Generac 80kW QT08046AVAN Standby Generator Manual

Generac 80kW QT08046AVAN Standby Generator Manual

Serial Number STATIONARY EMERGENCY GENERATOR

OWNER'S MANUAL 4.6L

80kW Models EPA Certified

A new standard of reliability

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Not intended for use in critical life support applications.

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CAUTION

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ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!

. 0H3916 t No Par This manual should remain with the unit.

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Stationary Emergency Generator Table of Contents

SECTION PAGE SAFETY RULES

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1-1

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

Read this Manual Thoroughly .......................................................1-3 Operation and Maintenance ..........................................................1-3 How to Obtain Service .................................................................1-3

IDENTIFICATION RECORD ...............................................................2-1 EQUIPMENT DESCRIPTION .............................................................3-1

Equipment Description .....................................................................3-1 Engine Oil Recommendations ...........................................................3-1 Coolant Recommendations ..............................................................3-1

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

Coolant Temperature Sensing .......................................................4-1 Low Coolant Level .......................................................................4-1 Oil Pressure Sensing ....................................................................4-1 RPM Sensor Loss Shutdown........................................................4-1

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

Natural Gas Fuel System ..............................................................5-1 Propane Vapor Withdrawal Fuel System ........................................5-1 LP Fuel System ............................................................................5-1

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

Prior to Initial Start-up ..................................................................8-1 Initial Inspection for QT Genset Start-up ...........................................8-2

OPERATION .....................................................................................9-1

Generator Control and Operation ......................................................9-1 Operating Unit with Automatic Transfer Switch .................................9-1 Operating Unit with Manual Transfer Switch ......................................9-1 Engine Start-up and Transfer ........................................................9-1 Retransfer and Shutdown .............................................................9-1

MAINTENANCE ..............................................................................10-1

Maintenance Performed by Authorized Service Facilities .........................................................................10-1 Cooling System..............................................................................10-1 Checking Fluid Levels .....................................................................10-1 Check Engine Oil ........................................................................10-1 Maintenance Owner/Operator Can Perform .....................................10-2 Check Engine Oil Level ...............................................................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 Miscellaneous Maintenance ...........................................................10-3 Cleaning the Generator ...............................................................10-3 Weather and Maintenance Kits .....................................................6-2 4.6L Ignition Description ..................................................................6-2 Ignition Shutdown on Loss of Crank or CAM Signals ....................6-2 Diagnostic Blink Patterns (Red LED Located on the Ignition Control Board ........................................................6-2

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

Generator AC Lead Connections .......................................................7-1 Four-lead, Single-phase Stator ......................................................7-1 Alternator Power Winding Connections .............................................7-1

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

Installation .......................................................................................8-1 Preparation Before Start-up ..............................................................8-1 Generator Set Lubrication .............................................................8-1

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

30 kW - 150 kW Standby Gas Engine Driven Generator Sets .................................................................11-1

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

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

EMISSIONS WARRANTY ...............................................................13-1 NOTES EXPLODED VIEWS & PARTS LISTS WIRING DIAGRAMS & SCHEMATICS

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Safety Instructions n

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

INTRODUCTION

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

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

READ THIS MANUAL THOROUGHLY

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

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

INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.

Indicates a hazardous situation or action which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation or action which, if not avoided, could result in minor or moderate injury.

NOTE: Notes contain additional information important to a procedure and will be found within the regular text body of this manual.

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

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

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

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This symbol points out potential explosion hazard.

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This symbol points out potential fire hazard.

This symbol points out potential electrical shock hazard.

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

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

OPERATION AND MAINTENANCE

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

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

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

HOW TO OBTAIN SERVICE

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

When contacting a dealer about parts and service, always supply the complete Model Number, Serial Number and Type Code (where applicable) from the DATA LABEL that is affixed to the unit.

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Safety Instructions

SAFETY RULES

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

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

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

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

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

GENERAL HAZARDS

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

Installation, operation, servicing and repair of this (and related) equipment must always comply with applicable codes, stan dards, laws and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure that the generator is installed, operat ed and serviced in accordance with the manufacturer’s instruc tions and recommendations. Following installation, do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes, standards, laws and regulations.

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

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

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

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

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

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

Before performing any maintenance on the generator, discon nect its battery cables to prevent accidental start-up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last.

Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result in dan gerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

ELECTRICAL HAZARDS

• • All stationary emergency generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dan gerous voltages to the transfer switch as well as the generator. Avoid contact with bare wires, terminals, connections, etc., on the generator as well as the transfer switch, if applicable. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce shock hazard.

Do not handle any kind of electrical device while stand ing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT.

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

The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be con nected to an approved earth ground. This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator or by static electricity. Never disconnect the ground wire.

Wire gauge sizes of electrical wiring, cables and cord sets must be adequate to handle the maximum electrical current (ampac ity) to which they will be subjected.

Before installing or servicing this (and related) equipment, make sure that all power voltage supplies are positively turned off at their source. Failure to do so will result in hazardous and pos sibly fatal electrical shock.

Connecting this unit to an electrical system normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distribution system when the generator is operating. Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy.

Stationary emergency generators installed with an automatic transfer switch will crank and start automatically when normal (utility) source voltage is removed or is below an acceptable preset level. To prevent such automatic start-up and possible injury to personnel, disable the generator’s automatic start cir cuit (battery cables, etc.) before working on or around the unit. Then, place a “Do Not Operate” tag on the generator control panel and on the transfer switch.

In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not pos sible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help.

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

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.

CALIFORNIA PROPOSITION 65 WARNING

Engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

CALIFORNIA PROPOSITION 65 WARNING

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

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General Information IDENTIFICATION RECORD

DATA LABEL

Every generator set includes DATA LABEL that contains important information pertinent to the generator. The data label is attached to the lower connection box on the generator and lists the unit serial number, rated voltage, amps, wattage capacity, phase, frequency, rpm, power factor, and production date.

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.

Stationary Emergency Generator Model and Serial Number

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

Data Label

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. E 04/15 Identy005 Rev

Equipment Description EQUIPMENT DESCRIPTION

This equipment is a revolving field, alternating current Stationary Emergency Generator. It is powered by a gaseous fueled engine operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for 2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear units. See the Specifications section for exact numbers. The unit comes complete with a sound attenuated enclosure, internally mounted muffler, control console, mainline circuit breaker, bat tery charger, and protective alarms as explained in the following paragraph.

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

The Stationary Emergency Generator incorporates the following alternator features: • • Rotor and Stator insulation class is rated as defined by NEMA MG1-32.6, NEMA MG1-1.66. The generator is self ventilated and drip-proof constructed. Refer to the Specifications section or the data label for the class ratings.

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

ENGINE OIL RECOMMENDATIONS

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

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

NOTE: If not already equipped, it is strongly recommended to use the optional Cold Weather Start Kit for temperatures below 32° F. The part number for the Cold Weather Start Kit can be found in the Specifications section or by contacting an authorized dealer. The oil grade for temperatures below 32° F is 5W-30 synthetic oil.

COOLANT RECOMMENDATIONS

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

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Do not use any chromate base rust inhibitor with ethylene glycol base anti-freeze or chro mium hydroxide (“green slime”) forms and will cause overheating. Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding eth ylene 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.

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

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

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Engine Protective Devices ENGINE PROTECTIVE DEVICES

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.

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 infor mation.

COOLANT TEMPERATURE SENSING

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 tem perature increases, the resistance will decrease, causing the volt age to decrease. 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 coolant temperature.

The control panel will monitor and display the coolant temperature anytime the DC input to the control panel is present.

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.

LOW COOLANT LEVEL

A Low Coolant Level (LCL) sensor is placed in the generators cool ant system. This sensor allows the panel to detect a Low Coolant Level condition.

The LCL is a resistive device whose resistance changes rapidly based on the presence or absence of coolant.

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.

If the level of the engine coolant drops below the level of the low coolant level sensor, the engine shutdown will be initiated.

OIL PRESSURE SENSING

An analog Oil Pressure Sender (OPS) is used for monitoring the engine oil pressure. This sender allows the control panel to mea sure 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 4-20mA signal by a signal conditioner module. The corresponding 4-20mA signal is read by the control panel and displayed as the oil pressure.

The control panel will monitor and display oil pressure anytime the DC input to the control panel is present.

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.

OVERCRANK SHUTDOWN

When the control panel receives a start signal, it initiates the pro grammed 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".

OVERSPEED SHUTDOWN

A speed circuit controls engine cranking, start-up, operation and shutdown. Engine speed signals are delivered to the circuit board whenever the unit is running. Should the engine over speed above a safe, preset value, the circuit board initiates an automatic engine shutdown. Contact the nearest Authorized Dealer if this failure occurs.

RPM SENSOR LOSS SHUTDOWN

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

DC 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.)

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Fuel System

FUEL SYSTEM

FUEL REQUIREMENTS

The Stationary Emergency Generator may be equipped with one of the following fuel systems: • Natural gas fuel system • Propane vapor (PV) fuel system • Liquid propane (LP) fuel system Recommended fuels should have a Btu content of at least 1,000 Btu's per cubic foot for natural gas; or at least 2,520 Btu's per cubic foot for LP gas. Ask the fuel supplier for the Btu content of the fuel.

Required fuel pressure for natural gas is 11 inches to 14 inches

water column (0.4 to 0.5 psi); and for liquid propane, 11 inches to 14 inches of water column (0.4 to 0.5 psi).

NOTE: Any piping used to connect the generator to the fuel supply should be of adequate size to ensure the fuel pressure NEVER drops below 11 inches water column for natural gas or 11 inches water column for liquid propane for all load ranges. The fuel supply piping shall be sized according to the installation manual using the fuel consumption requirements identified in the Specifications section of the Owner's Manual.

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

NATURAL GAS FUEL SYSTEM

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

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

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

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

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

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: • The natural gas and LP gas systems are similar. However, the natural gas system delivers gas at a pressure of approximately five inches water column to the carburetor.

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

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

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

LP FUEL SYSTEM

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

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

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Stationary Emergency Generator Specifications SPECIFICATIONS

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STATIONARY EMERGENCY GENERATOR

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

Rotor Insulation .............................................................Class H Stator Insulation ............................................................Class H Total Harmonic Distortion .................................................< 5% Telephone Interference Factor (TIF) .................................. < 50 Alternator Output Leads 3-phase ..................................... 6-wire Bearings ..................................................................Sealed Ball Coupling ................................................................Flexible Disc Load Capacity (Standby Rating) .....................................80kW* * NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349, ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural gas.

Excitation System ......................................................Brushless

Generator Output Voltage/kW - 60 Hz kW Amp CB Size 120/240V, 1-phase, 1.0 pf 120/208V, 3-phase, 0.8 pf 120/240V, 3-phase, 0.8 pf 277/480V, 3-phase, 0.8 pf 77 80 80 80 320 278 249 120 400 300 300 150 Generator Locked Rotor KVA Available @ Voltage Dip of 35% Single-phase or 208 3-phase .................................... 160 KVA 480V, 3-phase .......................................................... 185 KVA ‹

ENGINE

Make ........................................................................... Generac Model ............................................................................. V-type Cylinders and Arrangement .....................................................8

Displacement ............................................................... 4.6 Liter Bore..............................................................................3.55 in.

Stroke ...........................................................................3.54 in.

Compression Ratio....................................................... 9.4-to-1 Air Intake System ......................................... Naturally Aspirated Valve Seats ................................................................ Hardened Lifter Type .................................................................. Hydraulic

Engine Parameters

Rated Synchronous RPM .......................................60 Hz, 3600 Gross HP at rated kW ..............................................60 Hz, 128

Exhaust System

Exhaust Flow at Rated Output 60 Hz .............................720 cfm Exhaust Temperature at Rated Output ..............................840° F

Combustion Air Requirements (Natural Gas)

Flow at rated power, 60 Hz ...........................................250 cfm

Governor

Type...........................................................................Electronic

Frequency Regulation .............................................Isochronous

Steady State Regulation ................................................± .25% Adjustments: Speed ..................................................................... Selectable Individual parameter adjustments can be made via GenLink.

Engine Lubrication System

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

Oil Filter .......................................................Full Flow, Cartridge Crankcase Oil Capacity ............................................ 6 U.S. qts.

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COOLING SYSTEM

Type Closed Water Pump ............................................................. Belt Driven Fan Speed .........................................................................1600

Fan Diameter ..............................................................26 inches Fan Mode ......................................................................... Puller Air Flow (inlet air including alternator and combustion air) ................................................. 5300 ft 3 /min.

Coolant Capacity ................................................. (4.0 U.S. gal.) Heat Rejection to Coolant ....................................316,000 Btu/h Maximum Operating Air Temp. on Radiator ......... 60° C (150° F) Maximum Ambient Temperature ......................... 50° C (140° F) ‹

FUEL SYSTEM

Type of Fuel ................................................. See Caution below Carburetor............................................................... Down Draft Secondary Fuel Regulator............................................ Standard Fuel Shut-off Solenoid ................................................. Standard Operating Fuel Pressure ............... 11 in. - 14 in. Water Column

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

Exercise Cycle 25% 50% 75% 100% Load Load Load Load

131/53 312/126 600/241 835/336 1154/465

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 Engine is not field convertible between natural gas and propane. Jet size and ignition timing are factory set for the specific fuel.

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ELECTRICAL SYSTEM

Battery Charge Alternator ......................................12V, 30 Amp Static Battery Charger .............................................12V, 2 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

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

Controller ............................................................... H-panel

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Stationary Emergency Generator Specifications

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WEATHER AND MAINTENANCE KITS

To keep the generator running at its peak, the following kits are offered: • Cold Weather Kit ~ ~ ~ Recommended for climates with temperatures below 32° F.

• Extreme Cold Weather Kit Recommended Block Heater Kit for protection in tempera tures below 32° F. This kit comes pre-installed on all indus trial gaseous units.

• Scheduled Maintenance Kit Kit includes the recommended parts to maintain the genera tor. Refer to the Service Schedule for regular maintenance intervals.

For additional information, or to order any of these kits, please contact an Authorized Service Dealer or Customer Service Representative.

4.6L IGNITION DESCRIPTION

The 4.6L Ignition Module operates with an 8-cylinder. The 4.6L engine uses a 36-1 crank sensor, a CAM sensor and coil-on-plug ignition coils for each spark plug.

‹

DIAGNOSTIC BLINK PATTERNS (RED LED LOCATED ON THE IGNITION CONTROL BOARD)

During normal ignition operation the RED LED, located on the igni tion control board, flashes at a 0.5 second ON and a 0.5 second OFF rate. This is considered one (1) blink.

RED LED Fault Codes are listed below, with priority as shown: 1. Overspeed Shutdown: LED blinks 4 times, is OFF for 3 sec onds and then repeats.

2. No Crank Signal; LED blinks 2 times, is OFF for 3 seconds and then repeats.

3. No Cam Signal; LED blinks 3 times, is OFF for 3 seconds and then repeats.

Only one LED fault code is displayed at a time. If multiple fault codes exist then the highest priority fault must be resolved prior to a lower priority fault code being displayed.

The LED fault code blink pattern is displayed for a minimum of two minutes after a fault has occurred and then the ignition will power itself down.

If an Ignition fault occurs, a signal is sent to the H-panel and then the H-Panel will shut the Generator down and display on it's front panel that an ignition fault has occurred.

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General Information ALTERNATOR AC LEAD CONNECTIONS

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. The voltage and phase are described on the generator data label. The number of lead wires can be identified using the Specifications section and the power output rating on the generator data label. For example, if the generator produces 130kW, 277/480 Volt, 3-phase power, the generator has 12 alternator output leads. Figure 7.3 describes the stator power winding connection for the generator.

FOUR-LEAD, SINGLE-PHASE STATOR

Four-lead alternators (see Figure 7.1) are designed to supply elec trical loads with voltage code “A” (240V, 1-phase, 60 Hz). Electrical power is produced in the stator power windings. These windings were connected at the factory to the main circuit breaker as shown in Figure 7.1.

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

Figure 7.1 — Four-lead, Single-phase Stator

ALTERNATOR POWER WINDING CONNECTIONS

3-PHASE ALTERNATORS ("Y" CONFIGURATION)

The Stationary Emergency Generator is designed to supply 3-phase electrical loads. Electric power is produced in the alterna tor power windings. These windings were connected at the factory to the main circuit breaker with a “Y” configuration as shown in Figures 7.2 through 7.6.

The rated voltage between circuit breaker terminals E1-E2, E1-E3 and E2-E3 is 480V, 208V or 600V depending on the model.

The rated voltage between each circuit breaker terminal and the neutral point 00 is 277V, 120V, or 346V depending on the model.

Figure 7.2 — Stator Power Winding Connections - 3-phase, 277/480V (6 Lead)

S1

E1

INTERNAL CONNECTIONS L - L S6 S5 S4 00 (NEUTRAL) S3

E3

L - N S2

E2

3-phase 277/480V 6 Lead

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

S1

E1 7-1

S3

E3

S4 S7 L - L S6 S9 S12 S11 S10 S8 S5 L - N 3-phase 277/480V 12 Lead . C 06/15 S2

E2

ACConn007 Rev

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General Information

Figure 7.4 — Stator Power Winding Connections - 3-phase, 120/208V (6 Lead)

INTERNAL CONNECTIONS

E1

S1 S1 S4 S6 S4 S5 00 (NEUTRAL) L-L S3 S6 S5 S2

E3

S3 L-N S2

E2

Figure 7.5 — Stator Power Winding Connections - 3-phase, 120/208V (12 Lead)

E1

S7 S1

3-PHASE ALTERNATORS ("DELTA" CONFIGURATION)

The Stationary Emergency Generator is designed to supply 3-phase electrical loads. Electric power is produced in the alterna tor power windings. These windings were connected at the factory to the main circuit breaker with a "Delta" configuration as shown in Figures 7.7 and 7.8.

The rated voltage between circuit breaker terminals E1-E2, E1-E3 and E2-E3 is 240V.

The rated voltage between E2 and the neutral point 00 is 208V. The rated voltage E1-00 and E3-00 is approximately 120V.

NOTE:

The voltage measured from E2 to 00 can greatly vary when single phase load is placed on alternator.

Figure 7.7 — Stator Power Winding Connections - 3-phase, 120/240V (6 Lead)

E2 240VAC 240VAC 208VAC 240VAC

S10 S12 S4 S5 L-L S9 S6 S11 S2

E3

S3 L-N S8

E2

Figure 7.6 — Stator Power Winding Connections - 3-phase, 346/600V (6 Lead)

S1

E1

INTERNAL CONNECTIONS L - L S6 S5 S4 00 (NEUTRAL) ACConn007 Rev S3

E3

L - N 3-phase 346/600V (6 Lead) S2

E2 7-2 S11 E1 S1

Figure 7.8 — Stator Power Winding Connections - 3-phase, 120/240V (12 Lead)

S2 E2 S12 S8 S5 NB S9 S6 240 VAC 240 VAC S10 S3 E3 240 VAC 120 VAC 120 VAC 208 VAC

Installation

INSTALLATION

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

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

PREPARATION BEFORE START-UP

The instructions in this section assume that the Stationary Emergency Generator has been properly installed, serviced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor. Be sure to read the “Safety Rules”, as well as all other safety information in this manual, before attempting to operate this (and related) equipment.

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

TRANSFER SWITCH

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

FUEL SYSTEM

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

GENERATOR SET LUBRICATION

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

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

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

PRIOR TO INITIAL START-UP

n

crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids (oil, coolant, fuel, etc.) may result in an engine failure.

ENGINE COOLANT

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

BELT TENSION

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

ELECTRICAL SYSTEM

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

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

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

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

INITIAL INSPECTION FOR GENSET STARTUP

Inspect for the following.

• Freight Damage.

• Manuals present.

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

• Correct fuel piping.

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

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

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

• Battery charger connection to 120 VAC.

• Unit secured to pad.

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Installation

START-UP CHECKLIST

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

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

PREPARATION FOR START-UP

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

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

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

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

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

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

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

• Check all hoses clamps fittings for leaks or damage.

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

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

• Open the valve to the engine fuel line.

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

• Open the generator main line circuit breaker.

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

• Insert the fuse into the control panel.

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

• Check voltage at the generator terminals.

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

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

• Close the generators main line circuit breaker.

• Turn the generator set off.

• Connect the UTILITY supply to the transfer switch.

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

• Disconnect utility power before the transfer switch.

Engine should start, transfer to load.

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

• Reconnect Utility power Transfer switch will transfer back to Utility and engine will shut down within the given time parameters set up for the specific transfer switch and controller.

• Install all covers, access plates and door panels.

• Put the Owners Manual in a safe and accessible place.

• Make certain the AUTO/OFF/MANUAL switch is in the AUTO position.

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Operation STATIONARY EMERGENCY GENERATOR CONTROL AND OPERATION

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

OPERATING UNIT WITH MANUAL TRANSFER SWITCH

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

ENGINE START-UP AND TRANSFER

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

n

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

n

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

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

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

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

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

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

Start the generator.

n

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

• • Let engine stabilize and warm up.

Check all applicable instrument and gauge readings. When • • certain that all readings are correct, move the transfer switch manual handle to the STANDBY (or EMERGENCY STANDBY) position, i.e., load circuits supplied by the generator.

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

Load circuits are now powered by the generator.

RETRANSFER AND SHUTDOWN

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

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

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

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

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

Shut down the generator.

OPERATING UNIT WITH AUTOMATIC TRANSFER SWITCH

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

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

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Maintenance

MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES

 Before working on the Stationary Emergency Generator, ensure the following:

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

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

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

EVERY THREE MONTHS

1. Check battery state of charge and condition.

2. Inspect and test fuel system.

3. Check transfer switch.

4. Inspect exhaust system.

5. Check engine ignition system.

6. Check fan belts.

ONCE EVERY SIX MONTHS

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

ONCE ANNUALLY

1. Test engine governor. Adjust or repair, if needed.

2. Clean, inspect generator.

3. Flush cooling system.

FIRST 30 OPERATING HOURS

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

FIRST 100 OPERATING HOURS

1. 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. Service air cleaner.

2. Check 3. Check engine DC alternator.

COOLING SYSTEM

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

Without sufficient cooling and ventilating air flow, the engine/gen erator quickly overheats, which causes it to shut down.

 The exhaust system parts from this product get extremely hot and remain hot after shut down. High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such mate rials may ignite and burn from the heat of the exhaust system.

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.

• 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.

Figure 10.1 - Oil Dipstick and Oil Fill Cap

Oil Fill Oil Dipstick Oil Filter

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.

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Maintenance

ENGINE COOLANT

Check coolant level in coolant recovery bottle. See the “Specifications” section.

• 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.

MAINTENANCE OWNER/ OPERATOR CAN PERFORM

INSPECT EXHAUST SYSTEM

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

CHECK FAN BELT

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

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

INSPECT ENGINE GOVERNOR

Visually inspect electronic governor.

 Before working on the generator, ensure the following:

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

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

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

• The negative battery cable has been removed.

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 dam age. Clean, tighten or replace as necessary.

EXERCISE SYSTEM

Start the Stationary Emergency Generator engine at least once every seven days and let it run at least 20 minutes. For more detailed exercise information, see the respective sections in the Control Panel Technical Manual that is supplied with the unit.

INSPECT COOLING SYSTEM

• Inspect engine cooling system at least once each month.

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

• Check hose clamps for tightness.

CHECK ENGINE COOLANT LEVEL

See the “Checking Fluid Levels” section.

PERFORM VISUAL INSPECTION

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

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

CHANGING ENGINE OIL

n Hot oil may cause burns. Allow engine to cool before draining oil. Avoid prolonged or repeated skin exposure with used oil. Thoroughly wash exposed areas with soap.

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

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

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

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

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

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

Maintenance 6. 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”.

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

7. Start engine and check for oil leaks.

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

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

Figure 10.2 - Oil Filter SPARK PLUGS

Reset the spark plug gap or replace the spark plugs as neces sary.

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

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

3. Check the spark plug gap using a wire feeler gauge. Adjust the gap per the following chart. (Figure 10.4).

Before Serial # 5576484 Serial # 5576484 and After 0.94-1.07mm (0.037"-0.042") 1.30-1.42mm (0.051"-0.056")

Figure 10.4 – Setting the Spark Plug Gap

Oil Dipstick Oil Filter

CHANGING THE ENGINE AIR CLEANER

To replace the engine air cleaner, remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover.

Figure 10.3 — Engine Air Filter

Air Filter

COOLANT CHANGE

Every year, have an Authorized Service Facility drain, flush and refill the cooling system. See the “Specifications” section for cool ing system recommendations.

MISCELLANEOUS MAINTENANCE

CLEANING THE STATIONARY EMERGENCY GENERATOR

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

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

Once each year, have the generator cleaned and inspected by 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 genera tor may require drying.

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

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BATTERY

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

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

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

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

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

BATTERY MAINTENANCE

The battery should be inspected per the “Service Schedule” sec tion. The following procedure should be followed for inspection: 1. Inspect the battery posts and cables for tightness and corro sion. Tighten and clean as necessary.

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

3. Have the state of charge and condition checked. This should be done with an automotive-type battery hydrometer.  Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explo sion can shatter the battery and cause blind ness 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.

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

n Do not use any jumper cables or booster battery to crank and start the generator engine. If the battery has completely dis charged, remove it from the generator for recharging. n Be sure the AUTO/OFF/MANUAL switch is set to the OFF position before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are con nected.

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

BATTERY REPLACEMENT

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.

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

REPAIR PARTS

The latter portion of this manual consists of exploded views, parts lists and electrical data pertaining to this generator set. The parts lists consist of (a) an item number, (b) a part number, (c) the quantity required, and (d) a description of the part. The item number corresponds to an identical number on the exploded view drawing.

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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.

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Service Schedule

Maintenance Tasks

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

2. Check the engine oil level. Adjust as necessary.

3. Check the engine coolant level.

Adjust as necessary.

4. Check the engine coolant thermal protection level.

Correct as necessary.

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

6. Check the air inlets and outlets of the enclosure and radiator for debris. Clean as necessary.

7. Check the battery electrolyte level and specific gravity if accessible. Adjust as necessary.

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

Correct as necessary.

9. Check the unit wiring for loose connections, corrosion, and damage. Correct as necessary.

Level 1 Level 2 Level 3 Level 4 Level 5

Recom mended Task Required Task Required Task Comp. to be done 3 months/ Comp. (Date- to be done Semi- Comp. (Date- Required Task Required Task Comp. to be done Bi- Comp.

(Date 10 hrs. 30 hrs. 50 hrs. 100 hrs. 250 hrs.

G 06/10 ev.

SrvSchd001 R

11-2

Service Schedule

Maintenance Tasks Level 1

Recom mended 10 hrs.

Level 2

30 hrs.

Level 3

Task Required Task Required Task Comp. to be done Comp. to be done Comp. to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Date monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) annually/ Initials) 50 hrs.

Level 4

Task Required Task Required Comp. to be done Comp.

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

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

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

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

Correct as necessary.

15. Replace the engine accessory drive belts.

16. Check gearbox oil level (if equipped).

17. Change gearbox oil (if equipped).

** Not required for engines equipped with hydraulic lifters. See the "Specification" section for lifter type.

Level5

250 hrs.

11-3

G 06/10 ev.

SrvSchd001 R

Service Schedule

Maintenance Tasks

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

Correct as necessary.

19. Perform an engine oil analysis (send a sample to a lab for results).

Change the engine oil and filters if the analysis results indicate this is required.

20. Change the engine oil.

21. Replace the engine oil filter(s).

22. Replace engine spark plugs.

Clean and re-gap or replace as necessary.

23. Replace the engine air filter(s).

24. Perform a 5 minute no-load operational run of the unit looking for any post service problems.

25. Return the unit to standby setup for operation when required.

Level 1 Level 2 Level 3 Level 4 Level5

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

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

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11-4

Troubleshooting TROUBLESHOOTING GUIDE

PROBLEM CAUSE

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

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

2. Plugged fuel line. 3. Defective spark plugs. 4. Fuel pressure incorrect. Engine starts then shuts down. engine continues to run 5. Defective Control Module circuit board. 6. Coolant Level is Low. 7. Defective Low Coolant Level Switch AUTO/OFF/MANUAL Switch at OFF, 1. Defective AUTO/OFF/MANUAL switch 2. Open/disconnected wire #15A between AUTO/OFF/MANUAL switch and Control Module circuit board.

3. Defective Control Module circuit board No AC output from generator. 1. Check main line circuit breaker. 2. Check circuit breaker & fuses. 3. Transfer switch set to NORMAL position 1. Engine oil level is low. 2. Engine is overheated. 3. Defective Low Oil Pressure Switch 4. Defective Coolant Temperature Switch 4. Generator internal failure. 5. Thermal circuit breaker open.

CORRECTION

1. Replace fuse.

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

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

6. Replace fuse.* 1. Replenish fuel.

2. Replace solenoid.* 3. Reconnect wire.

4. Clean, regap or replace plugs.

5. Close door on tank.

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

3. Clean, regap or replace plugs.

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

1. Check oil and add oil as needed.

2. Check cooling system for leaks.

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

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

2. Reset and replace, if necessary.

3. Set to GENERATOR position.

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

*Contact the nearest Dealer for assistance.

12-1

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United States Environmental Protection Agency Warranty Statement (Stationary Emergency Spark-Ignited Generators) Warranty Rights, Obligations and Coverage

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

Purchaser's/Owner's Warranty Responsibilities

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

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

Important Note

This warranty statement explains your rights and obligations under the Emission Control System Warranty, which is provided to you by Gen erac pursuant to federal law. Note that this warranty shall not apply to any incidental, consequential, or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part(s). This warranty is in place of all other warranties, expressed or implied. Specifically, Generac makes no other warranties as to the merchantability or fitness for a particular purpose. Any implied warranties which are allowed by law, shall be limited in duration to the terms of the express warranty provided herein. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

Emission Related Parts Include the Following (if so equipped)

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

United States Environmental Protection Agency Compliance Requirements (Stationary Emergency Spark-Ignited Generators) Purchaser's/Owner's Record Keeping Responsibilities

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

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

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

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

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

Emission-Related Installation Instructions

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

EmsnWrnty001 Revision F (04/15)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0F9952 0F3417 0F2984 0F9949 0F3418 0F2985 0F9950 0F9951 0G6319 0F6183 0F6187 0F6184 0F6212 0G2023 0F8757 068405C 0F3013 072878 0C9708 0F3726B 0F2689 023454 059980 046526 0A2601 072879 022473 022097 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 REF 1 1 1 4 4 1 1 8/12 4/6 ASSY ROTOR 2390 80KB3 CPL ASSY ROTOR 390 2P 100K BRSHLS ASSY ROTOR 390 2P 150K BRSHLS ASSY STATOR 80KW 1PH 2P BRSHLS ASSY STATOR 390 2P 100K BRSHLS ASSY STATOR 390 2P 150K BRSHLS UL STATOR 2390 80 GB3 CPL STATOR 2390 80 KB3 CPL STR 2390 80 JB3 CPL ASSY STR 390 100KW 2P 3PH 208V ASSY STR 100KW 1PH 2P BRSHLS ASSY STR 390 150KW 2P 3PH 208V ASSY STR 150KW 1PH 2P BRSHLS ASSY STR 390 150KW 2P 3PH 240V STR-2390-150LB4 CPL EXITER FIELD 2" LG SPD CONN ASSY EXCITER 2.0" STACK 2P KEY SQ 3/8 X 3-1/4 STEEL HYPOT TEST PROCEDURE (NOT SHOWN) ASSY FLYWHEEL CPL RING PRESSURE 390 STATOR CAN KEY WOODRUFF #E SCREW HHC M10-1.5 X 25 C10.9 WASHER LOCK M10 SCREW HHC M16-2.0 X 45 G8.8 SPACER .69 X 2.75 X .37 ST/ZNC WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 * 51 52 53 60 61 62 63 64 65 66 67 68 69 0C2454 092950 04576100CF 052646 043123 051779 022392 052259 051769 0E7230 0F3033 0F9492 0F2722 077043F 020151 023365 033133 033143 086032 090063 090064 090152 022661L 028739A 085662D 068113 068406 0F7272 023484N 023484N 0F6819 REF. 0C2428 022155 042568 049813 052624 0F7030 0F7047 0F7029 0F3834 KIT PARTS 0F3846B 0F3892 0A2496A 056326 022097 022473 045757 047411 0A2110 11 1 4 4 4 4 2 2 3 3 1 1 1 1 1 3 1 2 2 1 1 1 1 2 1 1 1 6 SCREW THF M6-1 X 16 N WA Z/JS COLLAR SLIP FIT 390 MM STUD M14-2.0 X 760 G5 ZINC WASHER FLAT M14 WASHER LOCK M14 NUT HEX M14-2.0 G8 YEL CHR 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 SHIELD ALT EXCITER 5.4/6.8 (1 PHASE) COVER EXCITER SHIELD CONDUIT FLEX 1.25” ID 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 SCREW HHC M12-1.75 X 60 G10.9 SCREW 1/4-20 X 5/8" TAPTITE SS 1 2 1 2/3 2 2 BUSHING SNAP SB-2.5-31 BUSHING SNAP SB-2.5-31 (FOR 5.4/6.8 1 PHASE) MOUNT CT'S 5.4L 100KW TRANSFORMER SCREW PHTT #6-32 X 1/2 ZYC WASHER LOCK #6 4/6 4/6 1 1 1 1 1 SCREW HHC M6-1.0 X 20 G8.8 NUT HEX M6 X 1.0 G8 YEL CHR BEARING BALL 6212 SEALED SHROUD UPPER ALTERNATOR EXCITR SHROUD CENTER ALTERNATR EXCITR SHROUD LOWER ALTERNATOR EXCITR ASSY SCROLL 390 X 60MM CPL I/N’S: 61 THRU 69 2 2 2 8.4 FT. 6 6 2 SHROUD ALT SHEET METAL CPL 2P SCREEN, 390 SAE ALT 60MM WIDE BRACKET SAE SCROLL TENSIONER VINYL TRIM 1/8” GAP WASHER, SPLIT 1/4”-M6 WASHER FLAT 1/4 ZINC SCREW HHC M6-1.0 x 25 LONG 4 12 SCREW HHC M6-1.0 X 16 G8.8 SCREW SWAGE 1/4-20 X 1/2 Z/YC * ROTOR REPLACEMENT PARTS. ** 1 PHASE UNITS REQUIRE SEPERATION OF LEADS. QTY. REQ: 1 PHASE / 3 PHASE

EXPLODED VIEW: CPL H CONTROL CB CONNECTION DRAWING #: 0H3917 APPLICABLE TO:

ITEM

1 2 3 4 5 6 7 8 9 10 (1) 11 12 13 14 D E F G H J K L D E F G H J K L 2.) A C 1.) A C 29 30 31 32 33 34 35 15 16 (1) 17 18 19 20 21 22 23 (2) 24 25 26 (2) 27 28

PART# QTY. DESCRIPTION

081008 0F6156 029289 0F3685 0F2885 051713 049226 0C2266 0C2428 022155 0D4698 0F4464 0F4677 067617030A 067617030B 043180 022264 0C3990 057701 024469 025433 067210A 0F3618 0A9457 057073 0D5466 022237 022241 0A7822 0F9637 0C2454 047411 022097 022473 023484N 077043J 0D6029 0F2887 0D5572 0D5573 0D5575 0D5576 1 1 1 1 1 2 6 6 2 2 1 1 1 - - 4 4 4 REF. 1 1 1 1 1 2 REF. 4 4 REF. 1 8 4 4 4 2 4 4 UL CIRCUIT BREAKER (FD) 1 REF REF REF REF 0F0199 065960 022473 022097 022127 0C2454 029289 0F1733 1 4 4 4 4 4 1 1 UL CIRCUIT BREAKER (JD+LD) GROMMET 1.25 X .25 X .75 PLATE WIRE SNGL GALV TAPE ELEC 1/2 FOAM (AS REQ’D) STAND LH CONTROL C5 GRBX PANEL CB CONN BOX WASHER FLAT M5 WASHER LOCK M5 SCREW PHTT M5-0.8 X 16 ZYC SCREW PHTT #6-32 X 1/2 ZYC WASHER LOCK #6 BLOCK TERM 20A 6 X 3 X 1100V DECAL CUST CONN 120V UTILITY ASSY PCB INTERFACE 1PH 240V INTERFACE 3PHS 416/480V INTERFACE 3PH 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 SCREW HHTT #10-32 X 3/8 CZ LUG SLDLSS #6-14 X 13/64 CU DECAL GROUND LUG DECAL CPL CUST CONN H CTRL DECAL NEUTRAL JUNCTION BLOCK 3/8-16 BUS BAR NEUTRAL BLOCK 390 WASHER LOCK 3/8 NUT HEX 3/8-16 STEEL LUG SLDLSS 600/250-1/0 X 1/4-28 STAND RH CONTROL, TWO HOLE SCREW THF M6-1 X 16 N WA Z/JS SCREW HHC M6-1.0 X 16 G8.8 WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC BUSHING SNAP SB-2.5-31 CONDUIT FLEX 2.0" ID HHTT M6-1.0 X 16 ZYC COVER FD FRM CB CB 0150A 3P 600V S FD6 LL CB 0175A 3P 600V S FD6 LL CB 0225A 3P 600V S FD6 LL CB 0250A 3P 600V S FD6 LL INSULATOR CB FD FRAME 30MIL SCREW SHC 1/4-20 X 4 G8.8 NZ WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 NUT HEX 1/4-20 STEEL SCREW THF M6-1 X 16 N WA Z/JS TAPE ELEC 1/2 FOAM (AS REQ’D) DECAL CUSTOMER CONNECT INSIDE 0F2721 0D5577 0D5578 0D5579 0D5581 0D5585 0F2353 022770 022473 022097 022127 0C2454 029289 0F1733 1 REF REF REF REF REF 2 4 4 4 4 7 1 1 COVER CIR BRKR JD/LD CB 0300A 3P 600V S JD6 LL CB 0350A 3P 600V S JD6 LL CB 0400A 3P 600V S JD6 LL CB 0600A 3P 600V S LD6 CB 0450A 3P 600V S LD6 LL INSULATOR CIRCUIT BR. JD/LD SCREW RHM 1/4-20 X 3 WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 NUT HEX 1/4-20 STEEL SCREW THF M6-1 X 16 N WA Z/JS TAPE ELEC 1/2 FOAM (AS REQ’D) DECAL CUSTOMER CONNECT INSIDE (1) (2) ITEM INCLUDED WITH HARNESS. ITEM INCLUDED WITH 0D5464B. GROUP A REVISION: H-5277-B DATE: 11/18/09 Page 3 of 6

EXPLODED VIEW: CPL H CONTROL CB CONNECTION DRAWING #: 0H3917 APPLICABLE TO:

DESCRIPTION ITEM PART# QTY.

(1) W X Y 4.) A M N P R S T U V 3.) A C D E F G H J K L (2) L (2) M N P R C D E F G H J K (1) S T U V (2) W (2) X Y 5.) A C E F G R S 6.) A C H J K L M N P Q E H J K L M N P Q UL CIRCUIT BREAKER (225AF) 0F4173 0F4165$ 0F4186 036261 053640 038150 022264 022471 029289 0F1733 022129 0F8432 0C2454 0F8451 049897 022145 045771 0F8843 W/CB 0G3259 058306 UL CIRCUIT BREAKER 400AF) 0F4175 0F4166$ 0F1733 042419 023897 022152 022158 0C2454 029289 052647 046526 W/CB 0A7822 022131 W/CB 023334 022097 022473 2 6 6 6 W/CB W/CB 2/3 2/3 0G3259 UL CIRCUIT BREAKER (3P FG FRAME) 1 0F4173 0H5492 0H5721 038150 022264 1 REF 4 4 4 1 REF 1 4 4 4 4 7 1 2/3 2/3 3 3 3 1 REF 1 4 4 4 4 4 2 1 9 1 7 3 6 6 3 3 2 1 3 022471 0C2454 029289 023897 049226 051716 052619 0H4698A 0H5560 036261 1 4 UL CIRCUIT BREAKER (KG FRAME) 0H5871 0H5582 1 REF 4 7 1 6 3 3 3 1 0H5584 0D2157 0D3700 0C2454 029289 022145 022129 045771 049897 0H5581A REF 4 4 7 1 6 3 3 3 1 COVER CB C5 225AF CIRCUIT BREAKERS 200A FRAME COVER CB DISH 225AF RIVET POP .125 X .275 SS SCREW RHM #8-32 X 3-1/4 WASHER FLAT #8 ZINC WASHER LOCK #8-M4 NUT HEX #8-32 STEEL TAPE ELEC ½ FOAM DECAL CUSTOMER CONNECT INSIDE WASHER LOCK M8-5/16 INSULATOR CB 225AF SCREW THF M6-1 X 16 N WA Z/JS LUG SLDLSS 300 MCM-6 AL/CU SCREW SHC M8-1.25 X 20 G8 WASHER FLAT 5/16-M8 ZINC NUT HEX M8-1.25 G8 CLEAR ZINC BUS BAR 200A LUG ADAPTOR TERMINAL COVER CB DECAL TERMINAL SHOCK HZD BI SCREW SHC M8-1.25 X 25 G12.9 COVER CB C5 400AF CIRCUIT BREAKERS 400A FRAME DECAL CUSTOMER CONNECT INSIDE SCREW RHM 10-32 X 4 WASHER FLAT #10 ZINC WASHER LOCK #10 NUT HEX #10-32 STEEL SCREW THF M6-1 X 16 N WA Z/JS TAPE ELEC 1/2 FOAM SCREW SHC M10-1.5 X 25 G12.9 WASHER LOCK M10 BUS BAR CB ADAPTER 225-400 A LUG SLDLSS 600/250-1/0 X 1/4-28 WASHER FLAT 3/8-M10 ZINC TERM COVER CB SCREW HHC 1/4-28 X 1/2 G5 WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC SCREW SHC M10-1.5 X 25 G12.9 WASHER LOCK M10 DECAL TERMINAL SHOCK HZD BI COVER CB G 225AF C5 CB 0150 3P 480V E FG LL SCREW PPHM #8-32 X 1-3/4 ZINC WASHER FLAT #8 ZINC WASHER LOCK #8-M4 NUT HEX #8-32 STEEL SCREW THF M6-1 X 16 N WA Z/JS TAPE ELEC 1/2 FOAM WASHER FLAT #10 ZINC WASHER LOCK M5 NUT HEX M5-0.8 G8 CLEAR ZINC SCREW HHC M5-0.8 X 20 G8.8 INSULATOR CB 3P E TYPE CC/FG COVER CB DISH 3P E FD RIVET POP .125 X .275 SS COVER CB E KG FRAME C5 CB 0300 3P 600V E KG LL CB 0400 3P 600V E KG LL SCREW SHC M6-1.0 X 50 C8.8 NUT FLANGE M6-1.0 NYLOK SCREW THF M6-1 X 16 N WA Z/JS TAPE ELEC 1/2 FOAM WASHER FLAT 5/16-M8 ZINC WASHER LOCK M8-5/16 NUT HEX M8-1.25 G8 CLEAR ZINC SCREW SHC M8-1.25 X 20 G8 INSULATOR CB E 3P KG GROUP A REVISION: H-5277-B DATE: 11/18/09 Page 4 of 6

EXPLODED VIEW: CPL H CONTROL CB CONNECTION DRAWING #: 0H3917 APPLICABLE TO:

ITEM

7.) A B C D E F G H

PART# QTY. DESCRIPTION

NEUTRAL BLOCK 390 / 200-400A. 0D5466 2 BUS BAR NEUTRAL BLOCK 390 039287 022145 022129 045771 1 1 1 1 SCREW HHC M8-1.25 X 45 G8.8 FT WASHER FLAT 5/16-M8 ZINC WASHER LOCK M8-5/16 NUT HEX M8-1.25 G8 YEL CHR 045335 022097 2 2 SCREW HHC 1/4-28 X 3/4 G5 WASHER LOCK M6-1/4 0A7822 1 LUG SLDLSS 600/250-1/0X1/4-28 (1) HARDWARE FOR MTG. CB TERMINAL COVERS IS SUPPLIED WITH CIRCUIT BREAKERS. (2) 2/3 QTY. 2POLE & 3 POLE CB. GROUP A REVISION: H-5277-B DATE: 11/18/09 Page 5 of 6

EXPLODED VIEW: CPL H CONTROL CB CONNECTION DRAWING #: 0H3917 APPLICABLE TO:

GROUP A

THIS PAGE LEFT INTENTIONALLY BLANK

REVISION: H-5277-B DATE: 11/18/09 Page 6 of 6

22 23 24 25 26 27 28 29 30 A B C D E 60 61 62 63 64 50 51 52 53 54 55 56 57 58 59 65 66 67 68 69 70 71 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 0F5884 055014 022264 0G 3546 0C2265 0G 3648 0F6305 0F6305A 0G 4329 0F1263 0F1262 0F1264 0E9049B 055911 056739 - - 0F2627A 022287 022473 022097 043182 051714 052777 0C2323 0F5459 0F5461 022127 0F5460 0E7403C 0E7403B 0F6145 091526 0C2699 051713 049226 0F1823CST 03 0F1824AST 03 0F2606 036261 0F5763 0F1732 0E9764 0F1725C 0F1958 0F2256 0E3161 029673 049226 079224 051713 0F5886 051716 043180 0C3990 0F4333 0F5883 3 3 1 1 1 1 7 4 7 2 5 COMPONENTS INCL UDED IN 0G4139E 1 ENCL H/G CO NTROL PANEL 1 1 CO VER CONTRO L PANEL HING E CONT INUOUS H PANEL 6 1 1 1 1 1 1 RIVET POP .125 X .275 SS ASSY PROGRAMMED H- 100 DECAL FUSES LO CAT ED INSIDE RAIL SNAPTRACK PCB HO LDER BULK ( 12” LG) ASSY PCB 2AMP 12V UL BATT CHG R PLATE HARNESS CLAMP ASSY PCB PW R AVR W /AMP HEADER ASSY PCB BOSCH G OV DRIVER DIO BR IDG E 25A 600V W ASHER LO CK M5 SCREW PPHM M5- 0.8 X 30 SS W ASHER FLAT M5 SCREW HHPM M5-0.8 X 12 NUT HEX M5-0.8 G8 YEL CHR W ASHER FLAT M4 SCREW PHTT M4- 0.7 X 10 Z YC CO NN DUST CAP W/CHAIN DB9 W ASHER FLAT M3.5 1 10 10 1 4 1 SCREW PHTT M3.5- 0.6 X 10 SCREW PPHM M4- 0.7 X 8 BLX O X W ASHER LO CK #8-M4 DECAL W RN B AT T CHRG 12/24V BI SCREW PHTT M4- 0.7 X 12 Z YC M5-0.8 CAPT IVE PANEL KNLD HD 2 1 1 SEAL COVER 3.18 X 12.7 X 382 SEAL COVER 3.18 X 12.7 X 283 HARNESS H-PNL INTEGRATED SW (NO T SHO WN) COMPONENTS INCL UDED IN WIRE HARNESS 1 ADPTR RH SIDE W ICKMANN 178.6191 4 1 1 HO LDER F USE WICKMANN 178.6150 ADPTR LH SIDE W ICKMANN 178.6192 ASSY PCB G-PANEL RELAY 12VDC 1 BL OCK TERM 20A 12 X 6 X 1100V COMPONENTS NO T INCLUDED IN 0G 4139E O R WIRE HARNESS 2 1 1 2 1 1 1 1 1 2 4 2 3 3 3 RELAY CONTACTO R 12VDC DPE B REAKER SEE DRAW ING 0F9280 BO OST RESIST OR SEE DRAWING 0F 9280 CO VER CONTRO L PANEL SIDE SCREW HHC 1/4- 20 X 3/4 G 5 W ASHER FLAT M6-1/4 W ASHER LO CK M6-1/4 W ASHER LO CK M3 NUT HEX M3-0.5 G8 YEL CHR W ASHER FLAT M3 SCREW PHTT #6-32 X 5/8 Z YC DECAL CPL CONTRO L PANEL FUSES DECAL CPL 5.4/6.8L TB3 NUT HEX 1/4-20 STEEL DECAL CPL 5.4/6.8L RELAY BO ARD 1 2 A/R 4 2 4 4 F USE ATO TYPE 15 AMP (BL UE) F USE ATO TYPE 10 AMP (RED) SEAL WEATHER .45"DIA SCREW PPHM M5- 0.8 X 12 Z NC SCREW PHTT #6-32 X 3/8 Z YC W ASHER FLAT M5 W ASHER LO CK M5

1 2 3 4 5 6 7 8 9 10 11 12 13 14 0F3408 0F3411 058208 022131 050331A 050331 038805U 038804U 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 18.00

CABLE BATT RED #1 X 28.00

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 12 13 14 15 16 17 18 19 20 21 22 23 24 0F30990ST03 065852 052252 052257 052259 055597 052251A 052860 0F8864 0F8865 045764 061383 045757 049813 022473 057192 022131 046526 0536210410 0E7230 027482 022097 090502 0J45320ST03 1 1 5 5 5 4 5 4 1 1 1 1 2 2 3 6 6 6 1 1 2 2 3 1 MTG BASE C5 4.6/80KW 5.4/100KW 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 4.6L LH SUPPORT ENG 4.6L RH SCREW HHTT M4-0.7 X 8 BP LUG SOLDERLESS 3/0-#4 X 13/32 CU SCREW HHC M6-1.0 X 25 G8.8 NUT HEX M6 X 1.0 G8 YEL CHR WASHER FLAT 1/4-M6 ZINC SCREW SHC M10-1.5 X 30 G12.9 WASHER FLAT 3/8-M10 ZINC WASHER LOCK M10 ASSY WIRE 14.00” SCREW HHC M12-1.75 X 80 G10.9 WASHER SHAKEPROOF EXT 5/16 STL WASHER LOCK M6-1/4 SCREW SHC M10-1.5 X 60 C12.9 SUPPORT ENGINE LH

1 2 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 26 27 28 29 30

EXPLODED VIEW: EV MUFFLER 4.6/5.4/6.8L CPL C5 DRAWING #: 0F2969 ITEM PART# QTY. DESCRIPTION

0F2807C 0F2807E 0F9207 0F2807B 0F2807D 0F9208 0A6765 0F4710 0F7200 080762 0F2809 0F2981A 0F2962 0C2454 022097 0F2830 0F2773C 0F2773D 0D3159 088775 0F2808 0F5447 022473 0F6214 0L1789 049813 049721 088510 0C9748 1 1 1 1 1 1 2 6 6 8 1 2 2 4 12 2 2 2 1 6 2 1 20 2 8 8 12 6 1 PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5) PIPE EXH MAN R/H 5.4L G/B & 2P (5.4L C5) PIPE EXH MANIFOLD 4.6L RH PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5) PIPE EXH MAN L/H 5.4L G/B & 2P (5.4L C5) PIPE EXH MANIFOLD 4.6L LH RING GASKET 2.5 DIA 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 THF M6-1 X 16 N WA Z/JS WASHER LOCK M6-1/4 MUFFLER BRACKET STIFFENER EXHAUST BLANKET 900MM LONG (6.8L C5) EXHAUST BLANKET 850MM LONG (5.4L C5) FLANGE EXHAUST WASHER FLAT 3/8 SS EXHUAST OUTLET PIPE CPL BRKT MUFFLER WASHER FLAT 1/4-M6 ZINC PIPE ELBOW EXHAUST MUFFLER MUFFLER STRAP UPPER/LOWER NUT HEX M6 X 1.0 G8 YEL CHR SCREW HHC M6-1.0 X 35 G8.8 BLK NUT HEX M10-1.5 SS PLUG M18-1.50

GROUP D

REVISION: K-1591-J DATE: 1/29/15 Page 2 of 2

1 2 3 4 5 6 7 8 9 10 11 12 13

EXPLODED VIEW: EV AIR CLEANER DRAWING #: 0F3569 ITEM PART# QTY. DESCRIPTION

0D2513D 0D2513E 0F5419 0F4268 0F4270A 0F6977 037561 047411 022097 057795B 0F4269 022473 0A4256 0G5954 1 1 1 1 1 1 1 4 4 1 1 3 1 1

GROUP D

AIR CLNR BTM PLT W/CPLR 8.1L PLATE AIR CLEANER W/COUPLER 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 BARBED EL 90 5/8 PLASTIC GASKET MIXER BODY WASHER FLAT 1/4-M6 ZINC INDICATOR FILTER MINDER (USE WITH ITEM #1 P/N 0D2513E) GROMMET .625 X 1.25 X .433 REVISION: J-9801-E DATE: 9/19/14 Page 2 of 2

EXPLODED VIEW: EV KIT GLASS PACK SHIP LOOSE DRAWING #: 0F6332A ITEM PART# QTY. DESCRIPTION GROUP

1 2 3 4 0F4462 080762 0F4505A 0C2454 (2) 5 (2) 6 (1) 7 (3) 8 0F4367 0F4368 0G3263 077992 2 1 3 14 HEAT SHIELD EXHAUST STACK CAP HEAT SHIELD EXHAUST STACK DECAL WARNING HOT SURFACES BI NUT HEX LOCK M6-1.0 SS NY INS NOTE: SOME “QT SERIES” UNITS WILL REQUIRE (2) GLASS PACK KITS. 0FXXXX = TAN (1) DECALS APPLIED TO EXHAUST AT THE FACTORY. (2) PART NUMBER SHOWN IS FOR TAN. SEE GUIDE BELOW FOR AVAILABLE COLOR AND PART NUMBER FORMAT. 0FXXXX0AL08 = GRAY / ALUMINUM 0FXXXX0AL13 = BISQUE / ALUMINUM 0FXXXX0AL05 = WHITE / ALUMINUM 0FXXXX0AL14 = GRAY / ALUMINUM (3) ) ALUMINUM ENCLOSURE NOTE: ITEM NUMBER 5 TO BE SECURED USING ITEM NUMBERS 4 (THREAD FORMING FASTENER) & 8 (LOCK NUT). THE LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS. 1 1 1 14 RAIN CAP 2-1/2" AL BOLT U 3/8-16 X 2.62 MUFF SEC 23.5" X 2.55IN/2.5OUT SCREW THF M6-1X16 N WA Z/JS GLASS PACK KIT ASSEMBLY INSTRUCTIONS: 1)Disconnect battery cables to prevent accidental start-up. Disconnect the negative battery cable first from the battery post indicated by (-) or NEG. 2)Slide the U-bolt (080762, I/N 2 ) and muffler (0F4505, I/N 3) over the exhaust pipe protruding from the enclosure. The exhaust pipe should be inserted 2 to 3 inches into the inlet of the muffler (0F4505, I/N 3). Position the U-bolt over the inlet of the muffler and tighten. 3)Sub-assemble the heat shield panels (0F4367, I/N 5) and the heat shield cap (0F4368, I/N 6) using the screws provided (0C2454, I/N 4). Lock nuts (077992, I/N 8) should be installed after the fastener has penetrated through the extrusions in the heat shield panels. 4)Slide the heat shield subassembly over the muffler. 5)Fasten the heat shield assembly to the enclosure using the screws provided (0C2454, I/N 4). Lock nuts (077992, I/N 8) should be installed after the fastener has penetrated through the extrusions in the enclosure. An access panel may need to be removed to complete this step. 6)Install the rain cap over the outlet of the muffler and tighten (0F4462, I/N 1). REVISION: K-3230-E DATE: 7/1/15 Page 2 of 2

EXPLODED VIEW: ENGCOMPRT LH 4.6L G3 DRAWING #: 0H3914 APPLICABLE TO:

ITEM PART# QTY.

1 (1)2 3 4 (1)5 6 (1)7 (1)8 (1)9 (1)10 (1)11 (1)12 13 (1) 14 15 (1)16 (1)17 (1)18 19 (1)20 21 22 23 24 (1)25 (1)26 (3)(2)27 28 29 30 31 32 33 (1)34 35 36 37 38 39 40 41 42 43 44 45 46 REF 022145 REF REF 0G5515B 0E0502 0G5511 0H3920 0F6151 057823 0G5148 022129 042907 077996 REF 0G6274 0G6406 0H3922 REF 0G6393 0G5954 0F9505 057822 065386 0H4361 0F7316C 0F7316D 029333A 022473 042568 0F4612 036277 0D5419 0D3488R 0G1815B 0F2776A 0D8026 0D8030 043107 022129 022145 0F9016 022131 046526 045772 0H39440ST03 022097 47 48 49 50 51 (1)52 53 54 55 (3)56 57 0E9868A 0F9381 064416 0F3216D 0F3217 0E0992A 045771 055934C 0H4787 0H3874 0F2776 1 1 1 1 1 8 2 1 REF 1 1 (1) NOTE: PART OF ENGINE MAKE (SEE I/N 26) 0F7316C = ENGINE MAKE 0H3913 0F7316D = ENGINE MAKE 0H5742 (3) NOTE: NOT SHOWN (2) NOTE: I/N 27 IS FOR HOLDING SENSOR TO I/N 35. 1 4 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 2 1 1 1 2 1 1 1 1 1 2 2 1 1 REF 1 1 1 3 1 3 6 6 1 2 1 1 1 2

GROUP D DESCRIPTION

CONNECTION WATER OUTLET WASHER FLAT 5/16-M8 ZINC GASKET THERMOSTAT HOUSING G3 THERMOSTAT ASSY ADAPTER THERMOSTAT 4.6L G3 TEMPERATURE SENDER, DELPHI GASKET THERMOSTAT 4.2L SPACER COOLANT BYPASS CAP RUBBER CLAMP HOSE #10 .56-1.06 SCREW IHHC M8-1.25 X 140 G8.8 WASHER LOCK M8-5/16 SCREW HHC M8-1.25 X 16 C8.8 CAP ANTIFREEZE RUBBER O-RING 29mm I.D. X 36mm O.D. X 3.5mm PRESSURE RELIEF VALVE SPRING COMPRESSION .711 X 1.00 TUBE ASSY EGR OUTLET REWORK SCREW HHC M6-1.0 X 15 LONG BOLT STRIP 3/8-16 X 1-1/4 GROMMET 15.87 X 31.75 X 11 BARB CONNECTOR 5/8" HOSE POLYE CLAMP HOSE #8 .53-1.00 HOSE COOL 5/8 ID 100R6 (15”LG) REWORK VENT FITTING 4.6L G3 ENGINE 4.6L COMPLETE ENGINE G4.6L G3 COMPLETE TIE WRAP UL 7.4"X .19" BLK WASHER FLAT 1/4 ZINC SCREW HHC M6-1.0 X 20 G8.8 SENDER OIL PRESSURE 1/8"NPT ELBOW 90D STREET 1/8 OIL FILTER BELT SERPENTINE 54.72" REWORK HARMONIC BALANCER 4.6L BRACKET, SIGNAL CONDITIONER OLT HEX FL HD M8-1.25 X 31 TENSIONER, ENG. AUTOMATIC BELT SCREW HHC M8-1.25 X 25 G8.8 WASHER LOCK M8-5/16 WASHER FLAT 5/16-M8 ZINC BRACKET DC ALTERNATOR 4.6L WASHER FLAT 3/8-M10 ZINC WASHER LOCK M10 NUT HEX M10-1.5 G8 YEL CHR BRACKET INTAKE MANIFOLD LOWER WASHER LOCK M6-1/4 ALTERNATOR DC W/OUT PULLEY ALTERNATOR STRAP SCREW HHC M10-1.5 X 45 G8.8 FT PULLEY 160 OD DC ALTERNATOR SPACER DC ALTERNATOR PULLEY PLUG EXPANSION 14 OD NUT HEX M8-1.25 G8 CLEAR ZINC CLAMP STL/VNL .5 X .406 Z SPARK PLUG HARN ENG G4.6L G3 H-PANEL CPL BRACKET, SIGNAL CONDITIONER

REVISION: H-6318-C DATE: 3/26/10 PAGE 2 OF 2

EXPLODED VIEW:

ENG COM PRT RH 4.6L G3

DRAWING #:0H3914A APPLICABLE TO:

ITEM PART# QTY.

1 2 3 4 5 069860E 022158 0C7649 0D2244M 022129 1 2 1 1 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 039253 0F5454 0F2929 071623 046526 055934M 052625 0F9965D 0F3844 0D5417 049821 0D5418 043107 097474 REF 0F1820 070006 0D9913 0F3534 070008 26 27 28 29 30 (1)31 (1)32 33 34 35 36 37 38 39 40 41 042909 0D2608 0F5114 0F6104 082121A 048031C 0E9974 036943 023897 0H4243 0H40910ST03 022152 042568 022097 022473 022145 42 43 44 0H3874 023762 0F7316C 0F7316D REF 1 REF REF (1) NOTE: PART OF ENGINE MAKE (SEE I/N 44) 0F7316C = ENGINE MAKE 0H3913 2 8 1 1 2 3 3 2 2 1 1 2 4 4 4 1 0F7316D = ENGINE MAKE 0H5742 1 1 1 1 2 5 2 3 2 6 6 3 1 1 1 4 2 24 14 2 8

DESCRIPTION

HOSE DRAIN ASSY 28" NUT HEX #10-32 STEEL CLAMP HOSE .38-.87 ASSY MAGPICKUP(3/8-24 MALE) WASHER LOCK M8-5/16 SCREW HHC M8-1.25 X 20 G8.8 PLATE MAG PICK-UP ADAPTOR ENGINE ADAPTER SCREW SHC M10-1.5 X 55 G12.9 WASHER LOCK M10 CLAMP STL/VNL .75 X .343 Z SCREW SHC M10-1.5 X 35 C12.9 FLEX PLATE 2 POLE 4.6L G3 WASHER FLAT .43 X 1.00 SCREW HHC M10-1.0 X 25 G10.9 SCREW SHC M8-1.25 X 30 C12.9 STARTER MOTOR V-10 G3 ENGINE SCREW HHC M8-1.25 X 25 C12.9 BANJO ASSY M14-1.5 GASKET, EXHAUST MANIFOLD MACHINED MANIFOLD,EXHAUST WASHER LOCK M8 SSTL SCREW SHC M8-1.25 X 35 SS HEAT SHLD EXHAUST MANIFOLD WASHER FLAT M8 SS SCREW HHC M8-1.25 X 30 C8.8 SCREW HHC 5/16-18 X 1/2 SSTL DECAL REFER TO OWNERS MANUAL COVER STARTER 5.4 & 6.8 FORD CPL CLIP-J VINYL COAT .375 ID CLAMP HOSE BAND .50 CAP VINYL 3/8"ID X 1"DP BLK SCREW PPHM #10-32 X 2 WASHER FLAT #10 ZINC ASSY PCB 4.6L IGN MOD PRGRMMED BRACKET IGN CONTROL 4.6L G3 WASHER LOCK #10 SCREW HHC M6-1.0 X 20 C8.8 WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC WASHER FLAT 5/16-M8 ZINC HARN ENG G4.6L G3 H-PANEL CPL WASHER SHAKEPROOF EXT #10 STL ENGINE 4.6L G3 COMPLETE ENGINE G4.6L G3 COMPLETE

GROUP D

REVISION:-A- DATE: 7/16/09 PAGE 2 OF 2

ITEM

1 2 3 4 (2) 5 6 7 8 9 10 11 (2) 12 13 14 15 (2) 16 17 18 19 (2) 20 21 22 23 (2) 24 25 26 27 28 29 (2) 30 39 40 41 42 31 32 33 34 35 36 37 38 43 44 45 46 47 (1) 48 49 50 51 52 53 54 55 56 57 58 59 60 (3) 61 62 63 64

EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.6L CP DRAWING #: 0H3915 APPLICABLE TO: PART#

0H20530ST03 0F2611 0F5254 046526 059981 0C2454 052250 076749 0F2573 0F2610 0H20620ST03 0H2051 0F2862 0F2560 022131 039287 0C8566 0F2561 0C8165 0D6795 0C7043 0G1039 (4) 0H5380 048031C 0C8146 082774 0H3909 (4) 0F2686 0H3908 (4) 0F5463 0F8695 0F4032 042911 0F2872 022304 022195 022196 049813 052677 090283 0F2776A 022145 022129 052644 035685 045764 065852 0C7649 043790 (4) 055596 069860E 069811 080713 022473 022097 042568 0F5050B (4) 0F5050 039253 051769 0C8145 0H1827 0H23980ST03 029032 049820 0H2844 0G53150AL0R 051756 099502

QTY.

1 1 1 1 1 1 REF 1 1 3 1 8 24 16 8 1 1 1 1 2 2 (REF) 1 4 2 1 1 1 9 4 2 2 1 1 1 1 1 1 1 1 1 4 1 8 1 8 1 2 1 12 2 1 1 1 1 1 1 1 4 2 1 2 1 1 1 1 8 1 1 1

DESCRIPTION

WELDMENT RADIATOR SUPPORT C5 RADIATOR 680 X 680 X 70 CPL V-BELT 31/64" X 62-3/8" WASHER LOCK M10 SCREW HHC M10-1.5 X 30 C10.9 SCREW THF M6-1 X 16 N WA Z/JS TAPE FOAM 1 X 1 (26.75” LG) TANK COOLANT RECOVERY PULLEY FAN V-GROOVE 9" FAN 26" LH ROTATION ARM BELT TENSIONER SHOULDER BOLT 1/2 X 2-1/4" SPRING TENSION CPL PULLEY V-BELT 4" FLANGED WASHER FLAT 3/8-M10 ZINC SCREW HHC M8-1.25 X 45 C8.8 SCREW HHFC M6-1.0 X 20 G8.8 HUB FLEX PLATE NUT HEX LOCK 5/16-24 NY INS SCREW HHC M12-1.5 X 60 G8.8 DISK FLEX COUPLING FLEX HUB MACHINED COUPLING FLEX HUB MACHINED CLAMP HOSE BAND 1/4 SCREW HHC 5/16-24 X 1.124 KEY WOODRUFF 4 X 19D HOSE RADIATOR UPPER C5 CPL HOSE, RADIATOR UPPER, CPL HOSE RADIATOR LOWER C5 CPL HOSE LOWER RAD CPL C5 6.8L ASSY BRG/SHAFT CPL FANDRIVE PULLEY 5.5" DIA MACHINED SCREW HHC M10-1.5 X 30 G8.8 SCREW HHC 1/2-13 X 2" G8 WASHER FLAT 1/2 ZINC WASHER LOCK 1/2 NUT HEX 1/2-13 STEEL NUT HEX M6 X 1.0 G8 YEL CHR WASHER NYLON .50 X .87 X .06 CAP RADIATOR 13 PSI BRACKET, SIGNAL CONDITIONER WASHER FLAT 5/16-M8 ZINC WASHER LOCK M8-5/16 SPACER .5 X 1.5 X .25 STL/ZINC CLAMP HOSE #28 1.32-2.25 SCREW HHTT M4-0.7 X 8 BP SPRING CLIP HOLDER .37-.62 CLAMP HOSE .38-.87 BARBED EL 90 3/8 NPT X 3/8 BARBED STR 3/8NPT X 3/8 HOSE DRAIN ASSY 28" CAP HEX 1/4 NPT BRASS BRACKET COOLANT TANK WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 SCREW HHC M6-1.0 X 20 G8.8 SHIELD RADIATOR SHIELD RADIATOR SCREW HHC M8-1.25 X 20 G8.8 WASHER LOCK M12 WASHER FLEX (THIN) PROBE COOLANT LEVEL 3/8-18NPTF BRACKET TENSIONER SPRING HOSE 9/32 ID (43”LG) NUT HEX LOCK M8-1.25 NY INS BEARING SLEEVE 1/2/ X 3/4 X 1 SPACER CPL COOLING FAN 1/8" SCREW HHC M10-1.5 X 20 C8.8 CLAMP HOSE #24 B1.06-2.00

REVISION: H-5378-B DATE: 12/16/09 GROUP D

Page 2 of 6

EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.6L CP DRAWING #: 0H3915 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION (5) 65 (5) 66 (5) 67 0D6029 055934H 072252 1 1 1 (1) ITEM 48 IS INCLUDED WITH 47. (2) APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THREADS. (3) ITEM 61 IS INCLUDED WITH ITEM 1. (4) THESE PARTS ARE 5.4L 80KW SPECIFIC. (5) CATALYST EQUIPPED UNITS ONLY. SCREW HHTT M6-1.0 X 16 ZYC CLAMP STL/VNL .62 X .406 Z GROMMET 1.37 X .06 X 1.00

REVISION: H-5378-B DATE: 12/16/09 GROUP D

Page 3 of 6

EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.6L CP DRAWING #: 0H3915 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 1 2 3 0G15310GS0R 0G15320GS0R 0G15300GS0R 4 5 6 0G15290GS0R (2) 0H30010GS0R 0G15330GS0R 0C2454 (1) 7 (1) 8 0D3215B 0C2454 (1) NOT REQUIRED FOR UNITS WITH CATALYST. (2) CATALYST EQUIPPED UNITS ONLY 2 2 1 1 1 1 20 2 8 PANEL C5 FRONT SIDES PANEL C5 REAR SIDES PANEL LOWER FRONT PANEL C5 TOP PANEL C5 TOP PANEL C5 TOP MOUNT SCREW THF M6-1 X 16 N WA Z/JS ACCESS COVER 160 X 170 GALV SCREW THF M6-1 X 16 N WA Z/JS

REVISION: H-5378-B DATE: 12/16/09 GROUP D

Page 5 of 6

EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.6L CP DRAWING #: 0H3915 APPLICABLE TO:

GROUP D

THIS PAGE LEFT INTENTIONALLY BLANK

Page 6 of 6

REVISION: H-5378-B DATE: 12/16/09

EXPLODED VIEW: FUEL SYSTEM NG 4.6L 80KW DRAWING #:0H3918 APPLICABLE TO: ITEM PART# 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 1 2 3 4 5 6 7 8 9 10 11 12 13 16 17 0G9240B 057822 059057 0F4408 059057 0H4537 026915 0A8064 064346 031015 0E7162 039130 065908 022304 052645 0G3167 0F3691C 0H39430ST03 059057 022195 045773 0F3885 086133E 0F0960 086133D 0G7104 0E4392 0E4390 0H3766A 097962 022097 042568 049811 0D3700 0H3894 0H3921 082121A 026073A 063831 QTY. 1 4 4 2 2 6 1 1 1 1 1 1 1 4 2 1 8 1 1 2 1 2 2 2 1 1 2 1 1 1 2 2 1 1 1 1 4 1 2 DESCRIPTION REG ASSY 4.6L 80KW NG CPL CLAMP HOSE #8 .53-1.00 HOSE 3/4 ID SAE-30R2 (41.5” LG) Y CONNECTOR 500 SERIES BARBS HOSE 3/4 ID SAE-30R2 (11” LG) HARN FUEL JUMPER DUAL REG NIPPLE CLOSE 3/4 X 1.375 BSHG RDCR HEX 1-1/4-3/4 PIPE TEE 1-1/4 NPT NIPPLE PIPE 1-1/4 NPT X 3 BSHG RDCR HEX 1-1/4 X 1/4FNPT NIPPLE CLOSE 1.25 NPT X 1.625 SUPPORT NAT GAS SOLENOID WASHER FLAT 1/2 ZINC SCREW HHC M12-1.75 X 30 C8.8 O-RING 2-3/4 X 3/32 X 2-15/16 VENTURI THROTTLE 38MM BRACKET INTAKE MANIFOLD UPPER HOSE 3/4 ID SAE-30R2 (47.5” LG) WASHER LOCK ½ NUT HEX M12-1.75 G8 YEL CHR MIXER 40/60MM ACTUATOR ASSY CLAMP HI TORQUE 2.75 - 3.625 REDUCER 3.0" TO 2.75" TURBO CLAMP HI TORQUE 2.25 - 3.125 SCREW SHC M6-1.0 X 60 C12.9 ACTUATOR BOSCH 60 GOVERNOR GASKET GOVERNOR ACTUATOR RESTRICTOR INTAKE 4.6L G3 NG SCREW SHC M6-1.0 X 25 C12.9 ZP WASHER LOCK M6-1/4 SCREW HHC M6-1.0 X 20 C8.8 WASHER FLAT M6 NUT FLANGE M6-1.0 NYLOK INTAKE ELBOW 4.6L G3 GASKET AIR INTAKE 4.6L G3 CLIP-J VINYL COAT .375 ID PLUG STD PIPE 1/4 STEEL SQ HD PLUG PIPE 1.25 SQ HD ZINC

GROUP E REVISION: K-2798-D DATE: 5/13/15 PAGE 2 OF 2

EXPLODED VIEW: FUEL SYSTEM LP VAPOR 4.6L 80KW DRAWING #:0H3919 APPLICABLE TO: ITEM

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 1 2 3 4 5 6 7 8 9 10 11 12 13 16 17

PART#

0G9239D 057822 0H3894 082121A 0H3921 0H4537 026915 0A8064 064346 031015 030131 039130 065908 022304 052645 0G3167 0F3691C 0H39430ST03 059057 022195 045773 0F3885 086133E 0F0960 086133D 0G7104 0E4392 0E4390 0H3766B 097962 022097 042568 049811 0D3700 063831

QTY.

1 1 1 4 2 1 4 1 1 1 1 2 2 1 1 2 1 1 2 2 2 1 1 1 1 4 1 2 1 4 4 2 2 6 1

DESCRIPTION

REG ASSY 4.6L 80KW LPV 2009CPL CLAMP HOSE #8 .53-1.00 INTAKE ELBOW 4.6L G3 CLIP-J VINYL COAT .375 ID GASKET AIR INTAKE 4.6L G3 HARN FUEL JUMPER DUAL REG NIPPLE CLOSE 3/4 X 1.375 BSHG RDCR HEX 1-1/4-3/4 PIPE TEE 1-1/4 NPT NIPPLE PIPE 1-1/4 NPT X 3 ELBOW 90D 1-1/4 NPT NIPPLE CLOSE 1.25 NPT X 1.625 SUPPORT NAT GAS SOLENOID WASHER FLAT 1/2 ZINC SCREW HHC M12-1.75 X 30 C8.8 O-RING 2-3/4 X 3/32 X 2-15/16 VENTURI THROTTLE 38MM BRACKET INTAKE MANIFOLD UPPER HOSE 3/4 ID SAE-30R2 (47.5” LG) WASHER LOCK ½ NUT HEX M12-1.75 G8 YEL CHR MIXER 40/60MM ACTUATOR ASSY CLAMP HI TORQUE 2.75 - 3.625 REDUCER 3.0" TO 2.75" TURBO CLAMP HI TORQUE 2.25 - 3.125 SCREW SHC M6-1.0 X 60 C12.9 ACTUATOR BOSCH 60 GOVERNOR GASKET GOVERNOR ACTUATOR RESTRICTOR INTAKE 4.6L G3 LPV SCREW SHC M6-1.0 X 25 C12.9 ZP WASHER LOCK M6-1/4 SCREW HHC M6-1.0 X 20 C8.8 WASHER FLAT M6 NUT FLANGE M6-1.0 NYLOK PLUG PIPE 1.25 SQ HD ZINC GROUP E REVISION: K-2798-D DATE: 5/13/15 PAGE 2 OF 2

36 37 38 39 40 42 43 (1) 44 45 46 47 48 49 50 51 (2) 1 (2) 2 (2) 3 (3) 4 (2) 5 (2) 6 (3) 7 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 0F58730ST01 0F58680ST01 0F58720ST01 0F58710AL01 0F58690ST01 0F58700ST01 0F58670AL01 0C2454 0F2766 0F3181 0F3185 0F3416 0F3949 0F4487A 022473 022097 022127 0F3072 078115 0F3949B 0F3949A 0F5048D 0E5968 0F5049 0F3949L 0F3949E 0F3890A 087233 0F3949C 0F3949D 0F3949G 0F3949J 1 4 2 2 2 1 1 86 2 4 2 2 2 1 5 1 1 20 58 3 4 4 1 4 2 1 9 2 1 4 1 2 REAR WRAP C5 DOOR C5 CENTER SUPPORT C5 DISCHARGE DUCT LH & RH SIDE C5 FRONT CORNERS C5 DISCHARGE CENTER DUCT C5 ROOF C5 ALUM SCREW THF M6-1 X 16 N WA Z/JS SPLITTER SPLITTER SHORT STRINGER SPLITTER C3 SUPPORT SPLITTER C5 130KW INSULATION CORNER POST ASSEMBLY COVER ACCESS WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 NUT HEX 1/4-20 STEEL INSULATION RETAINMENT HANGER WASHER SELF LOCKING DOME #4-40 INSULATION SPLITTER INSULATION SHORT LOUVER VISE-ACTION LATCH SLOTTED CIR GASKET EXTRUDED TRIM (566” LG) TAB PULL INSULATION SPLITTER SML INSULATION ROOF TOP REAR RETAINER INSULATION (740) RIVET POP .1875 X .450 SS INSULATION ROOF TOP INSULATION DOOR INSULATION DISCHARGE DUCT INSULATION CENTER SUPPORT 0F3949K 0F3949F 0F3890B 0F3890 042568 022447 049813 077992 0912970094 0F2766A 1 2 4 14 4 4 4 28 4 1 INSULATION DISCHARGE DUCT TOP INSULATION INNER DUCT SIDE RETAINER INSULATION (820) RETAINER INSULATION (450) 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 SPLITTER C5 0F3949M 0F8869D 0E3257 1 1 6 INSULATION SPLITTER SHRT MPS KEY VISE-ACTION LATCH SLOT CIR SCREW TH-FRM M6 W/CAP SHKPRF W 078115A 066760 12 1 WASHER SELF LOCKING DOME #8-32 STRIP SEALANT 1/8 X 1 (44.52”LG) (1) ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE SECURED USING ITEM 11 & 49 THREAD FORMING FASTENER AND ITEM 44 LOCK NUT. LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS. ALL ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER. (2) NOTE: PART NUMBER SHOWN IS FOR TAN / STEEL. REFER TO THE SAMPLE GUIDE BELOW FOR AVAILABLE COLOR AND/OR ALUMINUM PART NUMBER FORMAT. 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

v. A 04/07 BackPg001 Re

United States Environmental Protection Agency Warranty Statement (Stationary Emergency Spark-Ignited Generators) Warranty Rights, Obligations and Coverage

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

Purchaser's/Owner's Warranty Responsibilities

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

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

Important Note

This warranty statement explains your rights and obligations under the Emission Control System Warranty, which is provided to you by Gen erac pursuant to federal law. Note that this warranty shall not apply to any incidental, consequential, or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part(s). This warranty is in place of all other warranties, expressed or implied. Specifically, Generac makes no other warranties as to the merchantability or fitness for a particular purpose. Any implied warranties which are allowed by law, shall be limited in duration to the terms of the express warranty provided herein. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

Emission Related Parts Include the Following (if so equipped)

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

United States Environmental Protection Agency Compliance Requirements (Stationary Emergency Spark-Ignited Generators) Purchaser's/Owner's Record Keeping Responsibilities

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

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

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

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

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

Emission-Related Installation Instructions

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

EmsnWrnty001 Revision F (04/15)

1 2 3 4 5 6 7 8 9 10 11 12 13

EXPLODED VIEW: EV AIR CLEANER DRAWING #: 0F3569 ITEM PART# QTY. DESCRIPTION

0D2513D 0D2513E 0F5419 0F4268 0F4270A 0F6977 037561 047411 022097 057795B 0F4269 022473 0A4256 0G5954 1 1 1 1 1 1 1 4 4 REF 1 3 1 1

GROUP D

AIR CLNR BTM PLT W/CPLR 8.1L PLATE AIR CLEANER W/COUPLER 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 BARBED EL 90 5/8 PLASTIC GASKET MIXER BODY WASHER FLAT 1/4-M6 ZINC INDICATOR FILTER MINDER (USE WITH ITEM #1 P/N 0D2513E) GROMMET .625 X 1.25 X .433 REVISION: CN-0008186-G DATE: 7/11/17 Page 2 of 2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0F9952 0F3417 0F2984 0F9949 0F3418 0F2985 0F9950 0F9951 0G6319 0F6183 0F6187 0F6184 0F6212 0G2023 0F8757 068405C 0F3013 072878 0C9708 0F3726B 0F2689 023454 059980 046526 0A2601 072879 022473 022097 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 REF 1 1 1 4 4 1 1 8/12 4/6 ASSY ROTOR 2390 80KB3 CPL ASSY ROTOR 390 2P 100K BRSHLS ASSY ROTOR 390 2P 150K BRSHLS ASSY STATOR 80KW 1PH 2P BRSHLS ASSY STATOR 390 2P 100K BRSHLS ASSY STATOR 390 2P 150K BRSHLS UL STATOR 2390 80 GB3 CPL STATOR 2390 80 KB3 CPL STR 2390 80 JB3 CPL ASSY STR 390 100KW 2P 3PH 208V ASSY STR 100KW 1PH 2P BRSHLS ASSY STR 390 150KW 2P 3PH 208V ASSY STR 150KW 1PH 2P BRSHLS ASSY STR 390 150KW 2P 3PH 240V STR-2390-150LB4 CPL EXITER FIELD 2" LG SPD CONN ASSY EXCITER 2.0" STACK 2P KEY SQ 3/8 X 3-1/4 STEEL HYPOT TEST PROCEDURE (NOT SHOWN) ASSY FLYWHEEL CPL RING PRESSURE 390 STATOR CAN KEY WOODRUFF #E SCREW HHC M10-1.5 X 25 C10.9 WASHER LOCK M10 SCREW HHC M16-2.0 X 45 G8.8 SPACER .69 X 2.75 X .37 ST/ZNC WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 * 51 52 53 60 61 62 63 64 65 66 67 68 69 0C2454 092950 04576100CF 052646 043123 051779 022392 052259 051769 0E7230 0F3033 0F9492 0F2722 077043F 020151 023365 033133 033143 086032 090063 090064 090152 022661L 028739A 085662D 068113A 068406 0F7272 023484N 023484N 0F6819 REF. 0C2428 022155 042568 049813 052624 0F7030 0F7047 0F7029 0F3834 KIT PARTS 0F3846B 0F3892 0A2496A 056326 022097 022473 045757 047411 0A2110 11 1 4 4 4 4 2 2 3 3 1 1 1 1 1 3 1 2 2 1 1 1 1 2 1 1 1 SCREW THF M6-1 X 16 N WA Z/JS COLLAR SLIP FIT 390 MM STUD M14-2.0 X 760 G5 ZINC WASHER FLAT M14 WASHER LOCK M14 NUT HEX M14-2.0 G8 YEL CHR 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 SHIELD ALT EXCITER 5.4/6.8 (1 PHASE) COVER EXCITER SHIELD CONDUIT FLEX 1.25” ID 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 6 1 2 1 2/3 2 2 4/6 4/6 1 1 1 1 1 SCREW 1/4-20 X 5/8" TAPTITE SS BUSHING SNAP SB-2.5-31 BUSHING SNAP SB-2.5-31 (FOR 5.4/6.8 1 PHASE) MOUNT CT'S 5.4L 100KW TRANSFORMER SCREW PHTT #6-32 X 1/2 ZYC WASHER LOCK #6 SCREW HHC M6-1.0 X 20 G8.8 NUT HEX M6 X 1.0 G8 YEL CHR BEARING BALL 6212 SEALED SHROUD UPPER ALTERNATOR EXCITR SHROUD CENTER ALTERNATR EXCITR SHROUD LOWER ALTERNATOR EXCITR ASSY SCROLL 390 X 60MM CPL 2 2 2 8.4 FT. 6 6 2 I/N’S: 61 THRU 69 SHROUD ALT SHEET METAL CPL 2P SCREEN, 390 SAE ALT 60MM WIDE BRACKET SAE SCROLL TENSIONER VINYL TRIM 1/8” GAP WASHER, SPLIT 1/4”-M6 WASHER FLAT 1/4 ZINC SCREW HHC M6-1.0 x 25 LONG 4 12 SCREW HHC M6-1.0 X 16 G8.8 SCREW SWAGE 1/4-20 X 1/2 Z/YC * ROTOR REPLACEMENT PARTS. ** 1 PHASE UNITS REQUIRE SEPERATION OF LEADS. QTY. REQ: 1 PHASE / 3 PHASE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 0F30990ST03 065852 052252 052257 052259 055597 052251A 052860 0F8864 0F8865 045764 061383 045757 049813 022473 057192 022131 046526 0536210410 0E7230 027482 022097 090502 0J45320ST03 1 1 5 5 5 4 5 4 1 1 1 1 2 2 3 6 6 6 1 1 2 2 3 1 MTG BASE C5 4.6/80KW 5.4/100KW 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 4.6L LH SUPPORT ENG 4.6L RH SCREW HHTT M4-0.7 X 8 BP LUG SOLDERLESS 3/0-#4 X 13/32 CU SCREW HHC M6-1.0 X 25 G8.8 NUT HEX M6 X 1.0 G8 YEL CHR WASHER FLAT 1/4-M6 ZINC SCREW SHC M10-1.5 X 30 G12.9 WASHER FLAT 3/8-M10 ZINC WASHER LOCK M10 ASSY WIRE 14.00” SCREW HHC M12-1.75 X 80 G10.9 WASHER SHAKEPROOF EXT 5/16 STL WASHER LOCK M6-1/4 SCREW SHC M10-1.5 X 60 C12.9 SUPPORT ENGINE LH

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

EXPLODEDVIEW: EV BATTERY 4.6L, 80KW & 6.8L 150KW DRAWING#: 0F3675 APPLICABLETO:

ITEM PART# QTY. DESCRIPTION

0F3408 0F3411 G058208 G022131 050331A G050331 038805U 038804U G045771 G022129 G027482 G075763 0C2454 0F3409 0J3501 1 1 1 1 1 1 1 1 1 1 1 1 8 1 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 18.00 CABLE BATT RED #1 X 28.00 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

GROUP C

REVISION: CN-0021496 DATE: 11/9/18 Page 2 of 2

36 37 38 39 40 42 43 (1) 44 45 46 47 48 49 50 51 (2) 1 (2) 2 (2) 3 (3) 4 (2) 5 (2) 6 (3) 7 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 0F58730ST01 0F58680ST01 0F58720ST01 0F58710AL01 0F58690ST01 0F58700ST01 0F58670AL01 0C2454 0F2766 0F3181 0F3185 0F3416 0F3949 0F4487A 022473 022097 022127 0F3072 078115 0F3949B 0F3949A 0F5048D 0E5968 0F5049 0F3949L 0F3949E 0F3890A 087233 0F3949C 0F3949D 0F3949G 0F3949J 1 4 2 2 2 1 1 86 2 4 2 2 2 1 5 1 1 20 58 3 4 4 1 4 2 1 9 2 1 4 1 2 REAR WRAP C5 DOOR C5 CENTER SUPPORT C5 DISCHARGE DUCT LH & RH SIDE C5 FRONT CORNERS C5 DISCHARGE CENTER DUCT C5 ROOF C5 ALUM SCREW THF M6-1 X 16 N WA Z/JS SPLITTER SPLITTER SHORT STRINGER SPLITTER C3 SUPPORT SPLITTER C5 130KW INSULATION CORNER POST ASSEMBLY COVER ACCESS WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 NUT HEX 1/4-20 STEEL INSULATION RETAINMENT HANGER WASHER SELF LOCKING DOME #4-40 INSULATION SPLITTER INSULATION SHORT LOUVER VISE-ACTION LATCH SLOTTED CIR GASKET EXTRUDED TRIM (566” LG) TAB PULL INSULATION SPLITTER SML INSULATION ROOF TOP REAR RETAINER INSULATION (740) RIVET POP .1875 X .450 SS INSULATION ROOF TOP INSULATION DOOR INSULATION DISCHARGE DUCT INSULATION CENTER SUPPORT 0F3949K 0F3949F 0F3890B 0F3890 042568 022447 049813 077992 0912970094 0F2766A 1 2 4 14 4 4 4 28 4 1 INSULATION DISCHARGE DUCT TOP INSULATION INNER DUCT SIDE RETAINER INSULATION (820) RETAINER INSULATION (450) 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 SPLITTER C5 0F3949M 0F8869D 0E3257 1 1 6 INSULATION SPLITTER SHRT MPS KEY VISE-ACTION LATCH SLOT CIR SCREW TH-FRM M6 W/CAP SHKPRF W 078115A 066760 12 1 WASHER SELF LOCKING DOME #8-32 STRIP SEALANT 1/8 X 1 (44.52”LG) (1) ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE SECURED USING ITEM 11 & 49 THREAD FORMING FASTENER AND ITEM 44 LOCK NUT. LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS. ALL ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER. (2) NOTE: PART NUMBER SHOWN IS FOR TAN / STEEL. REFER TO THE SAMPLE GUIDE BELOW FOR AVAILABLE COLOR AND/OR ALUMINUM PART NUMBER FORMAT. 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

EXPLODED VIEW: FUEL SYSTEM NG 4.6L 80KW DRAWING #:0H3918 APPLICABLE TO: ITEM PART# 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 1 2 3 4 5 6 7 8 9 10 11 12 13 16 17 0G9240B 057822 059057 0F4408 059057 0H4537 026915 0A8064 064346 031015 0E7162 039130 065908 022304 052645 0G3167 0F3691C 0H39430ST03 059057 022195 045773 0F3885 086133E 0F0960 086133D 0G7104 0E4392 0E4390 0H3766A 097962 022097 042568 049811 0D3700 0H3894 0H3921 082121A 026073A 063831 QTY. 1 4 4 2 2 6 1 1 1 1 1 1 1 4 2 1 8 1 1 2 1 2 2 2 1 1 2 1 1 1 2 2 1 1 1 1 4 1 2 DESCRIPTION REG ASSY 4.6L 80KW NG CPL CLAMP HOSE #8 .53-1.00 HOSE 3/4 ID SAE-30R2 (41.5” LG) Y CONNECTOR 500 SERIES BARBS HOSE 3/4 ID SAE-30R2 (11” LG) HARN FUEL JUMPER DUAL REG NIPPLE CLOSE 3/4 X 1.375 BSHG RDCR HEX 1-1/4-3/4 PIPE TEE 1-1/4 NPT NIPPLE PIPE 1-1/4 NPT X 3 BSHG RDCR HEX 1-1/4 X 1/4FNPT NIPPLE CLOSE 1.25 NPT X 1.625 SUPPORT NAT GAS SOLENOID WASHER FLAT 1/2 ZINC SCREW HHC M12-1.75 X 30 C8.8 O-RING 2-3/4 X 3/32 X 2-15/16 VENTURI THROTTLE 38MM BRACKET INTAKE MANIFOLD UPPER HOSE 3/4 ID SAE-30R2 (47.5” LG) WASHER LOCK ½ NUT HEX M12-1.75 G8 YEL CHR MIXER 40/60MM ACTUATOR ASSY CLAMP HI TORQUE 2.75 - 3.625 REDUCER 3.0" TO 2.75" TURBO CLAMP HI TORQUE 2.25 - 3.125 SCREW SHC M6-1.0 X 60 C12.9 ACTUATOR BOSCH 60 GOVERNOR GASKET GOVERNOR ACTUATOR RESTRICTOR INTAKE 4.6L G3 NG SCREW SHC M6-1.0 X 25 C12.9 ZP WASHER LOCK M6-1/4 SCREW HHC M6-1.0 X 20 C8.8 WASHER FLAT M6 NUT FLANGE M6-1.0 NYLOK INTAKE ELBOW 4.6L G3 GASKET AIR INTAKE 4.6L G3 CLIP-J VINYL COAT .375 ID PLUG STD PIPE 1/4 STEEL SQ HD PLUG PIPE 1.25 SQ HD ZINC

GROUP E REVISION: K-2798-D DATE: 5/13/15 PAGE 2 OF 2

EXPLODED VIEW: FUEL SYSTEM LP VAPOR 4.6L 80KW DRAWING #:0H3919 APPLICABLE TO: ITEM

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 1 2 3 4 5 6 7 8 9 10 11 12 13 16 17

PART#

0G9239D 057822 0H3894 082121A 0H3921 0H4537 026915 0A8064 064346 031015 030131 039130 065908 022304 052645 0G3167 0F3691C 0H39430ST03 059057 022195 045773 0F3885 086133E 0F0960 086133D 0G7104 0E4392 0E4390 0H3766B 097962 022097 042568 049811 0D3700 063831

QTY.

1 1 1 4 2 1 4 1 1 1 1 2 2 1 1 2 1 1 2 2 2 1 1 1 1 4 1 2 1 4 4 2 2 6 1

DESCRIPTION

REG ASSY 4.6L 80KW LPV 2009CPL CLAMP HOSE #8 .53-1.00 INTAKE ELBOW 4.6L G3 CLIP-J VINYL COAT .375 ID GASKET AIR INTAKE 4.6L G3 HARN FUEL JUMPER DUAL REG NIPPLE CLOSE 3/4 X 1.375 BSHG RDCR HEX 1-1/4-3/4 PIPE TEE 1-1/4 NPT NIPPLE PIPE 1-1/4 NPT X 3 ELBOW 90D 1-1/4 NPT NIPPLE CLOSE 1.25 NPT X 1.625 SUPPORT NAT GAS SOLENOID WASHER FLAT 1/2 ZINC SCREW HHC M12-1.75 X 30 C8.8 O-RING 2-3/4 X 3/32 X 2-15/16 VENTURI THROTTLE 38MM BRACKET INTAKE MANIFOLD UPPER HOSE 3/4 ID SAE-30R2 (47.5” LG) WASHER LOCK ½ NUT HEX M12-1.75 G8 YEL CHR MIXER 40/60MM ACTUATOR ASSY CLAMP HI TORQUE 2.75 - 3.625 REDUCER 3.0" TO 2.75" TURBO CLAMP HI TORQUE 2.25 - 3.125 SCREW SHC M6-1.0 X 60 C12.9 ACTUATOR BOSCH 60 GOVERNOR GASKET GOVERNOR ACTUATOR RESTRICTOR INTAKE 4.6L G3 LPV SCREW SHC M6-1.0 X 25 C12.9 ZP WASHER LOCK M6-1/4 SCREW HHC M6-1.0 X 20 C8.8 WASHER FLAT M6 NUT FLANGE M6-1.0 NYLOK PLUG PIPE 1.25 SQ HD ZINC GROUP E REVISION: K-2798-D DATE: 5/13/15 PAGE 2 OF 2

EXPLODED VIEW: EV KIT GLASS PACK SHIP LOOSE DRAWING #: 0F6332A ITEM PART# QTY. DESCRIPTION GROUP

1 2 3 4 0F4462 080762 0F4505A 0C2454 (2) 5 (2) 6 (1) 7 (3) 8 0F4367 0F4368 0G3263 077992 2 1 3 14 HEAT SHIELD EXHAUST STACK CAP HEAT SHIELD EXHAUST STACK DECAL WARNING HOT SURFACES BI NUT HEX LOCK M6-1.0 SS NY INS NOTE: SOME “QT SERIES” UNITS WILL REQUIRE (2) GLASS PACK KITS. 0FXXXX = TAN (1) DECALS APPLIED TO EXHAUST AT THE FACTORY. (2) PART NUMBER SHOWN IS FOR TAN. SEE GUIDE BELOW FOR AVAILABLE COLOR AND PART NUMBER FORMAT. 0FXXXX0AL08 = GRAY / ALUMINUM 0FXXXX0AL13 = BISQUE / ALUMINUM 0FXXXX0AL05 = WHITE / ALUMINUM 0FXXXX0AL14 = GRAY / ALUMINUM (3) ) ALUMINUM ENCLOSURE NOTE: ITEM NUMBER 5 TO BE SECURED USING ITEM NUMBERS 4 (THREAD FORMING FASTENER) & 8 (LOCK NUT). THE LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS. 1 1 1 14 RAIN CAP 2-1/2" AL BOLT U 3/8-16 X 2.62 MUFF SEC 23.5" X 2.55IN/2.5OUT SCREW THF M6-1X16 N WA Z/JS GLASS PACK KIT ASSEMBLY INSTRUCTIONS: 1)Disconnect battery cables to prevent accidental start-up. Disconnect the negative battery cable first from the battery post indicated by (-) or NEG. 2)Slide the U-bolt (080762, I/N 2 ) and muffler (0F4505, I/N 3) over the exhaust pipe protruding from the enclosure. The exhaust pipe should be inserted 2 to 3 inches into the inlet of the muffler (0F4505, I/N 3). Position the U-bolt over the inlet of the muffler and tighten. 3)Sub-assemble the heat shield panels (0F4367, I/N 5) and the heat shield cap (0F4368, I/N 6) using the screws provided (0C2454, I/N 4). Lock nuts (077992, I/N 8) should be installed after the fastener has penetrated through the extrusions in the heat shield panels. 4)Slide the heat shield subassembly over the muffler. 5)Fasten the heat shield assembly to the enclosure using the screws provided (0C2454, I/N 4). Lock nuts (077992, I/N 8) should be installed after the fastener has penetrated through the extrusions in the enclosure. An access panel may need to be removed to complete this step. 6)Install the rain cap over the outlet of the muffler and tighten (0F4462, I/N 1). REVISION: K-3230-E DATE: 7/1/15 Page 2 of 2

22 23 24 25 26 27 28 29 30 A B C D E 60 61 62 63 64 50 51 52 53 54 55 56 57 58 59 65 66 67 68 69 70 71 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 0F5884 055014 022264 0G 3546 0C2265 0G 3648 0F6305 0F6305A 0G 4329 0F1263 0F1262 0F1264 0E9049B 055911 056739 - - 0F2627A 022287 022473 022097 043182 051714 052777 0C2323 0F5459 0F5461 022127 0F5460 0E7403C 0E7403B 0F6145 091526 0C2699 051713 049226 0F1823CST 03 0F1824AST 03 0F2606 036261 0F5763 0F1732 0E9764 0F1725C 0F1958 0F2256 0E3161 029673 049226 079224 051713 0F5886 051716 043180 0C3990 0F4333 0F5883 3 3 1 1 1 1 7 4 7 2 5 COMPONENTS INCL UDED IN 0G4139E 1 ENCL H/G CO NTROL PANEL 1 1 CO VER CONTRO L PANEL HING E CONT INUOUS H PANEL 6 1 1 1 1 1 1 RIVET POP .125 X .275 SS ASSY PROGRAMMED H- 100 DECAL FUSES LO CAT ED INSIDE RAIL SNAPTRACK PCB HO LDER BULK ( 12” LG) ASSY PCB 2AMP 12V UL BATT CHG R PLATE HARNESS CLAMP ASSY PCB PW R AVR W /AMP HEADER ASSY PCB BOSCH G OV DRIVER DIO BR IDG E 25A 600V W ASHER LO CK M5 SCREW PPHM M5- 0.8 X 30 SS W ASHER FLAT M5 SCREW HHPM M5-0.8 X 12 NUT HEX M5-0.8 G8 YEL CHR W ASHER FLAT M4 SCREW PHTT M4- 0.7 X 10 Z YC CO NN DUST CAP W/CHAIN DB9 W ASHER FLAT M3.5 1 10 10 1 4 1 SCREW PHTT M3.5- 0.6 X 10 SCREW PPHM M4- 0.7 X 8 BLX O X W ASHER LO CK #8-M4 DECAL W RN B AT T CHRG 12/24V BI SCREW PHTT M4- 0.7 X 12 Z YC M5-0.8 CAPT IVE PANEL KNLD HD 2 1 1 SEAL COVER 3.18 X 12.7 X 382 SEAL COVER 3.18 X 12.7 X 283 HARNESS H-PNL INTEGRATED SW (NO T SHO WN) COMPONENTS INCL UDED IN WIRE HARNESS 1 ADPTR RH SIDE W ICKMANN 178.6191 4 1 1 HO LDER F USE WICKMANN 178.6150 ADPTR LH SIDE W ICKMANN 178.6192 ASSY PCB G-PANEL RELAY 12VDC 1 BL OCK TERM 20A 12 X 6 X 1100V COMPONENTS NO T INCLUDED IN 0G 4139E O R WIRE HARNESS 2 1 1 2 1 1 1 1 1 2 4 2 3 3 3 RELAY CONTACTO R 12VDC DPE B REAKER SEE DRAW ING 0F9280 BO OST RESIST OR SEE DRAWING 0F 9280 CO VER CONTRO L PANEL SIDE SCREW HHC 1/4- 20 X 3/4 G 5 W ASHER FLAT M6-1/4 W ASHER LO CK M6-1/4 W ASHER LO CK M3 NUT HEX M3-0.5 G8 YEL CHR W ASHER FLAT M3 SCREW PHTT #6-32 X 5/8 Z YC DECAL CPL CONTRO L PANEL FUSES DECAL CPL 5.4/6.8L TB3 NUT HEX 1/4-20 STEEL DECAL CPL 5.4/6.8L RELAY BO ARD 1 2 A/R 4 2 4 4 F USE ATO TYPE 15 AMP (BL UE) F USE ATO TYPE 10 AMP (RED) SEAL WEATHER .45"DIA SCREW PPHM M5- 0.8 X 12 Z NC SCREW PHTT #6-32 X 3/8 Z YC W ASHER FLAT M5 W ASHER LO CK M5

EXPLODED VIEW: ENGCOMPRT LH 4.6L G3 DRAWING #: 0H3914 APPLICABLE TO:

ITEM PART# QTY.

1 (1)2 3 4 (1)5 6 (1)7 (1)8 (1)9 (1)10 (1)11 (1)12 13 (1) 14 15 (1)16 (1)17 (1)18 19 (1)20 21 22 23 24 (1)25 (1)26 (3)(2)27 28 29 30 31 32 33 (1)34 35 36 37 38 39 40 41 42 43 44 45 46 REF 022145 REF REF 0G5515B 0E0502 0G5511 0H3920 0F6151 057823 0G5148 022129 042907 077996 REF 0G6274 0G6406 0H3922 REF 0G6393 0G5954 0F9505 057822 065386 0H4361 0F7316C 0F7316D 029333A 022473 042568 0F4612 036277 0D5419 0D3488R 0G1815B 0F2776A 0D8026 0D8030 043107 022129 022145 0F9016 022131 046526 045772 0H39440ST03 022097 47 48 49 50 51 (1)52 53 54 55 (3)56 57 0E9868A 0F9381 064416 0F3216D 0F3217 0E0992A 045771 055934C 0H4787 0H3874 0F2776 1 1 1 1 1 8 2 1 REF 1 1 (1) NOTE: PART OF ENGINE MAKE (SEE I/N 26) 0F7316C = ENGINE MAKE 0H3913 0F7316D = ENGINE MAKE 0H5742 (3) NOTE: NOT SHOWN (2) NOTE: I/N 27 IS FOR HOLDING SENSOR TO I/N 35. 1 4 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 2 1 1 1 2 1 1 1 1 1 2 2 1 1 REF 1 1 1 3 1 3 6 6 1 2 1 1 1 2

GROUP D DESCRIPTION

CONNECTION WATER OUTLET WASHER FLAT 5/16-M8 ZINC GASKET THERMOSTAT HOUSING G3 THERMOSTAT ASSY ADAPTER THERMOSTAT 4.6L G3 TEMPERATURE SENDER, DELPHI GASKET THERMOSTAT 4.2L SPACER COOLANT BYPASS CAP RUBBER CLAMP HOSE #10 .56-1.06 SCREW IHHC M8-1.25 X 140 G8.8 WASHER LOCK M8-5/16 SCREW HHC M8-1.25 X 16 C8.8 CAP ANTIFREEZE RUBBER O-RING 29mm I.D. X 36mm O.D. X 3.5mm PRESSURE RELIEF VALVE SPRING COMPRESSION .711 X 1.00 TUBE ASSY EGR OUTLET REWORK SCREW HHC M6-1.0 X 15 LONG BOLT STRIP 3/8-16 X 1-1/4 GROMMET 15.87 X 31.75 X 11 BARB CONNECTOR 5/8" HOSE POLYE CLAMP HOSE #8 .53-1.00 HOSE COOL 5/8 ID 100R6 (15”LG) REWORK VENT FITTING 4.6L G3 ENGINE 4.6L COMPLETE ENGINE G4.6L G3 COMPLETE TIE WRAP UL 7.4"X .19" BLK WASHER FLAT 1/4 ZINC SCREW HHC M6-1.0 X 20 G8.8 SENDER OIL PRESSURE 1/8"NPT ELBOW 90D STREET 1/8 OIL FILTER BELT SERPENTINE 54.72" REWORK HARMONIC BALANCER 4.6L BRACKET, SIGNAL CONDITIONER OLT HEX FL HD M8-1.25 X 31 TENSIONER, ENG. AUTOMATIC BELT SCREW HHC M8-1.25 X 25 G8.8 WASHER LOCK M8-5/16 WASHER FLAT 5/16-M8 ZINC BRACKET DC ALTERNATOR 4.6L WASHER FLAT 3/8-M10 ZINC WASHER LOCK M10 NUT HEX M10-1.5 G8 YEL CHR BRACKET INTAKE MANIFOLD LOWER WASHER LOCK M6-1/4 ALTERNATOR DC W/OUT PULLEY ALTERNATOR STRAP SCREW HHC M10-1.5 X 45 G8.8 FT PULLEY 160 OD DC ALTERNATOR SPACER DC ALTERNATOR PULLEY PLUG EXPANSION 14 OD NUT HEX M8-1.25 G8 CLEAR ZINC CLAMP STL/VNL .5 X .406 Z SPARK PLUG HARN ENG G4.6L G3 H-PANEL CPL BRACKET, SIGNAL CONDITIONER

REVISION: H-6318-C DATE: 3/26/10 PAGE 2 OF 2

EXPLODED VIEW:

ENG COM PRT RH 4.6L G3

DRAWING #:0H3914A APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 25 26 27 28 29 30 (1)31 (1)32 17 18 19 20 21 22 23 24 33 34 35 36 069860E G022158 0C7649 0D2244M G022129 G039253 0F5454 0F2929 G071623 G046526 055934M G052625 0F9965D 0F3844 0D5417 G049821 0D5418 G043107 G097474 REF 0F1820 G070006 0D9913 0J7168 G070008 G042909 0D2608 0F5114 0F6104 082121A 048031C 0E9974 G036943 G023897 0H4243 0H40910ST03 37 38 39 40 41 42 43 44 G022152 G042568 G022097 G022473 G022145 0H3874 G023762 0F7316C 2 4 4 4 1 REF 1 REF 0F7316D REF (1) NOTE: PART OF ENGINE MAKE (SEE I/N 44) 0F7316C = ENGINE MAKE 0H3913 0F7316D = ENGINE MAKE 0H5742 1 2 1 1 5 1 1 1 2 6 6 3 2 5 2 3 2 2 1 1 1 1 1 4 2 24 14 2 8 2 8 1 1 2 3 3 HOSE DRAIN ASSY 28" NUT HEX #10-32 STEEL CLAMP HOSE .38-.87 ASSY MAGPICKUP(3/8-24 MALE) WASHER LOCK M8-5/16 SCREW HHC M8-1.25 X 20 G8.8 PLATE MAG PICK-UP ADAPTOR ENGINE ADAPTER SCREW SHC M10-1.5 X 55 G12.9 WASHER LOCK M10 CLAMP STL/VNL .75 X .343 Z SCREW SHC M10-1.5 X 35 C12.9 FLEX PLATE 2 POLE 4.6L G3 WASHER FLAT .43 X 1.00 SCREW HHC M10-1.0 X 25 G10.9 SCREW SHC M8-1.25 X 30 C12.9 STARTER MOTOR V-10 G3 ENGINE SCREW HHC M8-1.25 X 25 C12.9 BANJO ASSY M14-1.5 GASKET, EXHAUST MANIFOLD MACHINED MANIFOLD,EXHAUST WASHER LOCK M8 SSTL SCREW SHC M8-1.25 X 35 SS HEAT SHLD EXH MANF SS WASHER FLAT M8 SS SCREW HHC M8-1.25 X 30 C8.8 SCREW HHC 5/16-18 X 1/2 SSTL DECAL REFER TO OWNERS MANUAL COVER STARTER 5.4 & 6.8 FORD CPL CLIP-J VINYL COAT .375 ID CLAMP HOSE BAND .50 CAP VINYL 3/8"ID X 1"DP BLK SCREW PPHM #10-32 X 2 WASHER FLAT #10 ZINC ASSY PCB 4.6L IGN MOD PRGRMMED BRACKET IGN CONTROL 4.6L G3 WASHER LOCK #10 SCREW HHC M6-1.0 X 20 C8.8 WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC WASHER FLAT 5/16-M8 ZINC HARN ENG G4.6L G3 H-PANEL CPL WASHER SHAKEPROOF EXT #10 STL ENGINE 4.6L G3 COMPLETE ENGINE G4.6L G3 COMPLETE

GROUP D

REVISION: CN-0013956-B DATE: 3/14/18 PAGE 2 OF 2

1 2 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 26 27 28 29 30

EXPLODED VIEW: EV MUFFLER 4.6/5.4/6.8L CPL C5 DRAWING #: 0F2969 ITEM PART# QTY. DESCRIPTION

0F2807C 0F2807E 0F9207 0F2807B 0F2807D 0F9208 0A6765 0F4710 0F7200 080762 0F2809 0F2981A 0F2962 0C2454 022097 0F2830 0F2773C 0F2773D 0D3159 088775 0F2808 0F5447 022473 0F6214 0L1789 049813 049721 088510 0C9748 1 1 1 1 1 1 2 6 6 8 1 2 2 4 12 2 2 2 1 6 2 1 20 2 8 8 12 6 1 PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5) PIPE EXH MAN R/H 5.4L G/B & 2P (5.4L C5) PIPE EXH MANIFOLD 4.6L RH PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5) PIPE EXH MAN L/H 5.4L G/B & 2P (5.4L C5) PIPE EXH MANIFOLD 4.6L LH RING GASKET 2.5 DIA 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 THF M6-1 X 16 N WA Z/JS WASHER LOCK M6-1/4 MUFFLER BRACKET STIFFENER EXHAUST BLANKET 900MM LONG (6.8L C5) EXHAUST BLANKET 850MM LONG (5.4L C5) FLANGE EXHAUST WASHER FLAT 3/8 SS EXHUAST OUTLET PIPE CPL BRKT MUFFLER WASHER FLAT 1/4-M6 ZINC PIPE ELBOW EXHAUST MUFFLER MUFFLER STRAP UPPER/LOWER NUT HEX M6 X 1.0 G8 YEL CHR SCREW HHC M6-1.0 X 35 G8.8 BLK NUT HEX M10-1.5 SS PLUG M18-1.50

GROUP D

REVISION: K-1591-J DATE: 1/29/15 Page 2 of 2

1 2 8 9 10 11 4 5 6 7 12 13 18 19 20 21 22 23 24 26 27 28 29 30 0F2807C 0F2807E 0F9207 0F2807B 0F2807D 0F9208 0A6765 0F4710 0F7200 080762 0F2809 0F2981A 0F2962 0C2454 022097 0F2830 0F2773C 0F2773D 0D3159 088775 0F2808 0F5447 022473 0F6214 0F6803 049813 049721 088510 0C9748 1 1 1 1 1 1 2 6 6 8 1 2 2 4 8 2 2 2 1 6 2 1 12 2 4 4 8 6 1 PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5) PIPE EXH MAN R/H 5.4L G/B & 2P (5.4L C5) PIPE EXH MANIFOLD 4.6L RH PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5) PIPE EXH MAN L/H 5.4L G/B & 2P (5.4L C5) PIPE EXH MANIFOLD 4.6L LH RING GASKET 2.5 DIA 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 THF M6-1 X 16 N WA Z/JS WASHER LOCK M6-1/4 MUFFLER BRACKET STIFFENER EXHAUST BLANKET 900MM LONG (6.8L C5) EXHAUST BLANKET 850MM LONG (5.4L C5) FLANGE EXHAUST WASHER FLAT 3/8 SS EXHUAST OUTLET PIPE CPL BRKT MUFFLER WASHER FLAT 1/4-M6 ZINC PIPE ELBOW EXHAUST MUFFLER MUFFLER STRAP UPPER/LOWER NUT HEX M6 X 1.0 G8 YEL CHR SCREW HHC M6-1.0 X 35 G8.8 BLK NUT HEX M10-1.5 SS PLUG M18-1.50

ITEM

1 2 3 4 (2) 5 6 7 8 9 10 11 (2) 12 13 14 15 (2) 16 17 18 19 (2) 20 21 22 23 (2) 24 25 26 27 28 29 (2) 30 39 40 41 42 31 32 33 34 35 36 37 38 43 44 45 46 47 (1) 48 49 50 51 52 53 54 55 56 57 58 59 60 (3) 61 62 63 64

EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.6L CP DRAWING #: 0H3915 APPLICABLE TO: PART#

0H20530ST03 0F2611 0F5254 046526 059981 0C2454 052250 076749 0F2573 0F2610 0H20620ST03 0H2051 0F2862 0F2560 022131 039287 0C8566 0F2561 0C8165 0D6795 0C7043 0G1039 (4) 0H5380 048031C 0C8146 082774 0H3909 (4) 0F2686 0H3908 (4) 0F5463 0F8695 0F4032 042911 0F2872 022304 022195 022196 049813 052677 090283 0F2776A 022145 022129 052644 035685 045764 065852 0C7649 043790 (4) 055596 069860E 069811 080713 022473 022097 042568 0F5050B (4) 0F5050 039253 051769 0C8145 0H1827 0H23980ST03 029032 049820 0H2844 0G53150AL0R 051756 099502

QTY.

1 1 1 1 1 1 REF 1 1 3 1 8 24 16 8 1 1 1 1 2 2 (REF) 1 4 2 1 1 1 9 4 2 2 1 1 1 1 1 1 1 1 1 4 1 8 1 8 1 2 1 12 2 1 1 1 1 1 1 1 4 2 1 2 1 1 1 1 8 1 1 1

DESCRIPTION

WELDMENT RADIATOR SUPPORT C5 RADIATOR 680 X 680 X 70 CPL V-BELT 31/64" X 62-3/8" WASHER LOCK M10 SCREW HHC M10-1.5 X 30 C10.9 SCREW THF M6-1 X 16 N WA Z/JS TAPE FOAM 1 X 1 (26.75” LG) TANK COOLANT RECOVERY PULLEY FAN V-GROOVE 9" FAN 26" LH ROTATION ARM BELT TENSIONER SHOULDER BOLT 1/2 X 2-1/4" SPRING TENSION CPL PULLEY V-BELT 4" FLANGED WASHER FLAT 3/8-M10 ZINC SCREW HHC M8-1.25 X 45 C8.8 SCREW HHFC M6-1.0 X 20 G8.8 HUB FLEX PLATE NUT HEX LOCK 5/16-24 NY INS SCREW HHC M12-1.5 X 60 G8.8 DISK FLEX COUPLING FLEX HUB MACHINED COUPLING FLEX HUB MACHINED CLAMP HOSE BAND 1/4 SCREW HHC 5/16-24 X 1.124 KEY WOODRUFF 4 X 19D HOSE RADIATOR UPPER C5 CPL HOSE, RADIATOR UPPER, CPL HOSE RADIATOR LOWER C5 CPL HOSE LOWER RAD CPL C5 6.8L ASSY BRG/SHAFT CPL FANDRIVE PULLEY 5.5" DIA MACHINED SCREW HHC M10-1.5 X 30 G8.8 SCREW HHC 1/2-13 X 2" G8 WASHER FLAT 1/2 ZINC WASHER LOCK 1/2 NUT HEX 1/2-13 STEEL NUT HEX M6 X 1.0 G8 YEL CHR WASHER NYLON .50 X .87 X .06 CAP RADIATOR 13 PSI BRACKET, SIGNAL CONDITIONER WASHER FLAT 5/16-M8 ZINC WASHER LOCK M8-5/16 SPACER .5 X 1.5 X .25 STL/ZINC CLAMP HOSE #28 1.32-2.25 SCREW HHTT M4-0.7 X 8 BP SPRING CLIP HOLDER .37-.62 CLAMP HOSE .38-.87 BARBED EL 90 3/8 NPT X 3/8 BARBED STR 3/8NPT X 3/8 HOSE DRAIN ASSY 28" CAP HEX 1/4 NPT BRASS BRACKET COOLANT TANK WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 SCREW HHC M6-1.0 X 20 G8.8 SHIELD RADIATOR SHIELD RADIATOR SCREW HHC M8-1.25 X 20 G8.8 WASHER LOCK M12 WASHER FLEX (THIN) PROBE COOLANT LEVEL 3/8-18NPTF BRACKET TENSIONER SPRING HOSE 9/32 ID (43”LG) NUT HEX LOCK M8-1.25 NY INS BEARING SLEEVE 1/2/ X 3/4 X 1 SPACER CPL COOLING FAN 1/8" SCREW HHC M10-1.5 X 20 C8.8 CLAMP HOSE #24 B1.06-2.00

REVISION: H-5378-B DATE: 12/16/09 GROUP D

Page 2 of 6

EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.6L CP DRAWING #: 0H3915 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION (5) 65 (5) 66 (5) 67 0D6029 055934H 072252 1 1 1 (1) ITEM 48 IS INCLUDED WITH 47. (2) APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THREADS. (3) ITEM 61 IS INCLUDED WITH ITEM 1. (4) THESE PARTS ARE 5.4L 80KW SPECIFIC. (5) CATALYST EQUIPPED UNITS ONLY. SCREW HHTT M6-1.0 X 16 ZYC CLAMP STL/VNL .62 X .406 Z GROMMET 1.37 X .06 X 1.00

REVISION: H-5378-B DATE: 12/16/09 GROUP D

Page 3 of 6

EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.6L CP DRAWING #: 0H3915 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 1 2 3 0G15310GS0R 0G15320GS0R 0G15300GS0R 4 5 6 0G15290GS0R (2) 0H30010GS0R 0G15330GS0R 0C2454 (1) 7 (1) 8 0D3215B 0C2454 (1) NOT REQUIRED FOR UNITS WITH CATALYST. (2) CATALYST EQUIPPED UNITS ONLY 2 2 1 1 1 1 20 2 8 PANEL C5 FRONT SIDES PANEL C5 REAR SIDES PANEL LOWER FRONT PANEL C5 TOP PANEL C5 TOP PANEL C5 TOP MOUNT SCREW THF M6-1 X 16 N WA Z/JS ACCESS COVER 160 X 170 GALV SCREW THF M6-1 X 16 N WA Z/JS

REVISION: H-5378-B DATE: 12/16/09 GROUP D

Page 5 of 6

EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.6L CP DRAWING #: 0H3915 APPLICABLE TO:

GROUP D

THIS PAGE LEFT INTENTIONALLY BLANK

Page 6 of 6

REVISION: H-5378-B DATE: 12/16/09

EXPLODED VIEW: CPL H CONTROL CB CONNECTION DRAWING #: 0H3917 APPLICABLE TO:

ITEM

1 2 3 4 5 6 7 8 9 10 (1) 11 12 13 14 D E F G H J K L D E F G H J K L 2.) A C 1.) A C 29 30 31 32 33 34 35 15 16 (1) 17 18 19 20 21 22 23 (2) 24 25 26 (2) 27 28

PART# QTY. DESCRIPTION

081008 0F6156 029289 0F3685 0F2885 051713 049226 0C2266 0C2428 022155 0D4698 0F4464 0F4677 067617030A 067617030B 043180 022264 0C3990 057701 024469 025433 067210A 0F3618 0A9457 057073 0D5466 022237 022241 0A7822 0F9637 0C2454 047411 022097 022473 023484N 077043J 0D6029 0F2887 0D5572 0D5573 0D5575 0D5576 1 1 1 1 1 2 6 6 2 2 1 1 1 - - 4 4 4 REF. 1 1 1 1 1 2 REF. 4 4 REF. 1 8 4 4 4 2 4 4 UL CIRCUIT BREAKER (FD) 1 REF REF REF REF 0F0199 065960 022473 022097 022127 0C2454 029289 0F1733 1 4 4 4 4 4 1 1 UL CIRCUIT BREAKER (JD+LD) GROMMET 1.25 X .25 X .75 PLATE WIRE SNGL GALV TAPE ELEC 1/2 FOAM (AS REQ’D) STAND LH CONTROL C5 GRBX PANEL CB CONN BOX WASHER FLAT M5 WASHER LOCK M5 SCREW PHTT M5-0.8 X 16 ZYC SCREW PHTT #6-32 X 1/2 ZYC WASHER LOCK #6 BLOCK TERM 20A 6 X 3 X 1100V DECAL CUST CONN 120V UTILITY ASSY PCB INTERFACE 1PH 240V INTERFACE 3PHS 416/480V INTERFACE 3PH 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 SCREW HHTT #10-32 X 3/8 CZ LUG SLDLSS #6-14 X 13/64 CU DECAL GROUND LUG DECAL CPL CUST CONN H CTRL DECAL NEUTRAL JUNCTION BLOCK 3/8-16 BUS BAR NEUTRAL BLOCK 390 WASHER LOCK 3/8 NUT HEX 3/8-16 STEEL LUG SLDLSS 600/250-1/0 X 1/4-28 STAND RH CONTROL, TWO HOLE SCREW THF M6-1 X 16 N WA Z/JS SCREW HHC M6-1.0 X 16 G8.8 WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC BUSHING SNAP SB-2.5-31 CONDUIT FLEX 2.0" ID HHTT M6-1.0 X 16 ZYC COVER FD FRM CB CB 0150A 3P 600V S FD6 LL CB 0175A 3P 600V S FD6 LL CB 0225A 3P 600V S FD6 LL CB 0250A 3P 600V S FD6 LL INSULATOR CB FD FRAME 30MIL SCREW SHC 1/4-20 X 4 G8.8 NZ WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 NUT HEX 1/4-20 STEEL SCREW THF M6-1 X 16 N WA Z/JS TAPE ELEC 1/2 FOAM (AS REQ’D) DECAL CUSTOMER CONNECT INSIDE 0F2721 0D5577 0D5578 0D5579 0D5581 0D5585 0F2353 022770 022473 022097 022127 0C2454 029289 0F1733 1 REF REF REF REF REF 2 4 4 4 4 7 1 1 COVER CIR BRKR JD/LD CB 0300A 3P 600V S JD6 LL CB 0350A 3P 600V S JD6 LL CB 0400A 3P 600V S JD6 LL CB 0600A 3P 600V S LD6 CB 0450A 3P 600V S LD6 LL INSULATOR CIRCUIT BR. JD/LD SCREW RHM 1/4-20 X 3 WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 NUT HEX 1/4-20 STEEL SCREW THF M6-1 X 16 N WA Z/JS TAPE ELEC 1/2 FOAM (AS REQ’D) DECAL CUSTOMER CONNECT INSIDE (1) (2) ITEM INCLUDED WITH HARNESS. ITEM INCLUDED WITH 0D5464B. GROUP A REVISION: H-5277-B DATE: 11/18/09 Page 3 of 6

EXPLODED VIEW: CPL H CONTROL CB CONNECTION DRAWING #: 0H3917 APPLICABLE TO:

DESCRIPTION ITEM PART# QTY.

(1) W X Y 4.) A M N P R S T U V 3.) A C D E F G H J K L (2) L (2) M N P R C D E F G H J K (1) S T U V (2) W (2) X Y 5.) A C E F G R S 6.) A C H J K L M N P Q E H J K L M N P Q UL CIRCUIT BREAKER (225AF) 0F4173 0F4165$ 0F4186 036261 053640 038150 022264 022471 029289 0F1733 022129 0F8432 0C2454 0F8451 049897 022145 045771 0F8843 W/CB 0G3259 058306 UL CIRCUIT BREAKER 400AF) 0F4175 0F4166$ 0F1733 042419 023897 022152 022158 0C2454 029289 052647 046526 W/CB 0A7822 022131 W/CB 023334 022097 022473 2 6 6 6 W/CB W/CB 2/3 2/3 0G3259 UL CIRCUIT BREAKER (3P FG FRAME) 1 0F4173 0H5492 0H5721 038150 022264 1 REF 4 4 4 1 REF 1 4 4 4 4 7 1 2/3 2/3 3 3 3 1 REF 1 4 4 4 4 4 2 1 9 1 7 3 6 6 3 3 2 1 3 022471 0C2454 029289 023897 049226 051716 052619 0H4698A 0H5560 036261 1 4 UL CIRCUIT BREAKER (KG FRAME) 0H5871 0H5582 1 REF 4 7 1 6 3 3 3 1 0H5584 0D2157 0D3700 0C2454 029289 022145 022129 045771 049897 0H5581A REF 4 4 7 1 6 3 3 3 1 COVER CB C5 225AF CIRCUIT BREAKERS 200A FRAME COVER CB DISH 225AF RIVET POP .125 X .275 SS SCREW RHM #8-32 X 3-1/4 WASHER FLAT #8 ZINC WASHER LOCK #8-M4 NUT HEX #8-32 STEEL TAPE ELEC ½ FOAM DECAL CUSTOMER CONNECT INSIDE WASHER LOCK M8-5/16 INSULATOR CB 225AF SCREW THF M6-1 X 16 N WA Z/JS LUG SLDLSS 300 MCM-6 AL/CU SCREW SHC M8-1.25 X 20 G8 WASHER FLAT 5/16-M8 ZINC NUT HEX M8-1.25 G8 CLEAR ZINC BUS BAR 200A LUG ADAPTOR TERMINAL COVER CB DECAL TERMINAL SHOCK HZD BI SCREW SHC M8-1.25 X 25 G12.9 COVER CB C5 400AF CIRCUIT BREAKERS 400A FRAME DECAL CUSTOMER CONNECT INSIDE SCREW RHM 10-32 X 4 WASHER FLAT #10 ZINC WASHER LOCK #10 NUT HEX #10-32 STEEL SCREW THF M6-1 X 16 N WA Z/JS TAPE ELEC 1/2 FOAM SCREW SHC M10-1.5 X 25 G12.9 WASHER LOCK M10 BUS BAR CB ADAPTER 225-400 A LUG SLDLSS 600/250-1/0 X 1/4-28 WASHER FLAT 3/8-M10 ZINC TERM COVER CB SCREW HHC 1/4-28 X 1/2 G5 WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC SCREW SHC M10-1.5 X 25 G12.9 WASHER LOCK M10 DECAL TERMINAL SHOCK HZD BI COVER CB G 225AF C5 CB 0150 3P 480V E FG LL SCREW PPHM #8-32 X 1-3/4 ZINC WASHER FLAT #8 ZINC WASHER LOCK #8-M4 NUT HEX #8-32 STEEL SCREW THF M6-1 X 16 N WA Z/JS TAPE ELEC 1/2 FOAM WASHER FLAT #10 ZINC WASHER LOCK M5 NUT HEX M5-0.8 G8 CLEAR ZINC SCREW HHC M5-0.8 X 20 G8.8 INSULATOR CB 3P E TYPE CC/FG COVER CB DISH 3P E FD RIVET POP .125 X .275 SS COVER CB E KG FRAME C5 CB 0300 3P 600V E KG LL CB 0400 3P 600V E KG LL SCREW SHC M6-1.0 X 50 C8.8 NUT FLANGE M6-1.0 NYLOK SCREW THF M6-1 X 16 N WA Z/JS TAPE ELEC 1/2 FOAM WASHER FLAT 5/16-M8 ZINC WASHER LOCK M8-5/16 NUT HEX M8-1.25 G8 CLEAR ZINC SCREW SHC M8-1.25 X 20 G8 INSULATOR CB E 3P KG GROUP A REVISION: H-5277-B DATE: 11/18/09 Page 4 of 6

EXPLODED VIEW: CPL H CONTROL CB CONNECTION DRAWING #: 0H3917 APPLICABLE TO:

ITEM

7.) A B C D E F G H

PART# QTY. DESCRIPTION

NEUTRAL BLOCK 390 / 200-400A. 0D5466 2 BUS BAR NEUTRAL BLOCK 390 039287 022145 022129 045771 1 1 1 1 SCREW HHC M8-1.25 X 45 G8.8 FT WASHER FLAT 5/16-M8 ZINC WASHER LOCK M8-5/16 NUT HEX M8-1.25 G8 YEL CHR 045335 022097 2 2 SCREW HHC 1/4-28 X 3/4 G5 WASHER LOCK M6-1/4 0A7822 1 LUG SLDLSS 600/250-1/0X1/4-28 (1) HARDWARE FOR MTG. CB TERMINAL COVERS IS SUPPLIED WITH CIRCUIT BREAKERS. (2) 2/3 QTY. 2POLE & 3 POLE CB. GROUP A REVISION: H-5277-B DATE: 11/18/09 Page 5 of 6

EXPLODED VIEW: CPL H CONTROL CB CONNECTION DRAWING #: 0H3917 APPLICABLE TO:

GROUP A

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REVISION: H-5277-B DATE: 11/18/09 Page 6 of 6

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