Generac 100kW QT10068JVAC Standby Generator Manual

Generac 100kW QT10068JVAC Standby Generator Manual

Owner's Manual Stationary Emergency Generator

Not intended for use in critical life support applications.

Only qualified electricians or contractors should attempt installation! Deadly exhaust fumes. Outdoor installation only!

6.8L

100/130/150kW Models EPA Certified with Catalyst

This manual should remain with the unit.

. 0J0216 t No Par v. C 07/12 Cover198 Re

Table of Contents

SECTION PAGE

INTRODUCTION ....................................................................1-1 SAFETY RULES ....................................................................1-2 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

Engine Protective Devices .....................................................4-1

FUEL SYSTEMS ...................................................................5-1 SPECIFICATIONS ..................................................................6-1 GENERAL INFORMATION .....................................................7-1

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

CONTROL PANEL .................................................................8-1

Control Panel Interface ..........................................................8-1 Activate the Generator ...........................................................8-1 Display Interface Menus ........................................................8-1 Setting the Exercise Timer .....................................................8-3 User Adjustable Settings .......................................................8-3 Fuel Conversion ....................................................................8-3 Operation ..............................................................................8-3 Auto Start .............................................................................8-4 Manual Start .........................................................................8-4 Alarm and Warning Messages ...............................................8-4 Common Alarm Relay ...........................................................8-6 Maintenance Alerts ...............................................................8-6 Menu System ........................................................................8-7

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

Stationary Emergency Generator Control and Operation .........9-1 Operating Unit with Manual Transfer Switch ...........................9-1 Operating Unit with Automatic Transfer Switch ......................9-1

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

Maintenance Performed by Authorized Service Dealers .......10-1 Cooling System...................................................................10-1 Checking Fluid Levels ..........................................................10-1 Maintenance Owner/Operator Can Perform ..........................10-2 Miscellaneous Maintenance ................................................10-3

SERVICE SCHEDULE ..........................................................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.

 

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.

n

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.

n

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 set. It is powered by a gaseous fueled engine operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for 2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear units. See the Specifications section for exact numbers. The unit comes complete with a sound attenuated enclosure, inter nally mounted muffler, control console, mainline circuit breaker, battery charger, and protective alarms as explained in the following paragraph.

All AC connections, including the power leads from the 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 generator features: • Rotor and Stator insulation is Class H rated as defined by NEMA MG1-32.6, MG1-1.66. The generator is self ventilated and drip proof constructed.

• The voltage waveform deviation, total harmonic content of the AC waveform and telephone influence factor have been 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 (synthetic oil is recommended).

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: For temperatures below 32° F, it is strongly recommended to use the optional Cold Weather Start Kit. The oil grade for tem peratures below 32° F is 5W-30 synthetic oil.

COOLANT RECOMMENDATIONS

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

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

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

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

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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.

HIGH COOLANT TEMPERATURE SENDER

An analog coolant temperture sender, located in the engine's cooling system will cause an engine shutdown if the temperature should exceed approximately 125° C (257° F). The generator will automatically restart once the temperature has returned to a safe operating level.

LOW COOLANT LEVEL SENSOR

To prevent overheating, the engine has a low coolant level sensor. If the level of engine coolant drops below the level of the low cool ant level sensor, the engine automatically shuts down.

LOW OIL PRESSURE SWITCH

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

OVERCRANK SHUTDOWN

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

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

• • • • •

Approximate Crank Cycle Times

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

OVERSPEED SHUTDOWN

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

RPM SENSOR LOSS SHUTDOWN

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

DC FUSES

A fuse (7.5 amp) is located on the control panel. It protects the panel 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.

A fuse (25 amp) is located in the engine wire harness adjacent to the DC alternator. It is used to prevent circuit failure due to DC alternator falure. It will also protect the system in the event of a wiring short-dircuit. If this fuse is blown, the generator will not operate. Replace these fuses with the same size, type, and rating.

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EngProt003 R

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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 (LPV) 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.

NOTE: The fuel consumption requirements are identified in the Specifications section of the Owner's Manual. Refer to the Installation Manual if assistance is required for the sizing of the pipe diameter for the generator. Any piping used to connect the generator to the fuel supply should be of adequate size to achieve the 100% load fuel consumption requirements identi fied in the Specifications section regardless of actual load.

NOTE: The recommended fuel pressure is identified in the Specifications section this 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 must never 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: • When ambient temperatures are low and engine fuel consump tion is high, the vapor withdrawal system may not function efficiently.

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

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

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ev. F 04/11 FuelSys001 R

Specifications SPECIFICATIONS

GENERATOR

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

Total Harmonic Distortion ..............................................< 3.5% Telephone Interference Factor (TIF) .................................. < 50 Alternator Output Leads 1-phase ..................................... 4-wire Alternator Output Leads 3-phase (150 kW) ..................... 6-wire Alternator Output Leads 3-phase (100/130 kW) ............ 12-wire Bearings ..................................................................Sealed Ball Coupling 100/130 kW ...........................................................Gear Drive 150 kW ...............................................................Flexible Disk Excitation System ......................................................Brushless

Generator Locked Rotor kVA Available @ Voltage Dip of 35% 100 kW 130 kW 150 kW 240 V, 1-phase 240 V, 3-phase 208 V, 3-phase 480 V, 3-phase 200 240 270 320 320 350 Refer to the Data Label on the generator for rated watts, amperes, frequency, volt age, phase and other pertinent information.

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.

ENGINE

Make ........................................................................... Generac Model ............................................................................. V-type Cylinders and Arrangement ...................................................10

Displacement ............................................................... 6.8 Liter Bore............................................................ 90.2 mm (3.55 in.) Stroke ....................................................... 105.9 mm (4.17 in.) Compression Ratio.......................................................... 9-to-1 Air Intake System ......................................... Naturally Aspirated Valve Seats ................................................................ Hardened Lifter Type .................................................................. Hydraulic

Engine Parameters

Rated Synchronous rpm..........................60 Hz, See Data Label

Exhaust System

Exhaust Flow at Rated Output 60Hz .........................See Chart 1 Exhaust Temperature at Rated Output ......................See Chart 1

Combustion Air Requirements (Natural Gas)

Flow at rated power, 60 Hz ......................................See Chart 1

Chart 1

kW 100 130 150 Exhaust Flow cfm 888 1119 1535 Exhaust Temp °F 960 970 1100 Combustion Air Flow cfm 262 336 410

LP Circuit Breaker Size (Amps)

Voltage 120/240 V - 1 ø 120/208 V - 3 ø 120/240 V - 3 ø 277/480 V - 3 ø Amps 417 347 301 150

NG Circuit Breaker Size (Amps)

Voltage 120/240 V - 1 120/208 V - 3 120/240 V - 3 277/480 V - 3 ø ø ø ø Amps 371 326 283 141 100 kW CB 500 400 350 175 100 kW CB 500 400 350 175 kW 100 100 100 100 kW 89 94 94 94 Amps 542 451 391 195 130 kW CB 600 500 450 225 kW 130 130 130 130 Amps 488 423 367 183 130 kW CB 600 500 450 225 kW 117 122 122 122 Amps 625 520 451 225 150 kW CB 700 600 500 250 Amps 567 493 427 214 150 kW CB 700 600 500 250 kW 136 142 142 142 kW 144 150 150 150

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Specifications

Governor

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

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

Steady State Regulation ............................................ ± 0.25 %

Engine Lubrication System

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

Oil Filter .......................................................Full Flow, Cartridge Crankcase Oil Capacity ............................................ 5 U.S. qts.

COOLING SYSTEM

Type............................................................................... Closed Water Pump ............................................................. Belt Driven Fan Speed ...............................................................See Chart 2 Fan Diameter ..............................................................26 inches Fan Mode ......................................................................... Puller Air Flow (inlet air including alternator and combustion air) ....................................................See Chart 2 Coolant Capacity ................................................. (4.5 U.S. gal.) Heat Rejection to Coolant ........................................See Chart 2 Maximum Operating Air Temp. on Radiator ......... 60 °C (150 °F) Maximum Ambient Temperature ......................... 50 °C (140 °F) kW 100 130 150 Cooling Airflow ft 3 /min 5500 6450 7800

Chart 2

Fan Speed rpm 1670 1950 2200 Heat Rejection BTU/hr 342,000 496,000 568,000

FUEL SYSTEM

Type of Fuel ..............................Liquid Propane or Natural Gas* Carburetor............................................................... Down Draft Secondary Fuel Regulator............................................ Standard Fuel Shut-off Solenoid ................................................. Standard Operating Fuel Pressure .................. 11 in. - 14 in. Water Column are factory set for the specific fuel.

Fuel Consumption - ft 3

Recommended * Engine is not field convertible between natural gas and propane. Jet size and ignition timing

/hr (Natural Gas/LPV) @ 11 in H20/68 °F

kW 100 130 150 Exercise Cycle 130/52 135/54.5

155/63 25% Load 371/149 482/193 556/224 50% Load 713/287 927/373 1070/431 75% Load 991/400 1292/520 1491/600 100% Load 1260/507 1786/719 2061/830

ELECTRICAL SYSTEM

Battery Charge Alternator .....................................12 V, 30 Amp Smart Charger .......................................................12 V, 2 Amp Recommended Battery 100/130 kW ......................................... 27F, 700 CCA @ 0 °F 150 kW ................................................ 24F, 525 CCA @ 0 °F System Voltage ............................................................ 12 Volts

NOTE: Battery dimensions (L x W x H) for the Group 27 battery should not exceed 12 1/2" x 6 13/16" x 8 15/16" (318 mm x 173 mm x 227 mm). Dimensions for the Group 24 battery should not exceed 10 3/4" x 6 13/16" x 9" (273 mm x 173 mm x 229 mm).

Voltage Regulator

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

Regulation ........................................................................± 1%

Power Adjustment for Ambient Conditions

Temperature Deration 3% for every 10 °C above °C ..............................................25

1.65% for every 10 °F above °F ..........................................77

Altitude Deration 1% for every 100 m above m............................................183

3% for every 1000 ft. above ft. .........................................600

Controller ................................................................... Nexus

WEATHER AND MAINTENANCE KITS

To keep the generator running at its peak, the following kits are offered: • Cold Weather Kit • 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.

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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

. C 06/15

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

Control Panel

CONTROL PANEL INTERFACE

USING THE AUTO/OFF/MANUAL SWITCH

 With the switch set to AUTO, the engine may crank and start at any time without warning. Such automatic starting occurs when utility power source voltage drops below a preset level or during the normal exercise cycle. To prevent possible injury that might be caused by such sudden starts, always set the switch to OFF and remove the fuse before work ing on or around the generator or transfer switch. Then, place a “DO NOT OPERATE” tag on the generator panel and on the trans fer switch.

1. “AUTO” Position – Selecting this switch activates fully auto matic system operation. It also allows the unit to automati cally start and exercise the engine every seven days with the setting of the exercise timer (see the Setting the Exercise Timer section).

2. “OFF” Position – This switch position shuts down the engine. This position also prevents automatic operation.

3. “MANUAL” Position – Set the switch to MANUAL to crank and start the engine. Transfer to standby power will not occur unless there is a utility failure.

ACTIVATE THE GENERATOR

When battery power is applied to the generator during the instal lation process, the controller will turn ON and the LCD screen will illuminate. However, the generator still needs to be activated before it will automatically run in the event of a power outage.

Activating the generator is a simple one time process that is guided by the controller screen prompts. Once the product is activated, the controller screen will not prompt you again, even if you discon nect the generator battery.

To obtain the activation code, record the generator serial number and log onto www.activategen.com or call 1-888-9ACTIVATE and follow the steps to retrieve the activation code.

After obtaining your activation code, please complete the following steps at the generator’s control panel in the Activation Chart on the following page.

NOTE: The generator will only run in manual until the passcode has been entered.

Upon power up, this controller will go through a system self test which will check for the presence of utility voltage on the DC circuits. This is done to prevent damage if the installer mistakenly connects AC utility power sense wires into the DC terminal block. If utility voltage is detected, the controller will display a warning message and lock out the generator, preventing damage to the controller. Power to the controller must be removed to clear this warning.

Utility voltage must be turned on and present at the N1 and N2 terminals inside the generator control panel for this test to be performed and pass.

NOTE: DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT WIRES IS NOT WARRANTABLE!

This test will be performed each time the controller is powered up.

Next, the user must enter the minimum settings to operate. These settings are current date and time and exercise day and time. The maintenance intervals will be initialized (i.e. started) the first time the clock is set. If the clock is never set at power up, the mainte nance intervals will be reset every time power is applied.

If a subsequent power loss (loss of battery power) occurs the Installation assistant will operate upon power restoration. The self test routine will be run and then the customer will be required to re-enter the time and date, as this is not retained during a power loss. The unit will not require re-activation.

DISPLAY INTERFACE MENUS

The LCD display is organized as detailed below: • The “Home” page, this page is the default page which will be displayed if no keys are pressed for 30 seconds. This page normally shows the current Status message and the current date and time. The highest priority active Alarm and/or Warning will be automatically posted on this page as well as flashing the backlight when such an event is detected. In the case of multiple Alarms or Warnings, only the first message will be displayed. To clear an Alarm or Warning, see the Protection Systems section - Clear Alarm.

• The display backlight is normally off. If the user presses any key, the backlight will come on automatically and remain on for 30 seconds after the last key was pressed.

• The “Main Menu” page will allow the user to navigate to all other pages or sub-menus by using the Left/Right and Enter keys. This page can be accessed at any time with several presses of the dedicated Escape key. Each press of the Escape key takes you back to the previous menu until the main menu is reached. This page displays the following options: HISTORY; STATUS; EDIT; AND DEBUG. (See the Appendix - "Menu System".) . E 12/11 CntrlNexusus001 Rev

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Control Panel

ACTIVATION CHART

CHOOSE LANGUAGE

Display Reads:

Language - English Escape Enter

Use ARROW keys to scroll to desired lan guage. Press ENTER to select.

TROUBLESHOOTING

If the wrong language is chosen, it can be changed later using the “edit” menu.

Display Reads:

Activate me (ENT) or ESC to run in manual Escape Enter

Display Reads:

To Activate go to www.activategen.com

Escape Enter

Press ENTER to begin the activation pro cess.

If ESCAPE is pressed instead of ENTER, your generator will only run in manual mode (for test purposes) and NOT ACTIVATED will be displayed. You will need to remove the generator control panel fuse AND disconnect the T1, N1 and N2 connector in the external connection box (if equipped); or disconnect utility input (main breaker) to the transfer switch for 3-5 seconds and reconnect, then begin with Step 1.

If you do not have your activation code, go to www.activategen.com or call 1-888-9ACTIVATE (922-8482).

If you already have your activation code, wait 3-5 seconds for the next display.

ENTER ACTIVATION CODE (Passcode)

Display Reads:

Serial 123456789 Passcode XXXXX +/ Escape Enter

Display Reads:

“SELECT HOUR (0-23)” “ 6 +” Escape Enter

Use ARROW keys to scroll and find the first number of your Activation Code.

Press ENTER to select.

Repeat this step until all digits have been entered. Use ESCAPE to correct previous digits.

TROUBLESHOOTING

Activation is complete when all digits are entered above and your screen shows this display.

Follow the controller prompts to continue setting the time function. Refer to your Owner’s Manual with questions.

What happens if “Wrong Passcode Try Again” appears?

Re-enter the activation code. If a second attempt is unsuccessful, check the number against the code given on activategen.com. If it is correct and the generator will not accept it, contact 1-888-9ACTIVATE (922 8482).

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Control Panel

INSTALLATION ASSISTANT

Interconnect System Self Test Feature

(follow the on-screen prompts).

Upon power up, this controller will go through a system self test which will check for the presence of utility voltage on the DC circuits. This is done to prevent damage if the installer mistakenly connects AC utility power sense wires into the DC terminal block. If utility voltage is detected, the controller will display a warning message and lock out the generator, preventing damage to the controller. Power to the controller must be removed to clear this warning.

Utility voltage must be turned on and present at the N1 and N2 terminals inside the generator control panel for this test to be performed and pass.

NOTE: DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT WIRES IS NOT WARRANTABLE!

This test will be performed each time the controller is powered up.

Upon first power up of the generator, the display interface will begin an installation assistant. The assistant will prompt the user to set the minimum settings to operate. These settings are simply: Current Date/Time and Exercise Day/Time. The maintenance inter vals will be initialized when the exercise time is entered.

The exercise settings can be changed at any time via the "EDIT" menu (see Appendix, "Menu System").

If the 12 volt battery is disconnected or the fuse removed, the Installation Assistant will operate upon power restoration. The only difference is the display will only prompt the customer for the current Time and Date.

IF THE INSTALLER TESTS THE GENERATOR PRIOR TO INSTALLATION, PRESS THE “ENTER” KEY TO AVOID SETTING UP THE EXERCISE TIME. THIS WILL ENSURE THAT WHEN THE CUSTOMER POWERS UP THE UNIT, HE WILL STILL BE PROMPTED TO ENTER AN EXERCISE TIME.

• If utility is still lost after the “line interrupt period”, run the engine up to normal RPM and transfer the load. At this time the con troller will exit the exercise routine and assume full automatic operation.

USER ADJUSTABLE SETTINGS

Setting

Exercise time Exercise day Current Time Current Day Current Month Current Year Language Contrast

Factory Default

2 pm Wed 12 am Sun Jan 2008 English 80%

Minimum Setting

00:00 (12 am) Sun 00:00 (12 am) Sun Jan 2008 French 0%

Maximum Setting

23:59 (11:59 pm) Sat 23:59 (11:59 pm) Sat Dec 2100 Spanish 100%

Increment

1 min 1 day 1 min 1 day 1 month 1 year N/A 1%

FUEL CONVERSION

For fuel conversion steps, refer to the GenSpec section, RECONFIGURING THE FUEL SYSTEM.

OPERATION

This system is intended to supply standby power in the event of a utility failure. The control system will monitor the utility voltage to determine if stand-by power is required. Should the utility voltage fail, the generator will start and run normally, detaching from the utility and supplying the customer load from the generator. When utility power returns, the controller will re-transfer the customer load back to utility and shut down the generator.

SETTING THE EXERCISE TIMER

This generator is equipped with an exercise timer. Once it is set, the generator will start and exercise every seven days, on the day of the week and at the time of day specified. During this exercise period, the unit runs for approximately 12 minutes and then shuts down. Transfer of loads to the generator output does not occur during the exercise cycle unless utility power is lost.

LOW SPEED EXERCISE

The standard start sequence will be initiated.

• All 1800 rpm units will exercise at 1400 RPM • All 3600 rpm units will exercise at 1800 RPM If utility is lost during exercise the controller will do the following: • Wait for the “line interrupt period” for utility to return. If utility returns within the “line interrupt period”, continue to exercise at low RPM.

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AUTOMATIC TRANSFER OPERATION

To select automatic operation, do the following: 1. Make sure the transfer switch main contacts are set to their UTILITY position, i.e., loads connected to the utility power source.

2. Be sure that normal UTILITY power source voltage is avail able to transfer switch terminal lugs N1 and N2 (Refer to the Electrical Data section).

3. Set the generator’s AUTO/OFF/MANUAL switch to AUTO.

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

With the preceding steps complete, the generator will start auto matically when utility source voltage drops below a preset level. After the unit starts, loads are transferred to the standby power source. Refer to the Sequence of Automatic Operation section.

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Control Panel

SEQUENCE OF AUTOMATIC OPERATION

Initial Conditions: Generator in Auto ready to run, load being sup plied by the Utility Source through the transfer switch.

1. When the utility voltage fails (falls below 60% of nominal), a 10-30 second (programmable) “line interrupt” delay timer is started. The factory set time delay is 10 seconds. If at the end of the line interrupt time the utility voltage is above 60% the engine will not crank. If the utility voltage is still below the 60% of nominal at the end of the line interrupt time, the unit will crank and start. If the unit cranks for more than 10 seconds and the utility voltage rises above 80% of nominal (programmed pickup voltage) and the unit has not started, the crank cycle will abort.

2. As soon as the unit starts a 5 second “warm-up” timer is initi ated. When the warm-up timer expires the control will transfer the load to the generator (through the RTS switch) if the utility voltage is less than 80% of nominal. If the utility voltage is greater than the 80% of nominal at the end of the warm-up time the load will not be transferred to the generator and a one minute low-speed cool down period will start. At the end of the one minute cool down period the generator will stop. 3. Once the unit is running and the switch has transferred the load to the generator the unit will monitor utility voltage. When utility voltage returns (above the programmable pickup voltage, normally 80% of nominal), a 15 second “Return to Utility” timer will start. At the end of the return to utility time, if the utility voltage is still above the pickup voltage, the unit will transfer the load back to the utility source and run the unit through a one minute cool down period. When the cool down period is over the unit will shut down and be ready for the next outage. 4. If during the cool down period utility voltage should fall below 60% of nominal the 5 second warm-up timer is initiated and the unit will transfer the load back to the generator and con tinue to monitor the utility.

CRANK CYCLES AND OVERCRANK SHUTDOWN

If the unit fails to start during a cranking period it will display the Overcrank Shutdown Alarm. The system will control the cranking cycles as follows: The first crank cycle is a 16 second crank time followed by a 7 second rest. The next 5 cycles will be 7 seconds of cranking time each followed by a 7 second rest time.

If the unit fails to start by the end of the 6 crank/rest cycles the Overcrank Shutdown Alarm will display and the unit will not attempt to crank until the alarm is reset.

AUTO START

This unit is designed to automatically start in the event of a util ity failure or brown out condition. Brown out is defined as utility voltage less than 60% nominal, while utility is considered good when it is restored to at least the pickup value, 80% of nominal. These levels are fixed. The “Line Interrupt period” is an adjustable parameter by the dealer. If 2-wire start mode is activated, the unit will start when 2-wire start is active.

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MANUAL START

Allows the user to start and run the generator manually.

Transfer of the load to the generator will occur if utility is lost while the unit is running in the manual mode (only if activated).

ALARM AND WARNING MESSAGES

Alarms are defined as “Latching” which means they must be cleared before the alarm message on the screen will clear. They can be of type “Shutdown” or not and are logged in the alarm log. Alarms are all annunciated on the display).

Warnings are “Non Latching” meaning the message automati cally clears when the warning condition goes away. Warnings can not be of type “Shutdown” but they are logged in the alarm log. Warnings are all annunciated on the display.

LOW OIL PRESSURE SHUTDOWN ALARM

There is a 10 second delay before oil pressure is monitored.

HIGH COOLANT TEMPERATURE SHUTDOWN ALARM

There is a 10 second delay before engine temperature is moni tored.

Once running there is a 1/4 second delay before shut down. The limit is set at 125° C or 257° F.

OVERCRANK SHUTDOWN ALARM

Occurs if the engine has not started within the specified crank cycle.

OVERSPEED SHUTDOWN ALARM

Warning indicator is measured and calculated by the microproces sor. Overspeed is defined as +20% of nominal engine speed for 3 seconds, or +25% immediate. Nominal engine speed = 60.0 Hz

RPM SENSOR FAILURE SHUTDOWN ALARM

During cranking: If the board does not see a valid RPM signal within four (4) seconds of cranking it will shut down and lock out on RPM sensor loss.

During running: If the RPM signal is lost for one full second the board will shut the engine down, wait 15 seconds, then re-crank the engine if in AUTO, it will not re-crank in MANUAL.

If no RPM signal is detected within the first four (4) seconds of cranking, the control board will shut the engine down and latch out on RPM sensor loss.

If the RPM signal is detected the engine will start and run normally. If the RPM signal is subsequently lost the control board will try two more re-cranks before latching out and flashing the RPM Sensor Failure message (if it is in AUTO).

Control Panel

Figure 1 – Generator Control Panel CHECK ENGINE MESSAGE

The control system has detected an emissions related fault. This fault cannot be cleared using the control panel interface. The unit will continue to operate in automatic mode. Contact your local servicing dealer.

UNDER-FREQUENCY SHUTDOWN ALARM

After starting, if the generator stays under frequency for more than 30 seconds, it will shutdown.

LOW BATTERY ALARM

While running, if the average battery voltage falls below 11.9 volts for one (1) minute, the low battery alarm will be displayed.

LOW BATTERY WARNING

The microprocessor will continually monitor the battery voltage and display the Low Battery Voltage message if the battery voltage falls below 12.2 Volts for one (1) minute.

No other action is taken on a low battery warning condition. The warning will automatically clear if the battery voltage rises above 12.2 volts.

NOTE: The battery sentinel is a separate feature that monitors battery condition.

LOW COOLANT LEVEL ALARM

This is a shutdown alarm. The sensor will be continuously moni tored. If an error condition is seen for five (5) consecutive sec onds, the alarm will be displayed.

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MISSING CAM PULSE ALARM

This is a shutdown alarm. The alarm will activate after five (5) seconds of continuously missing cam pulses.

MISSING CRANK PULSE ALARM

This is a shutdown alarm. The alarm will activate after 12 con secutive revs where crank pulses are missing.

LOW FUEL PRESSURE WARNING

Fuel pressure is monitored by a digital sensor with a fixed setpoint of below five (5) inches water column.

GOVERNOR SENSOR FAULT ALARM

The governor position is monitored by an analog feedback signal. If the throttle position is seen outside of the normal operating range, a shutdown alarm is displayed. If the throttle is commanded to move, and no movement is seen, a shutdown alarm is displayed.

WIRING ERROR ALARM

When power is first apllied to the contoller, the software will per form a check on the wiring of the transfer output, and ensure it does not have high voltage on the wire. If this is the case, it will signal a miswire alarm and will not run. The test can be skipped by use of the escape key.

UNDERVOLTAGE ALARM

If the generator voltage falls below 60% for >5 seconds, an alarm will be issued.

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Control Panel

OVERVOLTAGE ALARM

If the generator voltage rises above 110% for >3 seconds, an alarm will be issued.

If the generator voltage rises above 130% for >0.2 seconds, an alarm will be issued.

INTERNAL FAILURE SHUTDOWN ALARM

Any internal failure that can be detected such as corrupted firmware will cause this shutdown alarm. This alarm cannot be cleared.

CANBUS ALARM

Where applicable, if the Canbus communications link fails to com municate, a “Canbus Alarm” will be generated. This only applies to systems with external ignition modules. The alarm may be generated if: 1. The physical link is broken.

2. The Ignition Module fails or resets.

3. The Nexus Controller fails or resets.

4. Having the Battery Chargers 120 VAC connected without a battery installed.

5. A blown 10 amp Ignition Module fuse (approximately 12 inches away from the starter).

6. A blown 25 amp system fuse (located approximately 12 inches away from the DC alternator).

NOTE: The “Canbus Alarm” will not clear on its own. To clear the alarm, press the “enter” key to acknowledge the alarm. The alarm will clear and if the fault is still present, the alarm will reoccur.

IGNITION ALARM

When an ignition alarm occurs, a generic message “Ignition Fault” will be displayed as the fault code.

MAINTENANCE WARNING

When a maintenance period expires, a warning message will be posted. The warning can be reset by hitting the Enter key. Resetting will clear the warning and reset the maintenance counters for the condition annunciated. The history log will reflect the maintenance warning.

ALARM CANCEL

When the generator is shut down due to a latching alarm, the Auto /Off/ Manual switch must be set to the off position and the ENTER key pressed to unlatch any active fault and clear the corresponding fault alarm message.

COMMON ALARM RELAY

The common alarm relay will be activated if there is a shutdown alarm. It will not activate on warnings or indicate that the Auto/Off/ Manual switch is in the OFF position. The OFF position will clear the alarms and the relay. The relay will not be used to indicate a generator is not activated.

The common alarm connections are wired to a set of potential free (dry) contacts on the Nexus controller board. These Normally Open (N.O.) contacts close when an alarm condition occurs and are used to activate a remote signaling device. The circuit is rated for a maximum of 130mA at 24 VDC. The connections are a short set of free hanging wires that exit the engine harness loom directly behind the Nexus Control Panel and are labeled numbers 209 and 210.

MAINTENANCE ALERTS

Maintenance alerts will be provided for these conditions.

SERVICE SCHEDULE ‘A’

Inspect Accessory Drive Alert Coolant Change & Flush Inspect Spark Plugs Alert Change Oil & Filter Alert Inspect Battery Alert Change / Inspect Air Filter Alert 1yr / 100hrs* 1yr / 100hrs 1yr / 100hrs 1yr / 100hrs* 1yr / 100hrs 1yr / 100hrs Clean/Inspect Air Inlet & Exhaust 6mo / 50hrs* * Items require a 3 month / 30 hour break-in change or check.

SERVICE SCHEDULE ‘B’

Change / Inspect spark plugs alert 2yr/ 250hr . E 12/11 CntrlNexus001 Rev

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Control Panel

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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

GENERAL MAINTENANCE

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

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

• • • The control panel 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

Check engine crankcase oil level (Figure 10.1) according to the Service Schedule and SIB10-10-L24G.

• • 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

CHANGING ENGINE OIL

n

Oil Filter

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.

10-1

Refer to the Service Schedule for engine oil and filter change fre quencies.

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 the drain hose from its retaining clip or cut the zip-tie securing the oil drain hose.

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 secure drain hose with a new zip-tie, or place the hose in its retaining clip.

4. Turn OIL FILTER (Figure 10.1) counterclockwise and remove. Properly dispose of old filter.

5. Apply light coating of new engine oil to seal of new oil fil ter. Install FILTER and tighten by hand only. DO NOT OVER TIGHTEN.

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

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.

COOLING INTAKE/OUTLET

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

Without sufficient cooling and ventilating air flow, the engine/gen erator quickly overheats, which causes it to shut down. (See the installation diagram.)  The exhaust system parts from this product get extremely hot and remains 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.

INSPECT COOLING SYSTEM

• • • Inspect engine cooling system. See the Service Schedule.

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

Check hose clamps for tightness.

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ENGINE COOLANT

Check coolant level in coolant recovery bottle. See the Specifications and Service Schedule sections.

• • Add recommended coolant mixture as necessary.

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

COOLANT CHANGE

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

OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM

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

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

EXERCISE SYSTEM

Starts the Stationary Emergency Generator engine once every seven days and lets it run for 12 minutes.

PERFORM VISUAL INSPECTION

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

INSPECT EXHAUST SYSTEM

Inspect the exhaust system at least once every year. Check all exhaust system pipes, mufflers, clamps, etc. for condition, tight ness, leaks, security, damage.

CHECK FAN BELT

• • • Inspect fan belts every year. Replace any damaged, deterio rated, worn or otherwise defective belt.

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

Check fan belt alignment (see Figure 10.2).

Figure 10.2 – Fan Belt INSPECT ENGINE GOVERNOR

Visually inspect electronic governor.

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 THE ENGINE AIR FILTER

To replace the engine air filter, remove the air filter cover and replace the air filter making sure it is positioned properly before reattaching the cover (Figure 10.3).

See the Service Schedule for air filter maintenance.

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Figure 10.3 – Engine Air Filter

Air Filter

n Battery electrolyte fluid is an extremely cor rosive sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If fluid is spilled, flush the affected area immediate ly 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.

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. See the Specifications section for the required spark plug gap.

BATTERY MAINTENANCE

The battery should be inspected per the Service Schedule section. 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 necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP WATER IN BATTERIES.

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

10-3

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 connected.

  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

NOTE: Unit DOES NOT include battery.

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

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

BATTERY FLUID

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

CLEANING THE STATIONARY EMERGENCY GENERATOR

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

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

Once each year have the generator cleaned and inspected by a Service Dealer. That dealer will use dry, low pressure air to clean internal windings.

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

. A 10/10 Maint029 Rev

Service Schedule SERVICE SCHEDULE

System / Component Frequency Procedure

Weekly - W Monthly - M Yearly - Y Inspect Change Clean

Fuel

Fuel Lines & Connections

Lubrication

Oil Level Oil Oil Filter

Cooling

Engine Coolant Lines & Connections Engine Coolant Level Engine Coolant Enclosure Louvers

Engine

Air Cleaner Spark Plugs

Battery

Remove Corrosion, Ensure Dryness Clean & Tighten Battery Terminals Check Charge State Check Electrolyte Level M M Y Y M M Y W Y Y M M M M X X* X X X X X X X X X X** X** X X*** X*** X*** X*** X X X

General Condition

Vibration, Noise, Leakage, Temperature

Generator System

Complete Tune-up and System Inspection

Footnotes

M Y X To be completed by an Authorized Service Dealer.

* Inspect the oil level monthly or every 12 hours during continuous operation.

** Change oil and oil filter after the first 30 hours of operation and then every 100 hours or annually thereafter, whichever occurs first. Change sooner when operating under heavy load or in a dusty or dirty environment or in high ambient temperatures.

*** Replace as necessary.

B 05/10 ev.

SrvSchd004 R

11-1

Troubleshooting TROUBLESHOOTING GUIDE

PROBLEM CAUSE

Engine won’t crank. Engine cranks but won't start. Engine starts hard, runs rough. 1. Control panel 7.5 amp fuse blown. 2. Loose or corroded or defective battery cables. 3. Defective starter contactor. 4. Defective starter motor. 5. Dead or Defective Battery. 1. Out of fuel. 2. Fuel solenoid (FS) is defective 3. Spark plugs defective. 1. Air cleaner plugged or damaged. 2. Defective spark plugs. 3. Fuel pressure incorrect. 4. Insufficient fuel supply. 5. Fuel system set to wrong fuel type. Engine starts then shuts down. 1. Engine oil level is low. 2. Engine is overheated. 3. Defective Low Oil Pressure Switch 4. Defective Coolant Temperature Switch 5. Defective Control Module circuit board. 6. Coolant Level is Low. 7. Defective Low Coolant Level Switch AUTO/OFF/MANUAL Switch at OFF, 1. Defective AUTO/OFF/MANUAL switch engine continues to run. No AC output from generator. 2. Defective Control Module circuit board 1. Main line circuit breaker is tripped/open. 2. Generator internal failure. 3. Thermal circuit breaker open.

CORRECTION

1. Replace fuse.* 2. Tighten, clean or replace battery cables as necessary.* 3. Replace contactor.* 4. Replace starter motor.* 5. Remove, change or replace battery.* 1. Replenish fuel/turn on fuel valve.

2. Replace solenoid.* 3. Clean, regap or replace plugs.

1. Clean or replace as needed.

2. Clean, regap or replace plugs.

3. Confirm fuel pressure to regulator is as recommended in SPECIFICATIONS.* 4. Confirm fuel pressure to regualtor is as recommended in SPECIFICATIONS.* 5. Reconfigure the fuel system. (See RECONFIGURING THE FUEL SYSTEM in manual.* 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 board.* 2. Replace board.* 1. Reset to ON/CLOSED.

2. * 3. Auto-reset - Wait 5 min. and attempt restart.

*Contact the nearest Dealer for assistance.

12-1

B 05/10 ev.

Trblsht003 R

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)

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

EXPLODED VIEW: EV ALTERNATOR CPL GB DRAWING #: 0F3577 ITEM PART# QTY. DESCRIPTION

44 45 46 47 48 49 29 30 31 32 33 34 35 40 41 42 43 1 2 4 5 6 7 8 * 9 10 11 12 13 14 15 16 17 18 19 20 21 22 25 26 27 28 055173 022129 0E2747A 0A3870 0A3009 0F5564D 0F5563D 0A3881D 0A3881B 0A3882B 0A3883B 052624 0A5580 0A1633 0F7024J 0F7351 0F7349 0F7348 0F7350 0F7024D 068113 022392 043123 051779 052259 051769 068406 072878 087272 068405C 092950 090063 090152 023365 033143 1 1 3 2 3 1 1 1 1 6 6 1 1 1 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 2 4 4 2 3 SCREW HHC M8-1.25 X 20 G10.9 WASHER LOCK M8-5/16 FAN SAE ALTERNATOR (G/B) KEY SQ 3/8 X 1-9/16 STEEL HUB DRIVE 390 SAE GB RTR 390 100KB3 GB SAE TECHUM RTR 390 130KB4 GB SAE TECHUM RTR 390 80GB BR BRLSS RTR 390 80GB 1P BRLSS RTR 390 100GB 1P BRLSS RTR 390 125GB 1P BRLSS BEARING BALL 6212 SEALED SCREW HHC M14-2.0 X 140 G8.8 WASHER 390 SAE ALT. STR-390-80LB3 SAE STR 390 130 GB4 CPL STR 390 80 AB3 CPL STR 390 100 AB3 CPL STR 390 130 AB4 CPL ASSY STR 390 80KB3 SAE CARRIER REAR BRG 15" PIN DOWEL 1/2 X 1-1/4 WASHER LOCK M14 NUT HEX M14-2.0 G8 YEL CHR WASHER FLAT M12 WASHER LOCK M12 SCREW HHC M12-1.75 X 60 G10.9 KEY SQ 3/8 X 3-1/4 STEEL ASSY EXCITER 2.00" STK EXITER FIELD 2" LG SPD CONN COLLAR SLIP FIT 390 MM BRIDGE SUPPORT DIODE 15" ASSY BRIDGE RECTIFIER WASHER SHAKEPROOF INT #8 SCREW HHM #8-32 X 7/8 090064 083485 031980 083401 042561 1 2 2 1 1 CAP END ROTOR 390MM PLATE NUT TIE WRAP UL 14.6 X .14 NATL BRACKET-STATOR WIRE CLAMP HOSE #36 1.88-2.7 033212 083549 0A4089 2 1 1 SCREW HHC 5/16-18 X 1-1/4 G5 SLEEVE RUBBER ASSY SCROLL 390 SAE KIT PARTS I/N’S: 41 THRU 49 (INCLUDED IN I/N 40) 0A2491 2 SHROUD ALT SHEET METAL 0A2497 0A2496 2 2 SCREEN SHROUD SAE BRKT TENSIONER SAE SCROLL 056326 022097 022473 045757 047411 0A2110 * ROTOR REPLACEMENT PART 8.4 FT. 6 6 2 4 14 TRIM VINYL BLACK 1/8 GP WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC SCREW HHC M6-1.0 X 25 G8.8 SCREW HHC M6-1.0 X 16 G8.8 SCREW SWAGE 1/4-20 X 1/2 ZYC

GROUP A

REVISION: K-2886-K DATE: 5/21/15 Page 2 of 2

1 2 4 5 6 7 8 * 9 10 11 12 13 14 15 16 17 18 19 20 21 22 25 26 27 28 29 30 31 32 33 34 49 35 40 41 42 43 44 45 46 47 48 055173 022129 0E2747A 0A3870 0A3009 0F5564D 0F5563D 0A3881D 0A3881B 0A3882B 0A3883B 052624 0A5580 0A1633 0F7024J 0F7351 0F7349 0F7348 0F7350 0F7024D 068113 022392 043123 051779 052259 051769 068406 072878 087272 068405C 092950 090063 090152 023365 033143 090064 083485 031980 083401 042561 033212 083549 0A4089 KIT PARTS 0A2491 0A2497 0A2496 056326 022307 022473 045757 047411 0A2110 6 6 1 1 1 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 2 4 4 2 3 3 SCREW HHC M8-1.25 X 20 G10.9 WASHER LOCK M8-5/16 FAN SAE ALTERNATOR (G/B) KEY SQ 3/8 X 1-9/16 STEEL HUB DRIVE 390 SAE GB RTR 390 100KB3 GB SAE TECHUM RTR 390 130KB4 GB SAE TECHUM RTR 390 80GB BR BRLSS RTR 390 80GB 1P BRLSS RTR 390 100GB 1P BRLSS RTR 390 125GB 1P BRLSS BEARING BALL 6212 SEALED SCREW HHC M14-2.0 X 140 G8.8 WASHER 390 SAE ALT. STR-390-80LB3 SAE STR 390 130 GB4 CPL STR 390 80 AB3 CPL STR 390 100 AB3 CPL STR 390 130 AB4 CPL ASSY STR 390 80KB3 SAE CARRIER REAR BRG 15" PIN DOWEL 1/2 X 1-1/4 WASHER LOCK M14 NUT HEX M14-2.0 G8 YEL CHR WASHER FLAT M12 WASHER LOCK M12 SCREW HHC M12-1.75 X 60 G10.9 1 1 1 1 1 1 3 2 1 2 2 1 1 2 1 1 2 2 2 8.4 FT. 6 6 2 4 KEY SQ 3/8 X 3-1/4 STEEL ASSY EXCITER 2.00" STK EXITER FIELD 2" LG SPD CONN COLLAR SLIP FIT 390 MM BRIDGE SUPPORT DIODE 15" ASSY BRIDGE RECTIFIER WASHER SHAKEPROOF INT #8 SCREW HHM #8-32 X 7/8 CAP END ROTOR 390MM PLATE NUT TIE WRAP UL 14.6 X .14 NATL BRACKET-STATOR WIRE CLAMP HOSE #36 1.88-2.7 SCREW HHC 5/16-18 X 1-1/4 G5 SLEEVE RUBBER ASSY SCROLL 390 SAE I/N’S: 41 THRU 49 (INCLUDED IN I/N 40) SHROUD ALT SHEET METAL SCREEN SHROUD SAE BRKT TENSIONER SAE SCROLL TRIM VINYL BLACK 1/8 GP WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC SCREW HHC M6-1.0 X 25 G8.8 SCREW HHC M6-1.0 X 16 G8.8 14 * ROTOR REPLACEMENT PART SCREW SWAGE 1/4-20 X 1/2 ZYC

EXPLODED VIEW: EV CPL ALTERNATOR BRUSHLESS DRAWING #: 0J0203 APPLICABLE TO:

GROUP A ITEM PART# QTY. DESCRIPTION 1 2 3 4 5 6 7 8 23 24 25 26 27 28 29 30 31 32 33 34 35 36 9 10 11 12 13 14 (2)15 16 17 18 19 20 21 22 0F9952 0F2984 0F9949 0F2985 0F9950 0F9951 0G6319 0F6184 0F6212 0G2023 068405C 0F3013 072878 0C9708 0F3726B 0F2689 023454 059980 046526 0A2601 072879 0F7029 0J232100ST0R 0C2454 092950 04576100CF 052646 043123 051779 022392 052259 051769 0E7230 0F9492 0F2722 077043F 020151 023365 033133 033143 086032 090063 090064 090152 1 1 1 1 1 1 1 1 1 1 1 1 1 REF 1 1 1 4 4 1 1 1 1 9 1 4 4 4 4 2 2 3 3 1 1 1 1 3 1 2 2 1 1 1 ASSY ROTOR 2390 80KB3 CPL ASSY ROTOR 390 2P 150K BRSHLS ASSY STATOR 80KW 1PH 2P 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 150KW 2P 3PH 208V ASSY STR 150KW 1PH 2P BRSHLS ASSY STR 390 150KW 2P 3PH 240V 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 SHROUD LOWER ALTERNATOR EXCITR SHIELD CENTER ALT EXCITER 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 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 37 38 39 40 41 42 43 44 (1)45 46 47 48 022661L 028739A 085662D 068113 068406 0F7272 023484N 023484N 0F7030 052624 0C2428 022155 0F3834 1 2 1 1 1 6 1 2 1 1 2 2 1 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 BUSHING SNAP SB-2.5-31 BUSHING SNAP SB-2.5-31 (FOR 5.4/6.8 1 PHASE) SHROUD UPPER ALTERNATOR EXCITR BEARING BALL 6212 SEALED SCREW PHTT #6-32 X 1/2 ZYC WASHER LOCK #6 ASSY SCROLL 390 X 60MM CPL 61 62 63 64 65 66 67 68 69 0F3846B 0F3892 0A2496A 056326 022097 022473 045757 047411 0A2110 KIT PARTS (I/N’S: 61 THRU 69) 2 2 2 8.4 FT. 6 6 2 4 12 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 SCREW HHC M6-1.0 X 16 G8.8 SCREW SWAGE 1/4-20 X 1/2 Z/YC (1) ROTOR REPLACEMENT PARTS. (2) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR). •

MANUFACTURING:

FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.

CUSTOMER:

FOR CORRECT MATERIAL AND COLOR OF REPLACEMENT PARTS REFER TO “REPLACEMENT SHEET METAL PARTS ORDERING GUIDE-

0H7169

” INCLUDED IN THE MANUAL OR AVAILABLE ON THE GENERAC WEBSITE. NOTE: 1 PHASE UNITS REQUIRE SEPERATION OF LEADS. REVISION: H-9892-C DATE: 10/24/11 Page 2 of 2

57 58 59 60 61 62 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 (1)6 (1)7 (1)8 (1)9 (3)10 (3)11 (3)12 (3)13 14 (2)15 (2)16 (2)17 31 32 33 34 35 36 37 38 39 40 41 42 43 (2)18 19 20 21 22 23 24 25 26 27 28 29 30 0F6640 0J0625 0H6169D 0H6267 056739 0F5376S0AR 0F5396S0AR 0D7393U 0D7393T 0H67330ST0R 0H81040AS0R 0H96120ST0R 0J10070ST0R 0C2265 0J0945 022097 0A8261 0A7822 0F8862 025507 061383 049814 0J1618 022131 046526 045772 0C2454 023484N 023897 036943 022152 022158 0F5458 0D3700 022473 042568 0D7177V 051713 049226 051716 0A2115 022237 0H7115 REF 045764 0D6029 022241 0H7293 057073 022264 0J0489 0H7292 0F8863 047411 049813 052777 043182 051714 054502 0F5752C 022097 0D7178T

EXPLODED VIEW: EV CONBOX 150KW 1PH C5 NEXUS DRAWING #: 0J0304 APPLICABLE TO: ITEM PART# DESCRIPTION QTY.

PAGE 1

1 3 3 1 1 6 1 1 2 6 2 1 2 4 1 1 1 4 4 3 1 1 1 1 1 1 2 4 1 4 4 2 1 1 1 1 2 2 12 6 18 2 2 2 2 2 2 2 2 2 1 2 1 1 1 1 2 1 16 2 4 2

GROUP A

CHAN ASSY CB SUPPORT PANEL CB CONNECTION ASSY PROG 2010 IGN MOD 10CYL COVER VOLTAGE SHIELD RELAY SOLENOID 12VDC PNL MNT MX150L SLRRMNT 22-18 8P W/O GA MX150L SLRRMNT 22-18 12P W/OGA TERM BLOCK 4P UL 12-20AWG TERM BLOCK 3P UL 12-20AWG BRACKET GIMBAL CONTROL PNL COVER DPE BREAKER NEXUS CHUTE C5 RAW SHIELD HIGH/LOW C5 SCREW PHTT M4-0.7 X 12 ZP BUS BAR NEUTRAL BLOCK WASHER LOCK M6-1/4 SCREW HHC 1/4-28 X 5/8 .625TH LUG SLDLSS 600/250-1/0X1/4-28 CHANNEL, SUPPORT WASHER LOCK EXT 7/16 STL LUG SLDLSS 3/0-#4 X 13/32 CU SCREW HHC M10-1.5 X 25 C8.8 HARN EXCITATION NEXUS C3/C5 (NOT SHOWN) WASHER FLAT 3/8-M10 ZINC WASHER LOCK M10 NUT HEX M10-1.5 G8 YEL CHR SCREW HWHT M6-1 X 16 N WA Z/JS BUSHING SNAP SB-2.5-31 WASHER FLAT #10 ZINC SCREW PPHM #10-32 X 2 WASHER LOCK #10 NUT HEX #10-32 STEEL SCREW HHSP #10 X 3/8 HI-LOW NUT FLANGE M6-1.0 NYLOK WASHER FLAT 1/4-M6 ZINC SCREW HHC M6-1.0 X 20 C8.8 DIODE BRIDGE 1P 35A 1000V WASHER FLAT M5 WASHER LOCK M5 NUT HEX M5-0.8 G8 CLEAR ZINC WASHER NYLON .257 WASHER LOCK 3/8 KNOB M6-1.0 CONTROL PANEL ASSY CTRL PROGRAMMED SCREW HHTT M4-0.7 X 8 ZP SCREW HHTT M6-1.0 X 16 ZYC NUT HEX 3/8-16 STEEL DECAL CONBOX TB1 CONNECTIONS JUNCTION BLOCK 3/8-1 WASHER LOCK #8-M4 DECAL CUSTOMER POWER CONNECT_ DECAL CUSTOMER CONTROL CONNECT CHANNEL, BRACE SCREW HHC M6-1.0 X 16 C8.8 NUT HEX M6-1.0 G8 CLEAR ZINC WASHER FLAT M3 WASHER LOCK M3 NUT HEX M3-0.5 G8 CLEAR ZINC CB 3A 1P ETA 46-500-P RES WW 50R 5% 25W QK CONN WASHER LOCK M6-1/4 FUSE ATO TYPE 7.5AMP (BROWN) REVISION: CN-0030633-E DATE: 10/2/2019 Page 3 of 4

EXPLODED VIEW: EV CONBOX 150KW 1PH C5 NEXUS DRAWING #: 0J0304 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION

63 64 65 66 056326 0A9457 067210A 0H8006 1 1 1 1 TRIM VINYL BLACK 1/8GP (3”LG) DECAL NEUTRAL DECAL GROUND LUG DECAL CAUTION ELEC SHOCK SM NOTES (UNLESS OTHERWISE SPECIFIED): (1) ITEMS INCLUDED WITH HARNESS P/N 0J0632. (2) ITEMS INCLUDED WITH NEUTRAL BLOCK P/N 0J0944. (3) SHEET METAL PARTS LISTED IN THE BOM TABLE, PRIOR TO 1/1/16, ARE REPRESENTING GENERIC PARTS (NO COLOR) : • MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO SAP BOM. • CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169). K L M N A B C D E F G H J P R S T U V W X Y Z AA 0J0624 0J0622A 0E2962 0D5582 0F6507 0F6507A 0C4112B 024196 022473 022097 022127 022237 023645 0D6585 022241 0C2454 0C3990 0F8926 043180 022264 051715 043097 022237 049451

PAGE 2

UL CIRCUIT BREAKER (SIEMENS) 1 1 2 1 2 2 REF 4 4 4 4 8 4 4 4 12 4 1 4 4 4 4 4 4 COVER FIXED LMD CB COVER SERVICE LMD CB W/BUMPOUT INSULATOR (NOMEX) CB 0700A 3P 600V S LMD6 LL BUS BAR 1/4X2 LMD L1 BUS BAR 1/4X2 LMD L1 LUG SIEMENS LMD/LD TA3K500 SCREW RHM 1/4-20 X 3-1/2 WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 NUT HEX 1/4-20 STEEL WASHER LOCK 3/8 SCREW SHC 3/8-16 X 1.25 G8.8 Z SCREW SHC 3/8-16 X 3.0 BLK OX NUT HEX 3/8-16 STEEL SCREW HWHT M6-1 X 16 N WA Z/JS SCREW PHTT M4-0.7 X 10 ZP INSUL CB COVER WASHER FLAT M4 WASHER LOCK #8-M4 NUT HEX M4-0.7 G8 YEL CHR SCREW SHC 3/8-16 X 1 G8.8NZ WASHER LOCK 3/8 WASHER FLAT .406ID X 1.62OD AB (1)AC AD 0F0710 0J0622BST0R 066760 4 1 1 RIVET POP .125 X 0.337 STEEL COVER BUMP OUT SERVICE LMD CB STRIP SEALANT 1/8 X 1 (36”LG) NOTES (UNLESS OTHERWISE SPECIFIED): (1) SHEET METAL PARTS LISTED IN THE BOM TABLE, PRIOR TO 1/1/16, ARE REPRESENTING GENERIC PARTS (NO COLOR) : • MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO SAP BOM. • CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).

GROUP A

REVISION: CN-0030633-E DATE: 10/2/2019 Page 4 of 4

EXPLODED VIEW: EV MTG BASE 6.8L 150KW CPL DRAWING #: 0F2975 ITEM PART# QTY. DESCRIPTION

(1)1 2 3 4 5 6 7 8 (1)9 10 11 0L05740ST0R G065852 G052252 G052257 G052259 G055597 052251A G052860 0L06890ST0R G045764 0A4456 1 1 5 5 5 5 5 4 1 1 1 MTG BASE C5 150KW 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 ENGINE SUPPORT 6.8L RH SCREW HHTT M4-0.7 X 8 BP WASHER LOCK SPECIAL 3/8 12 13 14 15 (1)16 17 18 19 20 21 22 23 24 25 (1)26 G061383 G043107 --- --- 0L01390ST0R G022131 046526 0536210410 --- 0C3168 G022129 G022145 G045771 --- 0L01480ST0R 1 2 -- -- 1 7 7 1 -- 1 1 2 2 -- 1 LUG SOLDERLESS 3/0-#4 X 13/32 CU SCREW HHC M8-1.25 X 25 G8.8 -------- -------- 5.4L RH ENGINE MOUNT SPACER WASHER FLAT 3/8-M10 ZINC WASHER LOCK M10 ASSY WIRE 14.00” -------- WASHER LOCK SPECIAL 5/16-M8 WASHER LOCK M8-5/16 WASHER FLAT 5/16-M8 ZINC NUT HEX M8-1.25 G8 YEL CHR -------- ENGINE MOUNT 6.8L LH SIDE 27 28 --- G052243 -- 6 -------- SCREW HHC M10-1.5 X 60 C8.8 29 G051735 1 SCREW HHC M10-1.5 X 70 C8.8 30 0L0123 1 SPACER .41 X .75 X 1.68 ST/ZNC NOTES (UNLESS OTHERWISE SPECIFIED): (1) SHEET METAL PARTS LISTED IN THE BOM TABLE, PRIOR TO 1/1/16, ARE REPRESENTING GENERIC PARTS (NO COLOR) : • MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO SAP BOM. • CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).

GROUP C

REVISION: CN-0027708-G DATE: 10/11/2019 Page 2 of 2

EXPLODED VIEW: EV MOUNTING BASE DRAWING #: 0F3587 ITEM PART# QTY. DESCRIPTION

(1)1 2 3 4 5 6 7 8 (1)9 10 11 0L0574AST0R G065852 G052252 G052257 G052259 G055597 052251A G052860 0L06890ST0R G045764 G052243 1 1 4 4 8 4 4 4 1 1 6 MTG BASE C5 100-130KW 6.8L G8 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 ENGINE SUPPORT 6.8L RH SCREW HHTT M4-0.7 X 8 BP SCREW HHC M10-1.5 X 60 C8.8 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 G061383 G043107 0A4456 --- (1)0L01390ST0R G022131 G046526 0536210410 --- 0C3168 G022129 G022145 G045771 G053557 0F2591 1 2 1 -- 1 7 7 1 -- 1 1 2 2 4 2 LUG SOLDERLESS 3/0-#4 X 13/32 CU SCREW HHC M8-1.25 X 25 G8.8 WASHER LOCK SPECIAL 3/8 -------- 5.4L RH ENGINE MOUNT SPACER WASHER FLAT 3/8-M10 ZINC WASHER LOCK M10 ASSY WIRE 14.00” -------- WASHER LOCK SPECIAL 5/16-M8 WASHER LOCK M8-5/16 WASHER FLAT 5/16-M8 ZINC NUT HEX M8-1.25 G8 YEL CHR SCREW HHC M12-1.75 X 40 G8.8 TOWER GB COMPROD C5 (1)27 28 29 30 31 0L01480ST0R --- --- --- G051735 1 -- -- -- 1 ENGINE MOUNT 6.8L LH SIDE -------- -------- -------- SCREW HHC M10-1.5 X 70 C8.8 32 0L0123 1 SPACER .41 X .75 X 1.68 ST/ZNC NOTES (UNLESS OTHERWISE SPECIFIED): (1) SHEET METAL PARTS LISTED IN THE BOM TABLE, PRIOR TO 1/1/16, ARE REPRESENTING GENERIC PARTS (NO COLOR) : • MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO SAP BOM. • CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).

GROUP C

REVISION: CN-0027708-F DATE: 7/25/2019 Page 2 of 2

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

EXPLODED VIEW: EV BATTERY 27F GEAR BOX DRAWING #: 0G0775 ITEM PART# QTY. DESCRIPTION

(1)1 2 3 4 5 6 7 8 9 10 11 0F3408AST0R 0F3411 G058665 G022131 050331A G050331 038805Z 038804U G045771 G022129 G027482 1 1 1 1 1 1 1 1 1 1 1 TRAY BATTERY 27F STRAP BATTERY RETAINMENT BATTERY 12VDC 90-AH 27F WASHER FLAT 3/8-M10 ZINC BATTERY POST COVER RED + BATTERY POST COVER BLK - CABLE BATTERY BACLK #1 X 26.00 CABLE BATTERY RED #1 X 28.00 NUT HEX M8-1.25 G8 YEL CHR WASHER LOCK M8-5/16 WASHER SHAKEPROOF EXT 5/16 STL 12 13 14 15 16 17 18 G075763 0C2454 0F3409 G022097 G049813 G042568 0G0783 1 8 1 2 2 2 1 BOOT BATTERY CABLE SCREW THF M6-1 X 16 N WA Z/JS SUPPORT BATTERY TRAY WASHER LOCK M6-1/4 NUT HEX M6 X 1.0 G8 YEL CHR SCREW HHC M6-1.0 X 20 G8.8 SUPPORT 27F BATTERY 19 0J3501 1 STRAP BATTERY 1.5X36" NOTES (UNLESS OTHERWISE SPECIFIED): (1) SHEET METAL PARTS LISTED IN THE BOM TABLE, PRIOR TO 1/1/16, ARE REPRESENTING GENERIC PARTS (NO COLOR) : • MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO SAP BOM. • CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).

GROUP C

REVISION: CN-0033024-B DATE: 1/8/2020 Page 2 of 2

EXPLODED VIEW: EV ENCLOSURE C5 EMISSION DRAWING #: 0J0204 APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION GROUP F

(2) 1 (2) 2 (2) 3 (2) 4 (2) 5 (2) 6 (2) 7 8 9 (1)10 (1)11 12 13 14 15 16 17 18 19 0F58730AL0R 0F5868AAL0R 0F5872AAL0R 0F58710AL0R 0F5869AAL0R 0K88730AL0R 0F58670AL0R G066760 078115A 0E3257 0C2454 0F2766 0F3181 0F3185 0F3416 0J0336 0F4487A G022473 G022097 2 4 2 2 2 1 5 1 1 4 2 2 2 1 1 1 12 16 80 REAR WRAP C5 DOOR C5 CENTER SUPPORT C5 DISCHARGE DUCT LH & RH SIDE C5 FRONT CORNERS C5 DUCT CENTER DISCHARGE RAW ROOF C5 ALUM STRIP SEALANT 1/8 X 1 (44.5”LG) WASHER SELF LOCKING DOME #8-32 SCREW TH-FRM M6 W/CAP SHKPRF W SCREW THF M6-1 X 16 N WA Z/JS SPLITTER SPLITTER SHORT STRINGER SPLITTER C3 SUPPORT SPLITTER C5 130KW INSUL CORNER POST ASSY ACCESS COVER WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 20 21 22 23 24 25 26 27 28 29 30 31 32 G022127 0F3072 G078115 0J0336B 0J0336A 0F5048D 0E5968 0F5049B 0J0336G 0J2624B 0F3890A G087233 0J0336C 1 20 30 3 1 3 2 1 4 4 1 4 2 NUT HEX 1/4-20 STEEL INSULATION RETAINMENT HANGER WASHER SELF LOCKING DOME #4-40 INSUL SPLITTER INSUL SHORT LOUVER VISE-ACTION LATCH SLOTTED CIR GASKET EXTRUDED TRIM (566” LG) PULL TAB DOOR LOCK SS INSUL SPLITTER SML INSUL ROOF TOP REAR RETAINER INSULATION (740) RIVET POP .1875 X .450 SS INSUL ROOF TOP FRT 33 34 35 36 37 0J0336D 0F3949G 0J0336F 0F3949K 0F3949F 4 1 2 1 2 INSUL DOOR INSUL DISCHARGE DUCT INSUL CENTER SUPPORT INSUL DISCHARGE DUCT TOP INSUL INNER DUCT SIDE 38 39 40 42 43 (1) 44 45 46 0F8869D 0F3890 G042568 G022447 G049813 G077992 0912970090 0F2766A 1 2 4 4 4 28 4 1 KEY VISE-ACTION LATCH SLOT CIR 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 14AWG GRN/YEL SPLITTER C5 47 0J0336H 1 INSUL SPLITTER SHRT MPS NOTES (UNLESS OTHERWISE SPECIFIED): (1) ENCLOSURE NOTE: ALL PANELS THAT FASTEN TO THE BASEFRAME MUST BE SECURED USING I/N 10 & 11 (THREAD FORMING FASTENERS) AND I/N 44 (LOCK NUT). LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS. ALL PANEL TO PANEL CONNECTIONS TO INCLUDE AT LEAST ONE CONNECTION POINT USING I/N 10 (THREAD FORMING FASTENER).NOTES (2) SHEET METAL PARTS LISTED IN THE BOM TABLE, PRIOR TO 1/1/16, ARE REPRESENTING GENERIC PARTS (NO COLOR) • MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO SAP BOM.

• CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169). REVISION: J-8755-G DATE: 5/19/14 PAGE 2 OF 2

37 38 39 40 41 44 45 46 47 48 49 50 51 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

EXPLODEDVIEW: EV GEARBOX ASSY 390 ALT DRAWING#: 0F1792 APPLICABLETO:

ITEM PART# QTY. DESCRIPTION 0F2123 0F2122 095613 051756 046526 049814 051735 0F2097 072879 097557B 0H3114 095970 095968 0E6866 070263 057019 026847 0H3113 095969 095967 0E6865 095966 095976 095971 096777 057019S 096379 048189 095979 021159 097557A 057163 0F6518 0F3201 020443 094666A 099828 099828A 026925 097557C 038591 025066 031578 052625 049814 0A1786 027175 045772 052243 057642 0F6487 0F6355 0F6477 0F6557 026924 1 6 REF. 10 2.5cc .200 GAL 10 10 2 4 1 .050 GAL 0.4cc 1 1 1 1 2 42 4 8 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 8 8 1 2 1 1 1 1 4 1 2 1 1 GEAR CASE ENG. MACHINED GEAR CASE ALT. MACHINED SEAL OIL SCREW HHC M10-1.5 X 20 G8.8 WASHER LOCK M10 SCREW HHC M10-1.5 X 25 G8.8 SCREW HHC M10-1.5 X 70 G8.8 GASKET 390 GEARBOX SPACER .69 X 2.75 X .37 ST/ZNC KEY 10 X 16 X 46 GEAR OUTPUT 1.65:1 GEAR OUT 390-50H 37T GEAR OUT 390-60H 35T GEAR OUTPUT 2:1 50HZ 390 SCREW HHC M16-2.0 X 35 G10.9 BALL BRG 65 X 120 X 23 BREATHER GEAR INPUT 1.65: 1 GEAR INPT 390-50 25T GEAR INPT 390-60 27T GEAR INPUT 2:1 50HZ 390 SHAFT 390 INPUT GEAR COLLAR HARDENED SEAL OIL SNAP RING INT 120MM BEARING #6213 SEALED PLATE INTRNL BRG RET PIN DOWEL M8 X 24 PLATE BEARING THRST SPACER STRESSPROOF KEY 10 X 16 X 40 PLUG PIPE 3/8" MAGNETIC SCREW HHFC M10-1.5 X 25 G10.9 COVER GEARBOX GUARD COUPLING INNER DRAWN COUPLING OUTER MACHN DAMPER GB CPLR VIBRA DAMPER GB CPLR VIBRA PLUG STD PIPE 3/8 STEEL SQ HD KEY 10 X 16 X 50 NIPPLE PIPE 3/8 NPT X 3-1/2 COUPLING FULL 3/8-18 SCREW HHC 3/8-16 X 1-1/2 G8 SCREW SHC M10-1.5 X 35 G12.9 (FORD ENGINES) SCREW HHC M10-1.5 X 25 G8.8 RETAINING COMPOUND LUBE GREASE SAE #90 80W90 (NOT SHOWN) NUT HEX M10-1.5 G8 YEL CHR SCREW HHC M10-1.5 X 60 G8.8 SCREW HHC M10-1.5 X 40 G10.9 WASHER FLAT M10 SEALING COPPER GASKET SEAL PLATE 390 GB ENHANCER GEAR OIL (NOT SHOWN) THREADLOCK AND SEALANT ELBOW 90D STREET 3/8 GROUP D REVISION: CN-0021689-G DATE: 11/14/2018 Page 2 of 2

EXPLODED VIEW: EV FUEL 6.8 130/150 NG CPL EMS DRAWING #: 0J0217 APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION 47 48 49 50 51 52 53 32 33 34 35 36 37 38 39 40 41 42 43 44 45 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 18 19 20 21 22 23 24 25 26 27 28 29 30 31 033212 065908 0G9783 0G9783A 052645 022304 022129 045773 022195 039130 0E7162 040181 040181 0J1318 057822 059057 0F4408 0J7476 0E4390 0E4392 0F0960 0F3885 0G3167 0F3691F 0F3691J 026915 0A8064 026073A 0D2157 039294 022097 049811 0D2698 042568 030131 059057 066212 0G46350ST03 059057 0G5652 039450 077879 077879 077879 077879 077879 0F1866A 022473 0K2771 0K2340 0K3795 0H3632 0L5885 4 1 1 1 2 4 4 2 2 1 1 1 1 1 12 2 2 1 1 1 4 1 8 2 1 1 1 2 1 1 2 2 1 2 1 1 1 1 1 1 4 1 2 1 1 2 1 4 1 1 1 1 1 GROUP E SCREW HHC 5/16-18 X 1-1/4 G5 SUPPORT NAT GAS SOLENOID REG 6.8L CPL 130KW N/G EMISS REG 6.8L CPL 150KW N/G EMISS SCREW HHC M12-1.75 X 30 C8.8

WASHER FLAT 1/2 ZINC WASHER LOCK M8-5/16 NUT HEX M12-1.75 G8 YEL CHR WASHER LOCK 1/2 NIPPLE CLOSE 1.25 NPT X 1.625 BSHG RDCR HEX 1-1/4 X 1/4FNPT NIPPLE PIPE 1-1/4 NPT X 7 (130KW ONLY) NIPPLE PIPE 1-1/4 NPT X 7 (150KW ONLY) HARNESS FUEL JUMPER DUAL REG CLAMP HOSE #8 .53-1.00 HOSE 3/4 ID SAE-30R2 (42” LG) Y CONNECTOR 500 SERIES BARBS ADAPTOR THROTTLE BODY GASKET GOVERNOR ACTUATOR ACTUATOR BOSCH 60 GOVERNOR REDUCER 3.0" TO 2.75" TURBO MIXER 40/60MM ACTUATOR ASSY O-RING 2-3/4 X 3/32 X 2-15/16 VENTURI THROTTLE 44MM (130KW) VENTURI THROTTLE 50MM (150KW) NIPPLE CLOSE 3/4 X 1.375 BSHG RDCR HEX 1-1/4-3/4 PLUG STD PIPE 1/4 STEEL SQ HD SCREW SHC M6-1.0 X 50 C8.8 CLAMP HOSE #44 2.31-3.25 WASHER LOCK M6-1/4 WASHER FLAT M6 GASKET ADAPTER THROT BODY SCREW HHC M6-1.0 X 20 G8.8 ELBOW 90D 1-1/4NPT HOSE 3/4 ID SAE-30R2 (12” LG) CLAMP HOSE #52 2.81-3.75 BRACKET, HOSE RISER HOSE 3/4 ID SAE-30R2 (9.5” LG) MANIFOLD, EMISSIONS VACUUM BARBED EL 90 3/16 X 1/8 HOSE VACUUM 5/32 (5”LG) HOSE VACUUM 5/32 (7”LG) HOSE VACUUM 5/32 (18”LG) HOSE VACUUM 5/32 (6”LG) HOSE VACUUM 5/32 (8”LG) BARBED EL W/VENT (.052") WASHER FLAT 1/4-M6 ZINC PIPE CROSS 1-1/4" NPT PLUG, PRESSURE GAUGE, 1/4" NPT HANG TAG FUEL PRESS TEST POINT TIE WRAP UL 5.6 X .10 BLACK PLUG PLASTIC 1.25" TAPERED CAP REVISION: K-3102-G DATE: 10/6/15 Page 2 of 2

EXPLODED VIEW: EV FUEL LP 6.8 100/130/150EMSN DRAWING #: 0J0218 APPLICABLE TO:

ITEM

1 2 3 4 31 32 33 34 35 36 37 38 39 40 41 42 5 6 7 8 9 10 11 12 13 14 15 18 19 20 21 22 23 24 25 26 27 28 29 30

PART#

033212 065908 0G9781 0G9781A 0G9781B 052645 022304 022129 045773 064346 0A8064 030131 031015 040181 026915 057823 059057 0D2698 0J7476 0E4390 0E4392 0F0960 0F3885 0G3167 0F3691E 0F3691F 0F3691J 022195 0J1318 026073A 0D2157 039294 022097 042568 049811 039130 066212 0G46350ST03 0C2454 0G4588 039450 077879 077879 0F1866A 063831

QTY.

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

GROUP E DESCRIPTION

SCREW HHC 5/16-18 X 1-1/4 G5 SUPPORT NAT GAS SOLENOID REG 6.8L 100KW LP CPL EMISS REG 6.8L 130KW LP CPL EMISS REG 6.8L 150KW LP CPL EMISS SCREW HHC M12-1.75 X 30 C8.8

WASHER FLAT 1/2 ZINC WASHER LOCK M8-5/16 NUT HEX M12-1.75 G8 YEL CHR PIPE TEE 1-1/4 NPT BSHG RDCR HEX 1-1/4-3/4 ELBOW 90D 1-1/4 NPT NIPPLE PIPE 1-1/4 NPT X 3 (100KW & 130KW) NIPPLE PIPE 1-1/4 NPT X 7 (150KW ONLY) NIPPLE CLOSE 3/4 X 1.375 CLAMP HOSE #10 .56-1.06 HOSE 3/4 ID SAE-30R2 (45” LG) GASKET ADAPTER THROT BODY ADAPTOR THROTTLE BODY GASKET GOVERNOR ACTUATOR ACTUATOR BOSCH 60 GOVERNOR REDUCER 3.0" TO 2.75" TURBO MIXER 40/60MM ACTUATOR ASSY O-RING 2-3/4 X 3/32 X 2-15/16 VENTURI THROTTLE 42MM (6.8L 100KW) VENTURI THROTTLE 44MM (6.8L 130KW) VENTURI THROTTLE 50MM (6.8L 150KW) WASHER LOCK 1/2 HARNESS FUEL JUMPER DUAL REG PLUG STD PIPE 1/4 STEEL SQ HD SCREW SHC M6-1.0 X 50 C8.8 CLAMP HOSE #44 2.31-3.25 WASHER LOCK M6-1/4 SCREW HHC M6-1.0 X 20 G8.8 WASHER FLAT M6 NIPPLE CLOSE 1.25 NPT X 1.625 CLAMP HOSE #52 2.81-3.75 BRACKET, HOSE RISER SCREW THF M6-1 X 16 N WA Z/JS PIPE TEE W/ BRACKET WELDED BARBED EL 90 3/16 X 1/8 HOSE VACUUM 5/32 (12.0”LG) HOSE VACUUM 5/32 (10.5”LG) BARBED EL W/VENT (.052") PLUG PIPE 1.25 SQ HD ZINC REVISION: K-2798-F DATE: 5/13/15 Page 2 of 2

ITEM 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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 18 19 20 21 22

EXPLODED VIEW: EV FUEL 6.8L 100KW NG CPL EMSN DRAWING #: 0J0309 APPLICABLE TO:

PART# 033212 065908 0G9782 052645 022304 022129 045773 022195 039130 0E7162 031015 0J1318 057822 059057 0F4408 0J7476 0E4390 0E4392 0F0960 0F3885 0G3167 0F3691E 026915 0A8064 026073A 0D2157 039294 022097 049811 0D2698 042568 064346 059057 066212 0G46350ST03 059057 059057 022097 077879 026073 077879 077879 077879 039450 0F1866A 0G5652 022473 0L5885 QTY. 4 1 1 2 4 4 2 2 1 1 1 1 8 1 1 1 1 1 1 1 2 1 4 2 1 2 1 2 2 2 4 1 6 1 1 1 1 2 1 1 1 1 1 3 1 1 2 1 DESCRIPTION SCREW HHC 5/16-18 X 1-1/4 G5 SUPPORT NAT GAS SOLENOID REG 6.8L CPL 100KW N/G EMISS SCREW HHC M12-1.75 X 30 C8.8

WASHER FLAT 1/2 ZINC WASHER LOCK M8-5/16 NUT HEX M12-1.75 G8 YEL CHR WASHER LOCK 1/2 NIPPLE CLOSE 1.25 NPT X 1.625 BSHG RDCR HEX 1-1/4 X 1/4FNPT NIPPLE PIPE 1-1/4 NPT X 3 HARNESS FUEL JUMPER DUAL REG CLAMP HOSE #8 .53-1.00 HOSE 3/4 ID SAE-30R2 (42” LG) Y CONNECTOR 500 SERIES BARBS ADAPTOR THROTTLE BODY GASKET GOVERNOR ACTUATOR ACTUATOR BOSCH 60 GOVERNOR REDUCER 3.0" TO 2.75" TURBO MIXER 40/60MM ACTUATOR ASSY O-RING 2-3/4 X 3/32 X 2-15/16 VENTURI, THROTTLE 42MM NIPPLE CLOSE 3/4 X 1.375 BSHG RDCR HEX 1-1/4-3/4 PLUG STD PIPE 1/4 STEEL SQ HD SCREW SHC M6-1.0 X 50 C8.8 CLAMP HOSE #44 2.31-3.25 WASHER LOCK M6-1/4 WASHER FLAT M6 GASKET ADAPTER THROT BODY SCREW HHC M6-1.0 X 20 G8.8 PIPE TEE 1-1/4 NPT HOSE 3/4 ID SAE-30R2 (45” LG) CLAMP HOSE #52 2.81-3.75 BRACKET, HOSE RISER HOSE 3/4 ID SAE-30R2 (9.5” LG) HOSE 3/4 ID SAE-30R2 (12” LG) WASHER LOCK M6-1/4 HOSE VACUUM 5/32 (5”LG) PLUG STD PIPE 1/8 STEEL SQ HD HOSE VACUUM 5/32 (18”LG) HOSE VACUUM 5/32 (6”LG) HOSE VACUUM 5/32 (8”LG) BARBED EL 90 3/16 X 1/8 BARBED EL W/VENT (.052") MANIFOLD, EMISSIONS VACUUM WASHER FLAT 1/4-M6 ZINC PLUG PLASTIC 1.25" TAPERED CAP GROUP E REVISION: K-3102-E DATE: 10/6/15 Page 2 of 2

EXPLODED VIEW: EV ENGCOMPRT R/H 6.8 (CPL) DRAWING #: 0F3058 ITEM PART# QTY. DESCRIPTION GROUP D

1 2 3 4 (3) 5 (3) 6 (1) 7 8 9 10 (2) 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 0D5623 0D5418 G022131 0F3514 G022473 0F2776A 029333A G057772 0F2929 0F9965C 0F9965C 0D5417 0K3440 G057765 G049340 069860E G042909 G022129 0D9913 G047290 G022097 G055596 G077996 0C7649 G047411 0G0321 0D3808 0D4255 G070010 0D2244M 0F3844 G052647 G046526 G039253 G070008 2 1 1 1 1 / 2 A/R 1 1 1 1 2 REF. 1 1 1 1 3 4 18 1 1 1 1 1 1 1 2 2 2 1 8 6 6 1 10 HEAT SHIELD EXHAUST STARTER MOTOR FORD V-10 ENGINE WASHER FLAT 3/8-M10 ZINC SPACER FLEXPLATE 5.4L/6.8L (1800 RPM UNITS ONLY) WASHER FLAT 1/4-M6 ZINC BRACKET SIGNAL CONDITIONER TIE WRAP UL 7.4" X .19" BLK (NOT SHOWN) WASHER NYLON .565 ENGINE ADAPTER 5.4L/6.8L FLEX PLATE 2 POLE (1800 RPM UNITS ONLY) FLEX PLATE 2 POLE (3600 RPM UNITS ONLY) SCREW HHC M10-1.0 X 25 G10.9 CLAMP HOSE 1.062OD DOUBLEWIRE (1800 RPM UNITS ONLY) ADAPTER M14-1.50 X 3/8 NPT BARBED EL 90 1/4NPT X 3/8 HOSE DRAIN ASSY 28" SCREW HHC M8-1.25 X 30 G8.8 WASHER LOCK M8-5/16 SCREW SHC M8-1.25 X 35 SS HOSE 3/8 ID SINGLE BRAID WASHER LOCK M6-1/4 BARBED STR 3/8 NPT X 3/8 CAP HOSE (1800 RPM UNITS ONLY) CLAMP HOSE .38-.87 SCREW HHC M6-1.0 X 16 G8.8 HOSE COOL 5/8" ID 250#WP (14”) EXH MANIFOLD MACH 6.8L V-10 GASKET EXHAUST MANIFOLD SCREW HHC M8-1.25 X 35 SS G8.8 ASSY MAGPICKUP (3/8-24 MALE) WASHER FLAT .43 X 1.00 SCREW SHC M10-1.5 X 25 G12.9 WASHER LOCK M10 SCREW HHC M8-1.25 X 20 G8.8 WASHER FLAT M8 SS 35 36 37 38 40 G070006 0D2608 0F5114 0F5454 0F6104 30 10 1 1 1 WASHER LOCK M8 SSTL SCREW HHC 5/16-18 X 1/2 SSTL DECAL REFER TO OWNERS MANUAL PLATE MAG PICK-UP ADAPTOR COVER STARTER 5.4 & 6.8 FORD CPL 43 44 45 048031P 048031J 0G1462 2 1 1 CLAMP HOSE BAND .88" CLAMP HOSE BAND .63 HOSE BARB REDUCER 5/8"-3/8"ID (1) NOTE: I/N 7 IS FOR HOLDING SENSORS TO I/N 6. (2) NOTE: I/N 11 IS PART OF ENGINE P/N 0D3454. (3) QTY. REQ. FOR NON-MQT / QTY REQ. FOR MQT EPA CERT. (NOT REQUIRED FOR NEXUS CONTROL PANELS) REVISION: CN-0016489-M DATE: 5/29/18 Page 2 of 2

EXPLODED VIEW: EV ENGCOMPRT 6.8L GB CPL R/H DRAWING #: 0F3557 ITEM PART# QTY. DESCRIPTION GROUP D

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 (2) 19 20 21 22 (1) 23 24 25 26 27 28 29 30 31 0D5418 G052625 G047411 0D5623 0D2608 G070006 G070008 G047290 0G0321 G046526 0K3440 G057765 G049340 0D5417 G049821 G022129 G070010 0F2776A G022097 G048191 G022473 029333A 0D9913 G055596 069860E 0D4255 G057772 0D6686 0D3803 0D3805 1 13 1 2 10 30 10 1 1 24 1 1 1 8 3 3 2 1 / 2 1 2 1 A/R 18 1 1 2 1 1 1 1 STARTER MOTOR FORD V-10 ENGINE SCREW SHC M10-1.5 X 35 G12.9 SCREW HHC M6-1.0 X 16 G8.8 HEAT SHIELD EXHAUST SCREW HHC 5/16-18 X 1/2 SSTL WASHER LOCK M8 SSTL WASHER FLAT M8 SS HOSE 3/8 ID SINGLE BRAID HOSE COOL 5/8" ID 250#WP (14”) WASHER LOCK M10 CLAMP HOSE 1.062OD DOUBLEWIRE (2300 & 3000RPM UNITS ONLY) ADAPTER M14-1.50 X 3/8 NPT BARBED EL 90 1/4NPT X 3/8 SCREW HHC M10-1.0 X 25 G10.9 SCREW SHC M8-1.25 X 30 G12.9 WASHER LOCK M8-5/16 SCREW HHC M8-1.25 X 35 SS F-TH BRACKET SIGNAL CONDITIONER WASHER LOCK M6-1/4 DOWEL PIN M10 X 24 WASHER FLAT 1/4 ZINC TIE WRAP UL 7.4" X .19" BLK (NOT SHOWN) SCREW SHC M8-1.25 X 35 SS BARBED STR 3/8 NPT X 3/8 HOSE DRAIN ASSY 28" GASKET EXHAUST MANIFOLD WASHER NYLON .565 ASSEMBLY 6.8L G-BOX FLYWHEEL FLYWHEEL HOUSING MACH 6.8L V10 COVER FLYWHEEL MACH 6.8L V-10 32 33 34 35 36 37 G021113 G077996 G022131 0C7649 G052647 0D2244M 1 1 7 1 9 1 PLATE DAMPNER RETNR CAP HOSE (2300 & 3000RPM UNITS ONLY) WASHER FLAT 3/8-M10 ZINC CLAMP HOSE .38-.87 SCREW SHC M10-1.5 X 25 G12.9 ASSY MAGPICKUP(3/8-24 MALE) 38 39 41 43 44 45 46 0D3808 0F5114 G079121 048031P 048031J G087599 0G1462 FOR NEXUS CONTROL PANELS) 2 1 2 2 1 1 1 (1) NOTE: I/N 23 IS FOR HOLDING SENSORS TO I/N 19. EXH MANIFOLD MACH 6.8L V-10 DECAL REFER TO OWNERS MANUAL SCREW SHC M10-1.50 X 100 G10.9 CLAMP HOSE BAND .88" CLAMP HOSE BAND .63 PLUG PLASTIC 3/8 NPT HOSE BARB REDUCER 5/8"-3/8"ID (2) QTY. REQ. FOR NON-MQT / QTY REQ. FOR MQT EPA CERT. (NOT REQUIRED REVISION: CN-0016489-M DATE: 5/29/18 Page 2 of 2

EXPLODED VIEW: EV ENGINE COM PRT L/H SIDE 6.8L

DRAWING #: 0J0212 APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION GROUP D

8 9 10 11 12 13 14 15 16 17 18 1 2 (2)3 (2)4 (1)5 6 7 0F3017 G039253 G022129 G022145 0D5419 0D7055 0D3488G 0D3488J 0D3488 0D3488K 057795B G065386 0F3287 0H9133 0E9868A 0G5954 0F3216 0F3216A 0F3216C 0F3216D G035579 0H7435 0D6658 0H0777 1 3 4/5 4/5 REF 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 19 20 21 22 23 24 25 26 27 (2)28 29 30 31 32 33 34 36 37 (2)38 39 40 (2)41 (2)42 (2)43 (2)44 (2)45 G022097 G022473 G042568 0D8027 0D8025 0D8026 0D8030 0F2846 0D8029 0D8028 045771 0H0923 022131 G046526 G064416 G045772 0F3217 0F6151 0F4308 0F3158 0G0015 0E0502 0G0866 0F4301 0E8286 047527 0K3440 6 6 2 4 1 3 1 1 1 1 1/2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 4 46 47 48 (2)49 0E0992A G078637 G047411 055934D G035473 10 A/R 4 4/7 1 50 (1) I/N 5 PART OF I/N 29. (2) PART OR QUANTITY REQUIRED FOR 150KW UNITS ONLY. BRACKET,D.C. ALTERNATOR LOWER SCREW HHC M8-1.25 X 20 C8.8 WASHER LOCK M8-5/16 WASHER FLAT 5/16-M8 ZINC OIL FILTER DIPSTICK TUBE, FORD 6.8L BELT SERPENTINE (65.0" LG) (1800 RPM) BELT SERPENTINE (65.3" LG) (2300 RPM) BELT SERPENTINE (67.16" LG) (3000 RPM) SERPENTINE BELT (68.3" LG) (3600 RPM) BARBED EL 90 5/8 PLASTIC HOSE COOL 5/8 ID 100R6 (16.75”LG) BRACKET DC ALTERNATOR UPPER HARN ENG G6.8L G3 NEXUS (USE WITH PROBE P/N 0H1827) (NOT SHOWN) ALTERNATOR DC W/OUT PULLEY GROMMET .625 X 1.25 X .433 PULLEY 80 OD DC ALTERNATOR (1800 RPM) PULLEY 102 OD DC ALTERNATOR (2300 RPM) PULLEY 132 OD DC ALTERNATOR (3000 RPM) PULLEY 160 OD DC ALTERNATOR (3600 RPM) BSHG RDCR HEX 1/4 TO 1/8 HARN LOW OIL PRESS SWITCH ASSY DIPSTICK G6.8L G3 DECAL LSI EPA CERTIFICATION WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC SCREW HHC M6-1.0 X 20 G8.8 SCREW WP PULLEY M8-1.25 X 19 BOLT HEX FL HD M8-1.25 X 28 BOLT HEX FL HD M8-1.25 X 31 TENSIONER ENG. AUTOMATIC BELT PULLEY WATER PUMP G3 (1800RPM UNITS) PULLEY ENGINE WATER PUMP (2-POLE & GEAR BOX) PULLEY GROOVED ENGINE IDLER NUT HEX M8-1.25 G8 CLEAR ZINC ENGINE G6.8L G3 V-10 (2009 +) WASHER FLAT 3/8-M10 ZINC WASHER LOCK M10 SCREW HHC M10-1.5 X 45 C8.8 FT NUT HEX M10-1.5 G8 YEL CHR SPACER DC ALTERNATOR PULLEY CAP RUBBER BRACKET DC ALT STABILIZER OIL COOLER G3 (150KW 3600RPM) CLAMP HOSE 7/8 OD DOUBLE WIRE TEMPERATURE SENDER DELPHI HOSE OIL COOLER PREFORMED 3/4 (150KW 3600RPM) HOSE OIL COOLER (150KW 3600RPM) ELBOW 45D STREET 1/2NPT BRASS (150KW 3600RPM) BARBED STR 1/2NPT X 3/4 (150KW 3600RPM) CLAMP HOSE 1.062OD DOUBLEWIRE (150KW 3600RPM) PLUG EXPANSION 14 OD ADHESIVE LOCTITE 620 SCREW HHC M6-1.0 X 16 C8.8 CLAMP STL/VNL 1.06 X .406 Z CLAMP HOSE #12 .50-1.25 REVISION: CN-0016489-D DATE: 5/29/18 Page 2 of 2

1 2 (1)3 (1)4 5 6 7 8 9 (1)10 (1)11 (5)12 13 14 15 16 17 18 (3)19 20 21 22 49 50 51 52 53 (2)54 (2)55 (2)56 (2)57 (2)58 (2)59 60 61 62 63 64 36 37 38 39 40 41 42 43 44 45 46 47 48 (5)23 24 25 26 27 28 29 30 31 (3)32 33 34 35 0H9221 0H6265 0F5376S0AR 0F5396S0AR 0H6169D 0H6169C 0H6267 G057073 0J0489 0H6160 0D7393T 0D7393U 0H67330ST0R 0D3700 0A2115 G022473 G022097 0H7115 REF -- G052777 G043182 G051714 0H81040AS0R G045764 0C2454 G023897 G036943 0D7177V G051713 G049226 G051716 -- G056326 G022237 G022241 0H8006 0D3580 G025507 G061383 G022131 G049814 G029289 G046526 G045772 G056739 G042568 0F5458 0D6029 G052857 G022152 G022158 0H7292 0H7293 G067989 0D5466 0A7822 G083896 G045335 G039287 0D7178T 0J1618 0H97300ST0R 0J3060 0A9457

EXPLODED VIEW: EV CONBOX C5 NEXUS DRAWING #: 0H9370 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION

PAGE 1 1 1 1 1 1 1 1 2 1 1 2 2 1 6 2 12 2 2 1 1 3 3 3 4 2 2 1 1 1 2 1 2 2 1 1 1 1 1 1 1 4 2 1 2 1 1 1 1 1 2 12 4 1 2 10 4 2 2 6 6 6 1 1 2 2 GROUP A BACK PANEL CONNBOX SUPPORT C5 TOP PANEL CONNBOX SUPPORT C2 MX150L SLRRMNT 22-18 8P W/O GA MX150L SLRRMNT 22-18 12P W/OGA ASSY PROG 2010 IGN MOD 10CYL ASSY PROG 2010 IGN MOD 8 CYL COVER VOLTAGE SHIELD JUNCTION BLOCK 3/8-16 DECAL CUSTOMER POWER CONNECT COVER WIRE ENTRY CONNBOX TERM BLOCK 3P UL 12-20AWG TERM BLOCK 4P UL 12-20AWG BRACKET GIMBAL CONTROL PNL NUT FLANGE M6-1.0 NYLOK WASHER NYLON .257 WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 KNOB M6-1.0 CONTROL PANEL ASSY CTRL PROGRAMMED SEE “C5 DPE BRKR & FIELD BOOST” CHART WASHER FLAT M3 WASHER LOCK M3 NUT HEX M3-0.5 G8 CLEAR ZINC COVER DPE BREAKER NEXUS RAW SCREW HHTT M4-0.7 X 8 ZP SCREW HWHT M6-1 X 16 N WA Z/JS WASHER FLAT #10 ZINC SCREW PPHM #10-32 X 2 DIODE BRIDGE 1P 35A 1000V WASHER FLAT M5 WASHER LOCK M5 NUT HEX M5-0.8 G8 CLEAR ZINC SEE “C5 DPE BRKR & FIELD BOOST” CHART TRIM VINYL BLACK 1/8GP (63“LG) WASHER LOCK 3/8 NUT HEX 3/8-16 STEEL DECAL CAUTION ELEC SHOCK SM SCREW SHC M5-0.8 X 20 C12.9 WASHER LOCK EXT 7/16 STL LUG SLDLSS 3/0-#4 X 13/32 CU WASHER FLAT 3/8-M10 ZINC SCREW HHC M10-1.5 X 25 C8.8 TAPE ELEC 1/2 FOAM WASHER LOCK M10 NUT HEX M10-1.5 G8 YEL CHR RELAY SOLENOID 12VDC PNL MNT SCREW HHC M6-1.0 X 20 C8.8 SCREW HHSP #10 X 3/8 HI-LOW SCREW HHTT M6-1.0 X 16 ZYC NUT TOP LOCK FL M6-1.0 WASHER LOCK #10 NUT HEX #10-32 STEEL DECAL CUSTOMER CONTROL CONNECT DECAL CONBOX TB1 CONNECTIONS NUT HEX FL WHIZ M8-1.25 BUSBAR NEUTRAL BLOCK 390 LUG SLDLSS 600/250-1/0X1/4-28 WASHER LOCK 1/4-M6 SS SCREW HHC 1/4-28 X 3/4 G5 SCREW HHC M8-1.25 X 45 C8.8 FUSE ATO TYPE 7.5AMP (BROWN) HARN EXCITATION NEXUS C3/C5 (NOT SHOWN) SHIELD HIGH/LOW C5 RAW GASKET WIRE ENTRY COVER DECAL NEUTRAL REVISION: CN-0032843-K DATE: 1/7/2020 Page 4 of 8

EXPLODED VIEW: EV CONBOX C5 NEXUS DRAWING #: 0H9370 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION

65 A B C D K L M N E F G H J E F (4)G (4)H J K L M (4)N (4)P (4)R S P R S T U V W X A B C (4)D A B C D (4)E (4)F G H J K (4)L (4)M (4)N (4)P R S T A B C 0H9271 0F8185 0F8189 0F8433 0H9272 0F9721 0D2157 G069232 G023897 G022152 G022158 G052647 G022131 G022237 G045772 0C2454 G036261 0G3257 0H9375 0H5582 0H5581A 067210A 0J0662 0F4149 0F4150 0F8432 0H7311 0F4186 G053640 G049897 G022129 G038150 G022264 G022471 0C2454 G022145 1 UL CIRCUIT BREAKER (225AF) 1 1 1 1 1 1 4 6 9 4 4 4 12 6 G036261 G058306 0F8451 0F8843 G045771 4 3 3 3 3 0G3257 10000023360 1 1 10000028391 2 UL CIRCUIT BREAKER (400AF) 0H9220 0F4153 G036261 0A7822 1 1 4 2/3 0H9270 G042419 G052647 G046526 G023897 G022152 G022158 0C2454 G022473 G022097 G045335 0G3257 1 4 2/3 2/3 4 4 4 8 4/6 4/6 4/6 1 PAGE 2 UL CIRCUIT BREAKER (800AF) 1 1 1 2 1 2/3 4/6 4 8 4 4 2/3 2/3 2/3 2/3 8 4 1 UL CIRCUIT BREAKER (KG) 1 1 1 DECAL GROUND LUG COVER CB G 225AF C5 CB 0150A 3P 480V G 225AF CB 0175A 3P 480V G 225AF INSUL CB 225AF STANDOFF CB BOX CONBOX COVER CB DISH 3P G 225AF SCREW RHM #8-32 X 3-1/4 SCREW SHC M8-1.25 X 20 G8 WASHER LOCK M8-5/16 WASHER FLAT #8 ZINC WASHER LOCK #8-M4 NUT HEX #8-32 STEEL SCREW HWHT M6-1 X 16 N WA Z/JS WASHER FLAT 5/16-M8 ZINC RIVET POP .125 X .275 SS SCREW SHC M8-1.25 X 25 C12.9 LUG SLDLSS 300 MCM-6 AL/CU BUS BAR 200A LUG ADAPTOR NUT HEX M8-1.25 G8 CLEAR ZINC DECAL TERMINAL SHOCK HZD BI ST03 LOCKOUT BRACKET VITZRO 225AF NUT TAMPER RESISTANT M5-0.8 COVER CB G 400AF C5 CB 0250A 3P 480V G 400AF RIVET POP .125 X .275 SS LUG SLDLSS 600/250-1/0X1/4-28 COVER CB DISH G 400AF C5 SCREW RHM 10-32 X 4 SCREW SHC M10-1.5 X 25 C12.9 WASHER LOCK M10 WASHER FLAT #10 ZINC WASHER LOCK #10 NUT HEX #10-32 STEEL SCREW HWHT M6-1 X 16 N WA Z/JS WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 SCREW HHC 1/4-28 X 3/4 G5 DECAL TERMINAL SHOCK HZD BI COVER CB G 800AF C5 CB 0630A 2P 480V G 800AF CB 0630A 3P 480V G 800AF INSUL CB 800AF COVER CB DISH G 800AF C5 LUG SLDLSS 3/0-400X3 MCM AL/CU SCREW SHC M6-1.0 X 50 C8.8 SCREW RHM #10-32 X 3-3/4 WASHER FLAT #10 ZINC WASHER LOCK #10 NUT HEX #10-32 STEEL SCREW SHC M10-1.5 X 25 C12.9 WASHER FLAT 3/8-M10 ZINC WASHER LOCK 3/8 NUT HEX M10-1.5 G8 YEL CHR SCREW HWHT M6-1 X 16 N WA Z/JS RIVET POP .125 X .275 SS DECAL TERMINAL SHOCK HZD BI COVER CB 3P E KG C5 CB 0300 3P 600V E KG LL INSULATOR CB E 3P KG GROUP A REVISION: CN-0032843-K DATE: 1/7/2020 Page 5 of 8

EXPLODED VIEW: EV CONBOX C5 NEXUS DRAWING #: 0H9370 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION

D E F G H J K E F G H A B C D G H J K L M J K L M N P A B C D E F J A B A B C D E F G H C D E F G H J K L A B C D E F 0H9372 0D5572 0F0199 0H6734 G081320 G022473 G022097 G022127 0C2454 0H9376 0H7519 0H6734 G042419 G040976 G022129 G022145 G023897 G022152 G022158 0C2454 0J2468 0D5580 0F2353 0H6734 G022770 G022473 0H6734 0D2157 0D3700 G022129 G022145 G049821 0C2454 0H9373 0H5486 0H4698A 0H7311 0H7434 0H5721 0C2454 G049226 G023897 G052619 G038150 G022264 G022471 G036261 0H9374 0H5580 0H5576A 0H6734 G022770 0C2454 G022129 G022145 G049897 G022473 G022097 G022127 1 4 4 3 3 3 12 UL CIRCUIT BREAKER (FG) 1 1 1 1 1 4 12 3 3 3 4 4 4 4 UL CIRCUIT BREAKER (JG) 1 1 1 1 4 12 3 3 3 4 4 4 PAGE 3 UL CIRCUIT BREAKER (FD) 1 1 1 1 4 4 4 4 12 UL CIRCUIT BREAKER (VL-JG) 1 1 1 4 3 3 3 4 4 4 12 UL CIRCUIT BREAKER (LD) 1 1 2 1 4 4 STANDOFF CB MOUNT CONBOX SCREW SHC M6-1.0 X 50 C8.8 NUT FLANGE M6-1.0 NYLOK WASHER LOCK M8-5/16 WASHER FLAT 5/16-M8 ZINC SCREW SHC M8-1.25 X 30 C12.9 SCREW HWHT M6-1 X 16 N WA Z/JS COVER CB 3P E FG C5 CB 0060 3P 600V E FG LL INSULATOR CB 3P E TYPE CC/FG STANDOFF CB BOX CONBOX COVER CB DISH 3P E FG SCREW PPHM #8-32 X 1-3/4 ZINC SCREW HWHT M6-1 X 16 N WA Z/JS WASHER LOCK M5 WASHER FLAT #10 ZINC SCREW HHC M5-0.8 X 20 G8.8 WASHER FLAT #8 ZINC WASHER LOCK #8-M4 NUT HEX #8-32 STEEL RIVET POP .125 X .275 SS COVER CB 3P E JG C5 CB 0250 3P 600V E JG LL INSULATOR CB E 3P JG STANDOFF CB MOUNT CONBOX SCREW RHM 1/4-20 X 3 SCREW HWHT M6-1 X 16 N WA Z/JS WASHER LOCK M8-5/16 WASHER FLAT 5/16-M8 ZINC SCREW SHC M8-1.25 X 20 G8 WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 NUT HEX 1/4-20 STEEL COVER CB 3P S FD6 C5 CB 0150A 3P 600V S FD6 LL INSULATOR CB FD FRAME 30MIL STANDOFF CB MOUNT CONBOX SCREW SHC 1/4-20 X 4.5 G8.8 NZ WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 NUT HEX 1/4-20 STEEL SCREW HWHT M6-1 X 16 N WA Z/JS COVER CB 3P S VL C5 CB 0300A 3P 600V S JG-VL LL STANDOFF CB MOUNT CONBOX SCREW RHM 10-32 X 4 SCREW SHC M8-1.25 X 20 C12.9 WASHER LOCK M8-5/16 WASHER FLAT 5/16-M8 ZINC WASHER FLAT #10 ZINC WASHER LOCK #10 NUT HEX #10-32 STEEL SCREW HWHT M6-1 X 16 N WA Z/JS COVER CB 2P S LD6 C5 CB 0500A 3P 600V S LD6 INSUL CIRCUIT BREAKER JD/LD STANDOFF CB MOUNT CONBOX SCREW RHM 1/4-20 X 3 WASHER FLAT 1/4-M6 ZINC REVISION: CN-0032843-K DATE: 1/7/2020 GROUP A Page 6 of 8

EXPLODED VIEW: EV CONBOX C5 NEXUS DRAWING #: 0H9370 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION

G H J A B C D E F G H J K L G022097 G022127 0C2454 0J2405 0H5674 0H5672A 0H6734 0D2157 0D3700 G043107 G022145 0C2454 G022129 G045771 4 4 12 UL CIRCUIT BREAKER (LG) 1 1 1 1 4 4 3 6 12 3 3 SHIELD CONTROL STAND WASHER LOCK M6-1/4 NUT HEX 1/4-20 STEEL SCREW HWHT M6-1 X 16 N WA Z/JS COVER CB 2P E LG C5 CB 0500A 3P 600V E LG LL INSULATOR CB E 3P LG STANDOFF CB MOUNT CONBOX SCREW SHC M6-1.0 X 50 C8.8 NUT FLANGE M6-1.0 NYLOK SCREW HHC M8-1.25 X 25 C8.8 WASHER FLAT 5/16-M8 ZINC SCREW HWHT M6-1 X 16 N WA Z/JS WASHER LOCK M8-5/16 NUT HEX M8-1.25 G8 CLEAR ZINC A 0H9612 0J0036 1 1 SHIELD WIRING CHUTE 150KW SHIELD WIRING CHUTE 100/130 C5 0J0037 1 SHIELD WIRING CHUTE 80KW C5 B 0C2454 2 SCREW HWHT M6-1 X 16 N WA Z/JS NOTES (UNLESS OTHERWISE SPECIFIED): (1)ITEMS INCLUDED WITH HARNESS P/N 0J0372 (2)ITEMS INCLUDED WITH NEUTRAL BLOCK P/N 0D5464B (3)SEE “C5 DPE BREAKER & FIELD BOOST RESISTOR SELECTION” TABLE (4)QTY. REQ’D. FOR 2 POLE BREAKER/QTY. REQ’D. FOR 3 POLE BREAKER (5) SHEET METAL PARTS LISTED IN THE BOM TABLE, PRIOR TO 1/1/16, ARE REPRESENTING GENERIC PARTS (NO COLOR) : • MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO SAP BOM. • CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169). GROUP A REVISION: CN-0032843-K DATE: 1/7/2020 Page 7 of 8

EXPLODED VIEW: EV CONBOX C5 NEXUS DRAWING #: 0H9370 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION

THIS PAGE LEFT INTENTIONALLY BLANK GROUP A REVISION: CN-0032843-K DATE: 1/7/2020 Page 8 of 8

ITEM

17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

EXPLODED VIEW: EV MFL 6.8 CPL C5 EMSN DRAWING #: 0J0206 APPLICABLE TO:

PART#

0H9732A 0H9732 0F9071 0A6765 0F4710 0F7200 0E6778 0F2809 0F2981A 0F2962 0C2454 022097 0F2830 088510 049721 049813 0L1789 0F2773C 0D3159 088775 080762 0F5447 022473 0F6214B 0G3163A 0H2099A 0F5512 0F4462 0C8566 0D3700

QTY.

8 2 1 6 4 1 20 2 2 2 1 2 2 2 1 1 1 2 6 6 4 1 2 2 4 12 2 6 12 8

DESCRIPTION

PIPE,EXH MAN R/H 6.8L LSI CPL PIPE,EXH MAN L/H 6.8L LSI CPL SENSOR OXYGEN RING GASKET 2.5 DIA WASHER LOCK M10 SS SCREW HHC M10-1.5 X 50 SS FTH BOLT U 3/8-16 X 3.00" W/SADDLE 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 NUT HEX M10-1.5 SS SCREW HHC M6-1.0 X 35 G8.8 BLK NUT HEX M6 X 1.0 G8 YEL CHR MUFFLER STRAP UPPER/LOWER EXHAUST BLANKET 900MM LONG FLANGE EXHAUST WASHER FLAT 3/8 SS BOLT U 3/8-16 X 2.62 BRKT MUFFLER WASHER FLAT 1/4-M6 ZINC PIPE ELBOW EXHAUST MUFFLER BLANKET EXHAUST MUFFLER 584MM CATALYST 3-WAY REFLEX WRAP 13MM 13 X 460 (12”LG) RAINCAP 2-1/2" AL SCREW HHFC M6-1.0 X 20 G8.8 NUT FLANGE M6-1.0 NYLOK

GROUP D

REVISION: K-1591-D DATE: 1/28/15 Page 2 of 2

EXPLODED VIEW: EV COOLING SYS AND FAN DRIVE DRAWING #: 0J0207 APPLICABLE TO:

GROUP D ITEM PART# QTY. DESCRIPTION 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 31 32 33 34 35 36 37 38 39 40 41 0J01150ST03 0F2611 0F5254 0F7077 046526 059981 0C2454 052250 076749 0F2573 0F2610 0H20620ST03 0H2051 0F2862 0F2560 022131 039287 0C8566 0F2561 0C8165 0D6795 0C7043 0E8909 0E8909A 048031C 0C8146 082774 0F2686 0F5463 0F8695 0F4028 0F4030 0F4032 042911 0F2872 022304 022195 022196 049813 052677 090283 0D6029 022145 022129 10000027544 1 1 1 1 12 4 2 2 1 1 1 1 1 1 1 9 1 12 1 1 2 4 2 1 1 1 1 1 1 1 1 1 1 1 8 1 1 16 1 4 1 1 4 2 1 WELDMENT RADIATOR SUPPORT C5 RADIATOR 680 X 680 X 70 CPL V-BELT 31/64" X 62-3/8" V-BELT 1/2" X 63-3/8" (6.8L, 100KW & 130KW) 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 HUB FLEX (MACH) COUPLING HUB FLEX (MACHINING) CLAMP HOSE BAND 1/4 SCREW HHC 5/16-24 X 1.124 KEY WOODRUFF 4 X 19D HOSE RADIATOR UPPER CPL HOSE LOWER RAD CPL C5 6.8L ASSY BRG/SHAFT CPL FANDRIVE PULLEY 6.5" DIA MACHINED (6.8L 100KW) PULLEY 6" DIA MACHINED (6.8L 130KW) PULLEY 5.5" DIA MACHINED (5.4L 80KW & 6.8L 150KW) 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 SCREW HHTT M6-1.0 X 16 ZYC WASHER FLAT 5/16-M8 ZINC WASHER LOCK M8-5/16 SPACER .42 X 1.5 X .25 STL/ZINC 42 43 44 45 46 47 (1) 48 49 50 51 53 54 55 56 57 58 59 60 (3) 61 62 63 64 65 035685 045764 065852 0C7649 055596 069860E 069811 0L01050ST0R 022473 022097 0F5050B 039253 051769 0C8145 0H1827 0H23980ST03 029032 049820 0H2844 0G53150AL0R 051756 057192 055934H 4 1 1 1 1 1 REF 1 16 16 1 3 1 8 1 1 2 2 2 (REF) 1 4 3 1 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 STR 3/8 NPT 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 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 SCREW SHC M10-1.5 X 30 C12.9 CLAMP STL/VNL .62 X .406 Z 66 67 072252 0D3700 1 8 GROMMET 1.37 X .06 X 1.00 NUT FLANGE M6-1.0 NYLOK 68 085662 3 TIE WRAP UL 14.6 X .14 BLK (NOT SHOWN) (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) FASTEN HOSE TO RADIATOR SUPPORT USING TIE WRAP I/N 68. DIRECT HOSE TOWARD BASE OF UNIT AND AWAY FROM EXHAUST COMPONENTS. REVISION: CN-0017427-G DATE: 6/26/18 Page 2 of 2

EXPLODED VIEW: EV EXCITER SHIELDING DRAWING #: 0J0659 APPLICABLE TO:

ITEM PART#

1 2 0C2454 0C2428 3 4 5 6 7 8 9 022155 023484K 0F3518 0F3517 0F3519 0F3520 023484N * PARTS INCLUDED WITH ALTERNATOR.

QTY.

11 2 2 1 1 1 1 1 1

DESCRIPTION

SCREW THF M6-1 X 16 N WA Z/JS SCREW PHTT #6-32 X 1/2 ZYC WASHER LOCK #6 BUSHING SNAP SB-1750-22 SIDE LH EXCITER SHIELD SIDE RH EXCITER SHIELD BOTTOM EXCITER SHIELD REAR COVER EXCITER SHLD BUSHING SNAP SB-2.5-31

GROUP A

REVISION: -A- DATE: 8/2/10 Page 2 of 2

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