recommended fuel is supplied to the generator fuel
system. Thereafter, the owner/operator must make certain that
only the proper fuel is supplied.
‹ NATURAL GAS FUEL SYSTEM
Natural gas is supplied in its vapor state. In most cases, the gas
distribution company provides piping from the main gas distribution line to the standby generator site. The following information
applies to natural gas fuel systems.
• Gas pressure in a building is usually regulated by national, state
and local codes.
• To reduce gas pressure to a safe level before the gas enters a
building, a primary regulator is needed. The natural gas supplier
may or may not supply such a regulator.
• It is the responsibility of the gas supplier to make sure sufficient
gas pressure is available to operate the primary regulator.
• Gas pressure at the inlet to the fuel shutoff solenoid should not
exceed approximately 14 inches water column (0.5 psi).
FuelSys001 Rev. C 05/09
5-1
Stationary Emergency Generator
Specifications
SPECIFICATIONS
Engine Lubrication System
Type of Oil Pump ...................................................................... Gear
Oil Filter .............................................................Full Flow, Cartridge
Crankcase Oil Capacity ....................................................5 U.S. qts.
‹ STATIONARY EMERGENCY GENERATOR
Type ............................................................................. Synchronous
Rotor Insulation ......................Class F or Class H (see Data Label)
Stator Insulation .................................................................. Class H
Total Harmonic Distortion ......................................................< 3.5%
Telephone Interference Factor (TIF) ..........................................< 50
Alternator Output Leads 1-phase ........................................... 4-wire
Alternator Output Leads 3-phase ........................................... 6-wire
Bearings .........................................................................Sealed Ball
Coupling .......................................................................Flexible Disc
Load Capacity (Standby Rating) ............................................55kW*
* NOTE: Generator rating and perfomance in accordance with ISO8528-5, BS5514, SAE J1349,
‹ COOLING SYSTEM
Type .......................................................................................Closed
Water Pump.................................................................... Belt Driven
Fan Speed ................................................................................ 2090
Fan Diameter .....................................................................22 inches
Fan Mode ..............................................................................Pusher
Air Flow (inlet air including alternator and
combustion air) .......................................................... 4350 ft3/min.
Coolant Capacity ........................................................ (4.0 U.S. gal.)
Heat Rejection to Coolant ..........................................210,000 Btu/h
Maximum Operating Air Temp. on Radiator ..............60° C (150° F)
Maximum Ambient Temperature................................50° C (140° F)
ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural
gas.
Excitation System ............................................................. Brushless
Generator Output Voltage/kW - 60 Hz
kW
Amp CB Size
120/240V, 1-phase, 1.0 pf
55
229
250
120/208V, 3-phase, 0.8 pf
55
191
225
120/240V, 3-phase, 0.8 pf
55
165
200
277/480V, 3-phase, 0.8 pf
55
83
100
Generator Locked Rotor KVA Available @ Voltage Dip of 35%
Single-phase .................................................................... 115 KVA
480V, 3-phase .................................................................. 146 KVA
208V, 3-phase .................................................................. 110 KVA
240V, 3-phase .................................................................. 110 KVA
‹ FUEL SYSTEM
Type of Fuel ........................................Natural Gas, Propane Vapor*
Carburetor ...................................................................... Down Draft
Secondary Fuel Regulator .................................................Standard
Fuel Shut-off Solenoid ........................................................Standard
Operating Fuel Pressure ...................... 5 in. - 14 in. Water Column
Fuel Consumption - ft3/hr (Natural Gas/LPV)
Exercise
25%
50%
75%
100%
Cycle
Load
Load
Load
Load
95/38
204/82
392/157
547/220
756/302
‹ ENGINE
Make ................................................................................... Generac
Model ...................................................................................... V-type
Cylinders and Arrangement............................................................ 8
Displacement ....................................................................... 5.4 Liter
Bore ...................................................................................... 3.55 in.
Stroke ................................................................................... 4.17 in.
Compression Ratio ..................................................................9-to-1
Air Intake System ...............................................Naturally Aspirated
Valve Seats....................................................................... Hardened
Lifter Type .......................................................................... Hydraulic
* Engine is not field convertible between natural gas and propane. Jet size and ignition timing are
factory set for the specific fuel.
‹ ELECTRICAL SYSTEM
Battery Charge Alternator ............................................12V, 30 Amp
Static Battery Charger ..................................................12V, 10 Amp
Recommended Battery................................................ 24F 525CCA
System Voltage .....................................................................12 Volts
Voltage Regulator
Type ................................................................................. Full Digital
Sensing................................................................................ 3-phase
Regulation .............................................................................± 1/4%
Features ...........................................Built into H-100 Control Panel,
V/F Adjustable, Adjustable Voltage and Gain
Engine Parameters
Rated Synchronous RPM ..............................................60 Hz, 1800
HP at rated kW ..................................................................60 Hz, 88
Exhaust System
Exhaust Flow at Rated Output 60 Hz.................................. 414 cfm
Exhaust Temperature at Rated Output .................................. 800° F
Power Adjustment for Ambient Conditions
Temperature Deration
3% for every 10° C above °C ..................................................... 25
1.65% for every 10° above °F .................................................... 77
Altitude Deration
1% for every 100 m above m ................................................... 183
3% for every 1000 ft. above ft. ................................................. 600
Combustion Air Requirements (Natural Gas)
Flow at rated power, 60 Hz ................................................. 163 cfm
Governor
Type .................................................................................. Electronic
Frequency Regulation ...................................................Isochronous
Steady State Regulation.......................................................± 1/4 %
Controller .............................................. H-panel
GenSpec023 Rev. A 10/08
6-1
Stationary Emergency Generator
Specifications
Figure 1 — Interconnections
H-100 CONTROL
PANEL
Utility In
Transfer Switch
NEUTRAL
Gen
RS485 +
RS485 -
TO
ALTERNATOR
NEUTRAL
ALTERNATOR
CONNECTION
BOX
RS485 +
RS485 Grd.
Remote Start
Remote Start
CIRCUIT
BREAKER
GROUND
2 WIRE SHIELDED
CABLE W/GROUND
TO TRANSFER SW
GROUND AT
ALTERNATOR
CONNECTION BOX
ONLY
FRAME RAIL
STUB-UP AREA
See Install Dwg for
Dimensions
Ground Level
Concrete Slab
Figure 2 — AC Outlets for Block Heater and
Battery Charger (to be wired by installer)
6-2
2 WIRE
SHIELDED
CABLE
W/GROUND
TO
ALTERNATOR
CONNECTION
BOX
Sig B4 Xfer
Sig B4 Xfer
Load
Out
TO ALTERNATOR
CONNECTION BOX
GenSpec023 Rev. A 10/08
Stationary Emergency Generator
Specifications
5.4L & 6.8L IGNITION DESCRIPTION
NOTE:
This single-fire Ignition is intended to operate with
a 10-cylinder, 6.8L engine and an 8-cylinder, 5.4L
engine.
The ignition cover does not need to be removed to
see the LED.
The 6.8L engine uses a 40-1 crank sensor, a magpickup CAM sensor and individual coil-on-plug coils
for each spark-plug.
‹ IGNITION SHUTDOWN ON LOSS OF CRANK
OR CAM SIGNALS
The ignition will stop firing the coils immediately following the loss of the crank signal. The ignition will
stop firing the coils after approx. 3 seconds following
the loss of the cam signal.
The 5.4L engine uses a 36-1 crank sensor, a magpick-up CAM sensor and individual coil-on-plug coils
for each spark-plug.
With a single-fire ignition, each high-voltage coil output is connected to one spark plug resulting in that
spark plug being fired only during the compression
cycle.
‹ DIAGNOSTIC BLINK PATTERNS (RED LED
LOCATED ON THE IGNITION CONTROL
BOARD)
Engine Timing versus Engine Speed for the 6.8L
engine is:
During normal ignition operation the RED LED
flashes at a 0.5 sec ON and a 0.5 sec OFF rate. This
is considered one (1) blink.
RPM
NG/LP Engine Timing (BTDC)
1800 rpm
22 degrees
3600 rpm
24 degrees
Engine Timing versus Engine Speed for the 5.4L
engine is:
RPM
1800 rpm
3600 rpm
LED Fault Code with Priority as shown:
1. No Crank Signal: LED blinks 2 times, is OFF for
3.0 seconds and then repeats
2. No CAM Signal: LED blinks 3 times, is OFF for
3.0 seconds and then repeats
Only one fault is displayed at a time. If multiple faults
exist then the highest priority fault must be resolved
prior to a lower priority fault being displayed. In the
event that an ignition fault has occurred the ignition
will wait 60 seconds before powering down.
NG/LP Engine Timing (BTDC)
26 degrees
26 degrees
‹ IGNITION POWER-UP INPUT ("56 LINE
INPUT")
When battery voltage is applied to this input the ignition will power-up. For the ignition to power itself
down, battery voltage must be removed from this
input.
NOTE:
The ignition cover does not need to be removed to
see the LED.
‹ IGNITION ENABLE ("14 LINE INPUT")
This input must be connected to the +12V battery for
the ignition to turn-on the coils. If this input is connected to battery ground the ignition will stop firing
the coils and will power down within approximately
2 seconds. In the event that an ignition fault has
occurred, however, the ignition will wait 60 seconds
before powering down. This allows time to view the
diagnostic LED located on the ignition board.
GenSpec023 Rev. A 10/08
6-3
Stationary Emergency Generator
General Information
GENERATOR AC LEAD CONNECTIONS
‹ 3-PHASE ALTERNATORS ("Y" CONFIGURATION)
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.
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.
Voltage codes apply to the type of stator assembly
installed on a particular generator.
The rated voltage between each circuit breaker terminal and the neutral point 00 is either 277V or 120V
depending on the model.
ALTERNATOR POWER WINDING
CONNECTIONS
Figure 7.2 — Stator Power Winding
Connections - 3-phase, 120/208V (12 Lead)
‹ FOUR-LEAD, SINGLE-PHASE STATOR
Four-lead generators are built to supply electrical
loads with voltage code "A" (240V, 1-phase, 60Hz).
Electrical power is produced in the stator power
windings. These windings were connected at the factory to the main circuit breaker as shown in Figure
7.1.
E1
The rated voltage between each circuit breaker terminal is 240V. The rated voltage between each circuit
breaker terminal and the neutral point 00 is 120V.
S7
S1
S10
S12
S4
S5
L-L
Figure 7.1 — Four-lead, Single-phase Stator
S9
S2
S6
S11
E3
E2
S3
S8
L-N
Figure 7.3 — Stator Power Winding
Connections - 3-phase, 277/480V (12 Lead)
E1
S1
S4
S7
L-L
S6
S3
E3
7-1
S9
S10
S11
S8
S5
L-N
S2
E2
ACConn005 Rev. A 09/08
S12
Stationary Emergency Generator
General Information
‹ 3-PHASE ALTERNATORS
("DELTA" CONFIGURATION)
Figure 7.1 — Stator Power Winding
Connections - 3-phase, 346/600V (6 Lead)
The Stationary Emergency Generator is designed
to supply 3-phase electrical loads. Electric power is
produced in the alternator power windings. These
windings were connected at the factory to the main
circuit breaker with a “Delta” configuration as shown
in Figures 7.5.
S1 E1
INTERNAL
CONNECTIONS
The rated voltage between circuit breaker terminals
E1-E2, E1-E3 and E2-E3 is 208V.
The rated voltage between E1 or E3 and the neutral
point 00 is 120V.
L-L
S6
S4
NEUTRAL
Figure 7.5 — Stator Power Winding
Connections - 3-phase, 120/240V (12 Lead)
S5
E3 S3
S2
E2
E2
L-N
E1
7-2
E
ACConn005 Rev. A 09/08
Stationary Emergency Generator
Installation
INSTALLATION
Also, if the engine is equipped with a mechanical governor, make sure the governor is properly lubricated
with clean engine oil.
Refer to the separate “Installation Guide QT Product
Line” supplied with the unit.
‹ PRIOR TO INITIAL START-UP
PREPARATION BEFORE START-UP
The instructions in this section assume that the
standby generator has been properly installed,
serviced, tested, adjusted and otherwise prepared
for use by a competent, qualified installation contractor. Be sure to read the “Safety Rules”, as well
as all other safety information in this manual,
before attempting to operate this (and related)
equipment.
to initially starting the generator, it must
 Prior
be properly prepared for use. Any attempt to
crank or start the engine before it has been
properly serviced with the recommended types
and quantities of engine fluids (oil, coolant, fuel,
etc.) may result in an engine failure.
Before starting the generator for the first time, the
installer must complete the following procedures. For
follow-up maintenance information and/or service
intervals, please refer to the “Maintenance” section
and the “Service Schedule”.
‹ ENGINE COOLANT
Have the engine cooling system properly filled with
the recommended coolant mixture. Check the system
for leaks and other problems. See “Specifications”
and “Coolant” sections.
‹ TRANSFER SWITCH
‹ BELT TENSION
If this generator is used to supply power to any electrical system normally powered by an electric utility,
the National Electrical Code requires that a transfer
switch be installed. The transfer switch prevents electrical backfeed between two different electrical systems. (For additional information, see the applicable
transfer switch manual for this unit.) The transfer
switch, as well as the generator and other electrical
components, must be properly located and mounted
in strict compliance with applicable codes, standards
and regulations.
Check-the engine-fan belt tension and condition prior
to placing the unit into service and at recommended
intervals. Belt tension is correct when a force of
approximately 22 pounds (10 kg), applied midway
between pulleys, deflects the belt about 3/8- to 5/8inch (10 to 16 mm).
‹ ELECTRICAL SYSTEM
Make sure the generator is properly connected to an
approved earth ground.
Make sure the generator battery is fully charged,
properly installed and interconnected, and ready for
use.
‹ 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.
NOTE:
Battery charger must be connected to 120 VAC, 15
amp circuit to operate.
Check to ensure that there are no loose electrical connections. Restrain any loose wires to keep them clear
of any moving generator set components.
‹ GENERATOR SET LUBRICATION
Check the engine crankcase oil level before operating
and add oil to the proper level – the dipstick “FULL”
mark. Never operate the engine with the oil level
below the dipstick “ADD” mark. See “Specifications”
and “Engine Oil Recommendations”.
INITIAL INSPECTION FOR QT GENSET
STARTUP
Inspect for the following.
NOTE:
•
•
•
•
•
Freight Damage.
Manuals present.
Fluid Levels (Oil, coolant, battery, Gear Drive).
Correct fuel piping.
Correct muffler installation for QT45, QT55, QT80,
QT100 - QT150.
• Adequate air flow, clearances and ventilation per
installation drawings and applicable codes.
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.
8-1
Install006 Rev. B 10/08
This engine is shipped from the manufacturer
with “break-in” oil. This oil should be changed
after 30 hours of operation.
Stationary Emergency Generator
Installation
• 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.
• AC outlet connection.
• Communication wires connected between transfer
switch and generator (HTS only).
• Unit secured to pad.
• Insert the fuse into the control panel.
• Move the AUTO/OFF/MANUAL switch to the MANUAL position. The engine should now crank and
start.
• Check voltage at the generator terminals.
• For 3-phase units, check phase rotation at the
transfer switch terminals. The generator phase
rotation must match the utility phase rotation.
• Check for coolant, fuel, oil, and exhaust leaks.
• Close the generators main line circuit breaker.
• Turn the generator set off.
• Connect the UTILITY supply to the transfer
switch.
• Set the AUTO/OFF/MANUAL switch to AUTO.
• Disconnect utility power before the transfer
switch.
Engine should start, transfer to load.
Run at least 15 minutes on generator power.
Make certain all 3-phase loads are functioning
correctly (correct phase rotation).
• Reconnect Utility power
Transfer switch will transfer back to Utility and
engine will shut down within the given time
parameters set up for the specific transfer switch
and controller.
• Install all covers, access plates and door panels.
• Put the Owners Manual in a safe and accessible
place.
• Make certain the AUTO/OFF/MANUAL switch is in
the AUTO position.
START-UP CHECKLIST
working on the Stationary Emergency
 Before
Generator, ensure the following:
• The AUTO/OFF/MANUAL switch is in the OFF
position.
• The power to the block heater and to the battery
charger is switched OFF.
‹ PREPARATION FOR START-UP
• Remove the fuse from the the control panel. For
the H-100 and R-series: Open the front door of the
control box and remove the 15 Amp ATO fuse in
the lower left-hand corner of the control box.
• Connect the battery cables to the battery. Attach
negative battery cable last.
• Restore power to the GFCI outlet that provides
power to the battery charger.
• Measure the voltage at the battery before and after
the charger is turned on.
• Verify all AC electrical connections are tight at the
circuit breaker and transfer switch.
• Visually inspect entire area looking for loose paper,
plastic wrappings, leaves, etc.
• Check all hoses clamps fittings for leaks or damage.
• Check all electrical plugs throughout the generator. Ensure each plug is seated correctly and fully
inserted into its receptacle.
• Verify the AUTO/OFF/MANUAL switch is in OFF
position.
• Open the valve to the engine fuel line.
• Bleed the fuel system of air. (necessary for long fuel
lines).
• Open the generator main line circuit breaker.
• Connect a manometer to the gas line and record
the static pressure. It must be as listed in the
Specifications.
‹ START-UP INSPECTION
When a start-up is performed by an Authorized
Service Dealer, a standard three-part form titled
“Start-up Inspection for Standby Power Systems”
(part no. 067377), should be completed by the installation technician or engineer. See page 1-3 for information on locating the nearest Authorized Service
Dealer. The installer should complete the form and
disseminate copies as follows:
• White copy: Mail to Generac Warranty Department,
P.O. Box 340, 211 Murphy Dr., Eagle, WI 531192062.
• Pink Copy: For service file of installing dealer.
• Yellow Copy: For the customer’s records.
8-2
Install006 Rev. B 10/08
Stationary Emergency Generator
Operation
STATIONARY EMERGENCY
GENERATOR CONTROL AND
OPERATION
not crank the engine continuously for longer
 Do
than 30 seconds, or the heat may
Refer to the appropriate control panel operator’s manual for this
unit.
•
•
OPERATING UNIT WITH MANUAL
TRANSFER SWITCH
If the Stationary Emergency Generator was installed in conjunction
with a transfer switch capable of manual operation only, the following procedure applies. A manually operated transfer switch is
one that will not provide automatic start-up and does not include
an intelligence circuit.
•
•
damage the starter motor.
Let engine stabilize and warm up.
Check all applicable instrument and gauge readings. When
certain that all readings are correct, move the transfer switch
manual handle to the STANDBY position, i.e., load circuits supplied by the generator.
Set the generator’s main line circuit breaker to its ON (or
CLOSED) position.
Load circuits are now powered by the generator.
‹ RETRANSFER AND SHUTDOWN
For additional information, refer to the applicable control panel
manual for this unit, as well as any literature pertaining to the
specific transfer switch.
‹ ENGINE START-UP AND TRANSFER
For additional information, refer to the applicable control panel
manual for this unit, as well as any literature pertaining to the
specific transfer switch.
To transfer the load back to the utility power source and shut down
the generator, follow these directions:
• Set the generator’s main line circuit breaker to its OFF (or OPEN)
position.
• Manually move the transfer switch handle to its UTILITY
(NORMAL) position, i.e., load circuits connected to the utility.
• Turn ON the utility power supply to the transfer switch, using
the means provided (such as the utility power source main line
circuit breaker).
• Let the generator run at no-load for a few minutes to stabilize
internal temperatures.
• Shut down the generator.
DANGER
Maintenance Disconnect Switch and the
 The
AUTO/OFF/MANUAL switches (if so equipped)
must be set properly, or the generator will crank
and start as soon as the utility power to the
transfer switch is turned off. Refer to applicable
control panel and transfer switch manuals for
more information.
not proceed until certain that utility source
 Do
voltage is available to the transfer switch and
the transfer switch main contacts are set to
UTILITY.
OPERATING UNIT WITH AUTOMATIC
TRANSFER SWITCH
not attempt manual operation until all power
 Do
supplies to the transfer switch have been posi-
If the Stationary Emergency Generator has been installed with an
automatic transfer switch, the engine may be started and stopped
automatically or manually.
tively turned off, or extremely dangerous - possibly lethal - electrical shock will result.
NOTE:
switch enclosure doors should be kept
 Transfer
closed and locked. Only authorized personnel
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.”
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.
Oper001 Rev. B 06/09
9-1
Stationary Emergency Generator
Maintenance
MAINTENANCE PERFORMED BY
AUTHORIZED SERVICE DEALERS
exhaust system parts from this product get
 The
extremely hot and remain hot after shutdown.
High grass, weeds, brush, leaves, etc. must
remain clear of the exhaust. Such materials may
ignite and burn from the heat of the exhaust
system.
working on the Stationary Emergency
 Before
Generator, ensure the following:
•
•
•
•
The AUTO/OFF/MANUAL switch is in the OFF position.
The 15A fuse has been removed from the control box.
The 120VAC supply to the battery charger is switched OFF.
The negative battery cable has been removed.
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.
‹ EVERY THREE MONTHS
1.
2.
3.
4.
5.
6.
Check battery state of charge and condition.
Inspect and test fuel system.
Check transfer switch.
Inspect exhaust system.
Check engine ignition system.
Check fan belts.
•
•
•
•
‹ ONCE EVERY SIX MONTHS
1.
Figure 10.1 - Oil Dipstick and Oil Fill Cap
Test Engine Safety Devices (low oil pressure, low coolant
level, high coolant temperature).
Oil Fill
‹ ONCE ANNUALLY
1.
2.
3.
4.
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
Recommendations” for recommended oils.
Test engine governor. Adjust or repair, if needed.
Clean, inspect generator.
Flush cooling system.
Clean/re-gap spark plugs or replace as necessary.
‹ FIRST 30 OPERATING HOURS
1.
Change engine "break-in" oil and oil filter.
‹ FIRST 100 OPERATING HOURS
1.
Oil
Dipstick
Change engine oil and oil filter. (After initial change, service
engine oil and filter at 150 operating hours or 6 months,
whichever comes first.)
‹ EVERY 500 OPERATING HOURS
1.
2.
3.
Oil Filter
Service air cleaner.
Check starter.
Check engine DC alternator.
‹ BATTERY FLUID
Check battery electrolyte fluid at least once weekly. 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.
COOLING SYSTEM
Air intake and outlet openings in the generator compartment must
be open and unobstructed for continued proper operation. This
includes such obstructions as high grass, weeds, brush, leaves
and snow.
Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down.
Maint013 Rev. E 06/09
10-1
Stationary Emergency Generator
Maintenance
‹ ENGINE COOLANT
‹ INSPECT EXHAUST SYSTEM
Check coolant level in coolant recovery bottle. See the
“Specifications” section.
Inspect the exhaust system at least once every three months.
Check all exhaust system pipes, mufflers, clamps, etc. for condition, tightness, leaks, security, damage.
• Add recommended coolant mixture as necessary.
• Periodically remove radiator pressure cap to make sure the
coolant recovery system is functioning properly. Coolant
should be at bottom of radiator filler neck. If coolant level is
low, inspect gasket in radiator pressure cap. Replace cap, if
necessary. To have pressure cap tested, contact an Authorized
Service Dealer. Inspect cooling system and coolant recovery
system for leaks.
‹ CHECK FAN BELT
• Inspect fan belts every three months. Replace any damaged,
deteriorated, worn or otherwise defective belt.
• Check fan belt tension. Thumb pressure, exerted midway
between pulleys, should deflect about 3/8 to 5/8 inch. Adjust
belt tension as required.
• Check fan belt alignment.
MAINTENANCE OWNER/
OPERATOR CAN PERFORM
‹ INSPECT ENGINE GOVERNOR
Visually inspect electronic governor.
DANGER
working on the generator, ensure the fol Before
lowing:
•
•
•
•
not attempt to adjust the governor. Only
 Do
qualified service facilities should adjust the
The AUTO/OFF/MANUAL switch is in the OFF position.
The 15A fuse has been removed from the control box.
The 120VAC supply to the battery charger is switched OFF.
The negative battery cable has been removed.
governor. Excessively high operating speeds
are dangerous and increase the risk of personal
injury. Low speeds impose a heavy load on
the engine when adequate engine power is not
available and may shorten engine life. Correct
rated frequency and voltage are supplied only
at the proper governed speed. Some connected
electrical load devices may be damaged by
incorrect frequency and/or voltage. Only qualified service technicians should adjust the governed speed.
‹ CHECK ENGINE OIL LEVEL
Refer to the “Checking Fluid Levels” section.
‹ CHECK BATTERY
• Check battery fluid level each week as outlined under “Check
Fluid Levels”.
• Check battery cables for condition, tightness, corrosion or damage. Clean, tighten or replace as necessary.
‹ CHANGING ENGINE OIL
‹ EXERCISE SYSTEM
oil may cause burns. Allow engine to cool
 Hot
before draining oil. Avoid prolonged or repeated
Start the Stationary Emergency Generator engine at least once
every seven days and let it run at least 20 minutes. For more
detailed exercise information, see the respective sections in the
Control Panel Technical Manual that is supplied with the unit.
skin exposure with used oil. Thoroughly wash
exposed areas with soap.
Refer to maintenance performed by authorized service facilities for
engine oil and filter change frequencies.
‹ INSPECT COOLING SYSTEM
Drain the oil while the engine is still warm from running. This
means warm up the engine, shut it down and drain immediately
as follows:
• Inspect engine cooling system at least once each month.
• Check hoses for damage, deterioration, leaks, etc. Correct any
discrepancies found.
• Check hose clamps for tightness.
1.
2.
‹ CHECK ENGINE COOLANT LEVEL
3.
See the “Checking Fluid Levels” section.
4.
‹ PERFORM VISUAL INSPECTION
5.
Complete a thorough visual inspection of the entire engine-generator monthly. Look for obvious damage, loose, missing or corroded
nuts, bolts and other fasteners. Look for fuel, oil or coolant leaks.
10-2
Remove OIL DRAIN HOSE from its retaining clip.
Loosen and remove OIL DRAIN HOSE CAP. Drain oil completely into suitable container.
When all oil has drained, install and tighten OIL DRAIN HOSE
CAP, and re-install into its retaining clip.
Turn OIL FILTER (Figure 10.2) counterclockwise and remove.
Dispose of old filter.
Apply light coating of new engine oil to seal of new oil
filter.-Install FILTER and tighten by hand only. DO NOT
OVERTIGHTEN.
Maint013 Rev. E 06/09
Stationary Emergency Generator
Maintenance
6.
‹ SPARK PLUGS
Remove OIL FILL CAP. Add recommended oil (see
SPECIFICATIONS). DO NOT FILL ABOVE THE DIPSTICK
“FULL” MARK. Crankcase oil capacity is listed in the
“Specifications”.
Reset the spark plug gap or replace the spark plugs as necessary.
1.
refilling the crankcase with oil, always
 After
check oil level on dipstick. NEVER OPERATE
7.
8.
9.
2.
ENGINE WITH OIL BELOW THE DIPSTICK
“ADD” MARK.
Start engine and check for oil leaks.
Shut OFF engine and wait 10 minutes for the oil to settle down
into the oil pan. Recheck oil level on dipstick. DO NOT fill
above the dipstick "FULL" mark.
Dispose of used oil at a proper collection center.
3.
Clean the area around the base of the spark plugs to keep dirt
and debris out of the engine. Clean by scraping or washing
using a wire brush and commercial solvent. Do not blast the
spark plugs to clean.
Remove the spark plugs and check the condition. Replace
the spark plugs if worn or if reuse is questionable. See the
“Service Schedule” section for recommended inspection.
Check the spark plug gap using a wire feeler gauge. Adjust
the gap to 0.94 - 1.07 mm (0.037 - 0.042 inch) by carefully
bending the ground electrode (Figure 10.4).
Figure 10.4 – Setting the Spark Plug Gap
Figure 10.2 - Oil Filter
Oil
Dipstick
‹ COOLANT CHANGE
Every year, have an Authorized Service Facility drain, flush and
refill the cooling system. See the “Specifications” section for cooling system recommendations.
Oil Filter
‹ CHANGING THE ENGINE AIR CLEANER
MISCELLANEOUS MAINTENANCE
To replace the engine air cleaner, (part number 0A4637), remove
the air cleaner cover and replace the air filter making sure it is
positioned properly before reattaching the cover.
‹ 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.
Figure 10.3 — Engine Air Filter
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.
Air Filter
Once each year, have the generator cleaned and inspected by an
Authorized Service Dealer. That dealer will use dry, low pressure air
to clean internal windings. Parts inside the control console should
be cleaned and inspected at this time as well.
Finally, have the insulation resistance of stator and rotor windings
checked. If insulation resistances are excessively low, the generator may require drying.
See the “Service Schedule” section for air cleaner maintenance.
Maint013 Rev. E 06/09
10-3
Stationary Emergency Generator
Maintenance
‹ BATTERY
electrolyte fluid is an extremely caus Battery
tic sulfuric acid solution that can cause severe
All lead-acid storage batteries discharge when not in use. Refer to
specific instructions and warnings that accompany the battery. If
such information is not available, observe the following precautions when handling a battery:
burns. Do not permit fluid to contact eyes, skin,
clothing, painted surfaces, etc. Wear protective
goggles, protective clothing and gloves when
handling a battery. If the fluid is spilled, flush
the affected area immediately with clear water.
• DO NOT use jumper cables and a booster battery to crank or
start the generator engine.
• DO NOT recharge a weak battery while it is installed in the generator. Remove battery from generator and recharge in a wellventilated area, away from fuel vapors, sparks, heat or flames.
• Battery electrolyte fluid is an extremely caustic sulfuric solution
that can cause severe burns. DO NOT permit fluid to contact
eyes, skin, clothing, painted surfaces, wiring insulation, etc.
If any battery fluid is spilled, flush the affected area with clear
water immediately.
• Always wear safety glasses, rubber apron and gloves when
handling a battery.
• Batteries give off explosive hydrogen gas while charging. The
gas can form an explosive mixture around the battery for several hours after charging. Any spark, heat or flames can ignite
the gas and cause an explosion which can shatter the battery,
causing blindness or other serious injury.
not use any jumper cables or booster battery
 Do
to crank and start the generator engine. If the
battery has completely discharged, remove it
from the generator for recharging.
sure the AUTO/OFF/MANUAL switch is set to
 Be
the OFF position before connecting the battery
cables. If the switch is set to AUTO or MANUAL,
the generator can crank and start as soon as
the battery cables are connected.
sure the 120VAC power supply to the battery
 Be
is turned OFF, or sparking may occur at the battery posts as the cables are attached and cause
an explosion.
‹ BATTERY MAINTENANCE
‹ BATTERY REPLACEMENT
The battery should be inspected per the “Service Schedule” section. The following procedure should be followed for inspection:
1.
2.
3.
When replacing batteries, use the same number and type of battery
that was supplied with the unit, and is listed in the parts list in the
back of this manual.
Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary.
Check the battery fluid level of unsealed batteries and, if necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP
WATER IN BATTERIES.
Have the state of charge and condition checked. This should
be done with an automotive-type battery hydrometer.
NOTE:
The BCI number should be located directly on the battery.
DANGER
batteries give off explosive hydrogen
 Storage
gas. This gas can form an explosive mixture
around the battery for several hours after charging. The slightest spark can ignite the gas and
cause an explosion. Such an explosion can
shatter the battery and cause blindness or other
injury. Any area that houses a storage battery
must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing
tools or equipment near the battery.
10-4
Maint013 Rev. E 06/09
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:
• Disable the generator set from starting and/or connecting to the load by setting the control panel Auto/Off/
Manual switch to the “OFF” position.
• Remove the 15 amp control panel fuse.
• Turn off the battery charger.*
• Remove the negative battery cable.
* The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition
from burning out sensitive control panel components and circuits.
Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal operation when required.
2 A wear-in service inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any
potential problem areas.
Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be
performed only by a Service Dealer.
3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential
problem areas.
Performed semi-annually or following each 50 hours of operation of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be
performed only by a Service Dealer.
4 A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential
problem areas.
Performed annually or following each 100 hours of operation of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be
performed only by a Service Dealer.
5 A comprehensive inspection of the generator set to insure it is properly serviced and ready to operate and carry the load when required,
and to identify any potential problem areas.
Performed annually or following each 250 hours of operation of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be
performed only by a Service Dealer.
SrvSchd001 Rev. E 02/09
11-1
Stationary Emergency Generator
Service Schedule
Maintenance
Tasks
Level 1
Recommended
to be done
monthly/
10 hrs.
Level 2
Level 3
Task
Required
Task
Required
Comp. to be done Comp. to be done
(Date- 3 months/ (DateSemiInitials) Break-in Initials) annually/
30 hrs.
50 hrs.
1. Disable the unit
from operating
per the first page
warning.
2. Check the engine
oil level. Adjust
as necessary.
3. Check the engine
coolant level.
Adjust as
necessary.
4. Check the engine
coolant thermal
protection level.
Correct as
necessary.
5. Check the natural
gas delivery
system for leaks
and correct
pressure on gas
engine driven
units. Tighten
connections as
necessary.
6. Check the air
inlets and outlets
for debris. Clean
as necessary.
7. Check the battery
electrolyte level
and specific
gravity if
accessible. Adjust
as necessary.
8. Check the battery
posts, cables,
and charger for
loose
connections,
corrosion, and
proper operation.
Correct as
necessary.
9. Check the unit
wiring for loose
connections,
corrosion, and
damage. Correct
as necessary.
11-2
Level 4
Task
Comp.
(DateInitials)
Required
to be done
Annually/
100 hrs.
Level 5
Task
Comp.
(DateInitials)
Required
to be done
Biannually/
250 hrs.
Task
Comp.
(DateInitials)
SrvSchd001 Rev. E 02/09
Stationary Emergency Generator
Service Schedule
Maintenance
Tasks
Level 1
Recommended
to be done
monthly/
10 hrs.
Level 2
Level 3
Task
Required
Task
Required
Comp. to be done Comp. to be done
(Date- 3 months/ (DateSemiInitials) Break-in Initials) annually/
30 hrs.
50 hrs.
Level 4
Task
Comp.
(DateInitials)
Required
to be done
Annually/
100 hrs.
Level5
Task
Comp.
(DateInitials)
Required
to be done
Biannually/
250 hrs.
Task
Comp.
(DateInitials)
10. Check the engine
accessory drive
belts and fan
coupling device
if equipped for
correct tension,
wear, weather
cracking, and
damage. Replace
as necessary.
11. Check the engine
valve clearance/
lash. Adjust as
necessary.**
12. Visually inspect
the unit looking
for leaks, wear or
damage, loose
connections or
components, and
corrosion. Correct
as necessary.
13. Test the engine
and transfer
switch safety
devices. Correct
and/or adjust as
necessary.
14. Initiate an
automatic start
and transfer of
the unit to site
load and exercise
it for at least 1
hour looking for
leaks, loose
connections or
components, and
abnormal
operating
conditions.
Correct as
necessary.
15. Replace the
engine
accessory
drive belts.
16. Check gearbox
oil level (if
equipped).
17. Change gearbox
oil (if equipped).
** Not required for engines equipped with hydraulic lifters. See the "Specification" section for lifter type.
SrvSchd001 Rev. E 02/09
11-3
Stationary Emergency Generator
Service Schedule
Maintenance
Tasks
Level 1
Recommended
to be done
monthly/
10 hrs.
Level 2
Level 3
Task
Required
Task
Required
Comp. to be done Comp. to be done
(Date- 3 months/ (DateSemiInitials) Break-in Initials) annually/
30 hrs.
50 hrs.
18. Start and
exercise the unit
at full rated load
(use a load bank
if the site load is
not enough) for
at least 2 hours
looking for leaks,
loose
connections or
components, and
abnormal
operating
conditions.
Correct as
necessary.
19. Perform an
engine oil
analysis (send a
sample to a lab
for results).
Change the
engine oil and
filters if the
analysis results
indicate this is
required.
20. Change the
engine oil.
21. Replace the
engine oil filter(s).
22. Replace engine
spark plugs.
Clean and re-gap
or replace as
necessary.
23. Replace the
engine air
filter(s).
24. Perform a 5
minute no-load
operational run
of the unit
looking for any
post service
problems.
25. Return the unit
to standby setup
for operation
when required.
11-4
Level 4
Task
Comp.
(DateInitials)
Required
to be done
Annually/
100 hrs.
Level5
Task
Comp.
(DateInitials)
Required
to be done
Biannually/
250 hrs.
Task
Comp.
(DateInitials)
SrvSchd001 Rev. E 02/09
Stationary Emergency Generator
Troubleshooting
TROUBLESHOOTING GUIDE
PROBLEM
CAUSE
CORRECTION
Engine won’t crank.
1. 15 amp fuse blown.
2. Loose or corroded or defective
battery cables.
3. Defective starter contactor.
4. Defective starter motor.
5. Dead or Defective Battery.
6. 5 amp fuse blown.
1. Replace fuse.
2. Tighten, clean or replace
battery cables as necessary.
3. Replace contactor.*
4. Replace starter motor.*
5. Remove, change or replace battery.
6. Replace fuse.*
Engine cranks but won't start
1. Out of fuel.
2. Fuel solenoid (FS) is defective
3. Open Wire #14A from Engine Control
circuit board.
4. Spark plugs defective.
5. Door on tank not closed.
1. Replenish fuel.
2. Replace solenoid.*
3. Reconnect wire.
Engine starts hard, runs rough.
1. Flame arrestor (air cleaner) plugged or
damaged.
2. Plugged fuel line.
3. Defective spark plugs.
4. Fuel pressure incorrect.
1. Clean or replace as needed.
2. Unclog fuel line.
3. Clean, regap or replace plugs.
4. Confirm fuel pressure to regulator is as
recommended in SPECIFICATIONS.
Engine starts then shuts down.
1.
2.
3.
4.
5.
6.
7.
AUTO/OFF/MANUAL Switch at OFF,
engine continues to run
1. Defective AUTO/OFF/MANUAL switch
2. Open/disconnected wire #15A between
AUTO/OFF/MANUAL switch and Control
Module circuit board.
3. Defective Control Module circuit board
3. Replace board.*
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
Check main line circuit breaker.
Check circuit breaker & fuses.
Transfer switch set to NORMAL position
Generator internal failure.
Thermal circuit breaker open.
1.
2.
3.
4.
5.
6.
7.
Check oil and add oil as needed.
Check cooling system for leaks.
Replace switch.*
Replace switch.*
Replace board.*
Repair leak - Add coolant.
Replace Switch.*
1. Replace switch.*
2. Reconnect/close wire.
Reset to ON or CLOSED.
Reset and replace, if necessary.
Set to GENERATOR position.
*
Auto-reset - Wait 5 min. and
attempt restart.
*Contact the nearest Authorized Dealer for assistance.
12-1
Trblsht001 Rev. A 10/08
No AC output from generator.
Engine oil level is low.
Engine is overheated.
Defective Low Oil Pressure Switch
Defective Coolant Temperature Switch
Defective Control Module circuit board.
Coolant Level is Low.
Defective Low Coolant Level Switch
4. Clean, regap or replace plugs.
5. Close door on tank.
Stationary Emergency Generator
Notes
1
2
3
4
5
6
7
8
9
10
11
084918D
084427
049813
022097
057822
022473
042568
050967
0C4905
0A6283
044117
1
1
2
4
4
4
4
1
1
1
1
HEATER BLOCK 2000W 240V
BRACKET HEATER W/WELDNUTS
NUT HEX M6 X 1.0 G8 YEL CHR
WASHER LOCK M6-1/4
CLAMP HOSE #8 .53-1.00
WASHER FLAT 1/4-M6 ZINC
SCREW HHC M6-1.0 X 20 G8.8
HOSE COOL 5/8 ID 20R3 (24” LG)
BARBED EL 45 3/8 NPT X 5/8 OD
HOSE PREFORMED BLOCK HEATER
BARBED STR 3/8 NPT X 5/8
1
2
3
4
5
6
7
8
9 (1)
10
11
12
13
14
15 (2)
16 (2)
17
18
19
20
21
22
23
24
25
26 (4)
27
28
29
30
31
32
33
34
35
36
37 (3)
38
39
0F3137
0F3135
0F3136
023484N
0F4677
067617030A
067617030B
043180
022264
0C3990
057701
022155
0C2428
0F3618
0A9457
057073
0D5466
0A7822
022237
022241
049226
0C2266
0C2454
042568
022473
022097
049813
0E9764
0G6962B
025433
024469
067210A
0D6029
051713
081008
077043J
0F6156
029289
0F3113
047411
036943
1
1
1
1
1
4
6
6
REF.
2
2
1
1
2
REF.
REF.
2
2
6
6
8
4
12
8
4
6”
1
1
1
1
4
2
1
3
1
A/R
REF
4
2
PAN CB CONN BOX
STAND RH CONTROL
STAND LH CONTROL
BUSHING SNAP SB-2.5-31
ASSY PCB INTERFACE 1PH 240V
INTERFACE 3PHS 416/480V
INTERFACE 3PHS 208/240V
WASHER FLAT M4
WASHER LOCK #8-M4
SCREW PHTT M4-0.7 X 10 ZYC
BLOCK TERM 20A 8 X 6 X 1100V
WASHER LOCK #6
SCREW PHTT #6-32 X 1/2 ZYC
DECAL CPL CUST CONN H CTRL
DECAL NEUTRAL
JUNCTION BLOCK 3/8-16
BUS BAR NEUTRAL BLOCK 390
LUG SLDLSS 600/250-1/0 X 1/4-28
WASHER LOCK 3/8
NUT HEX 3/8-16 STEEL
WASHER LOCK M5
SCREW PHTT M5-0.8 X 16 ZYC
SCREW THF M6-1 X 16 N WA Z/JS
SCREW HHC M6-1.0 X 20 G8.8
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX M6 X 1.0 G8 YEL CHR
RAIL SNAPTRACK PCB HOLDER BULK
ASSY RELAY PCB 12VDC
LUG SLDLSS #6-14 X 13/64 CU
SCREW HHTT #10-32 X 3/8 CZ
DECAL GROUND LUG
SCREW HHTT M6-1.0 X 16 ZYC
WASHER FLAT M5
GROMMET 1.25 X .25 X .75
CONDUIT FLEX 2.0" ID
PLATE WIRE SNGL GALV
TAPE ELEC 1/2 FOAM (AS REQ’D)
ASSY PCB HSB CTRL IGN MODULE
SCREW HHC M6-1.0 X 16 G8.8
SCREW PPHM #10/32 X 2
40
41
42
43
44
45
023897
022152
022158
0F8565
045764
023762
A
C
0F4810
0D5556
0D5566
0D5568
0D9693
0F0492
048927
023897
022152
022158
0C2454
029289
0F1733
UL CIRCUIT BREAKER (ED)
1
COVER ED CB STAND C3
1
CB 0090A 3P 480V S ED4 LL
CB 0060A 3P 600V S ED6 LL
CB 0080A 3P 600V S ED6 LL
CB 0125A 3P 480V S ED4 LL
1
INSULATOR CB S (ED-3P)
4
SCREW RHM #10-32 X 4-1/2
4
WASHER FLAT #10 ZINC
4
WASHER LOCK #10
4
NUT HEX #10-32 STEEL
7
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
D
E
F
G
H
J
K
L
0F4811
0D5573
0D5574
0D5576
0F0199
065960
022473
022097
022127
0C2454
029289
0F1733
UL CIRCUIT BREAKER (FD)
1
COVER FD CB STAND C3
CB 0175A 3P 600V S FD6 LL
CB 0200A 3P 600V S FD6 LL
CB 0250A 3P 600V S FD6 LL
1
INSULATOR CB FD FRAME 30MIL
4
SCREW SHC 1/4-20 X 4 G8.8 NZ
4
WASHER FLAT 1/4-M6 ZINC
4
WASHER LOCK M6-1/4
4
NUT HEX 1/4-20 STEEL
7
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
A
C
D
E
F
G
H
J
K
L
0F4812
0D5577
0F2353
022770
022473
022097
022127
0C2454
029289
0F1733
UL CIRCUIT BREAKER (JD+LD)
1
COVER JD/LD CB STAND C3
1
CB 0300A 3P 600V S JD6 LL
2
INSULATOR CIRCUIT BR. JD/LD
4
SCREW RHM 1/4-20 X 3
4
WASHER FLAT 1/4-M6 ZINC
4
WASHER LOCK M6-1/4
4
NUT HEX 1/4-20 STEEL
7
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
1)
D
E
F
G
H
J
K
L
2)
A
C
3)
3
2
2
1
1
1
WASHER FLAT #10 ZINC
WASHER LOCK #10
NUT HEX #10-32 STEEL
DECAL H-100 RB3 CUST CONN
SCREW HHTT M4-0.7 X 8 ZP
WASHER SHAKEPROOF EXT #10 STL
(1) ITEM INCLUDED WITH HARNESS
(2) ITEM INCLUDED WITH 0D5464B
(3) ITEM IS PART OF 9R.
(4) ITEM IS PART OF 5R.
4.)
A
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W (1)
X
Y
0F8453
0F4165$
0F4186
036261
053640
038150
022264
022471
029289
0F1733
022129
0F8432
0C2454
0F8451
049897
022145
045771
0F8843
W/CB
0G3259
058306
UL CIRCUIT BREAKER (225AF)
1
COVER CB C3 225AF
REF
CIRCUIT BREAKERS 200A FRAME
1
COVER CB DISH 225AF
4
RIVET POP .125 X .275 SS
8
SCREW RHM #8-32 X 3-1/4
4
WASHER FLAT #8 ZINC
4
WASHER LOCK #8-M4
4
NUT HEX #8-32 STEEL
2
TAPE ELEC 1/2 FOAM
1
DECAL CUSTOMER CONNECT INSIDE
9
WASHER LOCK M8-5/16
1
INSULATOR CB 225AF
7
SCREW THF M6-1 X 16 N WA Z/JS
3
LUG SLDLSS 300 MCM-6 AL/CU
6
SCREW SHC M8-1.25 X 20 G8
6
WASHER FLAT 5/16-M8 ZINC
3
NUT HEX M8-1.25 G8 CLEAR ZINC
3
BUS BAR 200A LUG ADAPTOR
2
TERMINAL COVER CB
1
DECAL TERMINAL SHOCK HZD BI
3
SCREW SHC M8-1.25 X 25 G12.9
5.)
A
C
D
E
F
G
H
J
K
L
M
N
P
R
S (1)
T
U (2)
V (2)
W
0F8454
0F4166$
0F1733
042419
023897
022152
022158
0C2454
029289
052647
046526
W/CB
0A7822
022131
W/CB
023334
W/CB
W/CB
0G3259
UL CIRCUIT BREAKER (400AF)
1
COVER CB C3 400AF
REF
CIRCUIT BREAKERS 400A FRAME
1
DECAL CUSTOMER CONNECT INSIDE
4
SCREW RHM 10-32 X 4
4
WASHER FLAT #10 ZINC
4
WASHER LOCK #10
4
NUT HEX #10-32 STEEL
7
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM
3/2
SCREW SHC M10-1.5 X 25 G12.9
3/2
WASHER LOCK M10
3
BUS BAR CB ADAPTER 225-400 A
3
LUG SLDLSS 600/250-1/0 X 1/4-28
3
WASHER FLAT 3/8-M10 ZINC
2
TERM COVER CB
6
SCREW HHC 1/4-28 X 1/2 G5
3/2
SCREW SHC M10-1.5 X 25 G12.9
3/2
WASHER LOCK M10
1
DECAL TERMINAL SHOCK HZD BI
6.)
A
B
C
D
E
F
G
H
0D5466
039287
022145
022129
045771
045335
022097
0A7822
NEUTRAL BLOCK 390 / 200-400A
2
BUS BAR NEUTRAL BLOCK 390
1
SCREW HHC M8-1.25 X 45 G8.8 FT
1
WASHER FLAT 5/16-M8 ZINC
1
WASHER LOCK M8-5/16
1
NUT HEX M8-1.25 G8 YEL CHR
2
SCREW HHC 1/4-28 X 3/4 G5
2
WASHER LOCK M6-1/4
1
LUG SLDLSS 600/250-1/0X1/4-28
(1) HARDWARE FOR MTG. CB TERMINAL COVERS IS SUPPLIED WITH CIRCUIT BREAKERS.
(2) 3/2 QTY. 3 POLE & 2 POLE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44 *
0F3182
0F6194
0G0993
0G0998
0G0991
0G0997
0F3183
0F6195
0F6203
0G0994
0G0996
0G1000
0G1048
0G1049
0G0992
0G0995
0G0999
0G1094
0G1095
068405C
087272
072878
0C9708
0F3726B
0C2454
023454
0F8408
046526
0A2601
072879
052646
043123
051779
092950
04576100CJ
022155
0C2428
023484N
022392
052259
051769
0E7230
0F3033
0F2722
083549
020151
023365
033133
033143
086032
090063
090064
090152
022661L
028739A
085662D
068113A
068406
0F6834
023484N
052624
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
REF
1
9
1
4
4
1
1
4
4
4
1
4
2
2
1
2
2
3
3
1
1
4
1
3
1
2
2
1
1
1
1
2
1
1
1
1
1
1
ROTOR 390 70AB3 CPL
ROTOR 390 70KB3 CPL
ASSY RTR 390 45AB3 CPL
ASSY RTR 390 45KB3 CPL
ASSY RTR 390 55KB3 CPL
ASSY RTR 390 55AB3 CPL
STATOR 390 70AB3 CPL
STR 390 70KB3 CPL
STR 390 70GB3 CPL
ASSY STR 390 45GB3 CPL
ASSY STR 390 45KB3 CPL
ASSY STR 390 45AB3 CPL
ASSY STR 390 45JB3 CPL
ASSY STR 390 45 LB3 CPL
ASSY STR 390 55GB3 CPL
ASSY STR 390 55KB3 CPL
ASSY STR 390 55AB3 CPL
ASSY STR 390 55JB3 CPL
ASSY STR 390 55LB3 CPL
EXITER FIELD 2"LG SPD CONN
ASSY EXCITER 2.00" STK
KEY SQ 3/8 X 3-1/4 STEEL
INSTR HYPOT TEST (NOT SHOWN)
ASSY FLYWHEEL CPL
SCREW THF M6-1 X 16 N WA Z/JS
KEY WOODRUFF #E
SCREW HHC M10-1.50 X 16 G10.9
WASHER LOCK M10
SCREW HHC M16-2.0 X 45 G8.8
SPACER .69 X 2.75 X .37 ST/ZNC
WASHER FLAT M14
WASHER LOCK M14
NUT HEX M14-2.0 G8 YEL CHR
COLLAR SLIP FIT 390 MM
STUD M14-2.0 X 650 G5 ZINC
WASHER LOCK #6
SCREW PHTT #6-32 X 1/2 ZYC
BUSHING SNAP SB-2.5-31
PIN DOWEL 1/2 X 1-1/4
WASHER FLAT M12
WASHER LOCK M12
SCREW HHC M12-1.75 X 80 G10.9
SHIELD ALT EXCITER 390
COVER EXCITER SHIELD
SLEEVE RUBBER
CLAMP VINYL .312 X .203 Z
WASHER SHAKEPROOF INT #8
SCREW HHM #8-32 X 3/8
SCREW HHM #8-32 X 7/8
LUG RT-ANG #10/10-12
BRIDGE SUPPORT DIODE 15"
CAP END ROTOR 390MM
ASSY BRIDGE RECTIFIER
SLEEVING UL #0 .330 ID (3” LG)
TIE WRAP UL 3.9" X .10" BLK
TIE WRAP UL 17.7 X .35 BLK HT
REAR BEARING CARRIER CPL
SCREW HHC M12-1.75 X 60 G10.9
MOUNT CT'S 5.4L & 6.8L
BUSHING SNAP SB-2.5-31
BEARING BALL 6212 SEALED
* ROTOR REPLACEMENT PARTS.
** PARTS INCLUDED WITH TRANSFORMER.
1
2
3
4
5
6
7
8
9
10
11
12
13
16
17
18
19
20
21
22
23
24
25
0F3150
065852
052252
052257
052259
055597
052251A
052860
0F2895
045764
057192
090502
061383
043107
057192
022131
046526
0536210410
042909
022261
022129
022145
045771
0F2910
0F2895
1
1
4
4
4
4
4
4
1
1
4
4
1
1
4
8
8
1
1
2
1
2
2
1
1
BASE CP 6.8L70KW/5.4L 55KW DD
SPRING CLIP HOLDER .37-.62
DAMPENER VIBRATION
SPACER .49 X .62 X 1.87 PWDR/ZINC
WASHER FLAT M12
SCREW HHC M12-1.75 X 85 G8.8
DAMPENER VIBRATION 50 WHITE
NUT LOCKING M12-1.75
SUPPORT ENG 5.4L LH/RH 6.8L RH
SCREW HHTT M4-0.7 X 8 BP
SCREW SHC M10-1.5 X 30 G12.9 (5.4L)
SCREW SHC M10-1.5 X 60 G12.9 (6.8L)
LUG SOLDERLESS 3/0-#4 X 13/32 CU
SCREW HHC M8-1.25 X 25 G8.8
SCREW SHC M10-1.5 X 30 G12.9
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
ASSY WIRE 14.00”
SCREW HHC M8-1.25 X 30 G8.8
WASHER SHAKEPROOF INT 3/8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
NUT HEX M8-1.25 G8 YEL CHR
SUPPORT, ENGINE (6.8L LH SIDE)
SUPPORT ENG (5.4L LH SIDE)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
0F3408
0F3411
058208
022131
050331A
050331
038805T
038804Y
045771
022129
027482
075763
0C2454
0F3409
1
1
1
1
1
1
1
1
1
1
1
1
8
1
TRAY BATTERY
STRAP BATTERY RETAINMENT
BATT 12VDC 24F 625
WASHER FLAT 3/8-M10 ZINC
BATT POST COVER RED +
BATT POST COVER BLK CABLE BATT BLK #1 X 40.00
CABLE BATT RED #1 X 35.00
NUT HEX M8-1.25 G8 YEL CHR
WASHER LOCK M8-5/16
WASHER SHAKEPROOF EXT 5/16 STL
BOOT BATTERY CABLE
SCREW THF M6-1X16 N WA Z/JS
SUPPORT BATTERY TRAY
1
2
3
4
5
6
7
8
9
10
11
0D2513D
0F5419
0F4268
0F4270A
0F6977
037561
047411
022097
049811
0F4269
022473
1
1
1
1
1
1
4
4
4
1
1
AIR CLNR BTM PLT W/CPLR 8.1L
ELEMENT AIR FILTER
TOP PLATE VENTURI
HOLD DOWN AIR CLEANER PLATED
PLATE AIR CLEAN TOP 5.4L/6.8L
NUT WING 1/4-20 NYLK
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
WASHER FLAT M6
GASKET MIXER BODY
WASHER FLAT 1/4-M6 ZINC
1
2
3
4
5
6
7
8
9
10
11
12
13
14
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31 *
32
33
34
35
36
37
38
39
0F3144
035685
0F2857A
0F4168
0F4169
0E7854
0F2820
051756
046526
022131
052250
0F4412
0F4412A
039253
022129
022097
0C8566
0F4765
089685
0F5589
0C2454
055596
0C7649
069860E
045764
065852
080712
076749
048031C
069811
0F4770
089514
0E2507
0H1827
0F4767
090283
0F2776A
022145
022132
1
4
1
1
1
1
1
4
4
4
2
1
1
8
8
8
8
1
1
2
11
1
1
1
1
1
1
1
1
REF
1
1
1
1
1
1
1
8
1
W ELDMENT RAD SUPPORT C3 (22" )
CLAMP HOSE #28 1.32-2.25
RADIATO R 581 X 585 X 70 CPL LH
HOSE UPPER RADIATOR C3
HOSE LOWER RADIATOR C3
CLUTCH CO OLING FAN
FAN 22" DIA 10 BLADE
SCREW HHC M10- 1.5 X 20 G 8.8
W ASHER LOCK M10
W ASHER FLAT 3/8-M10 ZINC
TAPE FOAM 1 X 1 (23” LG)
SPACER FAN 6.8L
SPACER FAN 5.4L
SCREW HHC M8-1.25 X 20 G 8.8
W ASHER LOCK M8-5/16
W ASHER LOCK M6-1/4
SCREW HHFC M6-1.0 X 20 G8.8
FTG CMPN BLKHD 3/8" OD TUBE BRS
GROMMET .75 X .12 X .50
GUARD FAN C3 CPL
SCREW THF M6-1 X 16 N WA Z/JS
BARBED STR 3/8 NPT X 3/8
CLAMP HOSE .38-.87
HOSE DRAIN ASSY 28"
SCREW HHTT M4-0.7 X 8 BP
SPRING CL IP HOLDER .37-.62
BRKT CO OLANT RECOVERY TANK
TANK CO OLANT RECOVERY
CLAMP HOSE BAND 1/4
CAP HEX 1/4 NPT BRASS
TUBE FAN CLUTCH PREHTR LOWR C3
FTG CMPR 3/8TUBE X 3/8 NPT W/FERL
PROBE COOLANT LEVEL 3/8NPTF (USE WITH HARN P/N 0F5990 & 0F5991)
PROBE COOLANT LEVEL 3/8- 18NPT F ( USE W ITH HARN P/N 0H2595 & 0H3072)
TUBE FAN CLUTCH PREHTR UPPR C2
CAP RADIATO R 13 PSI
BRACKET SIGNAL CONDIT IO NER
W ASHER FLAT 5/16-M8 ZINC
W ASHER FLAT 9/16 ZINC
* ITEM 31 IS INCLUDED WITH ITEM 25.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
17
18
19
20
21
22
0F3224
0F3224A
0F3231
0F3231A
0F2808B
0A6765
0F4710
0F7200
080762
0F2809
0F2981A
0F2962
047411
022097
0F2830
0F4505
022473
0F2773D
0F2773E
088775
0F5447
0F6166 *
0F6166 **
0F6166A **
0C9748
1
1
1
1
2
2
6
6
10
1
2
2
4
4
2
2
4
2
2
6
1
2
1
1
1
NOTES:
* 6.8L ONLY
** 5.4L ONLY
PIPE EXH MANIFOLD 6.8L C3 RH (6.8L 70KW)
PIPE EXH MANIFOLD 5.4L C3 RH (5.4L 55KW)
PIPE EXH MANIFOLD 6.8L C3 LH (6.8L 70KW)
PIPE EXH MANIFOLD 5.4L C3 LH (5.4L 55KW)
PIPE EXHAUST MUFFLER OUT
RING GASKET, 2.5DIA
WASHER LOCK M10 SS
SCREW HHC M10-1.5 X 50 SS FTH
BOLT U 3/8-16 X 2.62
PIPE EXHAUST CROSSOVER
MFLR 7" X 9" X 25" (2) 2.5" IN/2.5" OUT
MUFFLER STRAP
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
MUFFLER BRACKET STIFFENER
GLASS PACK 23.5" LG 2.5" IN/OUT
WASHER FLAT 1/4-M6 ZINC
EXHAUST BLANKET 800MM LG (6.8L 70KW)
EXHAUST BLANKET 750MM LG (5.4L 55KW)
WASHER FLAT 3/8 SS
BRKT MUFFLER
PIPE LH MUFFLER SIDE
PIPE LH MUFFLER SIDE
PIPE RH MUFFLER SIDE
PLUG M18-1.50
(1) 1
(1) 2
3
4
(2) 5
(1) 6
7
8
9
10
11
(1) 12
0F3883
0F1960
0F2842
0F2843
0D5419
0F2849
0D3488G
0D3488L
0D3488K
057795A
059057
0F2844
0F2847
0F2839
1
1
8
1
1
1
1
1
1
1
1
1
1
1
TUBE HEATER WATER
ENGINE 5.4L FORD
IGNITION COIL ASSY FORD
GASKET THERMOSTAT HOUSING FORD
OIL FILTER FORD V-10 ENGINE
TUBE OIL LEVEL INDICATOR FORD
BELT SERPENTINE 65.0" (1800 RPM)
SERPENTINE BELT (66.0") (2650 RPM)
SERPENTINE BELT (68.3") (3600 RPM)
BARBED EL 90 3/4 PLASTIC
HOSE 3/4 ID SAE-30R2 (16.75”LG)
THERMOSTAT ASSY FORD
PULLEY FAN BELT FORD
GASKET INTAKE MANIFOLD RIGHT
(1) 13
(1) 14
15
16
(1) 17
18
19
20
21
22
23
24
25
26
27
28
29
30
(4) 31
32
33
(1) 34
(1) 35
(1) 36
(1) 37
(1) 38
(1) 39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
(4)(3) 55
56
57
58
59
(1) 60
0F2840
0F1959
035579
0F2851
0F2848A
055440
022097
022473
042568
022129
0F4612
0E9868A
022145
057796
0F3216
0F3216B
0F3216D
0F3217
0F3287
0F3017
0F5991
0H3072
1
1
1
1
1
8
3
3
3
6
1
1
7
1
1
1
1
1
1
1
1
1
051713
042914
051731
022129
022145
051756
046526
022131
039253
064416
022131
046526
0D8027
0D8025
0D8026
0D8030
0F2846
0D8029
0D8028
0F2776A
045772
045771
0E0992A
057823
029333A
0F6151
0E0502
0F4308
036277
0H0550
8
2
9
9
9
2
2
2
3
1
2
1
4
2
3
1
1
1
1
2
1
2
8
3
2
2
1
1
1
1
GASKET INTAKE MANIFOLD LEFT
INTAKE MANIFOLD 5.4L (PLASTIC)
BSHG RDCR HEX 1/4 TO 1/8
CONNECTION WATER OUTLET FORD
REWORK DIPSTICK 5.4L 27.75"
SCREW HHC M5-0.8 X 25 G8.8
WASHER LOCK M6-1/4
WASHER FLAT 1/4 ZINC
SCREW HHC M6-1.0 X 20 G8.8
WASHER LOCK M8-5/16
SENDER OIL PRESSURE 1/8"NPT
ALTERNATOR DC W/OUT PULLEY
WASHER FLAT 5/16 ZINC
GROMMET
PULLEY 80 OD DC ALTERNATOR (1800RPM)
PULLEY 117 OD DC ALTERNATOR (2650 RPM)
PULLEY 160 OD DC ALTERNATOR (3600 RPM)
SPACER DC ALTERNATOR PULLEY
BRKT DC ALTERNATOR UPPER
BRKT DC ALTERNATOR LOWER
HARN ENG 5.4L H-100 (USE WITH PROBE P/N 0E2507)
HARN ENG G5.4L G3 H-100 CPL (USE WITH PROBE
P/N 0H1827)
WASHER FLAT M5
SCREW HHC M8-1.25 X 90 G8.8
SCREW HHC M8-1.25 X 50 G8.8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
SCREW HHC M10-1.5 X 20 G8.8
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
SCREW HHC M8-1.25 X 20 G8.8
SCREW HHC M10-1.5 X 45 G8.8 FT
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
SCREW WP PULLEY M8-1.25 X 19
BOLT HEX FL HD M8-1.25 X 28
BOLT HEX FL HD M8-1.25 X 31
TENSIONER ENG. AUTOMATIC BELT
PULLEY WATER PUMP FORD (1800RPM)
PULLEY ENGINE WATER PUMP (2650 & 3600RPM)
PULLEY GROOVED ENGINE IDLER
BRACKET SIGNAL CONDITIONER
NUT HEX M10-1.5 G8 YEL CHR
NUT HEX M8-1.25 G8 YEL CHR
PLUG EXPANSION 14 OD
CLAMP HOSE #10 .56-1.06
TIE WRAP UL 7.4" X .19" BLK
CAP RUBBER
TEMPERATURE SENDER, DELPHI
BRACKET DC ALT STABILIZER
ELBOW 90D STREET 1/8
DECAL EPA STATIONARY EMERGENCY
(1) NOTE: PART OF ENGINE MAKE P/N 0F3902.
(2) NOTE: I/N 5 IS PART OF I/N 2.
(3) NOTE: I/N 55 IS FOR HOLDING SENSOR TO I/N 50.
(4) NOTE: NOT SHOWN
1
2
3
4
5
6
7
8*
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
41
42
43
0D9913
0G7461
0F3514
0F9965C
0F9965C
0F2776A
0D5417
0F3844
029333A
022131
055596
057772
057823
057765
0F3534
069860E
049821
022129
039253
0D2244M
044118
055934M
047411
071623
0G1818
022097
0F1820
0F1818
022473
048031J
0F2929
077996
046526
070008
070006
0D2608
0F5114
0F5454
047290
059057
040173
16
1
1
1
2
1
8
8
1
1
1
1
2
1
2
1
2
4
1
1
REF
1
1
4
1
1
2
2
1
1
1
2
6
8
24
8
1
1
1
1
1
SCREW SHC M8-1.25 X 35 SS
STARTER MOTOR 12V
SPACER FLEXPLATE 5.4L/6.8L (1800 RPM ONLY)
FLEX PLATE 2 POLE 5.4L/6.8L (1800 RPM UNITS ONLY)
FLEX PLATE 2 POLE 5.4L/6.8L (3600 RPM UNITS ONLY)
BRACKET, SIGNAL CONDITIONER
SCREW HHC M10-1.0 X 25 G10.9
WASHER FLAT .43 X 1.00
TIE WRAP UL 7.4" X .19" BLK (NOT SHOWN)
WASHER FLAT 3/8-M10 ZINC
BARBED STR 3/8 NPT X 3/8
WASHER NYLON .565
CLAMP HOSE #10 .56 - 1.06
ADAPTER M14-1.50 X 3/8 NPT
HEAT SHLD EXHAUST MANIFOLD
HOSE DRAIN ASSY 28"
SCREW SHC M8-1.25 X 30 G12.9
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 20 G8.8
ASSY MAGPICKUP(3/8-24 MALE)
BARBED STR 1/2 NPT X 5/8
CLAMP VINYL .75 X .343 Z
SCREW HHC M6-1.0 X 16 G8.8
SCREW SHC M10-1.5 X 55 G12.9
VALVE PCV G3
WASHER LOCK M6-1/4
MACHINED MANIFOLD EXHAUST 5.4L
GASKET EXHAUST MANIFOLD
WASHER FLAT 1/4-M6 ZINC
HOSE CLAMP BAND 5/8"
ENGINE ADAPTER 5.4L/6.8L
CAP HOSE
WASHER LOCK M10
WASHER FLAT M8 SS
WASHER LOCK M8 SSTL
SCREW HHC 5/16-18 X 1/2 SSTL
DECAL REFER TO OWNERS MANUAL
PLATE MAG PICK-UP ADAPTOR
HOSE 3/8 ID SINGLE BRAID (15” LG)
HOSE 3/4 ID SAE-30R2
CLAMP HOSE #5.5 .62-.62
* NOTE: I/N 8 IS FOR HOLDING SENSOR TO I/N 5.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
0F3224
0F3224A
0F3231
0F3231A
0F5447
0A6765
0F4710
0F7200
080762
0F2809
0F2981A
0F2962
047411
022097
0F2830
0D3159
022473
0F2773D
0F2773E
088775
0F6166 *
0F6166 **
0F6166A **
1
1
1
1
1
2
6
6
6
1
2
2
4
4
2
1
4
2
2
6
2
1
1
NOTES:
* 6.8L ONLY
** 5.4L ONLY
PIPE EXH MANIFOLD 6.8L C3 RH (6.8L 70KW)
PIPE EXH MANIFOLD 5.4L C3 RH (5.4L 55KW)
PIPE EXH MANIFOLD 6.8L C3 LH (6.8L 70KW)
PIPE EXH MANIFOLD 5.4L C3 LH (5.4L 55KW)
BRKT MUFFLER
RING GASKET, 2.5DIA
WASHER LOCK M10 SS
SCREW HHC M10-1.5 X 50 SS FTH
BOLT U 3/8-16 X 2.62
PIPE EXHAUST CROSSOVER
MFLR 7" X 9" X 25" (2) 2.5" IN/2.5" OUT
MUFFLER STRAP
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
MUFFLER BRACKET STIFFENER
FLANGE EXHAUST
WASHER FLAT 1/4-M6 ZINC
EXHAUST BLANKET 800MM LG (6.8L 70KW)
EXHAUST BLANKET 750MM LG (5.4L 55KW)
WASHER FLAT 3/8 SS
PIPE LH MUFFLER SIDE
PIPE LH MUFFLER SIDE
PIPE RH MUFFLER SIDE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31(1)
32
33
34
35
36
37
38
0F3144
035685
0F2857A
0F4168
0F4169
0E7854
0F2820
051756
046526
022131
052250
0F4412
0F4412A
0F8651
022129
022097
0C8566
0F4765
089685
0F2776A
0C2454
055596
0C7649
069860E
045764
065852
080712
076749
048031C
069811
0F4770
089514
0E2507
0H1827
0F4767
090283
022145
022132
1
4
1
1
1
1
1
4
4
4
2
1
1
8
8
8
8
1
1
1
11
1
1
1
1
1
1
1
1
REF
1
1
1
1
1
1
8
1
WELDMENT RAD SUPPORT C3 (22" )
CLAMP HOSE #28 1.32-2.25
RADIATO R 581 X 585 X 70 CPL LH
HOSE UPPER RADIATOR C3
HOSE LOW ER RADIATOR C3
CLUTCH CO OLING FAN
FAN 22" DIA 10 BLADE
SCREW HHC M10-1.5 X 20 G 8.8
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
TAPE FOAM 1 X 1 (23” LG)
SPACER FAN 6.8L
SPACER FAN 5.4L
SCREW HHFC M8-1.25 X 20 W/M6
WASHER LOCK M8-5/16
WASHER LOCK M6-1/4
SCREW HHFC M6-1.0 X 20 G8.8
FTG CMPN BLKHD 3/8" OD TUBE BRS
GROMMET .75 X .12 X .50
BRACKET SIGNAL CONDIT IO NER
SCREW THF M6-1 X 16 N W A Z/JS
BARBED STR 3/8 NPT X 3/8
CLAMP HOSE .38-.87
HOSE DRAIN ASSY 28"
SCREW HHTT M4-0.7 X 8 BP
SPRING CL IP HOLDER .37-.62
BRKT CO OLANT RECOVERY TANK
TANK CO OLANT RECOVERY
CLAMP HOSE BAND 1/4
CAP HEX 1/4 NPT BRASS
TUBE FAN CLUTCH PREHTR LOWR C3
FTG CMPR 3/8TUBE X 3/8 NPT W/FERL
PROBE COOLANT LEVEL 3/8 NPTF (USE WITH HARN P/N 0F 5990 & 0F5991)
PROBE COOLANT LEVEL 3/8-18NPT F (USE WITH HARN P/N 0H2595 & 0H3072)
TUBE FAN CLUTCH PREHTR UPPR C2
CAP RADIATO R 13 PSI
WASHER FLAT 5/16-M8 ZINC
WASHER FLAT 9/16 ZINC
( 1) ITEM 31 IS INCLUDED WITH ITEM 25.
1
2
3
4
5
6
7
8
9
10
0G16140GS0R
0G16150GS0R
0G15300GS0R
0G16130GS0R
0D3215B
0C2454
022097
049813
0C2634A
047411
2
2
1
1
2
32
1
1
1
1
PANEL C3 FRONT SIDES
PANEL C3 REAR SIDES
PANEL LOWER FRONT
PANEL C3 TOP
ACCESS COVER 160 X 170 GALV
SCREW THF M6-1 X 16 N WA Z/JS
WASHER LOCK M6-1/4
NUT HEX M6 X 1.0 G8 YEL CHR
ASSY ACCESS COVER
SCREW HHC M6-1.0 X 16 G8.8
1
2
3
4
5
6
7
8
0G17420GS0R
0G17390GS0R
0G17400GS0R
0G17410GS0R
056326
0C2454
056326
056326
1
1
1
1
1
22
1
1
GUARD BELT RIGHT HAND C3
GUARD BELT TOP C3
GUARD BELT BOTTOM C3
GUARD BELT LEFT HAND C3
TRIM VINYL BLACK 1/8GP (21” LG)
SCREW THF M6-1 X 16 N WA Z/JS
TRIM VINYL BLACK 1/8GP (10 .37” LG)
TRIM VINYL BLACK 1/8GP (12” LG)
COMPONENTS INCLUDED IN 0G4140E
1
ENCL H/G CONTROL PANEL
1
COVER CONTROL PANEL
1
HINGE CONTINUOUS H PANEL
7
RIVET POP .125 X .275 SS
1
ASSY PROGRAMMED H-100
1
DECAL FUSES LOCATED INSIDE
1
RAIL SNAPTRACK PCB HOLDER BULK (12”LG)
1
ASSY PCB 10A UL BATT CHRGR 12V
1
PLATE HARNESS CLAMP
1
ASSY PCB PWR AVR W/AMP HEADER
1
ASSY PCB BOSCH GOV DRIVER
1
DIO BRIDGE 25A 600V
11
WASHER LOCK M5
4
SCREW PPHM M5-0.8 X 30 SS
11
WASHER FLAT M5
6
SCREW HHPM M5-0.8 X 12
5
NUT HEX M5-0.8 G8 YEL CHR
3
WASHER FLAT M4
3
SCREW PHTT M4-0.7 X 10 ZYC
1
CONN DUST CAP W/CHAIN DB9
1
WASHER FLAT M3.5
1
SCREW PHTT M3.5-0.6 X 10
10
SCREW PPHM M4-0.7 X 8 BLX OX
10
WASHER LOCK #8-M4
1
DECAL WRN BATT CHRG 12/24V BI
1
M5-0.8 CAPTIVE PANEL KNLD HD
2
SEAL COVER 3.18 X 12.7 X 382
1
SEAL COVER 3.18 X 12.7 X 283
1
HARNESS H-PNL INTEGRATED SW (NOT SHOWN)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
0F1823CST06
0F1824AST06
0F2606
036261
0F5763
0F1732
0E9764
0F1740C
0F1958
0F2256
0E3161
029673
049226
079224
051713
0F5886
051716
043180
0C3990
0F4333
0F5883
0F5884
055014
022264
0G3546
0G3648
0F6305
0F6305A
0G4329
A
B
C
D
E
0F1263
0F1262
0F1264
0E9049B
055911
COMPONENTS INCLUDED IN WIRE HARNESS
1
ADPTR RH SIDE WICKMANN 178.6191
4
HOLDER FUSE WICKMANN 178.6150
1
ADPTR LH SIDE WICKMANN 178.6192
1
ASSY PCB G-PANEL RELAY 12VDC
1
BLOCK TERM 20A 12 X 6 X 1100V
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
056739
0F2627B
022287
022473
022097
043182
051714
052777
0C2323
0F5459
0F5461
022127
0F5460
0E7403C
0E7403B
0F6145
0C2699
0C2266
COMPONENTS NOT INCLUDED IN 0G4140E OR WIRE HARNESS
1
RELAY CONTACTOR 12VDC
1
DPE BREAKER SEE DRAWING 0F9280
1
BOOST RESISTOR SEE DRAWING 0F9280
1
COVER CONTROL PANEL SIDE
2
SCREW HHC 1/4-20 X 3/4 G5
4
WASHER FLAT M6-1/4
2
WASHER LOCK M6-1/4
3
WASHER LOCK M3
3
NUT HEX M3-0.5 G8 YEL CHR
3
WASHER FLAT M3
2
SCREW PHTT #6-32 X 5/8 ZYC
1
DECAL CPL CONTROL PANEL FUSES
1
DECAL CPL 5.4/6.8L TB3
2
NUT HEX 1/4-20 STEEL
1
DECAL CPL 5.4/6.8L RELAY BOARD
1
FUSE ATO TYPE 15 AMP (BLUE)
2
FUSE ATO TYPE 10 AMP (RED)
A/R
SEAL WEATHER .45"DIA
2
SCREW PHTT #6-32 X 3/8 ZYC
4
SCREW PHTT M5-0.8 X 16 ZYC
(2) 1
(2) 2
(2) 3
(3) 4
(2) 5
(2) 6
(3) 7
0F58660ST01
0F58610ST01
0F58650ST01
0F58640AL01
0F58620ST01
0F58630ST01
0F58600AL01
1
4
2
2
2
1
1
REAR WRAP C3
DOOR C3
CENTER SUPPORT C3
DISCHARGE DUCT LH & RH SIDE C3
FRONT CORNERS C3
DISCHARGE CENTER DUCT C3
ROOF C3 ALUM
8
9
10
11
12
14
15
16
17
18
19
20
21
22
25
26
27
29
30
31
32
33
34
35
36
37
38
40
41
(1) 42
43
44
45
46
0C2454
0E3257
0E5968
0F3949L
0F2766
0F3185
0F3416
0F3949E
0C2634A
022473
022097
022127
0F3072
078115
0F5048D
0F5049
0F3949B
0F4073A
0F4073F
087233
0F3180
0F3635C
0F4073
0F3890B
0F4073B
0F3890A
042568
022447
049813
077992
0912970094
0F8869D
078115A
066760
40
6
1
3
3
2
2
1
1
5
1
1
12
30
4
4
3
1
1
2
1
1
4
11
1
5
4
4
4
29
4
1
10
1
SCREW THF M6-1 X 16 N WA Z/JS
SCREW TH-FRM M6 W/CAP SHKPRF W
GASKET EXTRUDED TRIM (547” LG)
INSULATION SPLITTER SML
SPLITTER
STRINGER SPLITTER C3
SUPPORT SPLITTER C5 130KW
INSULATION ROOF TOP REAR
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
VISE-ACTION LATCH SLOTTED CIR
TAB PULL
INSULATION SPLITTER
INSULATION ROOF TOP
INSULATION DUCT TOP
RIVET POP .1875 X .450 SS
SPLITTER EXTENDED LENGTH
INSULATION SPLITTER EXTENDED LENGTH
INSULATION DOOR
RETAINER INSULATION (820)
INSULATION DUCT FRONT
RETAINER INSULATION (740)
SCREW HHC M6-1.0 X 20 G8.8
WASHER SHAKEPROOF INT 1/4
NUT HEX M6 X 1.0 G8 YEL CHR
NUT HEX LOCK M6-1.0 SS NY INS
ASSY WIRE 14 AWG 34.8" GRN/YEL
KEY VISE-ACTION LATCH SLOT CIR
WASHER SELF LOCKING DOME #8-32
STRIP SEALANT 1/8 X 1 (44.52”LG)
(2) NOTE: PART NUMBER SHOWN IS FOR TAN / STEEL. REFER TO THE SAMPLE
GUIDE BELOW FOR AVAILABLE COLOR AND/OR ALUMINUM PART NUMBER FORMAT.
0FXXXX0ST01 = TAN / STEEL
0FXXXX0ST13 = BISQUE / STEEL
0FXXXX0AL01 = TAN / ALUMINUM
0FXXXXALT13 = BISQUE / ALUMINUM
0FXXXX0ST08 = T- GRAY / STEEL
0FXXXX0ST14 = GRAY / STEEL
0FXXXX0AL08 = 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.
0FXXXX0AL08 = T- GRAY / ALUMINUM
0FXXXXALT13 = BISQUE / ALUMINUM
0FXXXX0AL05 = WHITE / ALUMINUM
0FXXXXALT14 = GRAY / ALUMINUM
1
2
3
4
5
6
7
0F6207
0F4776
0F7357
025393
0F7278
070208
0G0896
0G0897
1
1
1
2
1
1
REF
REF
OUTLET 20A GFCI
OUTLET 15A 250V NEMA 6-15R IVY
BOX SQUARE 4-11/16 W/KNO'S
SCREW HHTT #10-24 X 3/8 CZ
COVER DUAL RECEPT 120/240
GROMMET .87 X .25 X .62
HARN ALT CON BOX 1PH QT
HARN ALT CON BOX 3PH QT
Stationary Emergency Generator
Warranty
GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR
COMMERCIAL STATIONARY EMERGENCY PRODUCT 50kW AND ABOVE
For a period of two (2) years from the date of sale, Generac Power Systems, Inc. will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or an Authorized/Certified Generac Power Systems Dealer, or branch thereof, is found to be
defective under normal use and service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims
to be defective must be examined by the nearest Authorized/ Certified Generac Power Systems Dealer, or branch thereof. This warranty applies
only to Generac Power Systems Generators used in "Stationary Emergency" applications, as Generac Power Systems, Inc. has defined Stationary
Emergency, provided said generator has been properly installed and inspected on-site by appropriate personnel. Scheduled maintenance, as outlined
by the generator owner's manual, is highly recommended. This should be performed by an Authorized/Certified Generac Power Systems Dealer, or
branch thereof. This will verify service has been performed on the unit throughout the warranty period.
WARRANTY SCHEDULE
YEAR ONE — Limited comprehensive coverage on mileage, labor, and parts listed.
• - ALL COMPONENTS
YEAR TWO — Limited comprehensive coverage on parts listed.
• - ALL COMPONENTS
*Start-up and/or On-line Registration, or Registration Card, along with Proof of Purchase, must be performed and/or sent in.
Guidelines:
• Any and all warranty repairs and/or concerns, must be performed and/or addressed by an Authorized/Certified Generac Power Systems Dealer, or
branch thereof.
• A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a Non - Generac Power
Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the genset, no warranty coverage shall apply.
• All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty, Policies, and Procedures Flat Rate
Manual.
• Units that have been resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable except with change of
ownership of original structure.
• Unit enclosure is only covered against rust or corrosion the first year of the warranty provision.
• Use of Non-Generac replacement part(s) will void the warranty in its entirety.
• Engine coolant heaters (block-heaters), heater controls and circulating pumps are only covered during the first year of the warranty provision (If
applicable).
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Any unit built/manufactured prior to March 1, 2005.
Costs of normal maintenance (i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up).
Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze.
Units sold, rated or used for "Prime Power", "Trailer Mounted" or "Rental Unit" applications as Generac Power Systems have defined Prime Power,
Trailer Mounted or Rental Unit. Contact a Generac Power Systems Distributor for Prime Power, Trailer Mounted or Rental Unit definition.
Units used for prime power in place of existing utility power where utility is present or in place of utility power where utility power service does not
normally exist.
Failures caused by any act of God and other force majeure events beyond the manufactures control.
Products that are modified or altered in a manner not authorized by Generac Power Systems in writing.
Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing.
Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the
defective part(s).
Failure due to misapplication, misrepresentation, or bi-fuel conversion.
Telephone, facsimile, cell phone, satellite, internet, or any other communication expenses.
Rental equipment used while warranty repairs are being performed (i.e. rental generators, cranes, etc.).
Overtime, holiday, or emergency labor.
Planes, ferries, railroad, busses, helicopters, snowmobiles, snow-cats, off-road vehicle or any other mode of transportation deemed abnormal.
Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct
cause of the problem.
Starting batteries, fuses, light bulbs, engine fluids, and overnight freight cost for replacement part(s).
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC POWER SYSTEMS
MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Any implied warranties which
are allowed by law, shall be limited in duration to the terms of the express warranty provided herein. Some states do not allow limitations on how long
an implied warranty lasts, so the above limitation may not apply to purchaser/owner.
GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT
SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A
DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/
owner. Purchaser/owner agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gives purchaser/owner
specific legal rights. Purchaser/owner also may have other rights that vary from state to state
Generac Power Systems, Inc. • P.O. Box 8 • Waukesha, WI 53187
Ph: (262) 544-4811 • Fax: (262) 544-4851
1-888-GENERAC (1-888-436-3722)
Bulletin 0171370SVE / Rev. C 12.08 / Printed in U.S.A.
Printed in U.S.A.
EXPLODEDVIEW: EV BATTERY 6.8L CPL
GROUP C
DRAWING#: 0F3677
APPLICABLETO:
ITEM
PART#
QTY.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
0F3408
0F3411
G058208
G022131
050331A
G050331
038805T
038804Y
G045771
G022129
G027482
G075763
0C2454
0F3409
0J3501
1
1
1
1
1
1
1
1
1
1
1
1
8
1
1
REVISION: CN-0021496
DATE: 11/9/18
DESCRIPTION
TRAY BATTERY
STRAP BATTERY RETAINMENT
BATT 12VDC 24F 625
WASHER FLAT 3/8-M10 ZINC
BATT POST COVER RED +
BATT POST COVER BLK CABLE BATT BLK #1 X 40.00
CABLE BATT RED #1 X 35.00
NUT HEX M8-1.25 G8 YEL CHR
WASHER LOCK M8-5/16
WASHER SHAKEPROOF EXT 5/16 STL
BOOT BATTERY CABLE
SCREW THF M6-1X16 N WA Z/JS
SUPPORT BATTERY TRAY
STRAP BATTERY 1.5X36
Page 2 of 2
(2) 1
(2) 2
(2) 3
(3) 4
(2) 5
(2) 6
(3) 7
0F58660ST01
0F58610ST01
0F58650ST01
0F58640AL01
0F58620ST01
0F58630ST01
0F58600AL01
1
4
2
2
2
1
1
REAR WRAP C3
DOOR C3
CENTER SUPPORT C3
DISCHARGE DUCT LH & RH SIDE C3
FRONT CORNERS C3
DISCHARGE CENTER DUCT C3
ROOF C3 ALUM
8
9
10
11
12
14
15
16
17
18
19
20
21
22
25
26
27
29
30
31
32
33
34
35
36
37
38
40
41
(1) 42
43
44
45
46
0C2454
0E3257
0E5968
0F3949L
0F2766
0F3185
0F3416
0F3949E
0C2634A
022473
022097
022127
0F3072
078115
0F5048D
0F5049
0F3949B
0F4073A
0F4073F
087233
0F3180
0F3635C
0F4073
0F3890B
0F4073B
0F3890A
042568
022447
049813
077992
0912970094
0F8869D
078115A
066760
40
6
1
3
3
2
2
1
1
5
1
1
12
30
4
4
3
1
1
2
1
1
4
11
1
5
4
4
4
29
4
1
10
1
SCREW THF M6-1 X 16 N WA Z/JS
SCREW TH-FRM M6 W/CAP SHKPRF W
GASKET EXTRUDED TRIM (547” LG)
INSULATION SPLITTER SML
SPLITTER
STRINGER SPLITTER C3
SUPPORT SPLITTER C5 130KW
INSULATION ROOF TOP REAR
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
VISE-ACTION LATCH SLOTTED CIR
TAB PULL
INSULATION SPLITTER
INSULATION ROOF TOP
INSULATION DUCT TOP
RIVET POP .1875 X .450 SS
SPLITTER EXTENDED LENGTH
INSULATION SPLITTER EXTENDED LENGTH
INSULATION DOOR
RETAINER INSULATION (820)
INSULATION DUCT FRONT
RETAINER INSULATION (740)
SCREW HHC M6-1.0 X 20 G8.8
WASHER SHAKEPROOF INT 1/4
NUT HEX M6 X 1.0 G8 YEL CHR
NUT HEX LOCK M6-1.0 SS NY INS
ASSY WIRE 14 AWG 34.8" GRN/YEL
KEY VISE-ACTION LATCH SLOT CIR
WASHER SELF LOCKING DOME #8-32
STRIP SEALANT 1/8 X 1 (44.52”LG)
(2) NOTE: PART NUMBER SHOWN IS FOR TAN / STEEL. REFER TO THE SAMPLE
GUIDE BELOW FOR AVAILABLE COLOR AND/OR ALUMINUM PART NUMBER FORMAT.
0FXXXX0ST01 = TAN / STEEL
0FXXXX0ST13 = BISQUE / STEEL
0FXXXX0AL01 = TAN / ALUMINUM
0FXXXXALT13 = BISQUE / ALUMINUM
0FXXXX0ST08 = T- GRAY / STEEL
0FXXXX0ST14 = GRAY / STEEL
0FXXXX0AL08 = 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.
0FXXXX0AL08 = T- GRAY / ALUMINUM
0FXXXXALT13 = BISQUE / ALUMINUM
0FXXXX0AL05 = WHITE / ALUMINUM
0FXXXXALT14 = GRAY / ALUMINUM
COMPONENTS INCL UDED IN 0G4140E
1
ENCL H/G CO NTROL PANEL
1
CO VER CONTRO L PANEL
1
HING E CONT INUOUS H PANEL
7
RIVET POP .125 X .275 SS
1
ASSY PROGRAMMED H- 100
1
DECAL FUSES LO CAT ED INSIDE
1
RAIL SNAPTRACK PCB HO LDER BULK ( 12” LG)
1
ASSY PCB 10A UL BATT CHRG R 12V
1
PLATE HARNESS CLAMP
1
ASSY PCB PW R AVR W /AMP HEADER
1
ASSY PCB BOSCH G OV DRIVER
1
DIO BR IDG E 25A 600V
11
W ASHER LO CK M5
4
SCREW PPHM M5- 0.8 X 30 SS
11
W ASHER FLAT M5
6
SCREW HHPM M5-0.8 X 12
5
NUT HEX M5-0.8 G8 YEL CHR
3
W ASHER FLAT M4
3
SCREW PHTT M4- 0.7 X 10 Z YC
1
CO NN DUST CAP W/CHAIN DB9
1
W ASHER FLAT M3.5
1
SCREW PHTT M3.5- 0.6 X 10
10
SCREW PPHM M4- 0.7 X 8 BLX O X
10
W ASHER LO CK #8-M4
1
DECAL W RN B AT T CHRG 12/24V BI
1
M5-0.8 CAPT IVE PANEL KNLD HD
2
SEAL COVER 3.18 X 12.7 X 382
1
SEAL COVER 3.18 X 12.7 X 283
1
HARNESS H-PNL INTEGRATED SW (NO T SHO WN)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
0F1823CST 03
0F1824AST 03
0F2606
036261
0F5763
0F1732
0E9764
0F1740C
0F1958
0F2256
0E3161
029673
049226
079224
051713
0F5886
051716
043180
0C3990
0F4333
0F5883
0F5884
055014
022264
0G 3546
0G 3648
0F6305
0F6305A
0G 4329
A
B
C
D
E
0F1263
0F1262
0F1264
0E9049B
055911
COMPONENTS INCL UDED IN WIRE HARNESS
1
ADPTR RH SIDE W ICKMANN 178.6191
4
HO LDER F USE WICKMANN 178.6150
1
ADPTR LH SIDE W ICKMANN 178.6192
1
ASSY PCB G-PANEL RELAY 12VDC
1
BL OCK TERM 20A 12 X 6 X 1100V
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
056739
0F2627B
022287
022473
022097
043182
051714
052777
0C2323
0F5459
0F5461
022127
0F5460
0E7403C
0E7403B
0F6145
0C2699
0C2266
COMPONENTS NO T INCLUDED IN 0G 4140E O R WIRE HARNESS
1
RELAY CONTACTO R 12VDC
1
DPE B REAKER SEE DRAW ING 0F9280
1
BO OST RESIST OR SEE DRAWING 0F 9280
1
CO VER CONTRO L PANEL SIDE
2
SCREW HHC 1/4-20 X 3/4 G 5
4
W ASHER FLAT M6-1/4
2
W ASHER LO CK M6-1/4
3
W ASHER LO CK M3
3
NUT HEX M3-0.5 G8 YEL CHR
3
W ASHER FLAT M3
2
SCREW PHTT #6-32 X 5/8 Z YC
1
DECAL CPL CONTRO L PANEL FUSES
1
DECAL CPL 5.4/6.8L TB3
2
NUT HEX 1/4-20 STEEL
1
DECAL CPL 5.4/6.8L RELAY BO ARD
1
F USE ATO TYPE 15 AMP (BL UE)
2
F USE ATO TYPE 10 AMP (RED)
A/R
SEAL WEATHER .45"DIA
2
SCREW PHTT #6-32 X 3/8 Z YC
4
SCREW PHTT M5- 0.8 X 16 Z YC
(1) 1
(1) 2
3
4
(2) 5
(1) 6
7
8
9
10
11
(1) 12
0F3883
0F1960
0F2842
0F2843
0D5419
0F2849
0D3488G
0D3488L
0D3488K
057795A
059057
0F2844
0F2847
0F2839
1
1
8
1
1
1
1
1
1
1
1
1
1
1
TUBE HEATER WATER
ENGINE 5.4L FORD
IGNITION COIL ASSY FORD
GASKET THERMOSTAT HOUSING FORD
OIL FILTER FORD V-10 ENGINE
TUBE OIL LEVEL INDICATOR FORD
BELT SERPENTINE 65.0" (1800 RPM)
SERPENTINE BELT (66.0") (2650 RPM)
SERPENTINE BELT (68.3") (3600 RPM)
BARBED EL 90 3/4 PLASTIC
HOSE 3/4 ID SAE-30R2 (16.75”LG)
THERMOSTAT ASSY FORD
PULLEY FAN BELT FORD
GASKET INTAKE MANIFOLD RIGHT
(1) 13
(1) 14
15
16
(1) 17
18
19
20
21
22
23
24
25
26
27
28
29
30
(4) 31
32
33
(1) 34
(1) 35
(1) 36
(1) 37
(1) 38
(1) 39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
(4)(3) 55
56
57
58
59
(1) 60
0F2840
0F1959
035579
0F2851
0F2848A
055440
022097
022473
042568
022129
0F4612
0E9868A
022145
057796
0F3216
0F3216B
0F3216D
0F3217
0F3287
0F3017
0F5991
0H3072
1
1
1
1
1
8
3
3
3
6
1
1
7
1
1
1
1
1
1
1
1
1
051713
042914
051731
022129
022145
051756
046526
022131
039253
064416
022131
046526
0D8027
0D8025
0D8026
0D8030
0F2846
0D8029
0D8028
0F2776A
045772
045771
0E0992A
057823
029333A
0F6151
0E0502
0F4308
036277
0H0550
8
2
9
9
9
2
2
2
3
1
2
1
4
2
3
1
1
1
1
2
1
2
8
3
2
2
1
1
1
1
GASKET INTAKE MANIFOLD LEFT
INTAKE MANIFOLD 5.4L (PLASTIC)
BSHG RDCR HEX 1/4 TO 1/8
CONNECTION WATER OUTLET FORD
REWORK DIPSTICK 5.4L 27.75"
SCREW HHC M5-0.8 X 25 G8.8
WASHER LOCK M6-1/4
WASHER FLAT 1/4 ZINC
SCREW HHC M6-1.0 X 20 G8.8
WASHER LOCK M8-5/16
SENDER OIL PRESSURE 1/8"NPT
ALTERNATOR DC W/OUT PULLEY
WASHER FLAT 5/16 ZINC
GROMMET
PULLEY 80 OD DC ALTERNATOR (1800RPM)
PULLEY 117 OD DC ALTERNATOR (2650 RPM)
PULLEY 160 OD DC ALTERNATOR (3600 RPM)
SPACER DC ALTERNATOR PULLEY
BRKT DC ALTERNATOR UPPER
BRKT DC ALTERNATOR LOWER
HARN ENG 5.4L H-100 (USE WITH PROBE P/N 0E2507)
HARN ENG G5.4L G3 H-100 CPL (USE WITH PROBE
P/N 0H1827)
WASHER FLAT M5
SCREW HHC M8-1.25 X 90 G8.8
SCREW HHC M8-1.25 X 50 G8.8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
SCREW HHC M10-1.5 X 20 G8.8
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
SCREW HHC M8-1.25 X 20 G8.8
SCREW HHC M10-1.5 X 45 G8.8 FT
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
SCREW WP PULLEY M8-1.25 X 19
BOLT HEX FL HD M8-1.25 X 28
BOLT HEX FL HD M8-1.25 X 31
TENSIONER ENG. AUTOMATIC BELT
PULLEY WATER PUMP FORD (1800RPM)
PULLEY ENGINE WATER PUMP (2650 & 3600RPM)
PULLEY GROOVED ENGINE IDLER
BRACKET SIGNAL CONDITIONER
NUT HEX M10-1.5 G8 YEL CHR
NUT HEX M8-1.25 G8 YEL CHR
PLUG EXPANSION 14 OD
CLAMP HOSE #10 .56-1.06
TIE WRAP UL 7.4" X .19" BLK
CAP RUBBER
TEMPERATURE SENDER, DELPHI
BRACKET DC ALT STABILIZER
ELBOW 90D STREET 1/8
DECAL EPA STATIONARY EMERGENCY
(1) NOTE: PART OF ENGINE MAKE P/N 0F3902.
(2) NOTE: I/N 5 IS PART OF I/N 2.
(3) NOTE: I/N 55 IS FOR HOLDING SENSOR TO I/N 50.
(4) NOTE: NOT SHOWN
1
2
3
4
5
6
7
0F6207
0F4776
0F7357
025393
0F7278
070208
0G0896
0G0897
1
1
1
2
1
1
REF
REF
OUTLET 20A GFCI
OUTLET 15A 250V NEMA 6-15R IVY
BOX SQUARE 4-11/16 W/KNO'S
SCREW HHTT #10-24 X 3/8 CZ
COVER DUAL RECEPT 120/240
GROMMET .87 X .25 X .62
HARN ALT CON BOX 1PH QT
HARN ALT CON BOX 3PH QT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
17
18
19
20
21
(3) 22
23
24
25
26
27
28
29
30
31(1)
32
33
34
35
36
37
38
39
40
(2)41
0F3144
035685
0F2857A
0F4168
0F4169
0E7854
0F2820
051756
046526
022131
052250
0F4412
0F4412A
039253
022129
022097
0C8566
0F4765
089685
0F2776A
0C2454
055596
0C7649
069860E
045764
065852
080712
076749
048031C
069811
0F4770
089514
0E2507
0H1827
0F4767
090283
022145
022132
077043J
085662
0F5589
1
4
1
1
1
1
1
4
4
4
2
1
1
8
8
8
8
1
1
1
15 / 1
1
1
1
1
1
1
1
1
REF
1
1
1
1
1
1
8
1
1
5
2
WELDMENT RAD SUPPORT C3 (22")
CLAMP HOSE #28 1.32-2.25
RADIATOR 581 X 585 X 70 CPL LH
HOSE UPPER RADIATOR C3
HOSE LOWER RADIATOR C3
CLUTCH COOLING FAN
FAN 22" DIA 10 BLADE
SCREW HHC M10-1.5 X 20 G8.8
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
TAPE FOAM 1 X 1 (23” LG)
SPACER FAN 6.8L
SPACER FAN 5.4L
SCREW HHC M8-1.25 X 20 G8.8
WASHER LOCK M8-5/16
WASHER LOCK M6-1/4
SCREW HHFC M6-1.0 X 20 G8.8
FTG CMPN BLKHD 3/8" OD TUBE BRS
GROMMET .75 X .12 X .50
BRACKET SIGNAL CONDITIONER
SCREW THF M6-1 X 16 N WA Z/JS
BARBED STR 3/8 NPT X 3/8
CLAMP HOSE .38-.87
HOSE DRAIN ASSY 28"
SCREW HHTT M4-0.7 X 8 BP
SPRING CLIP HOLDER .37-.62
BRKT COOLANT RECOVERY TANK
TANK COOLANT RECOVERY
CLAMP HOSE BAND 1/4
CAP HEX 1/4 NPT BRASS
TUBE FAN CLUTCH PREHTR LOWR C3
FTG CMPR 3/8TUBE X 3/8 NPT W/FERL
PROBE COOLANT LEVEL 3/8 NPTF (USE WITH HARN P/N 0F5990 & 0F5991)
PROBE COOLANT LEVEL 3/8-18NPTF (USE WITH HARN P/N 0H2595 & 0H3072)
TUBE FAN CLUTCH PREHTR UPPR C2
CAP RADIATOR 13 PSI
WASHER FLAT 5/16-M8 ZINC
WASHER FLAT 9/16 ZINC
CONDUIT FLEX 2.0"ID
TIE WRAP UL 14.6 X .14 BLK
GUARD FAN C3 CPL
(1) ITEM 31 IS INCLUDED WITH ITEM 25.
(2) ENCLOSED SETS ONLY
(3) QTY. REQUIRED FOR ENCLOSED UNITS / QTY. REQUIRED FOR OPEN UNITS.
1
2
3
4
5
6
7
8
9
10
0G16140GS0R
0G16150GS0R
0G15300GS0R
0G16130GS0R
0D3215B
0C2454
022097
049813
0C2634A
047411
2
2
1
1
2
32
1
1
1
1
PANEL C3 FRONT SIDES
PANEL C3 REAR SIDES
PANEL LOWER FRONT
PANEL C3 TOP
ACCESS COVER 160 X 170 GALV
SCREW THF M6-1 X 16 N WA Z/JS
WASHER LOCK M6-1/4
NUT HEX M6 X 1.0 G8 YEL CHR
ASSY ACCESS COVER
SCREW HHC M6-1.0 X 16 G8.8
OPEN SETS ONLY
1
2
3
4
5
6
7
8
0G17420GS0R
0G17390GS0R
0G17400GS0R
0G17410GS0R
056326
0C2454
056326
056326
1
1
1
1
1
22
1
1
GUARD BELT RIGHT HAND C3
GUARD BELT TOP C3
GUARD BELT BOTTOM C3
GUARD BELT LEFT HAND C3
TRIM VINYL BLACK 1/8GP (21” LG)
SCREW THF M6-1 X 16 N WA Z/JS
TRIM VINYL BLACK 1/8GP (10 .37” LG)
TRIM VINYL BLACK 1/8GP (12” LG)
Stationary Emergency Generator
Warranty
GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR
COMMERCIAL STATIONARY EMERGENCY PRODUCT 50kW AND ABOVE
For a period of two (2) years from the date of sale, Generac Power Systems, Inc. will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or an Authorized/Certified Generac Power Systems Dealer, or branch thereof, is found to be
defective under normal use and service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims
to be defective must be examined by the nearest Authorized/ Certified Generac Power Systems Dealer, or branch thereof. This warranty applies
only to Generac Power Systems Generators used in "Stationary Emergency" applications, as Generac Power Systems, Inc. has defined Stationary
Emergency, provided said generator has been properly installed and inspected on-site by appropriate personnel. Scheduled maintenance, as outlined
by the generator owner's manual, is highly recommended. This should be performed by an Authorized/Certified Generac Power Systems Dealer, or
branch thereof. This will verify service has been performed on the unit throughout the warranty period.
WARRANTY SCHEDULE
YEAR ONE — Limited comprehensive coverage on mileage, labor, and parts listed.
• - ALL COMPONENTS
YEAR TWO — Limited comprehensive coverage on parts listed.
• - ALL COMPONENTS
*Start-up and/or On-line Registration, or Registration Card, along with Proof of Purchase, must be performed and/or sent in.
Guidelines:
• Any and all warranty repairs and/or concerns, must be performed and/or addressed by an Authorized/Certified Generac Power Systems Dealer, or
branch thereof.
• A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a Non - Generac Power
Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the genset, no warranty coverage shall apply.
• All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty, Policies, and Procedures Flat Rate
Manual.
• Units that have been resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable except with change of
ownership of original structure.
• Unit enclosure is only covered against rust or corrosion the first year of the warranty provision.
• Use of Non-Generac replacement part(s) will void the warranty in its entirety.
• Engine coolant heaters (block-heaters), heater controls and circulating pumps are only covered during the first year of the warranty provision (If
applicable).
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Any unit built/manufactured prior to March 1, 2005.
Costs of normal maintenance (i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up).
Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze.
Units sold, rated or used for "Prime Power", "Trailer Mounted" or "Rental Unit" applications as Generac Power Systems have defined Prime Power,
Trailer Mounted or Rental Unit. Contact a Generac Power Systems Distributor for Prime Power, Trailer Mounted or Rental Unit definition.
Units used for prime power in place of existing utility power where utility is present or in place of utility power where utility power service does not
normally exist.
Failures caused by any act of God and other force majeure events beyond the manufactures control.
Products that are modified or altered in a manner not authorized by Generac Power Systems in writing.
Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing.
Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the
defective part(s).
Failure due to misapplication, misrepresentation, or bi-fuel conversion.
Telephone, facsimile, cell phone, satellite, internet, or any other communication expenses.
Rental equipment used while warranty repairs are being performed (i.e. rental generators, cranes, etc.).
Overtime, holiday, or emergency labor.
Planes, ferries, railroad, busses, helicopters, snowmobiles, snow-cats, off-road vehicle or any other mode of transportation deemed abnormal.
Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct
cause of the problem.
Starting batteries, fuses, light bulbs, engine fluids, and overnight freight cost for replacement part(s).
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC POWER SYSTEMS
MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Any implied warranties which
are allowed by law, shall be limited in duration to the terms of the express warranty provided herein. Some states do not allow limitations on how long
an implied warranty lasts, so the above limitation may not apply to purchaser/owner.
GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT
SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A
DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/
owner. Purchaser/owner agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gives purchaser/owner
specific legal rights. Purchaser/owner also may have other rights that vary from state to state
Generac Power Systems, Inc. • P.O. Box 8 • Waukesha, WI 53187
Ph: (262) 544-4811 • Fax: (262) 544-4851
1-888-GENERAC (1-888-436-3722)
Bulletin 0171370SVE / Rev. C 12.08 / Printed in U.S.A.
Printed in U.S.A.