Generac 130kW QT13068ANSYA Standby Generator Manual

Generac 130kW QT13068ANSYA Standby Generator Manual
Serial Number
6.8L
Industrial
100/130kW Models
EPA Certified
STATIONARY EMERGENCY GENERATOR
OWNER'S MANUAL
A new standard of reliability
—CAUTION—
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
This manual should remain with the unit.
Cover182 Rev. A 08/09
Part No. 0H3220
Stationary Emergency Generator
Table of Contents
PAGE
INTRODUCTION ...............................................................................1-1
Read this Manual Thoroughly .......................................................1-1
Operation and Maintenance ..........................................................1-1
How to Obtain Service .................................................................1-1
SAFETY RULES ...............................................................................1-2
IDENTIFICATION RECORD ...............................................................2-1
Data Label ...................................................................................2-1
EQUIPMENT DESCRIPTION .............................................................3-1
Equipment Description .....................................................................3-1
Engine Oil Recommendations ...........................................................3-1
Coolant Recommendations ..............................................................3-1
ENGINE PROTECTIVE DEVICES .......................................................4-1
Engine Protective Devices ................................................................4-1
Coolant Temperature Sensing .......................................................4-1
Low Coolant Level .......................................................................4-1
Oil Pressure Sensing ....................................................................4-1
Overcrank Shutdown ....................................................................4-1
Overspeed Shutdown ...................................................................4-1
RPM Sensor Loss Shutdown........................................................4-1
DC Fuse .......................................................................................4-1
FUEL SYSTEMS ..............................................................................5-1
Fuel Requirements .......................................................................5-1
Natural Gas Fuel System ..............................................................5-1
Propane Vapor Withdrawal Fuel System........................................5-1
LP Liquid Fuel System..................................................................5-1
SPECIFICATIONS .............................................................................6-1
Stationary Emergency Generator ..................................................6-1
Engine .........................................................................................6-1
Cooling System............................................................................6-1
Fuel System .................................................................................6-2
Electrical System .........................................................................6-2
5.4L & 6.8L Ignition Description .......................................................6-2
Ignition Power-up Input ("56 Line Input") ......................................6-2
Ignition Enable ("14 Line Input") ...................................................6-2
Ignition Shutdown on Loss of Crank or Cam Signals ....................6-2
Diagnostic Blink Patterns (Red LED Located
on the Ignition Control Board) ...................................................6-2
Weather and Maintenance Kits .....................................................6-3
GENERAL INFORMATION.................................................................7-1
Alternator AC Lead Connections .......................................................7-1
Four-lead, Single-phase Stator......................................................7-1
Alternator Power Winding Connections .............................................7-1
3-phase Alternators......................................................................7-1
3-phase Alternators ("Delta" Configuration)...................................7-2
INSTALLATION ................................................................................8-1
Installation .......................................................................................8-1
Preparation Before Start-up ..............................................................8-1
Transfer Switch ............................................................................8-1
Fuel System .................................................................................8-1
Generator Set Lubrication .............................................................8-1
Prior to Initial Start-up ..................................................................8-1
Engine Coolant .............................................................................8-1
Belt Tension .................................................................................8-1
Electrical System .........................................................................8-1
Initial Inspection for Genset Start-up ................................................8-1
Start-up Checklist ............................................................................8-2
Preparation for Start-up................................................................8-2
OPERATION .....................................................................................9-1
Stationary Emergency Generator Control and Operation ....................9-1
Operating Unit with Manual Transfer Switch......................................9-1
Engine Start-up and Transfer ........................................................9-1
Retransfer and Shutdown .............................................................9-1
Operating Unit with Automatic Transfer Switch .................................9-1
MAINTENANCE ..............................................................................10-1
Maintenance Performed by Authorized Service Dealers ..................10-1
Every Three Months ...................................................................10-1
Once Every Six Months ..............................................................10-1
Once Annually............................................................................10-1
First 30 Operating Hours ............................................................10-1
First 100 Operating Hours ..........................................................10-1
Every 500 Operating Hours ........................................................10-1
Cooling System..............................................................................10-1
Checking Fluid Levels.....................................................................10-1
Check Engine Oil ........................................................................10-1
Battery Fluid...............................................................................10-1
Engine Coolant ...........................................................................10-2
Maintenance Owner/Operator Can Perform .....................................10-2
Check Engine Oil Level ...............................................................10-2
Check Battery ............................................................................10-2
Exercise System ........................................................................10-2
Inspect Cooling System .............................................................10-2
Check Engine Coolant Level .......................................................10-2
Perform Visual Inspection ..........................................................10-2
Inspect Exhaust System .............................................................10-2
Check Fan Belt ...........................................................................10-2
Inspect Engine Governor ............................................................10-2
Changing Engine Oil ...................................................................10-2
Changing the Engine Air Cleaner.................................................10-3
Spark Plugs ...............................................................................10-3
Coolant Change .........................................................................10-3
Miscellaneous Maintenance ...........................................................10-3
Cleaning the Stationary Emergency Generator ............................10-3
Battery .......................................................................................10-4
Battery Maintenance ..................................................................10-4
Battery Replacement ..................................................................10-4
SERVICE SCHEDULE .....................................................................11-1
TROUBLESHOOTING .....................................................................12-1
Troubleshooting Guide....................................................................12-1
EMISSIONS WARRANTY ...............................................................13-1
NOTES
EXPLODED VIEWS & PARTS LISTS
WIRING DIAGRAMS & SCHEMATICS
Content042 Rev. B 02/10
SECTION
Safety Instructions
THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential
nSAVE
hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this
equipment.
INTRODUCTION

This symbol points out potential electrical shock hazard.

This symbol points out potential fire hazard.
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.
The operator is responsible for proper and safe use of the equipment. The manufacturer strongly recommends that the operator
read this Owner's Manual and thoroughly understand all instructions before using this equipment. The manufacturer also strongly
recommends instructing other users to properly start and operate
the unit. This prepares them if they need to operate the equipment
in an emergency.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest
Service Dealer for starting, operating and servicing procedures.
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.
Throughout this publication, and on tags and decals affixed to the
generator, DANGER, WARNING, CAUTION and NOTE blocks are
used to alert personnel to special instructions about a particular
service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are
as follows:
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 contribute to the need for maintenance service.
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.
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.
Indicates a hazardous situation or action which, if not
avoided, could result in minor or moderate injury.
NOTE:
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.
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 preventing accidents.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs, simply contact
a Service Dealer for assistance. Service technicians are factorytrained and are capable of handling all service needs.
Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTION blocks. The type of information each
indicates is as follows:
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.
This symbol points out important safety information that,
if not followed, could endanger personal safety and/or
property of others.
n


This symbol points out potential explosion hazard.
Safety004 Rev. F 05/10
1-1
Safety Instructions
SAFETY RULES
• The engine exhaust fumes contain carbon monoxide gas, which
can be DEADLY. This dangerous gas, if breathed in sufficient
concentrations, can cause unconsciousness or even death. For
that reason, adequate ventilation must be provided. This should
be considered prior to installing the generator. The unit should
be positioned to direct exhaust gasses safely away from any
building where people, animals, etc., will not be harmed. Any
exhaust stacks that ship loose with the unit must be installed
properly per the manufacturer's instruction, and in strict compliance with applicable codes and standards.
• Keep hands, feet, clothing, etc., away from drive belts, fans,
and other moving or hot parts. Never remove any drive belt or
fan guard while the unit is operating.
• Adequate, unobstructed flow of cooling and ventilating air is
critical in any room or building housing the generator to prevent
buildup of explosive gases and to ensure correct generator
operation. Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seriously affect
safe operation of the generator.
• Keep the area around the generator clean and uncluttered.
Remove any materials that could become hazardous.
• When working on this equipment, remain alert at all times.
Never work on the equipment when physically or mentally
fatigued.
• Inspect the generator regularly, and promptly repair or replace
all worn, damaged or defective parts using only factoryapproved parts.
• Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start-up. Disconnect
the cable from the battery post indicated by a NEGATIVE, NEG
or (–) first. Reconnect that cable last.
• Never use the generator or any of its parts as a step. Stepping
on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel
leakage, oil leakage, etc.
Study these SAFETY RULES carefully before installing, operating
or servicing this equipment. Become familiar with this Owner’s
Manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and
maintained. Many accidents are caused by failing to follow simple
and fundamental rules or precautions.
The manufacturer cannot anticipate every possible circumstance
that might involve a hazard. The warnings in this manual, and on
tags and decals affixed to the unit are, therefore, not all inclusive.
If a procedure, work method or operating technique is used that
the manufacturer does not specifically recommend, ensure that it
is safe for others. Also make sure the procedure, work method or
operating technique utilized does not render the generator unsafe.
the safe design of this generator,
nDespite
operating this equipment imprudently, neglecting its maintenance or being careless can cause
possible injury or death. Permit only responsible and capable persons to install, operate or
maintain this equipment.
these machines. Ensure all steps are taken to
Potentially lethal voltages are generated by
render the machine safe before attempting to
work on the generator.
of the generator are rotating and/or hot
nParts
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, standards, laws and regulations. Adhere strictly to local, state and
national electrical and building codes. Comply with regulations
the Occupational Safety and Health Administration (OSHA) has
established. Also, ensure that the generator is installed, operated and serviced in accordance with the manufacturer’s instructions and recommendations. Following installation, do nothing
that might render the unit unsafe or in noncompliance with the
aforementioned codes, standards, laws and regulations.
ELECTRICAL HAZARDS
• All stationary emergency generators covered by this manual
produce dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely high and dangerous voltages to the transfer switch as well as the generator.
Avoid contact with bare wires, terminals, connections, etc.,
on the generator as well as the transfer switch, if applicable.
Ensure all appropriate covers, guards and barriers are in place
before operating the generator. If work must be done around
an operating unit, stand on an insulated, dry surface to reduce
shock hazard.
• Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
1-2
Safety004 Rev. F 05/10
Safety Instructions
FIRE HAZARDS
• If personnel must stand on metal or concrete while installing,
operating, servicing, adjusting or repairing this equipment,
place insulative mats over a dry wooden platform. Work on the
equipment only while standing on such insulative mats.
• The National Electrical Code (NEC) requires the frame and
external electrically conductive parts of the generator to be connected to an approved earth ground. This grounding will help
prevent dangerous electrical shock that might be caused by a
ground fault condition in the generator or by static electricity.
Never disconnect the ground wire.
• Wire gauge sizes of electrical wiring, cables and cord sets must
be adequate to handle the maximum electrical current (ampacity) to which they will be subjected.
• Before installing or servicing this (and related) equipment, make
sure that all power voltage supplies are positively turned off at
their source. Failure to do so will result in hazardous and possibly fatal electrical shock.
• Connecting this unit to an electrical system normally supplied
by an electric utility shall be by means of a transfer switch so as
to isolate the generator electric system from the electric utility
distribution system when the generator is operating. Failure to
isolate the two electric system power sources from each other
by such means will result in damage to the generator and may
also result in injury or death to utility power workers due to
backfeed of electrical energy.
• Stationary emergency generators installed with an automatic
transfer switch will crank and start automatically when normal
(utility) source voltage is removed or is below an acceptable
preset level. To prevent such automatic start-up and possible
injury to personnel, disable the generator’s automatic start circuit (battery cables, etc.) before working on or around the unit.
Then, place a “Do Not Operate” tag on the generator control
panel and on the transfer switch.
• In case of accident caused by electric shock, immediately
shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID
DIRECT CONTACT WITH THE VICTIM. Use a nonconducting
implement, such as a dry rope or board, to free the victim from
the live conductor. If the victim is unconscious, apply first aid
and get immediate medical help.
• Never wear jewelry when working on this equipment. Jewelry
can conduct electricity resulting in electric shock, or may get
caught in moving components causing injury.
• Keep a fire extinguisher near the generator at all times. Do NOT
use any carbon tetra-chloride type extinguisher. Its fumes are
toxic, and the liquid can deteriorate wiring insulation. Keep the
extinguisher properly charged and be familiar with its use. If
there are any questions pertaining to fire extinguishers, consult
the local fire department.
EXPLOSION HAZARDS
• Properly ventilate any room or building housing the generator to
prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any fuel or oil
spills immediately. Ensure that no combustible materials are left
in the generator compartment, or on or near the generator, as
FIRE or EXPLOSION may result. Keep the area surrounding the
generator clean and free from debris.
• These generators may operate using one of several types
of fuels. All fuel types are potentially FLAMMABLE and/or
EXPLOSIVE and should be handled with care. Comply with all
laws regulating the storage and handling of fuels. Inspect the
unit’s fuel system frequently and correct any leaks immediately.
Fuel supply lines must be properly installed, purged and leak
tested according to applicable fuel-gas codes before placing
this equipment into service.
• Diesel fuels are highly FLAMMABLE. Gaseous fluids such
as natural gas and liquid propane (LP) gas are extremely
EXPLOSIVE. Natural gas is lighter than air, and LP gas is heavier
than air; install leak detectors accordingly.
CALIFORNIA PROPOSITION 65 WARNING
Engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects
and other reproductive harm.
CALIFORNIA PROPOSITION 65 WARNING
This product contains or emits chemicals known to the
State of California to cause cancer, birth defects and
other reproductive harm.
Safety004 Rev. F 05/10
1-3
General Information
IDENTIFICATION RECORD
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.
DATA LABEL
Every generator set has a DATA LABEL that contains important
information pertinent to the generator. The data label, which can be
found attached to the generator’s lower connection box, lists the
unit’s serial number and its rated voltage, amps, wattage capacity,
phase, frequency, rpm, power factor, production date, etc.
Stationary Emergency Generator Model and Serial
Number
This number is the key to numerous engineering and manufacturing details pertaining to your unit. Always supply this number
when requesting service, ordering parts or seeking information.
Data Label
Identy005 Rev. D 05/10
2-1
Equipment Description
EQUIPMENT DESCRIPTION
COOLANT RECOMMENDATIONS
This equipment is a revolving field, alternating current Stationary
Emergency Generator. It is powered by a gaseous fueled engine
operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for
2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear
units. See the Specifications section for exact numbers. The unit
comes complete with a sound attenuated enclosure, internally
mounted muffler, control console, mainline circuit breaker, battery charger, and protective alarms as explained in the following
paragraph.
Use a mixture of half low silicate ethylene glycol base anti-freeze
and deionized water. Cooling system capacity is listed in the
specifications. Use only deionized water and only low silicate
anti-freeze. If desired, add a high quality rust inhibitor to the recommended coolant mixture. When adding coolant, always add the
recommended 50-50 mixture.
not use any chromate base rust inhibitor
nDo
with ethylene glycol base anti-freeze or chromium hydroxide (“green slime”) forms and will
All AC connections, including the power leads from the alternator, 120 volt battery charger input and control connections to the
transfer switch are available in the main connection box.
cause overheating. Engines that have been
operated with a chromate base rust inhibitor
must be chemically cleaned before adding ethylene glycol base anti-freeze. Using any high
silicate anti-freeze boosters or additives will
also cause overheating. The manufacturer also
recommends that any soluble oil inhibitor is
NOT used for this equipment.
The Stationary Emergency Generator incorporates the following
alternator features:
• Rotor and Stator insulation class is rated as defined by NEMA
MG1-32.6, NEMA MG1-1.66. The generator is self ventilated
and drip-proof constructed. Refer to the Specifications section
or the data label for the class ratings.
• The voltage waveform deviation, total harmonic content of the
AC waveform and telephone influence factor have been evaluated and are acceptable according to NEMA MG1-32.
not remove the radiator pressure cap while
nDo
the engine is hot or serious burns from boiling
liquid or steam could result.
ENGINE OIL RECOMMENDATIONS
The unit has been filled with 5W-20 engine oil at the factory. Use
a high-quality detergent oil classified “For Service SJ or SH.”
Detergent oils keep the engine cleaner and reduce carbon deposits.
When changing the engine oil, be sure to use 5W-30 engine oil.
glycol base antifreeze is poisonous.
nEthylene
Do not use mouth to siphon coolant from the
radiator, recovery bottle or any container. Wash
hands thoroughly after handling. Never store
used antifreeze in an open container because
animals are attracted to the smell and taste of
antifreeze even though it is poisonous to them.
attempt to crank or start the engine before
nAny
it has been properly serviced with the recommended oil may result in an engine failure.
NOTE:
If not already equipped, it is strongly recommended to use the
optional Cold Weather Start Kit for temperatures below 32° F.
The part number for the Cold Weather Start Kit can be found
in the Specifications section or by contacting an authorized
dealer. The oil grade for temperatures below 32° F is 5W-30
synthetic oil.
Equip001 Rev. G 05/10
3-1
Engine Protective Devices
ENGINE PROTECTIVE DEVICES
OIL PRESSURE SENSING
The Stationary Emergency Generator may be required to operate
for long periods of time without an operator on hand to monitor
such engine conditions as coolant temperature, oil pressure or
rpm. For that reason, the engine has several devices designed to
protect it against potentially damaging conditions by automatically
shutting down the unit when the oil pressure is too low, the coolant
temperature is too high, the coolant level is too low, or the engine
is running too fast.
An analog Oil Pressure Sender (OPS) is used for monitoring the
engine oil pressure. This sender allows the control panel to measure and display the Engine oil pressure.
The OPS is a resistive device, whose resistance changes based
on engine oil pressure. The resistance of the sender results in a
voltage being developed across the sender. As the oil pressure
increases, the resistance will decrease, causing the voltage to
decrease. This changing voltage is converted to 4-20mA signal by
a signal conditioner module. The corresponding 4-20mA signal is
read by the control panel and displayed as the oil pressure.
NOTE:
Engine protective switches and sensors are mentioned here for
the reader's convenience. Also refer to the applicable control
panel manual for additional automatic engine shutdown information.
The control panel will monitor and display oil pressure anytime the
DC input to the control panel is present.
Should the oil pressure drop below the 8 psi range, the engine
shutdown is initiated. The unit should not be restarted until oil is
added. Turn the AUTO/OFF/ MANUAL switch to the OFF position,
then back to AUTO to restart.
COOLANT TEMPERATURE SENSING
An analog Water Temperature Sender (WTS) is located in the
engine's cooling system. This sender is connected to the panel
and allows the panel to monitor and display the temperature of the
coolant system.
OVERCRANK SHUTDOWN
When the control panel receives a start signal, it initiates the programmed starting sequence. The start sequence consists of the
number of crank attempts, the length of each crank attempt, and
the rest time between each crank attempt. If the engine has not
started by the end of the final crank attempt, an Overcrank alarm
is generated, the control panel will sound the alarm and display the
message "Failed to start".
The WTS is a resistive device whose resistance changes based
on coolant temperature. The resistance of the sender results in a
voltage being developed across the sender. As the Coolant temperature increases, the resistance will decrease, causing the voltage to decrease. This changing voltage is converted to 4-20mA
signal by a signal conditioner module. The corresponding 4-20mA
signal is read by the control panel and displayed as the coolant
temperature.
OVERSPEED SHUTDOWN
The control panel will monitor and display the coolant temperature
anytime the DC input to the control panel is present.
If the temperature exceeds approximately 140° C (284° F), the
engine shutdown will be initiated. The generator will automatically
restart and the display will reset once the temperature has returned
to an operating level.
A speed circuit controls engine cranking, start-up, operation and
shutdown. Engine speed signals are delivered to the circuit board
whenever the unit is running. Should the engine over speed above
a safe, preset value, the circuit board initiates an automatic engine
shutdown. Contact the nearest Authorized Dealer if this failure
occurs.
LOW COOLANT LEVEL
RPM SENSOR LOSS SHUTDOWN
A Low Coolant Level (LCL) sensor is placed in the generators coolant system. This sensor allows the panel to detect a Low Coolant
Level condition.
If the speed signal to the control panel is lost, engine shutdown
will occur.
DC FUSE
The LCL is a resistive device whose resistance changes rapidly
based on the presence or absence of coolant.
This fuse is located inside of the control panel. It protects the panel
wiring and components from damaging overload. Always remove
this fuse before commencing work on the generator. The unit will
not start or crank if the fuse is blown. Replace the fuse with one of
the same size, type, and rating. (See the exploded views and parts
lists at the end of this manual for replacement part number.)
The resistance of the LCL results in a voltage being developed
across the LCL. This voltage changes as the resistance changes.
This changing voltage is converted to 4-20mA signal by a signal
conditioner module. The corresponding 4-20mA signal is read by
the control panel and displayed as the low coolant level.
If the level of the engine coolant drops below the level of the low
coolant level sensor, the engine shutdown will be initiated.
EngProt002 Rev. D 06/10
4-1
Fuel System
FUEL SYSTEM
PROPANE VAPOR WITHDRAWAL FUEL SYSTEM
This type of system utilizes the vapors formed above the liquid
fuel in the supply tank. Approximately 10 to 20 percent of the tank
capacity is needed for fuel expansion from the liquid to the vapor
state. The vapor withdrawal system is generally best suited for
smaller engines that require less fuel. The installer should be aware
of the following:
FUEL REQUIREMENTS
The Stationary Emergency Generator may be equipped with one of
the following fuel systems:
• Natural gas fuel system
• Propane vapor (PV) fuel system
• Liquid propane (LP) fuel system
Recommended fuels should have a Btu content of at least 1,000
Btu's per cubic foot for natural gas; or at least 2,520 Btu's per
cubic foot for LP gas. Ask the fuel supplier for the Btu content of
the fuel.
• The natural gas and LP gas systems are similar. However, the
natural gas system delivers gas at a pressure of approximately
five inches water column to the carburetor.
• When ambient temperatures are low and engine fuel consumption is high, the vapor withdrawal system may not function
efficiently.
• Ambient temperatures around the supply tank must be high
enough to sustain adequate vaporization, or the system will not
deliver the needed fuel volume.
• In addition to the cooling effects of ambient air, the vaporization
process itself provides an additional cooling effect.
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 fuel consumption requirements.
LP FUEL SYSTEM
NOTE:
The recommended fuel pressure is identified in the Specifications
section this manual.
LP is supplied as a liquid in pressure tanks. It is usually made up
of propane, butane, or a mixture of the two gases. Propane tends
to vaporize readily even at temperatures as low as -20° F (-29° C).
However, butane reverts to its liquid state when temperatures drop
below 32° F (0° C).
NATURAL GAS FUEL SYSTEM
LP in a liquid withdrawal system must be converted to its gaseous
state before it is introduced into the engine carburetor. A vaporizerconverter is generally used to accomplish this. In such a converter,
heated engine coolant is ported through the converter to provide
the necessary heat for conversion of the fuel from a liquid to a
gaseous state.
• Gas pressure in a building is usually regulated by national, state
and local codes.
• To reduce gas pressure to a safe level before the gas enters a
building, a primary regulator is needed. The natural gas supplier
may or may not supply such a regulator.
• It is the responsibility of the gas supplier to make sure sufficient
gas pressure is available to operate the primary regulator.
• Gas pressure at the inlet to the fuel shutoff solenoid should not
exceed approximately 14 inches water column (0.5 psi).
5-1
FuelSys006 Rev. C 06/10
Natural gas is supplied in its vapor state. In most cases, the gas
distribution company provides piping from the main gas distribution line to the standby generator site. The following information
applies to natural gas fuel systems.
Stationary Emergency Generator
Specifications
SPECIFICATIONS
Engine Parameters
Rated Synchronous RPM ...................................See Data Label
Gross HP at rated kW
NG (100/130/150) ................................ 60 Hz, (149/192/231)
LP (100/130/150)................................. 60 Hz, (162/208/231)
‹ 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 (150kW)....................... 6-wire
Alternator Output Leads 3-phase (100/130kW - 600V) .... 6-wire
Alternator Output Leads 3-phase (100/130kW - 208V,
240V, 480V) .............................................................. 12-wire
Bearings .................................................................. Sealed Ball
Coupling
100/130kW ............................................................Gear Drive
150kW.................................................................Flexible Disk
Excitation System ......................................................Brushless
Exhaust System
Exhaust Flow at Rated Output 60 Hz ........................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
Circuit Breaker Size (Amps)
100kW
130kW
150kW
120/240V - 1ø
500
600
700
120/208V - 3ø
400
500
600
120/240V - 3ø
350
450
500
277/480V - 3ø
175
225
250
600V - 3ø
150
N/A
200
130kW
150kW
240V, 1-phase
240V, 3-phase
208V, 3-phase
206
270
313
480V, 3-phase
275
320
350
600V, 3-phase
275
N/A
350
Exhaust Temp °F
Combustion Air
Flow CFM
100
888
960
262
130
1119
970
336
150
1535
1100
410
Governor
Type...........................................................................Electronic
Frequency Regulation .............................................Isochronous
Steady State Regulation ..............................................± 0.25%
Adjustments:
Speed ............................................................................... Yes
Droop ............................................................................... Yes
Generator Locked Rotor KVA Available @ Voltage Dip of 35%
100kW
Exhaust Flow
CFM
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)
Maximum External Press. Drop on Radiator ................. 0.5" H20
Refer to the Data Label on the generator for rated watts, amperes, frequency, voltage, 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.............................................................................. 3.55 in.
Stroke ........................................................................... 4.17 in.
Compression Ratio.......................................................... 9-to-1
Air Intake System ......................................... Naturally Aspirated
Valve Seats ................................................................ Hardened
Lifter Type.................................................................. Hydraulic
Chart 2
6-1
kW
Cooling Airflow
ft3/min
Fan Speed RPM
Heat Rejection
BTU/hr
100
5500
1670
342,000
130
6450
1950
496,000
150
7800
2200
568,000
GenSpec073 Rev. C 02/10
Voltage
kW
Stationary Emergency Generator
Specifications
‹ FUEL SYSTEM
Engine Timing versus Engine Speed for the 6.8L engine is:
Type of Fuel ........................................... LP Vapor/Natural Gas*
Carburetor............................................................... Down Draft
Secondary Fuel Regulator............................................ Standard
Fuel Shut-off Solenoid ................................................. Standard
Operating Fuel Pressure .................. 11 in. - 14 in. Water Column
Recommended
RPM
NG/LP Engine Timing (BTDC)
1800 rpm
22 degrees
3600 rpm
24 degrees
Engine Timing versus Engine Speed for the 5.4L engine is:
RPM
1800 rpm
3600 rpm
* Engine is not field convertible between natural gas and propane. Jet size and ignition timing
are factory set for the specific fuel.
Fuel Consumption - lb/hr (Natural Gas/LPV) @ 11 in
H20/68°F
kW
Exercise
Cycle
25% Load
50% Load
75% Load
100% Load
100
5.57/6.22
15.89/22.76
33.53/36.84
44.49/49.51
56.24/62.95
130
5.78/6.58
20.65/30.76
44.93/48.83
58.01/64.33
73.53/81.76
150
6.64/7.54
23.82/36.22
54.78/55.46
71.65/72.60
91.34/90.73
NG/LP Engine Timing (BTDC)
26 degrees
26 degrees
‹ IGNITION POWER-UP INPUT ("56 LINE INPUT")
When battery voltage is applied to this input the ignition will powerup. For the ignition to power itself down, battery voltage must be
removed from this input.
‹ IGNITION ENABLE ("14 LINE INPUT")
This input must be connected to the +12V battery for the ignition
to turn-on the coils. If this input is connected to battery ground
the ignition will stop firing the coils and will power down within
approximately 2 seconds. In the event that an ignition fault has
occurred, however, the ignition will wait 60 seconds before powering down. This allows time to view the diagnostic LED located on
the ignition board.
‹ ELECTRICAL SYSTEM
Battery Charge Alternator ......................................12V, 30 Amp
Static Battery Charger ...........................................12V, 10 Amp
Recommended Battery
100/130kW ........................................... 27F, 700 CCA @ 0°F
150kW................................................... 24F, 525 CCA @ 0°F
System Voltage ............................................................ 12 Volts
Voltage Regulator
Type.......................................................................... Full Digital
Sensing ....................................................................... 3-phase
Regulation.................................................................... ± 1/4%
Features ...................................... Built into H-100 Control Panel
V/F Adjustable, Adjustable
Voltage and Gain
NOTE:
The ignition cover does not need to be removed to see the
LED.
‹ IGNITION SHUTDOWN ON LOSS OF CRANK OR CAM
SIGNALS
The ignition will stop firing the coils immediately following the
loss of the crank signal. The ignition will stop firing the coils after
approx. 3 seconds following the loss of the cam signal.
Power Adjustment for Ambient Conditions
Temperature Deration
3% for every 10° C above °C ..............................................25
1.65% for every 10° above °F .............................................77
Altitude Deration
1% for every 100 m above m............................................183
3% for every 1000 ft. above ft. .........................................600
‹ DIAGNOSTIC BLINK PATTERNS (RED LED
LOCATED ON THE IGNITION CONTROL BOARD)
During normal ignition operation the RED LED flashes at a 0.5 sec
ON and a 0.5 sec OFF rate. This is considered one (1) blink.
LED Fault Code with Priority as shown:
Controller .............................................................. H-panel
1.
No Crank Signal: LED blinks 2 times, is OFF for 3.0 seconds
and then repeats
2. No CAM Signal: LED blinks 3 times, is OFF for 3.0 seconds
and then repeats
Only one fault is displayed at a time. If multiple faults exist then the
highest priority fault must be resolved prior to a lower priority fault
being displayed. In the event that an ignition fault has occurred the
ignition will wait 60 seconds before powering down.
5.4L & 6.8L IGNITION DESCRIPTION
This single-fire Ignition is intended to operate with a 10-cylinder,
6.8L engine and an 8-cylinder, 5.4L engine.
The 6.8L engine uses a 40-1 crank sensor, a mag-pickup CAM
sensor and individual coil-on-plug coils for each spark-plug.
The 5.4L engine uses a 36-1 crank sensor, a mag-pick-up CAM
sensor and individual coil-on-plug coils for each spark-plug.
NOTE:
The ignition cover does not need to be removed to see the
LED.
With a single-fire ignition, each high-voltage coil output is connected to one spark plug resulting in that spark plug being fired
only during the compression cycle.
6-2
GenSpec073 Rev. C 02/10
Stationary Emergency Generator
Specifications
‹ WEATHER AND MAINTENANCE KITS
To keep the generator running at its peak, the following kits are
offered:
• Cold Weather Kit
~ Recommended for climates with temperatures below 32° F.
• Extreme Cold Weather Kit
~ Recommended Block Heater Kit for protection in temperatures below 32° F. This kit comes pre-installed on all industrial gaseous units.
• Scheduled Maintenance Kit
~ Kit includes the recommended parts to maintain the generator. 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.
GenSpec073 Rev. C 02/10
6-3
General Information
ALTERNATOR AC LEAD
CONNECTIONS
ALTERNATOR POWER WINDING
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.
3-PHASE ALTERNATORS ("Y" CONFIGURATION)
The Stationary Emergency Generator is designed to supply
3-phase electrical loads. Electric power is produced in the alternator power windings. These windings were connected at the factory
to the main circuit breaker with a “Y” configuration as shown in
Figures 7.2 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.
FOUR-LEAD, SINGLE-PHASE STATOR
The rated voltage between each circuit breaker terminal and the
neutral point 00 is 277V, 120V, or 346V depending on the model.
Four-lead alternators (see Figure 7.1) are designed to supply electrical loads with voltage code “A” (240V, 1-phase, 60 Hz). Electrical
power is produced in the stator power windings. These windings
were connected at the factory to the main circuit breaker as shown
in Figure 7.1.
Figure 7.2 — Stator Power Winding
Connections - 3-phase, 277/480V (6 Lead)
E1
The rated voltage between each circuit breaker terminal is 240V.
The rated voltage between each circuit breaker terminal and the
neutral point 00 is 120V.
INTERNAL
CONNECTIONS
S1
Figure 7.1 — Four-lead, Single-phase Stator
L-L
S4
S6
00 (NEUTRAL)
S5
S2
S3
E3
E2
L-N
Figure 7.3 — Stator Power Winding
Connections - 3-phase, 277/480V (12 Lead)
E1
S1
S4
S7
L-L
S6
S9
S10
S11
S8
S5
S2
S3
E3
7-1
L-N
E2
ACConn007 Rev. B 05/10
S12
General Information
3-PHASE ALTERNATORS ("DELTA" CONFIGURATION)
Figure 7.4 — Stator Power Winding
Connections - 3-phase, 120/208V (6 Lead)
INTERNAL CONNECTIONS
The Stationary Emergency Generator is designed to supply
3-phase electrical loads. Electric power is produced in the alternator power windings. These windings were connected at the factory
to the main circuit breaker with a “Delta” configuration as shown
in Figures 7.7 and 7.8.
E1
S1
S1
The rated voltage between circuit breaker terminals E1-E2, E1-E3
and E2-E3 is 240V.
S6
S3
E3
S5
The rated voltage between E1 or E3 and the neutral point 00 is
120V.
L-L
S4
S4
00 (NEUTRAL)
Figure 7.7 — Stator Power Winding
Connections - 3-phase, 120/240V (6 Lead)
S2
S6 S5
S3
E2
E2
S2
S6
S2
L-N
INTERNAL
CONNECTIONS
Figure 7.5 — Stator Power Winding
Connections - 3-phase, 120/208V (12 Lead)
L-L
E1
S1
S7
S3
S5
S12
S9
E3
E1 S1
L-L
S4
S10
S4
E3
L-N
S5
00 (NEUTRAL)
S2
S6 S11
S3
S8
Figure 7.8 — Stator Power Winding
Connections - 3-phase, 120/240V (12 Lead)
E2
L-N
E2
S2
Figure 7.6 — Stator Power Winding
Connections - 3-phase, 346/600V (6 Lead)
E1
INTERNAL
CONNECTIONS
S12
S5
S1
S9
L-L
S8
L-L
S4
S6
S6
S3
S11
E1 S1
00 (NEUTRAL)
S5
S10 E3
L-N
00 (NEUTRAL)
S2
S3
E3
L-N
E2
7-2
ACConn007 Rev. B 05/10
Stationary Emergency Generator
Installation
INSTALLATION
‹ PRIOR TO INITIAL START-UP
Refer to the separate “Installation Guide” supplied with the unit.
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.
to initially starting the generator, it must
 Prior
be properly prepared for use. Any attempt to
crank or start the engine before it has been
properly serviced with the recommended types
and quantities of engine fluids (oil, coolant, fuel,
etc.) may result in an engine failure.
PREPARATION BEFORE START-UP
‹ ENGINE COOLANT
The instructions in this section assume that the Stationary
Emergency Generator has been properly installed, serviced, tested,
adjusted and otherwise prepared for use by a competent, qualified
installation contractor. Be sure to read the “Safety Rules”, as well
as all other safety information in this manual, before attempting to
operate this (and related) equipment.
Have the engine cooling system properly filled with the recommended coolant mixture. Check the system for leaks and other
problems. See “Specifications” and “Coolant” sections.
‹ BELT TENSION
Before starting the generator for the first time, the installer
must complete the following procedures. For follow-up maintenance information and/or service intervals, please refer to the
“Maintenance” section and the “Service Schedule”.
Check-the engine-fan belt tension and condition prior to placing
the unit into service and at recommended intervals. Belt tension is
correct when a force of approximately 22 pounds (10 kg), applied
midway between pulleys, deflects the belt about 3/8- to 5/8-inch
(10 to 16 mm).
‹ TRANSFER SWITCH
‹ ELECTRICAL SYSTEM
If this generator is used to supply power to any electrical system
normally powered by an electric utility, the National Electrical Code
requires that a transfer switch be installed. The transfer switch prevents electrical backfeed between two different electrical systems.
(For additional information, see the applicable transfer switch
manual for this unit.) The transfer switch, as well as the generator
and other electrical components, must be properly located and
mounted in strict compliance with applicable codes, standards
and regulations.
Make sure the generator is properly connected to an approved
earth ground.
Make sure the generator battery is fully charged, properly installed
and interconnected, and ready for use.
NOTE:
Battery charger must be connected to 120 VAC, 15 amp circuit
to operate.
‹ FUEL SYSTEM
Check to ensure that there are no loose electrical connections.
Restrain any loose wires to keep them clear of any moving generator set components.
Make sure the fuel supply system to the generator (a) delivers the
correct fuel at the correct pressure and (b) is properly purged and
leak tested according to code. No fuel leakage is permitted. See
“Specifications” for more information.
INITIAL INSPECTION FOR GENSET
STARTUP
‹ GENERATOR SET LUBRICATION
Inspect for the following.
Check the engine crankcase oil level before operating and add
oil to the proper level – the dipstick “FULL” mark. Never operate
the engine with the oil level below the dipstick “ADD” mark. See
“Specifications” and “Engine Oil Recommendations”.
•
•
•
•
•
Freight Damage.
Manuals present.
Fluid Levels (Oil, coolant, battery, Gear Drive).
Correct fuel piping.
Correct muffler installation for external applications (open units
only).
• Adequate air flow, clearances and ventilation per installation
drawings and applicable codes.
• Correct AC and DC wire size, connections and grounding.
Control and communication wiring to/from the transfer switch
must be run in a separate conduit from the AC power leads.
Check the oil level in the generator gearbox (if so equipped) prior to
initial use and at the intervals indicated by the “Service Schedule.”
The recommended oil is SAE 90 gear lubricant.
NOTE:
This engine is shipped from the manufacturer with “break-in”
oil. This oil should be changed after 30 hours of operation.
• Battery charger connection to 120 VAC.
• Unit secured to pad.
Install002 Rev. F 08/09
8-1
Stationary Emergency Generator
Installation
START-UP CHECKLIST
• Open the generator main line circuit breaker.
• Connect a manometer to the gas line and record the static pressure. It must be as listed in the Specifications.
• Insert the fuse into the control panel.
• Move the AUTO/OFF/MANUAL switch to the manual position.
The engine should now crank and start.
• Check voltage at the generator terminals.
• For 3-phase units, check phase rotation at the transfer switch
terminals. The generator phase rotation must match the utility
phase rotation.
• Check for coolant, fuel, oil, and exhaust leaks.
• Close the generators main line circuit breaker.
• Turn the generator set off.
• Connect the UTILITY supply to the transfer switch.
• Set the AUTO/OFF/MANUAL switch to AUTO.
• Disconnect utility power before the transfer switch.
Engine should start, transfer to load.
Run at least 15 minutes on generator power. Make certain all
3-phase loads are functioning correctly (correct phase rotation).
• Reconnect Utility power
Transfer switch will transfer back to Utility and engine will
shut down within the given time parameters set up for the
specific transfer switch and controller.
• Install all covers, access plates and door panels.
• Put the Owners Manual in a safe and accessible place.
• Make certain the AUTO/OFF/MANUAL switch is in the AUTO
position.
working on the Stationary Emergency
 Before
Generator, ensure the following:
• The AUTO/OFF/MANUAL switch is in the OFF position.
• The 120VAC supply to the battery charger is switched OFF.
‹ PREPARATION FOR START-UP
• Ensure that the 120VAC circuit breaker to the battery charger is
open.
• Remove the fuse from the the control panel. Open the front door
of the control box and remove the 15 Amp ATO fuse in the lower
left-hand corner of the control box.
• Connect the battery cables to the battery. Attach negative battery cable last.
• Close the 120VAC circuit breaker to the battery charger.
• Measure the voltage at the battery before and after the charger
is turned on.
• Verify all AC electrical connections are tight at the circuit breaker
and transfer switch.
• Visually inspect entire area looking for loose paper, plastic
wrappings, leaves, etc.
• Check all hoses clamps fittings for leaks or damage.
• Check all electrical plugs throughout the generator. Ensure each
plug is seated correctly and fully inserted into its receptacle.
• Verify the AUTO/OFF/MANUAL switch is in OFF position.
• Open the valve to the engine fuel line.
• Bleed the fuel system of air. (necessary for long fuel lines).
8-2
Install002 Rev. F 08/09
Operation
STATIONARY EMERGENCY
GENERATOR CONTROL AND
OPERATION
not crank the engine continuously for longer than 30 seconds, or the heat may
nDo
damage the starter motor.
Refer to the appropriate control panel operator’s manual for this
unit.
• Let engine stabilize and warm up.
• Check all applicable instrument and gauge readings. When
certain that all readings are correct, move the transfer switch
manual handle to the STANDBY (or EMERGENCY STANDBY)
position, i.e., load circuits supplied by the generator.
• Set the generator’s main line circuit breaker to its ON (or
CLOSED) position.
• Load circuits are now powered by the generator.
OPERATING UNIT WITH MANUAL
TRANSFER SWITCH
If the Stationary Emergency Generator was installed in conjunction
with a transfer switch capable of manual operation only, the following procedure applies. A manually operated transfer switch is
one that will not provide automatic start-up and does not include
an intelligence circuit.
RETRANSFER AND SHUTDOWN
For additional information, refer to the applicable control panel
manual for this unit, as well as any literature pertaining to the
specific transfer switch.
ENGINE START-UP AND TRANSFER
For additional information, refer to the applicable control panel
manual for this unit, as well as any literature pertaining to the
specific transfer switch.
To transfer the load back to the utility power source and shut down
the generator, follow these directions:
• Set the generator’s main line circuit breaker to its OFF (or OPEN)
position.
• Manually move the transfer switch handle to its UTILITY
(NORMAL) position, i.e., load circuits connected to the utility.
• Turn ON the utility power supply to the transfer switch, using
the means provided (such as the utility power source main line
circuit breaker).
• Let the generator run at no-load for a few minutes to stabilize
internal temperatures.
• Shut down the generator.
Maintenance Disconnect Switch and the
nThe
AUTO/OFF/MANUAL switches (if so equipped)
must be set properly, or the generator will
crank and start as soon as the utility power to
the transfer switch is turned off. Refer to applicable control panel and transfer switch manuals
for more information.
not proceed until certain that utility source
nDo
voltage is available to the transfer switch and
the transfer switch main contacts are set to
OPERATING UNIT WITH AUTOMATIC
TRANSFER SWITCH
UTILITY.
power supplies to the transfer switch have been
If the Stationary Emergency Generator has been installed with an
automatic transfer switch, the engine may be started and stopped
automatically or manually.
Do not attempt manual operation until all
positively turned off, or extremely dangerous possibly lethal - electrical shock will result.
NOTE:

Transfer switch enclosure doors should be kept
closed and locked. Only authorized personnel
should be allowed access to the transfer switch
interior. Extremely high and dangerous voltages
are present in the transfer switch.
In order to transfer load from the utility source to the generator,
follow these directions:
Refer to the applicable manual for your transfer switch and to
“Transfer Switch Start Signal Connections”. In addition, please
note the dangers under “Engine Start-up and Transfer.”
• Turn OFF or disconnect the utility power circuit to the transfer
switch, using the means provided (such as the utility source
main line circuit breaker).
• Set the transfer handle to its UTILITY (NORMAL) position with
load circuits connected to the utility power supply.
• Set the generator’s main line circuit breaker to its OFF (or OPEN)
position.
• Start the generator.
Oper001 Rev. D 05/10
9-1
Stationary Emergency Generator
Maintenance
MAINTENANCE PERFORMED BY
AUTHORIZED SERVICE DEALERS
exhaust system parts from this product get
 The
extremely hot and remain hot after shutdown.
High grass, weeds, brush, leaves, etc. must
remain clear of the exhaust. Such materials may
ignite and burn from the heat of the exhaust
system.

Before working on the Stationary Emergency
Generator, ensure the following:
• The AUTO/OFF/MANUAL switch is in the OFF position.
• The 15A fuse has been removed from the control box.
• The 120VAC supply to the battery charger is switched OFF.
CHECKING FLUID LEVELS
‹ EVERY THREE MONTHS
‹ CHECK ENGINE OIL
1.
2.
3.
4.
5.
6.
Check engine crankcase oil level (Figure 10.1) at least every 20
hours of operation, or prior to use.
Check battery state of charge and condition.
Inspect and test fuel system.
Check transfer switch.
Inspect exhaust system.
Check engine ignition system.
Check fan belts.
•
•
•
•
‹ ONCE EVERY SIX MONTHS
1.
Test Engine Safety Devices (low oil pressure, low coolant
level, high coolant temperature).
Figure 10.1 - Oil Dipstick and Oil Fill Cap
‹ ONCE ANNUALLY
1.
2.
3.
4.
Remove oil dipstick and wipe dry with a clean, lint-free cloth.
Install oil dipstick, then remove again.
Oil should be between FULL and ADD marks.
If oil level is below the dipstick ADD mark, remove oil fill cap.
Add the recommended oil to bring oil level up to the FULL
mark. DO NOT FILL ABOVE THE “FULL” MARK. See “Engine Oil
Recommendations” for recommended oils.
Oil Fill
Test engine governor. Adjust or repair, if needed.
Clean, inspect generator.
Flush cooling system.
Clean/re-gap spark plugs or replace as necessary.
Oil
Dipstick
‹ FIRST 30 OPERATING HOURS
1.
Change engine "break-in" oil and filter.
‹ FIRST 100 OPERATING HOURS
1.
Change engine oil and oil filter. (After initial change, service
engine oil and filter at 150 operating hours or 6 months,
whichever comes first.)
‹ EVERY 500 OPERATING HOURS
1.
2.
3.
Oil Filter
Service air cleaner.
Check starter.
Check engine DC alternator.
‹ BATTERY FLUID
Check battery electrolyte fluid at least once weekly. Fluid should
cover separators in all battery cells. If fluid level is low, add distilled
water to cover tops of separators. DO NOT USE TAP WATER IN
BATTERY.
COOLING SYSTEM
Air intake and outlet openings in the generator compartment must
be open and unobstructed for continued proper operation. This
includes such obstructions as high grass, weeds, brush, leaves
and snow.
Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down.
Maint004 Rev. F 06/09
10-1
Stationary Emergency Generator
Maintenance
‹ ENGINE COOLANT
‹ INSPECT EXHAUST SYSTEM
Check coolant level in coolant recovery bottle. See the
“Specifications” section.
Inspect the exhaust system at least once every three months.
Check all exhaust system pipes, mufflers, clamps, etc. for condition, tightness, leaks, security, damage.
• Add recommended coolant mixture as necessary.
• Periodically remove radiator pressure cap to make sure the
coolant recovery system is functioning properly. Coolant
should be at bottom of radiator filler neck. If coolant level is
low, inspect gasket in radiator pressure cap. Replace cap, if
necessary. To have pressure cap tested, contact an Authorized
Service Dealer. Inspect cooling system and coolant recovery
system for leaks.
‹ CHECK FAN BELT
• Inspect fan belts every three months. Replace any damaged,
deteriorated, worn or otherwise defective belt.
• Check fan belt tension. Thumb pressure, exerted midway
between pulleys, should deflect about 3/8 to 5/8 inch. Adjust
belt tension as required.
• Check fan belt alignment.
MAINTENANCE OWNER/
OPERATOR CAN PERFORM
‹ INSPECT ENGINE GOVERNOR
Visually inspect electronic governor.
DANGER
working on the generator, ensure the fol Before
lowing:
•
•
•
•
not attempt to adjust the governor. Only
 Do
qualified service facilities should adjust the
The AUTO/OFF/MANUAL switch is in the OFF position.
The 15A fuse has been removed from the control box.
The 120VAC supply to the battery charger is switched OFF.
The negative battery cable has been removed.
governor. Excessively high operating speeds
are dangerous and increase the risk of personal
injury. Low speeds impose a heavy load on
the engine when adequate engine power is not
available and may shorten engine life. Correct
rated frequency and voltage are supplied only
at the proper governed speed. Some connected
electrical load devices may be damaged by
incorrect frequency and/or voltage. Only qualified service technicians should adjust the governed speed.
‹ CHECK ENGINE OIL LEVEL
Refer to the “Checking Fluid Levels” section.
‹ CHECK BATTERY
• Check battery fluid level each week as outlined under “Check
Fluid Levels”.
• Check battery cables for condition, tightness, corrosion or damage. Clean, tighten or replace as necessary.
‹ CHANGING ENGINE OIL
‹ EXERCISE SYSTEM
oil may cause burns. Allow engine to cool
 Hot
before draining oil. Avoid prolonged or repeated
Start the Stationary Emergency Generator engine at least once
every seven days and let it run at least 20 minutes. For more
detailed exercise information, see the respective sections in the
Control Panel Technical Manual that is supplied with the unit.
skin exposure with used oil. Thoroughly wash
exposed areas with soap.
Refer to maintenance performed by authorized service facilities for
engine oil and filter change frequencies.
‹ INSPECT COOLING SYSTEM
Drain the oil while the engine is still warm from running. This
means warm up the engine, shut it down and drain immediately
as follows:
• Inspect engine cooling system at least once each month.
• Check hoses for damage, deterioration, leaks, etc. Correct any
discrepancies found.
• Check hose clamps for tightness.
1.
2.
‹ CHECK ENGINE COOLANT LEVEL
3.
See the “Checking Fluid Levels” section.
4.
‹ PERFORM VISUAL INSPECTION
5.
Complete a thorough visual inspection of the entire engine-generator monthly. Look for obvious damage, loose, missing or corroded
nuts, bolts and other fasteners. Look for fuel, oil or coolant leaks.
10-2
Remove OIL DRAIN HOSE from its retaining clip.
Loosen and remove OIL DRAIN HOSE CAP. Drain oil completely into suitable container.
When all oil has drained, install and tighten OIL DRAIN HOSE
CAP, and re-install into its retaining clip.
Turn OIL FILTER (Figure 10.2) counterclockwise and remove.
Dispose of old filter.
Apply light coating of new engine oil to seal of new oil
filter.-Install FILTER and tighten by hand only. DO NOT
OVERTIGHTEN.
Maint004 Rev. F 06/09
Stationary Emergency Generator
Maintenance
6.
‹ SPARK PLUGS
Remove OIL FILL CAP. Add recommended oil (see
SPECIFICATIONS). DO NOT FILL ABOVE THE DIPSTICK “FULL”
MARK. Crankcase oil capacity is listed in the SPECIFICATIONS
section.
Reset the spark plug gap or replace the spark plugs as necessary.
1.
refilling the crankcase with oil, always
 After
check oil level on dipstick. NEVER OPERATE
7.
8.
9.
2.
ENGINE WITH OIL BELOW THE DIPSTICK
“ADD” MARK.
Start engine and check for oil leaks.
Shut OFF engine and wait 10 minutes for the oil to settle down
into the oil pan. Recheck oil level on dipstick. DO NOT fill
above the dipstick "FULL" mark.
Dispose of used oil at a proper collection center.
3.
Clean the area around the base of the spark plugs to keep dirt
and debris out of the engine. Clean by scraping or washing
using a wire brush and commercial solvent. Do not blast the
spark plugs to clean.
Remove the spark plugs and check the condition. Replace
the spark plugs if worn or if reuse is questionable. See the
“Service Schedule” section for recommended inspection.
Check the spark plug gap using a wire feeler gauge. Adjust the
gap to 1.14 mm (0.045 inch) by carefully bending the ground
electrode (Figure 10.4).
Figure 10.4 – Setting the Spark Plug Gap
Figure 10.2 - Oil Filter
Oil Fill
Oil
Dipstick
‹ COOLANT CHANGE
Every year, have an Authorized Service Facility drain, flush and
refill the cooling system. See the “Specifications” section for cooling system recommendations.
Oil Filter
‹ CHANGING THE ENGINE AIR CLEANER
MISCELLANEOUS MAINTENANCE
To replace the engine air cleaner, remove the air cleaner cover and
replace the air filter making sure it is positioned properly before
reattaching the cover.
‹ CLEANING THE STATIONARY EMERGENCY
GENERATOR
Keep the generator as clean and as dry as possible. Dirt and
moisture that accumulates on internal generator windings have an
adverse effect on insulation resistance.
Figure 10.3 — Engine Air Filter
Periodically clean generator exterior surfaces. A soft brush may be
used to loosen caked on dirt. Use a vacuum system or dry, low
pressure air to remove any accumulations of dirt. The generator is
housed inside an all-weather enclosure, clean the enclosure with a
soft, damp cloth or sponge and water.
Air Filter
Once each year, have the generator cleaned and inspected by an
Authorized Service Dealer. That dealer will use dry, low pressure air
to clean internal windings. Parts inside the control console should
be cleaned and inspected at this time as well.
Finally, have the insulation resistance of stator and rotor windings
checked. If insulation resistances are excessively low, the generator may require drying.
See the “Service Schedule” section for air cleaner maintenance.
Maint004 Rev. F 06/09
10-3
Stationary Emergency Generator
Maintenance
‹ BATTERY
electrolyte fluid is an extremely caus Battery
tic sulfuric acid solution that can cause severe
All lead-acid storage batteries discharge when not in use. Refer to
specific instructions and warnings that accompany the battery. If
such information is not available, observe the following precautions when handling a battery:
burns. Do not permit fluid to contact eyes, skin,
clothing, painted surfaces, etc. Wear protective
goggles, protective clothing and gloves when
handling a battery. If the fluid is spilled, flush
the affected area immediately with clear water.
• DO NOT use jumper cables and a booster battery to crank or
start the generator engine.
• DO NOT recharge a weak battery while it is installed in the generator. Remove battery from generator and recharge in a wellventilated area, away from fuel vapors, sparks, heat or flames.
• Battery electrolyte fluid is an extremely caustic sulfuric solution
that can cause severe burns. DO NOT permit fluid to contact
eyes, skin, clothing, painted surfaces, wiring insulation, etc.
If any battery fluid is spilled, flush the affected area with clear
water immediately.
• Always wear safety glasses, rubber apron and gloves when
handling a battery.
• Batteries give off explosive hydrogen gas while charging. The
gas can form an explosive mixture around the battery for several hours after charging. Any spark, heat or flames can ignite
the gas and cause an explosion which can shatter the battery,
causing blindness or other serious injury.
not use any jumper cables or booster battery
 Do
to crank and start the generator engine. If the
battery has completely discharged, remove it
from the generator for recharging.
sure the AUTO/OFF/MANUAL switch is set to
 Be
the OFF position before connecting the battery
cables. If the switch is set to AUTO or MANUAL,
the generator can crank and start as soon as
the battery cables are connected.
sure the 120VAC power supply to the battery
 Be
is turned OFF, or sparking may occur at the battery posts as the cables are attached and cause
an explosion.
‹ BATTERY MAINTENANCE
‹ BATTERY REPLACEMENT
The battery should be inspected per the “Service Schedule” section. The following procedure should be followed for inspection:
1.
2.
3.
When replacing batteries, use the same number and the type of
battery that was supplied with the unit, and is listed in the parts
list in the back of this manual.
Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary.
Check the battery fluid level of unsealed batteries and, if necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP
WATER IN BATTERIES.
Have the state of charge and condition checked. This should
be done with an automotive-type battery hydrometer.
NOTE:
The BCI number should be located directly on the battery.
DANGER
batteries give off explosive hydrogen
 Storage
gas. This gas can form an explosive mixture
around the battery for several hours after charging. The slightest spark can ignite the gas and
cause an explosion. Such an explosion can
shatter the battery and cause blindness or other
injury. Any area that houses a storage battery
must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing
tools or equipment near the battery.
10-4
Maint004 Rev. F 06/09
Stationary Emergency Generator
Service Schedule
SERVICE SCHEDULE
22 KW - 150 KW GASEOUS STATIONARY EMERGENCY GENERATOR
The following is a recommended maintenance schedule for Gaseous Stationary Emergency Generator sets from 22kW to 150 kW in size. The
established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need
to be decreased (performed more frequently) if the unit is used in a severe application. Use calendar time, from the previous maintenance
interval to determine the next required maintenance interval.
Service Maintenance Interval Information:
The various service maintenance intervals are designated by interval numbers as follows:
1 An early inspection of the generator set to insure it is ready to operate when required and to identify any potential problem areas.
This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting
automatically without warning:
To prevent injury, perform the following steps in the order indicated before starting any maintenance:
• Disable the generator set from starting and/or connecting to the load by setting the control panel Auto/Off/
Manual switch to the “OFF” position.
• Remove the 15 amp control panel fuse.
• Turn off the battery charger.*
• Remove the negative battery cable.
* The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition
from burning out sensitive control panel components and circuits.
Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal operation when required.
2 A wear-in service inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any
potential problem areas.
Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be
performed only by a Service Dealer.
3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential
problem areas.
Performed semi-annually or following each 50 hours of operation of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be
performed only by a Service Dealer.
4 A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential
problem areas.
Performed annually or following each 100 hours of operation of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be
performed only by a Service Dealer.
5 A comprehensive inspection of the generator set to insure it is properly serviced and ready to operate and carry the load when required,
and to identify any potential problem areas.
Performed annually or following each 250 hours of operation of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be
performed only by a Service Dealer.
SrvSchd001 Rev. F 07/09
11-1
Stationary Emergency Generator
Service Schedule
Maintenance
Tasks
1. Disable the unit
from operating
per the first page
warning.
2. Check the engine
oil level. Adjust
as necessary.
3. Check the engine
coolant level.
Adjust as
necessary.
4. Check the engine
coolant thermal
protection level.
Correct as
necessary.
5. Check the natural
gas delivery
system for leaks
and correct
pressure on gas
engine driven
units. Tighten
connections as
necessary.
6. Check the air
inlets and outlets
of the enclosure
and radiator for
debris. Clean
as necessary.
7. Check the battery
electrolyte level
and specific
gravity if
accessible. Adjust
as necessary.
8. Check the battery
posts, cables,
and charger for
loose connections,
corrosion, and
proper operation.
Correct as
necessary.
9. Check the unit
wiring for loose
connections,
corrosion, and
damage. Correct
as necessary.
Level 1
Recommended
to be done
monthly/
10 hrs.
Level 2
Level 3
Task
Required
Task
Required
Comp. to be done Comp. to be done
(Date- 3 months/ (DateSemiInitials) Break-in Initials) annually/
30 hrs.
50 hrs.
11-2
Level 4
Task
Comp.
(DateInitials)
Required
to be done
Annually/
100 hrs.
Level 5
Task
Comp.
(DateInitials)
Required
to be done
Biannually/
250 hrs.
Task
Comp.
(DateInitials)
SrvSchd001 Rev. F 07/09
Stationary Emergency Generator
Service Schedule
Level 1
Recommended
to be done
monthly/
10 hrs.
Level 2
Level 3
Task
Required
Task
Required
Comp. to be done Comp. to be done
(Date- 3 months/ (DateSemiInitials) Break-in Initials) annually/
30 hrs.
50 hrs.
Level 4
Task
Comp.
(DateInitials)
Required
to be done
Annually/
100 hrs.
Level5
Task
Comp.
(DateInitials)
10. Check the engine
accessory drive
belts and fan
coupling device
if equipped for
correct tension,
wear, weather
cracking, and
damage. Replace
as necessary.
11. Check the engine
valve clearance/
lash. Adjust as
necessary.**
12. Visually inspect
the unit looking
for leaks, wear or
damage, loose
connections or
components, and
corrosion. Correct
as necessary.
13. Test the engine
and transfer
switch safety
devices. Correct
and/or adjust as
necessary.
14. Initiate an
automatic start
and transfer of
the unit to site
load and exercise
it for at least 1
hour looking for
leaks, loose
connections or
components, and
abnormal
operating
conditions.
Correct as
necessary.
15. Replace the
engine
accessory
drive belts.
16. Check gearbox
oil level (if
equipped).
17. Change gearbox
oil (if equipped).
** Not required for engines equipped with hydraulic lifters. See the "Specification" section for lifter type.
11-3
Required
to be done
Biannually/
250 hrs.
Task
Comp.
(DateInitials)
SrvSchd001 Rev. F 07/09
Maintenance
Tasks
Stationary Emergency Generator
Service Schedule
Maintenance
Tasks
18. Start and
exercise the unit
at full rated load
(use a load bank
if the site load is
not enough) for
at least 2 hours
looking for leaks,
loose
connections or
components, and
abnormal
operating
conditions.
Correct as
necessary.
19. Perform an
engine oil
analysis (send a
sample to a lab
for results).
Change the
engine oil and
filters if the
analysis results
indicate this is
required.
20. Change the
engine oil.
21. Replace the
engine oil filter(s).
22. Replace engine
spark plugs.
Clean and re-gap
or replace as
necessary.
23. Replace the
engine air
filter(s).
24. Perform a 5
minute no-load
operational run
of the unit
looking for any
post service
problems.
25. Return the unit
to standby setup
for operation
when required.
Level 1
Recommended
to be done
monthly/
10 hrs.
Level 2
Level 3
Task
Required
Task
Required
Comp. to be done Comp. to be done
(Date- 3 months/ (DateSemiInitials) Break-in Initials) annually/
30 hrs.
50 hrs.
11-4
Level 4
Task
Comp.
(DateInitials)
Required
to be done
Annually/
100 hrs.
Level5
Task
Comp.
(DateInitials)
Required
to be done
Biannually/
250 hrs.
Task
Comp.
(DateInitials)
SrvSchd001 Rev. F 07/09
Stationary Emergency Generator
Troubleshooting
TROUBLESHOOTING GUIDE
PROBLEM
CAUSE
CORRECTION
Engine won’t crank.
1. 15 amp fuse blown.
2. Loose or corroded or defective
battery cables.
3. Defective starter contactor.
4. Defective starter motor.
5. Dead or Defective Battery.
6. 5 amp fuse blown.
1. Replace fuse.
2. Tighten, clean or replace
battery cables as necessary.
3. Replace contactor.*
4. Replace starter motor.*
5. Remove, change or replace battery.
6. Replace fuse.*
Engine cranks but won't start
1. Out of fuel.
2. Fuel solenoid (FS) is defective
3. Open Wire #14A from Engine Control
circuit board.
4. Spark plugs defective.
5. Door on tank not closed.
1. Replenish fuel.
2. Replace solenoid.*
3. Reconnect wire.
Engine starts hard, runs rough.
1. Flame arrestor (air cleaner) plugged or
damaged.
2. Plugged fuel line.
3. Defective spark plugs.
4. Fuel pressure incorrect.
1. Clean or replace as needed.
2. Unclog fuel line.
3. Clean, regap or replace plugs.
4. Confirm fuel pressure to regulator is as
recommended in SPECIFICATIONS.
Engine starts then shuts down.
1.
2.
3.
4.
5.
6.
7.
AUTO/OFF/MANUAL Switch at OFF,
engine continues to run
1. Defective AUTO/OFF/MANUAL switch
2. Open/disconnected wire #15A between
AUTO/OFF/MANUAL switch and Control
Module circuit board.
3. Defective Control Module circuit board
3. Replace board.*
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
Check main line circuit breaker.
Check circuit breaker & fuses.
Transfer switch set to NORMAL position
Generator internal failure.
Thermal circuit breaker open.
1.
2.
3.
4.
5.
6.
7.
Check oil and add oil as needed.
Check cooling system for leaks.
Replace switch.*
Replace switch.*
Replace board.*
Repair leak - Add coolant.
Replace Switch.*
1. Replace switch.*
2. Reconnect/close wire.
Reset to ON or CLOSED.
Reset and replace, if necessary.
Set to GENERATOR position.
*
Auto-reset - Wait 5 min. and
attempt restart.
*Contact the nearest Authorized Dealer for assistance.
12-1
Trblsht001 Rev. A 10/08
No AC output from generator.
Engine oil level is low.
Engine is overheated.
Defective Low Oil Pressure Switch
Defective Coolant Temperature Switch
Defective Control Module circuit board.
Coolant Level is Low.
Defective Low Coolant Level Switch
4. Clean, regap or replace plugs.
5. Close door on tank.
Warranty
United States Environmental Protection Agency Warranty Statement
Warranty Rights, Obligations and Coverage
The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac), are pleased to
explain the Emission Control System Warranty on your new stationary emergency engine. If during the warranty period, any
emission control system or component on your engine is found defective in materials or workmanship Generac will repair
your engine at no cost to you for diagnosis, replacement parts and labor provided it be done by an Authorized Warranty
Service Facility. Your emission control system may include parts such as the fuel metering, ignition, and exhaust systems
and other related emission related components listed below. Generac will warrant the emissions control systems on your
2009 and later model year engines provided there has been no abuse, neglect, unapproved modification or improper maintenance of your engine. For engines less than 130 HP the warranty period is two years from the date of sale to the ultimate
purchaser. For engines greater than or equal to 130 HP the warranty period is three year from the date of the engine being
placed into service.
Purchaser’s/Owner’s Warranty Responsibilities
As the engine purchaser/owner you are responsible for the following. 1.) The engine must be installed and configured in
accordance to the installation specifications. 2.) The completion of all maintenance requirements listed in your Owner’s
Manual. 3.) Any engine setting adjustment must be done in accordance and consistent with the instructions in the Owner’s
Manual. 4.) Any emission control system or component must be maintained and operated appropriately in order to ensure
proper operation of the engine and control system to minimize emissions at all times.
Generac may deny any, or all Emission Control System Warranty coverage or responsibility of the engine, or an emission
control system or component on your engine thereof, if it has failed due to abuse, neglect, unapproved modification or
improper maintenance, or the use of counterfeit and/or ‘gray market’ parts not made, supplied or approved by Generac.
Warranty service/scheduled maintenance can be arranged by contacting your selling dealer or an Authorized Warranty
Service dealer. The purchaser/owner shall be responsible for any expenses or other charges incurred for service calls and/or
transportation of the product to/from the inspection or repair facilities. The purchaser/owner shall be responsible for any and/
or all damages or losses incurred while the engine is being transported/shipped for inspection or warranty repairs.
Emission Related Parts Include the Following (if so equipped)
3) Ignition System including
a) Spark plug, b) Ignition module,
c) ignition coil, d) Spark plug wirers
4) Exhaust system
a) Catalyst assembly, b) Exhaust manifold,
c) Muffler, d) Exhaust pipe, e) Muffler gasket
5) Crankcase Breather Assembly including
a) Breather connection tube, b) PCV valve
6) Oxygen Sensor
7) Diagnostic Emission-Control System
13-1
EmsnWrnty001 Rev. C 05/10
1) Fuel Metering System
1.1) Gasoline Carburetor assembly and internal components
a) Fuel filter, b) Carburetor, c) Fuel Pump
1.2) Carburetion assembly and its components
a) Fuel controller, b) Carburetor and its gaskets,
c) Mixer and it gaskets, d) Primary gas regulator
e) Liquid vaporizer
1.3) Fuel Regulator
2) Air Induction System including
a) Intake pipe/manifold, b) Air cleaner
Warranty
United States Environmental Protection Agency Compliance Requirements
Purchaser’s/Owner’s Recordkeeping Responsibilities
The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac), are pleased to
explain your recordkeeping requirements for compliance with Subpart JJJJ – Standards of Performance for Stationary Spark
Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60. As the engine
purchaser/owner who operates and maintains their certified emergency stationary engine and emission control system
according to applicable emission related guidelines as specified in this Owner’s Manual you are required to meet the following notification and recordkeeping requirements to demonstrate compliance. 1.) Maintain documentation that the engine
is certified to meet emission standards. 2.) Recordkeeping of maintenance conducted. 3.) Recordkeeping of the provision
allowing natural gas engines to operate using propane for a maximum of 100 hours per year as an alternate fuel solely 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.) Recordkeeping of hours of operation,
including what classified the operation as emergency and how many hours are spent for non-emergency operation. For
emergency engines greater than or equal to 130 HP, recordkeeping of hours of operation begins January 1, 2011. For emergency engines less than 130 HP, recordkeeping of hours of operation begins January 1, 2009; Engines are equipped with
non-resettable hour meters to facilitate recordkeeping.
Specific Air Quality Management or Air Pollution Control Districts may have different and additional record keeping/ reporting
requirements. Your permit to construct and/or operate the engine may be contingent upon compliance with those 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 emergency stationary ICE in emergency situations. The purchaser/owner may petition the
Administrator for approval of additional hours to be used for maintenance checks and readiness testing, but a petition is not
required if the owner maintains records indicating that Federal, State, or local standards require maintenance and testing of
emergency ICE beyond 100 hours per year. Emergency stationary ICE may operate up to 50 hours per year in non-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 nonemergency 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 with the specifications and guidelines in the Owner’s Manual, EPA will not require engine performance
testing. If not, your engine will be considered non-certified and you must demonstrate compliance according to Subpart JJJJ
– Standards of Performance for Stationary Spark Ignition Internal Combustion Engines as listed in the Electronic Code of
Federal Regulations Title 40 Part 60.
Emission-Related Installation Instructions
Your certified emergency stationary engine has pre-set emission control systems or components that require no adjustment.
Inspection and replacement of an emissions related component is required to be done in accordance with the requirements
cited in the United States Environmental Protection Agency Warranty Statement or can be arranged by contacting your selling dealer or an Authorized Warranty Service dealer. Failing to follow these instructions when installing a certified engine in a
piece of nonroad equipment violates federal law 40 CFR 1068.105 (b), subject to fines or penalties as described in the Clean
Air Act.
13-2
EmsnWrnty001 Rev. C 05/10
Notes
1
2
4
5
6
7
12
13
14
15
16
17
18
19
20
21
22
25
26
27
28
29
30
31
32
33
34
35
40
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
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
1
1
1
1
1
1
3
2
1
2
2
1
1
2
1
1
41
42
43
44
45
46
47
48
49
KIT PARTS
0A2491
0A2497
0A2496
056326
022307
022473
045757
047411
0A2110
2
2
2
8.4 FT.
6
6
2
4
14
8*
9
10
11
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
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
SCREW SWAGE 1/4-20 X 1/2 ZYC
* ROTOR REPLACEMENT PART
1
2
3
4
5
6
7
8
9
0C2454
0C2428
022155
023484K
0F3518
0F3517
0F3519
0F3520
023484N
11
2
2
1
1
1
1
1
1
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
* PARTS INCLUDED WITH ALTERNATOR.
** PARTS INCLUDED WITH TRANSFORMER.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
047411
022097
022473
084918G
0G0015
042568
055934D
084427
035467
049813
050967
022129
042907
0C4905
0C4905
0A6283
025066
059057
057823
0G8847
050967
0F4355
0G0153
057823
0G0866
2
4
4
1
4
2
1
1
1
2
1
1
1
2
1
1
1
1
2
1
1
REF.
REF.
REF.
REF.
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
WASHER FLAT 1/4 ZINC
HEATER ENG 1500W 120V
CLAMP HOSE 7/8” OD DOUBLE WIRE
SCREW HHC M6-1.0 X 20 G8.8
CLAMP VINYL 1.06 X .406 Z
BRACKET HEATER
NIPPLE CLOSE 3/8NPT X 1 VIBRA
NUT HEX M6-1.0 G8 YEL CHR
HOSE COOL 5/8 ID 20R3 (33”LG)
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 16 G8.8
BARBED EL 45 3/8NPT X 5/8OD
BARBED EL 45 3/8NPT X 5/8OD (150KW ONLY)
HOSE PREFORMED BLOCK HEATER
COUPLING FULL 3/8-18
HOSE 3/4 ID SAE-30R2 (8”LG) (150KW ONLY)
CLAMP HOSE #10 .56-1.06 (150KW ONLY)
BARB Y UNIVERSAL 5/8-3/4 HOSE (150KW ONLY)
HOSE COOL 5/8 ID 20R3 (24”LG) (150KW ONLY)
ADAPTER 1/2”NPT X 3/8”NPT (150KW ONLY)
BARBED EL 90 1/2NPT X 3/4 HOSE (150KW ONLY)
CLAMP HOSE #10 .56-1.06 (150KW ONLY)
HOSE OIL COOLER PREFORMED 3/4 (150KW ONLY) (SEE SPECIAL NOTE)
1
2
3
4
5
6
7
8
9*
10
11
12
13
14
15 **
16 **
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37 ***
38
39
40
41
42
43
44
45
0F2885
0F2883
0F3685
023484N
023484N
086961
067617030A
067617030B
072158
043180
022264
0C3990
057701
022155
0C2428
0F3618
0A9457
057073
0D5466
0A7822
022237
022241
049226
0C2266
0C2454
042568
022473
022097
049813
0E9764
0G6962B
025433
024469
067210A
0D6029
051713
081008
077043J
077043J
0F6156
029289
0F3113
047411
036943
023897
022152
022158
0F8565
045764
023762
1
1
1
1
2
1
4
6
6
REF.
2
2
1
1
2
REF.
REF.
4
4
6
6
10
4
12
8
4
6”
1
1
1
1
4
2
1
3
4
1
1
REF
4
2
3
2
2
1
1
1
PANEL CB CONN BOX
STAND RH CONTROL
STAND LH CONTROL C5 GRBX
BUSHING SNAP SB-2.5-31
BUSHING SNAP SB-2.5-31 (FOR 5.4L 1000KW 1PHASE)
INTERFACE 1PH 240V
INTERFACE 3PHS 416/480V
INTERFACE 3PHS 208/240V
ASSY INTFC 3PH 600V
WASHER FLAT M4
WASHER LOCK #8-M4
SCREW PHTT M4-0.7 X 10 ZYC
BLOCK TERM 20A 8 X 6 X 1100V
WASHER LOCK #6
SCREW PHTT #6-32 X 1/2 ZYC
DECAL CPL CUST CONN H CTRL
DECAL NEUTRAL
JUNCTION BLOCK 3/8-16
BUS BAR NEUTRAL BLOCK 390
LUG SLDLSS 600/250-1/0 X 1/4-28
WASHER LOCK 3/8
NUT HEX 3/8-16 STEEL
WASHER LOCK M5
SCREW PHTT M5-0.8 X 16 ZYC
SCREW THF M6-1 X 16 N WA Z/JS
SCREW HHC M6-1.0 X 20 G8.8
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX M6 X 1.0 G8 YEL CHR
RAIL SNAPTRACK PCB HOLDER BULK
ASSY RELAY PCB 12VDC
LUG SLDLSS #6-14 X 13/64 CU
SCREW HHTT #10-32 X 3/8 CZ
DECAL GROUND LUG
SCREW HHTT M6-1.0 X 16 ZYC
WASHER FLAT M5
GROMMET 1.25 X .25 X .75
CONDUIT FLEX 2.0" ID
CONDUIT FLEX 2.0" ID (FOR 5.4L/100KW 1 PHASE)
PLATE WIRE SNGL GALV
TAPE ELEC 1/2 FOAM (AS REQ’D)
ASSY PCB HSB CTRL IGN MODULE
SCREW HHC M6-1.0 X 16 G8.8
SCREW PPHM #10/32 X 2
WASHER FLAT #10 ZINC
WASHER LOCK #10
NUT HEX #10-32 STEEL
DECAL H-100 RB3 CUST CONN
SCREW HHTT M4-0.7 X 8 ZP
WASHER SHAKEPROOF EXT #10 STL
1.)
A
C
D
E
F
G
H
J
K
L
2.)
A
C
D
E
F
G
H
J
K
L
0F2887
0D5572
0D5573
0D5574
0D5575
0D5576
0F0199
065960
022473
022097
022127
0C2454
029289
0F1733
UL CIRCUIT BREAKER (FD)
1
COVER FD FRM CB
CB 0150A 3P 600V S FD6 LL
CB 0175A 3P 600V S FD6 LL
CB 0200A 3P 600V S FD6 LL
CB 0225A 3P 600V S FD6 LL
CB 0250A 3P 600V S FD6 LL
1
INSULATOR CB FD FRAME 30MIL
4
SCREW SHC 1/4-20 X 4 G8.8 NZ
4
WASHER FLAT 1/4-M6 ZINC
4
WASHER LOCK M6-1/4
4
NUT HEX 1/4-20 STEEL
4
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
0F2721
0D5577
0D5578
0D5579
0D5581
0D5585
0F2353
022770
022473
022097
022127
0C2454
029289
0F1733
UL CIRCUIT BREAKER (JD+LD)
1
COVER CIR BRKR JD/LD
CB 0300A 3P 600V S JD6 LL
CB 0350A 3P 600V S JD6 LL
CB 0400A 3P 600V S JD6 LL
CB 0600A 3P 600V S LD6
CB 0450A 3P 600V S LD6 LL
2
INSULATOR CIRCUIT BR. JD/LD
4
SCREW RHM 1/4-20 X 3
4
WASHER FLAT 1/4-M6 ZINC
4
WASHER LOCK M6-1/4
4
NUT HEX 1/4-20 STEEL
7
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
0F3327
0D5556
0D5566
0D5568
0D5570
0D9693
0F0492
048927
023897
022152
022158
0C2454
029289
0F1733
UL CIRCUIT BREAKER (ED)
1
COVER,ED CB TALL
1
CB 0090A 3P 480V S ED4 LL
CB 0060A 3P 600V S ED6 LL
CB 0080A 3P 600V S ED6 LL
CB 0100A 3P 600V S ED6 LL
CB 0125A 3P 480V S ED4 LL
1
INSULATOR CB S (ED-3P)
4
SCREW RHM #10-32 X 4-1/2
4
WASHER FLAT #10 ZINC
4
WASHER LOCK #10
4
NUT HEX #10-32 STEEL
7
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
3)
A
C
D
E
F
G
H
J
K
L
* ITEM INCLUDED WITH HARNESS.
** ITEM INCLUDED WITH 0D5464B.
*** ITEM IS PART OF 9R.
3.)
A
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W*
X
Y
4.)
A
C
D
E
F
G
H
J
K
L
M
N
P
R
S*
T
U
V
0F4173
0F4165$
0F4186
036261
053640
038150
022264
022471
029289
0F1733
022129
0F8432
0C2454
0F8451
049897
022145
045771
0F8843
W/CB
0G3259
058306
0F4175
0F4166$
0F1733
042419
023897
022152
022158
0C2454
029289
052647
046526
W/CB
0A7822
022131
W/CB
023334
022097
0G3259
1
REF
1
4
4
4
4
4
2
1
9
1
7
3
6
6
3
3
2
1
3
UL CIRCUIT BREAKER (225AF)
COVER CB C5 225AF
CIRCUIT BREAKERS 200A FRAME
COVER CB DISH 225AF
RIVET POP .125 X .275 SS
SCREW RHM #8-32 X 3-1/4
WASHER FLAT #8 ZINC
WASHER LOCK #8-M4
NUT HEX #8-32 STEEL
TAPE ELEC 1/2 FOAM
DECAL CUSTOMER CONNECT INSIDE
WASHER LOCK M8-5/16
INSULATOR CB 225AF
SCREW THF M6-1 X 16 N WA Z/JS
LUG SLDLSS 300 MCM-6 AL/CU
SCREW SHC M8-1.25 X 20 G8
WASHER FLAT 5/16-M8 ZINC
NUT HEX M8-1.25 G8 CLEAR ZINC
BUS BAR 200A LUG ADAPTOR
TERMINAL COVER CB
DECAL TERMINAL SHOCK HZD BI
SCREW SHC M8-1.25 X 25 G12.9
1
REF
1
4
8
4
4
7
1
6
6
3
3
3
2
6
6
1
UL CIRCUIT BREAKER (400AF)
COVER CB C5 400AF
CIRCUIT BREAKERS 400A FRAME
DECAL CUSTOMER CONNECT INSIDE
SCREW RHM 10-32 X 4
WASHER FLAT #10 ZINC
WASHER LOCK #10
NUT HEX #10-32 STEEL
SCREW THF M6-1 X 16 N WA Z/JS
TAPE ELEC 1/2 FOAM
SCREW SHC M10-1.5 X 25 G12.9
WASHER LOCK M10
BUS BAR CB ADAPTER 225-400 A
LUG SLDLSS 600/250-1/0 X 1/4-28
WASHER FLAT 3/8-M10 ZINC
TERM COVER CB
SCREW HHC 1/4-28 X 1/2 G5
WASHER LOCK M6-1/4
DECAL TERMINAL SHOCK HZD BI
5.)
A
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U*
V
W
0F4176
0F4167$
0F8433
024196
022473
022097
022127
0C2454
029289
060619
022131
022237
045772
0F9721
0D2157
0F1733
W/CB
0G3259
022097
1
REF
2
4
4
4
4
7
2
2/3
2/3
2/3
2/3
2/3
4/6
1
2
1
4/6
UL CIRCUIT BREAKER (800AF)
COVER CB C5 800AF
CIRCUIT BREAKERS 800A FRAME
INSULATOR CB 800AF
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
SCREW THF M6-1X16 N WA Z/JS
TAPE ELEC 1/2 FOAM
SCREW SHC M10-1.50 X 40 G12.9
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK 3/8
NUT HEX M10-1.5 G8 YEL CHR
LUG SLDLSS 3/0-400X3 MCM AL/CU
SCREW SHC M6-1.0 X 50 G8.8
DECAL CUSTOMER CONNECT INSIDE
TERM COVER VITZROTECH 400AF CB
DECAL TERMINAL SHOCK HZD BI
WASHER LOCK M6-1/4
6.)
A
B
C
D
E
F
G
H
0D5466
039287
022145
022129
045771
045335
022097
0A7822
2
1
1
1
1
2
2
1
NEUTRAL BLOCK 390 / 200-400A
BUS BAR NEUTRAL BLOCK 390
SCREW HHC M8-1.25 X 45 G8.8 FT
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
SCREW HHC 1/4-28 X 3/4 G5
WASHER LOCK M6-1/4
LUG SLDLSS 600/250-1/0X1/4-28
* HARDWARE FOR MTG. CB TERMINAL COVERS IS
SUPPLIED WITH CIRCUIT BREAKERS.
1
2
3
4
5
6
7
8
9*
10
11
12
13
14
15 **
16 **
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
0F2885
0G0171
0G0171A
0G0172
023484N
086961
067617030A
067617030B
043180
022264
0C3990
057701
022158
0F8565
0F3618
0A9457
057073
0D5466
0A7822
022237
022241
049226
0C2266
0C2454
042568
022473
022097
049813
0E9764
0G6962B
025433
024469
067210A
0D6029
051713
081008
077043J
0F6156
1
1
1
1
1
1
4
6
6
REF.
2
1
1
1
2
REF.
REF.
4
4
6
6
10
4
12
8
4
6”
1
1
1
1
4
2
1
3
1
PANEL CB CONN BOX
STAND RH CONTROL CPL C5
STAND RH CONTROL CPL C5 2 HOLE
STAND LH CONTROL CPL C5
BUSHING SNAP SB-2.5-31
INTERFACE 1PH 240V
INTERFACE 3PHS 416/480V
INTERFACE 3PHS 208/240V
WASHER FLAT M4
WASHER LOCK #8-M4
SCREW PHTT M4-0.7 X 10 ZYC
BLOCK TERM 20A 8 X 6 X 1100V
NUT HEX #10-32 STEEL
DECAL H-100 RB3 CUST CONN
DECAL CPL CUST CONN H CTRL
DECAL NEUTRAL
JUNCTION BLOCK 3/8-16
BUS BAR NEUTRAL BLOCK 390
LUG SLDLSS 600/250-1/0 X 1/4-28
WASHER LOCK 3/8
NUT HEX 3/8-16 STEEL
WASHER LOCK M5
SCREW PHTT M5-0.8 X 16 ZYC
SCREW THF M6-1 X 16 N WA Z/JS
SCREW HHC M6-1.0 X 20 G8.8
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX M6 X 1.0 G8 YEL CHR
RAIL SNAPTRACK PCB HOLDER BULK
ASSY RELAY PCB 12VDC
LUG SLDLSS #6-14 X 13/64 CU
SCREW HHTT #10-32 X 3/8 CZ
DECAL GROUND LUG
SCREW HHTT M6-1.0 X 16 ZYC
WASHER FLAT M5
GROMMET 1.25 X .25 X .75
CONDUIT FLEX 2.0" ID
PLATE WIRE SNGL GALV
36
37 ***
38
39
40
41
42
43
029289
0F3113
047411
036943
023897
022152
045764
023762
1.)
A
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T ****
U
V
0G0173
0F4167$
0F8433
022477
022473
022097
022127
0F1733
029289
060619
022131
022237
045772
0F9721
0D2157
W/CB
0G3259
022097
UL CIRCUIT BREAKER (800AF)
1
COVER, CB 803 C5
REF
CIRCUIT BREAKERS 800A FRAME
2
INSUL CB 800AF
4
SCREW RHM 1/4-20 X 1-1/2
8
WASHER FLAT 1/4-M6 ZINC
4
WASHER LOCK M6-1/4
4
NUT HEX 1/4-20 STEEL
1
DECAL CUSTOMER CONNECT INSIDE
2
TAPE ELEC 1/2 FOAM
2/3
SCREW SHC M10-1.50 X 40 G12.9
2/3
WASHER FLAT 3/8-M10 ZINC
2/3
WASHER LOCK 3/8
2/3
NUT HEX M10-1.5 G8 YEL CHR
2/3
LUG SLDLSS 3/0-400X3 MCM AL/CU
4/6
SCREW SHC M6-1.0 X 50 G8.8
2
TERM. COVER VITZROTECH 400AF CB
1
DECAL TERMINAL SHOCK HZD BI
4/6
WASHER LOCK M6-1/4
0D5466
039287
022145
022129
045771
045335
083896
0A7822
NEUTRAL BLOCK 390 / 200-400A
1
BUS BAR NEUTRAL BLOCK 390
1
SCREW HHC M8-1.25 X 45 G8.8 FT
1
WASHER FLAT 5/16-M8 ZINC
1
WASHER LOCK M8-5/16
1
NUT HEX M8-1.25 G8 YEL CHR
2
SCREW HHC 1/4-28 X 3/4 G5
2
WASHER LOCK 1/4-M6 SS
1
LUG SLDLSS 600/250-1/0 X 1/4-28
2.)
A
B
C
D
E
F
G
H
1
REF
4
2
3
2
1
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
ASSY PCB HSB CTRL IGN MODULE
SCREW HHC M6-1.0 X 16 G8.8
SCREW PPHM #10/32 X 2
WASHER FLAT #10 ZINC
WASHER LOCK #10
SCREW HHTT M4-0.7 X 8 ZP
WASHER SHAKEPROOF EXT #10 STL
* ITEM INCLUDED WITH HARNESS
** ITEM INCLUDED WITH 0D5464B
*** ITEM IS PART OF 9R.
**** HARDWARE FOR MTG. CB TERMINAL COVERS IS SUPPLIED WITH
CIRCUIT BREAKERS.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
0F3384
065852
052252
052257
052259
055597
052251A
052860
0F2895
045764
090502
061383
043107
022473
049813
057192
022131
046526
0536210410
042909
022261
022129
022145
045771
053557
0F2591
0F2910
038750
022097
022447
1
1
4
4
8
4
4
4
1
1
4
1
1
1
1
4
8
8
1
1
2
1
2
2
4
2
1
1
1
1
BASE CPL 100-130KW 6.8L GB
SPRING CLIP HOLDER .37-.62
DAMPENER VIBRATION
SPACER .49 X .62 X 1.87 PWDR/ZINC
WASHER FLAT M12
SCREW HHC M12-1.75 X 85 G8.8
DAMPENER VIBRATION 50 WHITE
NUT LOCKING M12-1.75
SUPPORT ENG 5.4L LH/RH 6.8L RH
SCREW HHTT M4-0.7 X 8 BP
SCREW SHC M10-1.5 X 60 G12.9
LUG SOLDERLESS 3/0-#4 X 13/32 CU
SCREW HHC M8-1.25 X 25 G8.8
WASHER FLAT 1/4-M6 ZINC
NUT HEX M6 X 1.0 G8 YEL CHR
SCREW SHC M10-1.5 X 30 G12.9
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
ASSY WIRE 14.00”
SCREW HHC M8-1.25 X 30 G8.8
WASHER SHAKEPROOF INT 3/8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
NUT HEX M8-1.25 G8 YEL CHR
SCREW HHC M12-1.75 X 40 G8.8
TOWER GB COMPROD C5
SUPPORT ENGINE 6.8L LH SIDE
SCREW HHC M6-1.0 X 30 G8.8
WASHER LOCK M6-1/4
WASHER SHAKEPROOF INT 1/4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
0F3408A
0F3411A
058665
022131
050331A
050331
038805Z
038804U
045771
022129
027482
075763
0C2454
0F3409
022097
049813
042568
0G0783
1
1
1
1
1
1
1
1
1
1
1
1
8
1
2
2
2
1
TRAY BATTERY 27F
STRAP BATTERY RETAINMENT 27F
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
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
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
37
38
39
40
41
44
45
46
47
48
49
50
51
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
1
1
2
44
4
8
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
4
1
1
1
8
8
2
1
1
1
6
REF.
10
2.5cc
.200 GAL
10
10
2
4
1
.050 GAL
0.4cc
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
2
3
(2) 4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
(2) 19
(2) 20
21
(2) 22
(1) 23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
41
43
44
45
0D5418
052625
047411
0D5623
0D2608
070006
070008
055934M
0G0321
046526
057823
057765
046964
0D5417
049821
022129
070010
0F2776A
022097
048191
022473
029333A
0D9913
055596
069860E
0D4255
057772
0D6686
0D3803
0D3805
021113
077996
022131
0C7649
052647
0D2244M
0D3808
0F5114
079121
057823
053660
087599
1
11
1/2
2
10
30
10
1
1
23
1
1
1
RE F.
3
3
2
1/2
1/2
2
1/2
1
18
1
1
2
1
1
1
1
1
1
7
1
9
1
2
1
2
2
1
1
STARTER MOTOR F ORD V-10 E NGINE
SCREW S HC M10-1.5 X 35 G12.9
SCREW HHC M 6-1.0 X 16 G8.8
HEAT S HIE LD EX HAUST
SCREW HHC 5/ 16-18 X 1/2 S STL
WAS HE R LOCK M8 SS TL
WAS HE R FLAT M8 SS
CLAM P V INYL .75 X .343 Z
HOSE COOL 5/8" ID 250#WP (14” )
WAS HE R LOCK M10
CLAM P HOSE #10 .56 - 1.06 (2300 & 3000RPM UNITS ONLY)
ADAPTE R M14-1.50 X 3/ 8 NP T
ELBOW 90D 1/4 NPT F-M BRASS
SCREW HHC M 10-1.0 X 25 G10.9
SCREW S HC M8-1.25 X 30 G12.9
WAS HE R LOCK M8-5/16
SCREW HHC M 8-1.25 X 35 S S F-TH
BRACKE T SIGNAL CONDITIONER
WAS HE R LOCK M6-1/4
DOWE L P IN M10 X 24
WAS HE R FLAT 1/4 ZINC
TIE WRAP UL 7.4" X .19" BLK (NOT S HOWN)
SCREW S HC M8-1.25 X 35 SS
BARBED STR 3/8 NPT X 3/8
HOSE DRAIN ASSY 28"
GASKET E XHAUST MANIFOLD
WAS HE R NY LON .565
ASSE MBLY 6. 8L G-BOX FLYWHEE L
FLY WHEE L HOUS ING MACH 6.8L V 10
COVER FL YWHE EL MACH 6.8L V-10
PLATE DAMP NE R RETNR
CAP HOSE (2300 & 3000RPM UNI TS ONLY )
WAS HE R FLAT 3/8-M10 ZINC
CLAM P HOSE .38-.87
SCREW S HC M10-1.5 X 25 G12.9
ASSY MAGPICKUP(3/8-24 M ALE )
EX H MANIFOLD MACH 6.8L V-10
DECAL RE FER TO OWNERS MANUAL
SCREW S HC M10-1.50 X 100 G10.9
CLAM P HOSE #10 .56-1. 06
BARBED STR 1/4 NPT X 5/8
PLUG P LASTIC 3/8 NP T
(1) NOT E: I/N 23 IS FOR HOLDING SE NS ORS TO I /N 19.
(2) QTY. REQ. FOR NON-MQT / QTY REQ. FOR MQT E PA CERT.
1
2
3
4
5
6
7
8
9
10
11
0D2513D
0F5419
0F4268
0F4270A
0F6977
037561
047411
022097
049811
0F4269
022473
1
1
1
1
1
1
4
4
4
1
1
AIR CLNR BTM PLT W/CPLR 8.1L
ELEMENT AIR FILTER
TOP PLATE VENTURI
HOLD DOWN AIR CLEANER PLATED
PLATE AIR CLEAN TOP 5.4L/6.8L
NUT WING 1/4-20 NYLK
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
WASHER FLAT M6
GASKET MIXER BODY
WASHER FLAT 1/4-M6 ZINC
1
2
3
4
5
6
7
8
9
10
0G17730GS0R
0G17710GS0R
0G17720GS0R
0G17740GS0R
056326
0C2454
022131
046526
051756
081008B
1
1
1
1
1
10
4
4
4
1
GUARD BELT RIGHT HAND C5
GUARD BELT TOP C5
GUARD BELT BOTTOM C5
GUARD BELT LEFT HAND C5
TRIM VINYL BLACK 1/8GP
SCREW THF M6-1 X 16 N WA Z/JS
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
SCREW HHC M10-1.5 X 20 G8.8
GROMMET 1.25 X .25 X 1.00
COMPONENTS INCL UDED IN 0G4140E
1
ENCL H/G CO NTROL PANEL
1
CO VER CONTRO L PANEL
1
HING E CONT INUOUS H PANEL
7
RIVET POP .125 X .275 SS
1
ASSY PROGRAMMED H- 100
1
DECAL FUSES LO CAT ED INSIDE
1
RAIL SNAPTRACK PCB HO LDER BULK ( 12” LG)
1
ASSY PCB 10A UL BATT CHRG R 12V
1
PLATE HARNESS CLAMP
1
ASSY PCB PW R AVR W /AMP HEADER
1
ASSY PCB BOSCH G OV DRIVER
1
DIO BR IDG E 25A 600V
11
W ASHER LO CK M5
4
SCREW PPHM M5- 0.8 X 30 SS
11
W ASHER FLAT M5
6
SCREW HHPM M5-0.8 X 12
5
NUT HEX M5-0.8 G8 YEL CHR
3
W ASHER FLAT M4
3
SCREW PHTT M4- 0.7 X 10 Z YC
1
CO NN DUST CAP W/CHAIN DB9
1
W ASHER FLAT M3.5
1
SCREW PHTT M3.5- 0.6 X 10
10
SCREW PPHM M4- 0.7 X 8 BLX O X
10
W ASHER LO CK #8-M4
1
DECAL W RN B AT T CHRG 12/24V BI
1
M5-0.8 CAPT IVE PANEL KNLD HD
2
SEAL COVER 3.18 X 12.7 X 382
1
SEAL COVER 3.18 X 12.7 X 283
1
HARNESS H-PNL INTEGRATED SW (NO T SHO WN)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
0F1823CST 03
0F1824AST 03
0F2606
036261
0F5763
0F1732
0E9764
0F1740C
0F1958
0F2256
0E3161
029673
049226
079224
051713
0F5886
051716
043180
0C3990
0F4333
0F5883
0F5884
055014
022264
0G 3546
0G 3648
0F6305
0F6305A
0G 4329
A
B
C
D
E
0F1263
0F1262
0F1264
0E9049B
055911
COMPONENTS INCL UDED IN WIRE HARNESS
1
ADPTR RH SIDE W ICKMANN 178.6191
4
HO LDER F USE WICKMANN 178.6150
1
ADPTR LH SIDE W ICKMANN 178.6192
1
ASSY PCB G-PANEL RELAY 12VDC
1
BL OCK TERM 20A 12 X 6 X 1100V
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
056739
0F2627B
022287
022473
022097
043182
051714
052777
0C2323
0F5459
0F5461
022127
0F5460
0E7403C
0E7403B
0F6145
0C2699
0C2266
COMPONENTS NO T INCLUDED IN 0G 4140E O R WIRE HARNESS
1
RELAY CONTACTO R 12VDC
1
DPE B REAKER SEE DRAW ING 0F9280
1
BO OST RESIST OR SEE DRAWING 0F 9280
1
CO VER CONTRO L PANEL SIDE
2
SCREW HHC 1/4-20 X 3/4 G 5
4
W ASHER FLAT M6-1/4
2
W ASHER LO CK M6-1/4
3
W ASHER LO CK M3
3
NUT HEX M3-0.5 G8 YEL CHR
3
W ASHER FLAT M3
2
SCREW PHTT #6-32 X 5/8 Z YC
1
DECAL CPL CONTRO L PANEL FUSES
1
DECAL CPL 5.4/6.8L TB3
2
NUT HEX 1/4-20 STEEL
1
DECAL CPL 5.4/6.8L RELAY BO ARD
1
F USE ATO TYPE 15 AMP (BL UE)
2
F USE ATO TYPE 10 AMP (RED)
A/R
SEAL WEATHER .45"DIA
2
SCREW PHTT #6-32 X 3/8 Z YC
4
SCREW PHTT M5- 0.8 X 16 Z YC
1
2
3
4
(2) 5
(2) 6
(1) 7
8
(3) 9
0F4462
080762
0H2099
0C2454
0G97740AL01
0G97750AL01
0G3263
0H0260
077992
1
2
1
18
2
1
4
1
18
RAIN CAP 2-1/2" AL
BOLT U 3/8-16 X 2.62
CATALYST 3-WAY
SCREW THF M6-1X16 N WA Z/JS
HEAT SHIELD EXHAUST STACK
CAP HEAT SHIELD EXHAUST STACK
DECAL WARNING HOT SURFACES BI
EMISS EXH OUTLET PIPE CPL
NUT HEX LOCK M6-1.0 SS NY INS
NOTE:
SOME UNITS MAY REQUIRE (2) KITS.
(1) DECALS APPLIED TO EXHAUST AT THE FACTORY.
(2) PART NUMBER SHOWN IS FOR TAN. SEE GUIDE BELOW FOR AVAILABLE COLOR AND PART NUMBER FORMAT.
0GXXXX0AL08 = GRAY / ALUMINUM
0GXXXXALT13 = BISQUE / ALUMINUM
0GXXXX0AL05 = WHITE / ALUMINUM
0GXXXXALT14 = GRAY / ALUMINUM
0GXXXX0GS0R = GALVANIZED / NO PAINT
(3) ) ALUMINUM ENCLOSURE NOTE: ITEM NUMBER 5 TO BE SECURED USING ITEM NUMBERS 4 (THREAD FORMING
FASTENER) & 9 (LOCK NUT). THE LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED
THROUGH EXTRUSIONS IN ENCLOSURE PANELS.
CATALYST AND HEAT SHIELD ASSEMBLY INSTRUCTIONS:
1)
Disconnect battery cables to prevent accidental start-up. Disconnect the negative battery cable first
from the battery post indicated by (-) or NEG.
2)
Insert the outlet pipe (0H0260 I/N 8) 2 to 3 inches into the outlet of the catalyst (0H2099, I/N 3). The
illustration identifies the catalyst inlet and outlet. Slide one U-bolt (080762, I/N 2) onto the outlet of
the catalyst and tighten.
3)
Slide the remaining U-bolt (080762, I/N 2 (not shown)) and catalyst (0H2099, I/N 3) over the exhaust
pipe protruding from the enclosure. The exhaust pipe should be inserted 2 to 3 inches into the inlet
of the catalyst (0H2099, I/N 3). The flat side of the catalyst should be aligned with the side of the
generator (as shown). Position the U-bolt over the inlet of the catalyst and tighten. This joint must be
tight and must not leak.
4)
Sub-assemble the heat shield panels (0G97740AL01, I/N 5) and the heat shield cap (0G97750AL01, I/N
6) using the screws provided (0C2454, I/N 4). Lock nuts (077992, I/N 9) should be installed after the
fastener has penetrated through the extrusions in the heat shield panels. Lock nuts (077992, I/N 9)
are not required on open set configurations.
5)
Slide the heat shield subassembly over the catalyst. The long side of the heat shield assembly
should be aligned with the long side of the generator (as shown).
6)
Fasten the heat shield assembly to the enclosure using the screws provided (0C2454, I/N 4). Lock
nuts (077992, I/N 9) should be installed after the fastener has penetrated through the extrusions in the
enclosure. An access panel may need to be removed to complete this step. Lock nuts (077992, I/N 9)
are not required on open set configurations.
7)
Install the rain cap over the outlet of the catalyst and tighten (0F4462, I/N 1). Open set configurations
do not require a rain cap.
Notes:
•
•
Catalyst must be mounted in described position.
Failing to follow these instructions when installing a certified engine in a piece of nonroad
equipment violates federal law 40 CFR 1068.105 (b), subject to fines or penalties as
described in the Clean Air Act.
1
2
3
4
(2) 5
6
7
8
9
10
(3) 11
12
13
14
15
16
17
(3) (1) 18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
(3) 49
0F3017
039253
022129
022145
0D5419
0D7055
0D3488G
0D3488J
0D3488
0D3488K
057795A
059057
0F3287
0G9989
0H3074
0E9868A
057796
0F3216
0F3216A
0F3216C
0F3216D
035579
0F4612
0D6658
029333A
022097
022473
042568
0D8027
0D8025
0D8026
0D8030
0F2846
0D8029
0D8028
045771
0D3454A
0H0923
022131
046526
064416
045772
0F3217
0F2776A
0F6151
0F4308
0F3158
057823
0E0502
0G0866
0F4301
0E8286
047527
057823
0E0992A
078637
0G7519
0H4672
1
3
4
4
REF
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
3
3
4
1
3
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
4
10
A/R
1
1
BRACKET,D.C. ALTERNATOR LOWER
SCREW HHC M8-1.25 X 20 G8.8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
OIL FILTER, FORD V-10 ENGINE
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 3/4 PLASTIC
HOSE 3/4 ID SAE-30R2 (16.75”LG)
BRACKET DC ALTERNATOR UPPER
HARN ENG G6.8L H-100 EMISSIONS (USE WITH PROBE P/N 0E2507)
HARN ENG G6.8L H-100 CPL EMSN (USE WITH PROBE P/N 0H1827)
ALTERNATOR DC W/OUT PULLEY
GROMMET
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
SENDER OIL PRESSURE 1/8" NPT
DIPSTICK 6.8L FORD
TIE WRAP UL 7.4" X .19" BLK
WASHER LOCK M6-1/4
WASHER FLAT 1/4 ZINC
SCREW HHC M6-1.0 X 20 G8.8
BOLT WATER PUMP PULLEY
BOLT GROOVED IDLER PULLEY
BOLT BELT TENSIONER
TENSIONER ENG. AUTOMATIC BELT
PULLEY WATER PUMP FORD (1800RPM UNITS)
PULLEY ENGINE WATER PUMP (2-POLE & GEAR BOX)
PULLEY GROOVED ENGINE IDLER
NUT HEX M8-1.25 G8 YEL CHR
ENGINE G6.8L G3 V-10
ENGINE G6.8L G3 V-10 (2009 +)
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
SCREW HHC M10-1.5 X 45 G8.8 FT
NUT HEX M10-1.5 G8 YEL CHR
SPACER DC ALTERNATOR PULLEY
BRACKET SIGNAL CONDITIONER
CAP RUBBER
BRACKET DC ALT STABILIZER
OIL COOLER FORD (150KW 3600RPM)
CLAMP HOSE #10 .56-1.06
TEMPERATURE SENDER DELPHI
HOSE OIL COOLER PREFORMED 3/4 (150KW 3600RPM)
HOSE OIL COOLER (150KW 3600RPM)
ELBOW 45D STREET 1/2NPT BRASS
BARBED STR 1/2NPT X 3/4
CLAMP HOSE #10 .56-1.06 (150KW 3600RPM)
PLUG EXPANSION 14 OD
ADHESIVE LOCTITE 620
DECAL EMISSION CTRL INFO 6.8L
HARN OXYGEN SENSOR EXTENSION
(1) NOTE: I/N 18 IS FOR HOLDING SENSOR TO I/N 35.
(2) I/N 5 PART OF I/N 29.
(3) NOTE: NOT SHOWN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
0F2807F
0F2807B
0F9071
0A6765
0F4710
0F7200
080762
0F2809
0F2981A
0F2962
0C2454
022097
0F2830
088510
049721
049813
0F6803
0F2773C
0D3159
088775
0F2808
0F2808C
0F5447
022473
0F6214
0G3163A
0H4445
0F5512
1
1
1
2
6
6
8
1
2
2
4
8
2
6
8
4
4
2
2
6
2
2
1
12
1
2
1
1
PIPE EXH MAN R/H 6/8 G/BCPLEPA
PIPE EXH MAN L/H 6.8L G/B 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 2.62
PIPE EXHAUST CROSSOVER
MFLR 7" X 9" X 25" (2) 2.5" IN/2.5" OUT
MUFFLER STRAP
SCREW THF M6-1 X 16 N WA Z/JS
WASHER LOCK M6-1/4
MUFFLER BRACKET STIFFENER
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
EXHUAST OUTLET PIPE CPL
EXHAUST OUTLET PIPE CPL (OPEN SET ONLY)
BRKT MUFFLER
WASHER FLAT 1/4-M6 ZINC
PIPE ELBOW EXHAUST MUFFLER
BLANKET EXHAUST MUFFLER 584MM
PIPE ELBOW EXHAUST O2 SENSOR
REFLEX WRAP 13MM 13 X 460 (12”LG)
1
2
3
4
(2) 5
6
7
8
9
10
0H20530ST03
0F2611
0F5254
0F7077
046526
059981
0C2454
052250
076749
0F2573
0F2610
1
1
1
1
12
4
2
2
1
1
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
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
42
43
44
45
46
47
(1) 48
49
50
51
52
53
54
55
56
57
58
59
60
(3) 61
62
(4) 63
64
(4) 65
66
67
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
0F2776A
022145
022129
052644
035685
045764
065852
0C7649
055596
069860E
069811
080713
022473
022097
042568
0F5050B
039253
051769
0C8145
0H1827
0H23980ST03
029032
049820
0H2844
0G53150AL0R
051756
052625
055934H
072252
0D6029
1
1
1
1
15
1
8
1
4
1
12
1
1
1
4
2
1
1
1
1
1
1
1
1
1
1
1
8
1
1
1
4
2
1
4
1
1
1
1
1
REF
1
24
16
8
1
3
1
8
1
1
1
2
2 (REF)
1
4/5
3
1/2
1
1
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
BRACKET, SIGNAL CONDITIONER
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
SPACER .5 X 1.5 X .25 STL/ZINC
CLAMP HOSE #28 1.32-2.25
SCREW HHTT M4-0.7 X 8 BP
SPRING CLIP HOLDER .37-.62
CLAMP HOSE .38-.87
BARBED 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
SCREW HHC M6-1.0 X 20 G8.8
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 35 G12.9
CLAMP STL/VNL .62 X .406 Z
GROMMET 1.37 X .06 X 1.00
SCREW HHTT M6-1.0 X 16 ZYC
(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) QTY REQ. FOR OPEN SETS. / QTY REQ. FOR ENCLOSED SETS.
1
2
3
4
5
6
(1) 7
(1) 8
0G15310GS0R
0G15320GS0R
0G15300GS0R
0G15290GS0R
0H30010GS0R
0G15330GS0R
0C2454
0D3215B
0C2454
2
2
1
1
1
1
20
2
8
PANEL C5 FRONT SIDES
PANEL C5 REAR SIDES
PANEL LOWER FRONT
PANEL C5 TOP
PANEL C5 TOP
PANEL C5 TOP MOUNT
SCREW THF M6-1 X 16 N WA Z/JS
ACCESS COVER 160 X 170 GALV
SCREW THF M6-1 X 16 N WA Z/JS
(1) NOT REQUIRED FOR UNITS WITH CATALYST.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
033212
065908
0G9782
052617
022304
022129
045773
022195
039130
030131
031015
0G5989
057822
059057
0F4408
0D1509
050279
0H2353
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
022097
045757
4
1
1
2
2
4
2
2
1
1
1
1
8
1
1
1
1
1
1
1
1
1
2
1
2
2
1
4
1
4
2
1
2
1
1
1
1
1
1
2
1
1
1
1
1
3
1
1
2
2
2
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 20 G8.8
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
ELBOW 90D 1-1/4 NPT
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
DECAL INLET PRESSURE
DECAL FUEL INLET NG
ASSY,ADAPTER,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
WASHER LOCK M6-1/4
SCREW HHC M6-1.0 X 25 G8.8
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
033212
065908
0G9781
0G9781A
0G9781B
052617
022304
022129
045773
064346
0A8064
030131
031015
088963
026915
057823
059057
0D2698
0D1509
050280
0H2353
0E4390
0E4392
0F0960
0F3885
0G3167
0F3691E
0F3691F
0F3691J
022195
0G5989
026073A
0D2157
039294
022097
042568
049811
039130
066212
0G46350ST03
022097
0G4588
039450
077879
077879
0F1866A
0C2454
4
1
1
1
1
2
2
4
2
1
2
1
1
1
2
4
2
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
4
1
4
2
2
1
1
1
2
1
2
2
1
1
1
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 20 G8.8
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 1.25 NPT X 5.5 BL IRN (150KW)
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
DECAL INLET PRESSURE
DECAL FUEL INLET LPG
ASSY,ADAPTER,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
WASHER LOCK M6-1/4
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")
SCREW THF M6-1 X 16 N WA Z/JS
(2) 1
(2) 2
(2) 3
(3) 4
(2) 5
(2) 6
(3) 7
0F58730ST01
0F58680ST01
0F58720ST01
0F58710AL01
0F58690ST01
0G97790ST01
0F58700ST01
0F58670AL01
1
4
2
2
2
1
1
1
REAR WRAP C5
DOOR C5
CENTER SUPPORT C5
DISCHARGE DUCT LH & RH SIDE C5
FRONT CORNERS C5
DUCT CENTER DISCHARGE (CATALYST EQUIPPED UNITS)
DUCT CENTER DISCHARGE (NON-CATALYST EQUIPPED UNITS)
ROOF C5 ALUM
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
42
43
(1) 44
45
46
47
48
49
50
51
0C2454
0F2766
0F3181
0F3185
0F3416
0F3949
0F4487A
022473
022097
022127
0F3072
078115
0F3949B
0F3949A
0F5048D
0E5968
0F5049
0F3949L
0F3949E
0F3890A
087233
0F3949C
0F3949D
0F3949G
0F3949J
0F3949K
0F3949F
0F3890B
0F3890
042568
022447
049813
077992
0912970094
0F2766A
0F3949M
0F8869D
0E3257
078115A
066760
86
2
4
2
2
2
1
5
1
1
20
58
3
4
4
1
4
2
1
9
2
1
4
1
2
1
2
4
14
4
4
4
28
4
1
1
1
6
12
1
SCREW THF M6-1 X 16 N WA Z/JS
SPLITTER
SPLITTER SHORT
STRINGER SPLITTER C3
SUPPORT SPLITTER C5 130KW
INSULATION CORNER POST
ASSY ACCESS COVER
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX 1/4-20 STEEL
INSULATION RETAINMENT HANGER
WASHER SELF LOCKING DOME #4-40
INSULATION SPLITTER
INSULATION SHORT LOUVER
VISE-ACTION LATCH SLOTTED CIR
GASKET EXTRUDED TRIM (566” LG)
TAB PULL
INSULATION SPLITTER SML
INSULATION ROOF TOP REAR
RETAINER INSULATION (740)
RIVET POP .1875 X .450 SS
INSULATION ROOF TOP
INSULATION DOOR
INSULATION DISCHARGE DUCT
INSULATION CENTER SUPPORT
INSULATION DISCHARGE DUCT TOP
INSULATION INNER DUCT SIDE
RETAINER INSULATION (820)
RETAINER INSULATION (450)
SCREW HHC M6-1.0 X 20 G8.8
WASHER SHAKEPROOF INT 1/4
NUT HEX M6 X 1.0 G8 YEL CHR
NUT HEX LOCK M6-1.0 SS NY INS
ASSY WIRE 14 AWG 34.8" GRN/YEL
SPLITTER C5
INSULATION SPLITTER SHRT MPS
KEY VISE-ACTION LATCH SLOT CIR
SCREW TH-FRM M6 W/CAP SHKPRF W
WASHER SELF LOCKING DOME #8-32
STRIP SEALANT 1/8 X 1 (44.52”LG)
(1) ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO
THE BASE FRAME MUST BE SECURED USING ITEM 11 & 49 THREAD FORMING
FASTENER AND ITEM 44 LOCK NUT. LOCK NUT IS TO BE INSTALLED AFTER THREAD
FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS. ALL ROOF PANELS
ARE TO BE SECURED IN THE SAME MANNER.
(2) NOTE: PART NUMBER SHOWN IS FOR TAN / STEEL. REFER TO THE SAMPLE
GUIDE BELOW FOR AVAILABLE COLOR AND/OR ALUMINUM PART NUMBER FORMAT.
0FXXXX0ST01 = TAN / STEEL
0FXXXX0ST13 = BISQUE / STEEL
0FXXXX0AL01 = TAN / ALUMINUM
0FXXXX0AL13 = BISQUE / ALUMINUM
0FXXXX0ST08 = T- GRAY / STEEL
0FXXXX0ST14 = GRAY / STEEL
0FXXXX0AL08 = T- GRAY / ALUMINUM
0FXXXX0AL14 = GRAY / ALUMINUM
0FXXXX0ST05 = WHITE / STEEL
0FXXXX0AL05 = WHITE / ALUMINUM
(3) PART NUMBER SHOWN IS FOR TAN. SEE GUIDE BELOW FOR AVAILABLE COLOR AND PART NUMBER
FORMAT.
0FXXXX0AL08 = T- GRAY / ALUMINUM
0FXXXX0AL13 = BISQUE / ALUMINUM
0FXXXX0AL05 = WHITE / ALUMINUM
0FXXXX0AL14 = GRAY / ALUMINUM
1
2
3
4
5
0F6207
0C9275
025393
0G0896
0G0897
070208
1
1
2
REF
REF
1
OUTLET 20A GFCI
BOX HANDY 2-1/8 X 4
SCREW HHTT #10-24 X 3/8 CZ
HARN ALT CON BOX 1PH QT
HARN ALT CON BOX 3PH QT
GROMMET .87 X .25 X .62
Notes
Notes
BackPg001 Rev. A 04/07
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 component on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diagnosis, replacement parts and labor provided it be done by 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 modification, 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 ultimate 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 warranty 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 Generac'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 component must be maintained and operated appropriately in order to ensure proper operation of the engine and control system to minimize
emissions at all times.
Generac may deny any/or all Emission Control System Warranty coverage or responsibility of the engine, or an emission control system or
component on your engine thereof, if it has failed due to abuse, neglect, unapproved modification or improper maintenance, or the use of
counterfeit and/or “gray market” parts not made, supplied or approved by Generac. Warranty service 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 transported/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 Generac 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
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
1.3) Fuel Regulator
6) Oxygen Sensor
2) Air Induction System Including A) Intake Pipe/Manifold,
B) Air Cleaner
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 operation 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 emergency stationary ICE in emergency situations. The purchaser/owner may petition the Administrator for approval of additional hours to be
used for maintenance checks and readiness testing, but a petition is not required if the owner maintains records indicating that Federal,
State, or local standards require maintenance and testing of emergency ICE beyond 100 hours per year. Emergency stationary ICE may
operate up to 50 hours per year in non 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 considered non-certified and you must demonstrate compliance according to Subpart JJJJ - Standards of Performance for Stationary Spark Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60.
Emission-Related Installation Instructions
Your certified emergency stationary engine has pre-set emission control systems or components that require no adjustment. Inspection and
replacement of an emissions related component is required to be done so in accordance with the requirements cited in the United States
Environmental Protection Agency Warranty Statement or can be arranged by contacting either your selling dealer or a Generac Authorized
Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. Failing to follow these instructions when installing a certified engine in a
piece of non-road equipment violates federal law 40 CFR 1068.105 (b), subject to fines or penalties as described in the Clean Air Act.
EmsnWrnty001
Revision F (04/15)
EXPLODED VIEW: EV AIR CLEANER
GROUP D
DRAWING #: 0F3569
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
PART#
QTY.
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
REVISION: CN-0008186-G
DATE: 7/11/17
DESCRIPTION
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
Page 2 of 2
EXPLODED VIEW: EV ALTERNATOR CPL GB
GROUP A
DRAWING #: 0F3577
ITEM
PART#
QTY.
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
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
1
1
1
1
1
1
3
2
1
2
2
1
1
2
1
1
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
35
40
41
42
43
44
45
46
47
48
49
DESCRIPTION
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
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
KIT PARTS I/N’S: 41 THRU 49 (INCLUDED IN I/N 40)
0A2491
2
SHROUD ALT SHEET METAL
0A2497
2
SCREEN SHROUD SAE
0A2496
2
BRKT TENSIONER SAE SCROLL
056326
8.4 FT.
TRIM VINYL BLACK 1/8 GP
022097
6
WASHER LOCK M6-1/4
022473
6
WASHER FLAT 1/4-M6 ZINC
045757
2
SCREW HHC M6-1.0 X 25 G8.8
047411
4
SCREW HHC M6-1.0 X 16 G8.8
0A2110
14
SCREW SWAGE 1/4-20 X 1/2 ZYC
* ROTOR REPLACEMENT PART
REVISION: K-2886-K
DATE: 5/21/15
Page 2 of 2
1
2
4
5
6
7
12
13
14
15
16
17
18
19
20
21
22
25
26
27
28
29
30
31
32
33
34
35
40
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
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
1
1
1
1
1
1
3
2
1
2
2
1
1
2
1
1
41
42
43
44
45
46
47
48
49
KIT PARTS
0A2491
0A2497
0A2496
056326
022307
022473
045757
047411
0A2110
2
2
2
8.4 FT.
6
6
2
4
14
8*
9
10
11
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
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
SCREW SWAGE 1/4-20 X 1/2 ZYC
* ROTOR REPLACEMENT PART
EXPLODED VIEW: EV MOUNTING BASE
GROUP C
DRAWING #: 0F3587
ITEM
(1)1
2
3
4
5
6
7
8
(1)9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
(1)27
28
29
30
31
32
PART#
QTY.
0L0574AST0R
G065852
G052252
G052257
G052259
G055597
052251A
G052860
0L06890ST0R
G045764
G052243
G061383
G043107
0A4456
--(1)0L01390ST0R
G022131
G046526
0536210410
--0C3168
G022129
G022145
G045771
G053557
0F2591
0L01480ST0R
------G051735
0L0123
1
1
4
4
8
4
4
4
1
1
6
1
2
1
-1
7
7
1
-1
1
2
2
4
2
1
---1
1
DESCRIPTION
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
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
ENGINE MOUNT 6.8L LH SIDE
---------------------SCREW HHC M10-1.5 X 70 C8.8
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).
REVISION: CN-0027708-F
DATE: 7/25/2019
Page 2 of 2
EXPLODED VIEW: EV BATTERY 27F GEAR BOX
GROUP C
DRAWING #: 0G0775
ITEM
PART#
QTY.
(1)1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
0F3408AST0R
0F3411
G058665
G022131
050331A
G050331
038805Z
038804U
G045771
G022129
G027482
G075763
0C2454
0F3409
G022097
G049813
G042568
0G0783
0J3501
1
1
1
1
1
1
1
1
1
1
1
1
8
1
2
2
2
1
1
DESCRIPTION
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
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
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).
REVISION: CN-0033024-B
DATE: 1/8/2020
Page 2 of 2
EXPLODED VIEW: EV ENCLOSURE C5 EMISSION
GROUP F
DRAWING #: 0G9784
APPLICABLE TO:
ITEM
PART#
QTY.
(2) 1
(2) 2
(2) 3
(2) 4
(2) 5
(2) 6
0F58730AL0R
0F5868AAL0R
0F5872AAL0R
0F58710AL0R
0F5869AAL0R
0G97790AL0R
0F58700AL0R
0F58670AL0R
066760
078115A
0E3257
0C2454
0F2766
0F3181
0F3185
0F3416
0J0336
0F4487A
022473
022097
022127
0F3072
078115
0J0336B
0J0336A
0F5048D
0E5968
0F5049
0J0336G
0J2624B
0F3890A
087233
0J0336C
0J0336D
0F3949G
0J0336F
0F3949K
0F3949F
0F8869D
0F3890
042568
022447
049813
077992
0912970090
0F2766A
0J0336H
1
4
2
2
2
1
1
1
1
12
6
86
2
4
2
2
2
1
5
1
1
20
30
3
4
4
1
4
2
1
2
2
1
4
1
2
1
2
1
2
4
4
4
28
4
1
1
(2) 7
8
9
(1)10
(1)11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
42
43
(1) 44
45
46
47
DESCRIPTION
REAR WRAP C5
DOOR C5
CENTER SUPPORT C5
DISCHARGE DUCT LH & RH SIDE C5
FRONT CORNERS C5
DUCT CENTER DISCHARGE
DUCT CNTR DISCHRG AL
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
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)
TAB PULL
INSUL SPLITTER SML
INSUL ROOF TOP REAR
RETAINER INSULATION (740)
RIVET POP .1875 X .450 SS
INSUL ROOF TOP FRT
INSUL DOOR
INSUL DISCHARGE DUCT
INSUL CENTER SUPPORT
INSUL DISCHARGE DUCT TOP
INSUL INNER DUCT SIDE
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
INSUL SPLITTER SHRT MPS
NOTES:
(1) ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO
THE BASE FRAME MUST BE SECURED USING ITEM 10 & 11 THREAD FORMING
FASTENER AND ITEM 44 LOCK NUT. LOCK NUT IS TO BE INSTALLED AFTER THREAD
FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS. ALL ROOF PANELS ARE TO BE
SECURED IN THE SAME MANNER.
NOTES (UNLESS OTHERWISE SPECIFIED):
(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: 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: CN-0008482-G
DATE: 7/20/17
PAGE 2 OF 2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
033212
065908
0G9782
052617
022304
022129
045773
022195
039130
030131
031015
0G5989
057822
059057
0F4408
0D1509
050279
0H2353
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
022097
045757
4
1
1
2
2
4
2
2
1
1
1
1
8
1
1
1
1
1
1
1
1
1
2
1
2
2
1
4
1
4
2
1
2
1
1
1
1
1
1
2
1
1
1
1
1
3
1
1
2
2
2
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 20 G8.8
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
ELBOW 90D 1-1/4 NPT
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
DECAL INLET PRESSURE
DECAL FUEL INLET NG
ASSY,ADAPTER,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
WASHER LOCK M6-1/4
SCREW HHC M6-1.0 X 25 G8.8
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
033212
065908
0G9781
0G9781A
0G9781B
052617
022304
022129
045773
064346
0A8064
030131
031015
088963
026915
057823
059057
0D2698
0D1509
050280
0H2353
0E4390
0E4392
0F0960
0F3885
0G3167
0F3691E
0F3691F
0F3691J
022195
0G5989
026073A
0D2157
039294
022097
042568
049811
039130
066212
0G46350ST03
022097
0G4588
039450
077879
077879
0F1866A
0C2454
4
1
1
1
1
2
2
4
2
1
2
1
1
1
2
4
2
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
4
1
4
2
2
1
1
1
2
1
2
2
1
1
1
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 20 G8.8
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 1.25 NPT X 5.5 BL IRN (150KW)
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
DECAL INLET PRESSURE
DECAL FUEL INLET LPG
ASSY,ADAPTER,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
WASHER LOCK M6-1/4
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")
SCREW THF M6-1 X 16 N WA Z/JS
1
2
3
4
(2) 5
(2) 6
(1) 7
8
(3) 9
0F4462
080762
0H2099
0C2454
0G97740AL01
0G97750AL01
0G3263
0H0260
077992
1
2
1
18
2
1
4
1
18
RAIN CAP 2-1/2" AL
BOLT U 3/8-16 X 2.62
CATALYST 3-WAY
SCREW THF M6-1X16 N WA Z/JS
HEAT SHIELD EXHAUST STACK
CAP HEAT SHIELD EXHAUST STACK
DECAL WARNING HOT SURFACES BI
EMISS EXH OUTLET PIPE CPL
NUT HEX LOCK M6-1.0 SS NY INS
NOTE:
SOME UNITS MAY REQUIRE (2) KITS.
(1) DECALS APPLIED TO EXHAUST AT THE FACTORY.
(2) PART NUMBER SHOWN IS FOR TAN. SEE GUIDE BELOW FOR AVAILABLE COLOR AND PART NUMBER FORMAT.
0GXXXX0AL08 = GRAY / ALUMINUM
0GXXXXALT13 = BISQUE / ALUMINUM
0GXXXX0AL05 = WHITE / ALUMINUM
0GXXXXALT14 = GRAY / ALUMINUM
0GXXXX0GS0R = GALVANIZED / NO PAINT
(3) ) ALUMINUM ENCLOSURE NOTE: ITEM NUMBER 5 TO BE SECURED USING ITEM NUMBERS 4 (THREAD FORMING
FASTENER) & 9 (LOCK NUT). THE LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED
THROUGH EXTRUSIONS IN ENCLOSURE PANELS.
CATALYST AND HEAT SHIELD ASSEMBLY INSTRUCTIONS:
1)
Disconnect battery cables to prevent accidental start-up. Disconnect the negative battery cable first
from the battery post indicated by (-) or NEG.
2)
Insert the outlet pipe (0H0260 I/N 8) 2 to 3 inches into the outlet of the catalyst (0H2099, I/N 3). The
illustration identifies the catalyst inlet and outlet. Slide one U-bolt (080762, I/N 2) onto the outlet of
the catalyst and tighten.
3)
Slide the remaining U-bolt (080762, I/N 2 (not shown)) and catalyst (0H2099, I/N 3) over the exhaust
pipe protruding from the enclosure. The exhaust pipe should be inserted 2 to 3 inches into the inlet
of the catalyst (0H2099, I/N 3). The flat side of the catalyst should be aligned with the side of the
generator (as shown). Position the U-bolt over the inlet of the catalyst and tighten. This joint must be
tight and must not leak.
4)
Sub-assemble the heat shield panels (0G97740AL01, I/N 5) and the heat shield cap (0G97750AL01, I/N
6) using the screws provided (0C2454, I/N 4). Lock nuts (077992, I/N 9) should be installed after the
fastener has penetrated through the extrusions in the heat shield panels. Lock nuts (077992, I/N 9)
are not required on open set configurations.
5)
Slide the heat shield subassembly over the catalyst. The long side of the heat shield assembly
should be aligned with the long side of the generator (as shown).
6)
Fasten the heat shield assembly to the enclosure using the screws provided (0C2454, I/N 4). Lock
nuts (077992, I/N 9) should be installed after the fastener has penetrated through the extrusions in the
enclosure. An access panel may need to be removed to complete this step. Lock nuts (077992, I/N 9)
are not required on open set configurations.
7)
Install the rain cap over the outlet of the catalyst and tighten (0F4462, I/N 1). Open set configurations
do not require a rain cap.
Notes:
•
•
Catalyst must be mounted in described position.
Failing to follow these instructions when installing a certified engine in a piece of nonroad
equipment violates federal law 40 CFR 1068.105 (b), subject to fines or penalties as
described in the Clean Air Act.
COMPONENTS INCL UDED IN 0G4140E
1
ENCL H/G CO NTROL PANEL
1
CO VER CONTRO L PANEL
1
HING E CONT INUOUS H PANEL
7
RIVET POP .125 X .275 SS
1
ASSY PROGRAMMED H- 100
1
DECAL FUSES LO CAT ED INSIDE
1
RAIL SNAPTRACK PCB HO LDER BULK ( 12” LG)
1
ASSY PCB 10A UL BATT CHRG R 12V
1
PLATE HARNESS CLAMP
1
ASSY PCB PW R AVR W /AMP HEADER
1
ASSY PCB BOSCH G OV DRIVER
1
DIO BR IDG E 25A 600V
11
W ASHER LO CK M5
4
SCREW PPHM M5- 0.8 X 30 SS
11
W ASHER FLAT M5
6
SCREW HHPM M5-0.8 X 12
5
NUT HEX M5-0.8 G8 YEL CHR
3
W ASHER FLAT M4
3
SCREW PHTT M4- 0.7 X 10 Z YC
1
CO NN DUST CAP W/CHAIN DB9
1
W ASHER FLAT M3.5
1
SCREW PHTT M3.5- 0.6 X 10
10
SCREW PPHM M4- 0.7 X 8 BLX O X
10
W ASHER LO CK #8-M4
1
DECAL W RN B AT T CHRG 12/24V BI
1
M5-0.8 CAPT IVE PANEL KNLD HD
2
SEAL COVER 3.18 X 12.7 X 382
1
SEAL COVER 3.18 X 12.7 X 283
1
HARNESS H-PNL INTEGRATED SW (NO T SHO WN)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
0F1823CST 03
0F1824AST 03
0F2606
036261
0F5763
0F1732
0E9764
0F1740C
0F1958
0F2256
0E3161
029673
049226
079224
051713
0F5886
051716
043180
0C3990
0F4333
0F5883
0F5884
055014
022264
0G 3546
0G 3648
0F6305
0F6305A
0G 4329
A
B
C
D
E
0F1263
0F1262
0F1264
0E9049B
055911
COMPONENTS INCL UDED IN WIRE HARNESS
1
ADPTR RH SIDE W ICKMANN 178.6191
4
HO LDER F USE WICKMANN 178.6150
1
ADPTR LH SIDE W ICKMANN 178.6192
1
ASSY PCB G-PANEL RELAY 12VDC
1
BL OCK TERM 20A 12 X 6 X 1100V
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
056739
0F2627B
022287
022473
022097
043182
051714
052777
0C2323
0F5459
0F5461
022127
0F5460
0E7403C
0E7403B
0F6145
0C2699
0C2266
COMPONENTS NO T INCLUDED IN 0G 4140E O R WIRE HARNESS
1
RELAY CONTACTO R 12VDC
1
DPE B REAKER SEE DRAW ING 0F9280
1
BO OST RESIST OR SEE DRAWING 0F 9280
1
CO VER CONTRO L PANEL SIDE
2
SCREW HHC 1/4-20 X 3/4 G 5
4
W ASHER FLAT M6-1/4
2
W ASHER LO CK M6-1/4
3
W ASHER LO CK M3
3
NUT HEX M3-0.5 G8 YEL CHR
3
W ASHER FLAT M3
2
SCREW PHTT #6-32 X 5/8 Z YC
1
DECAL CPL CONTRO L PANEL FUSES
1
DECAL CPL 5.4/6.8L TB3
2
NUT HEX 1/4-20 STEEL
1
DECAL CPL 5.4/6.8L RELAY BO ARD
1
F USE ATO TYPE 15 AMP (BL UE)
2
F USE ATO TYPE 10 AMP (RED)
A/R
SEAL WEATHER .45"DIA
2
SCREW PHTT #6-32 X 3/8 Z YC
4
SCREW PHTT M5- 0.8 X 16 Z YC
EXPLODED VIEW: EV ENGCOMPRT 6.8L GB CPL R/H
GROUP D
DRAWING #: 0F3557
ITEM
PART#
QTY.
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
32
33
34
35
36
37
38
39
41
43
44
45
46
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
G021113
G077996
G022131
0C7649
G052647
0D2244M
0D3808
0F5114
G079121
048031P
048031J
G087599
0G1462
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
1
1
7
1
9
1
2
1
2
2
1
1
1
DESCRIPTION
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
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)
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
(1) NOTE: I/N 23 IS FOR HOLDING SENSORS TO I/N 19.
(2) 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
1
2
3
4
(2) 5
6
7
8
9
10
(3) 11
12
13
14
15
16
17
(3) (1) 18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
(3) 49
0F3017
039253
022129
022145
0D5419
0D7055
0D3488G
0D3488J
0D3488
0D3488K
057795A
059057
0F3287
0G9989
0H3074
0E9868A
057796
0F3216
0F3216A
0F3216C
0F3216D
035579
0F4612
0D6658
029333A
022097
022473
042568
0D8027
0D8025
0D8026
0D8030
0F2846
0D8029
0D8028
045771
0D3454A
0H0923
022131
046526
064416
045772
0F3217
0F2776A
0F6151
0F4308
0F3158
057823
0E0502
0G0866
0F4301
0E8286
047527
057823
0E0992A
078637
0G7519
0H4672
1
3
4
4
REF
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
3
3
4
1
3
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
4
10
A/R
1
1
BRACKET,D.C. ALTERNATOR LOWER
SCREW HHC M8-1.25 X 20 G8.8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
OIL FILTER, FORD V-10 ENGINE
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 3/4 PLASTIC
HOSE 3/4 ID SAE-30R2 (16.75”LG)
BRACKET DC ALTERNATOR UPPER
HARN ENG G6.8L H-100 EMISSIONS (USE WITH PROBE P/N 0E2507)
HARN ENG G6.8L H-100 CPL EMSN (USE WITH PROBE P/N 0H1827)
ALTERNATOR DC W/OUT PULLEY
GROMMET
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
SENDER OIL PRESSURE 1/8" NPT
DIPSTICK 6.8L FORD
TIE WRAP UL 7.4" X .19" BLK
WASHER LOCK M6-1/4
WASHER FLAT 1/4 ZINC
SCREW HHC M6-1.0 X 20 G8.8
BOLT WATER PUMP PULLEY
BOLT GROOVED IDLER PULLEY
BOLT BELT TENSIONER
TENSIONER ENG. AUTOMATIC BELT
PULLEY WATER PUMP FORD (1800RPM UNITS)
PULLEY ENGINE WATER PUMP (2-POLE & GEAR BOX)
PULLEY GROOVED ENGINE IDLER
NUT HEX M8-1.25 G8 YEL CHR
ENGINE G6.8L G3 V-10
ENGINE G6.8L G3 V-10 (2009 +)
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
SCREW HHC M10-1.5 X 45 G8.8 FT
NUT HEX M10-1.5 G8 YEL CHR
SPACER DC ALTERNATOR PULLEY
BRACKET SIGNAL CONDITIONER
CAP RUBBER
BRACKET DC ALT STABILIZER
OIL COOLER FORD (150KW 3600RPM)
CLAMP HOSE #10 .56-1.06
TEMPERATURE SENDER DELPHI
HOSE OIL COOLER PREFORMED 3/4 (150KW 3600RPM)
HOSE OIL COOLER (150KW 3600RPM)
ELBOW 45D STREET 1/2NPT BRASS
BARBED STR 1/2NPT X 3/4
CLAMP HOSE #10 .56-1.06 (150KW 3600RPM)
PLUG EXPANSION 14 OD
ADHESIVE LOCTITE 620
DECAL EMISSION CTRL INFO 6.8L
HARN OXYGEN SENSOR EXTENSION
(1) NOTE: I/N 18 IS FOR HOLDING SENSOR TO I/N 35.
(2) I/N 5 PART OF I/N 29.
(3) NOTE: NOT SHOWN
EXPLODEDVIEW: EV GEARBOX ASSY 390 ALT
GROUP D
DRAWING#: 0F1792
APPLICABLETO:
ITEM
PART#
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
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
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
2
1
1
1
1
4
1
1
1
8
8
2
1
1
1
6
REF.
10
2.5cc
.200 GAL
10
10
2
4
1
.050 GAL
0.4cc
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
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
44
45
46
47
48
49
50
51
REVISION: CN-0021689-G
DATE: 11/14/2018
Page 2 of 2
1
2
3
4
5
6
7
8
9
0C2454
0C2428
022155
023484K
0F3518
0F3517
0F3519
0F3520
023484N
11
2
2
1
1
1
1
1
1
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
* PARTS INCLUDED WITH ALTERNATOR.
** PARTS INCLUDED WITH TRANSFORMER.
EXPLODED VIEW: EV BLOCK HEATER 6.8L
GROUP A
DRAWING #: 0G0878D
ITEM
PART#
QTY.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
047411
022097
022473
084918G
0G0015
042568
055934D
084427
035467
049813
050967
022129
042907
0C4905
0C4905
0A6283
025066
059057
057823
0L4800
050967
0F4355
0G0153
057823
0G0866
2
4
4
1
4
2
1
1
1
2
1
1
1
2
1
1
1
1
2
1
1
REF.
REF.
REF.
REF.
15
16
17
18
19
20
21
22
23
24
REVISION: K-2046-C
DATE: 12/21/15
DESCRIPTION
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
WASHER FLAT 1/4 ZINC
HEATER ENG 1500W 120V
CLAMP HOSE 7/8” OD DOUBLE WIRE
SCREW HHC M6-1.0 X 20 G8.8
CLAMP VINYL 1.06 X .406 Z
BRACKET HEATER
NIPPLE CLOSE 3/8NPT X 1 VIBRA
NUT HEX M6-1.0 G8 YEL CHR
HOSE COOL 5/8 ID 20R3 (33”LG)
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 16 G8.8
BARBED EL 45 3/8NPT X 5/8OD
BARBED EL 45 3/8NPT X 5/8OD (150KW ONLY)
HOSE PREFORMED BLOCK HEATER
COUPLING FULL 3/8-18
HOSE 3/4 ID SAE-30R2 (8”LG) (150KW ONLY)
CLAMP HOSE #10 .56-1.06 (150KW ONLY)
BARB Y 5/8 HOSE (150KW ONLY)
HOSE COOL 5/8 ID 20R3 (24”LG) (150KW ONLY)
ADAPTER 1/2”NPT X 3/8”NPT (150KW ONLY)
BARBED EL 90 1/2NPT X 3/4 HOSE (150KW ONLY)
CLAMP HOSE #10 .56-1.06 (150KW ONLY)
HOSE OIL COOLER PREFORMED 3/4 (150KW ONLY) (SEE SPECIAL NOTE)
Page 2 of 2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
047411
022097
022473
084918G
0G0015
042568
055934D
084427
035467
049813
050967
022129
042907
0C4905
0C4905
0A6283
025066
059057
057823
0G8847
050967
0F4355
0G0153
057823
0G0866
2
4
4
1
4
2
1
1
1
2
1
1
1
2
1
1
1
1
2
1
1
REF.
REF.
REF.
REF.
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
WASHER FLAT 1/4 ZINC
HEATER ENG 1500W 120V
CLAMP HOSE 7/8” OD DOUBLE WIRE
SCREW HHC M6-1.0 X 20 G8.8
CLAMP VINYL 1.06 X .406 Z
BRACKET HEATER
NIPPLE CLOSE 3/8NPT X 1 VIBRA
NUT HEX M6-1.0 G8 YEL CHR
HOSE COOL 5/8 ID 20R3 (33”LG)
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 16 G8.8
BARBED EL 45 3/8NPT X 5/8OD
BARBED EL 45 3/8NPT X 5/8OD (150KW ONLY)
HOSE PREFORMED BLOCK HEATER
COUPLING FULL 3/8-18
HOSE 3/4 ID SAE-30R2 (8”LG) (150KW ONLY)
CLAMP HOSE #10 .56-1.06 (150KW ONLY)
BARB Y UNIVERSAL 5/8-3/4 HOSE (150KW ONLY)
HOSE COOL 5/8 ID 20R3 (24”LG) (150KW ONLY)
ADAPTER 1/2”NPT X 3/8”NPT (150KW ONLY)
BARBED EL 90 1/2NPT X 3/4 HOSE (150KW ONLY)
CLAMP HOSE #10 .56-1.06 (150KW ONLY)
HOSE OIL COOLER PREFORMED 3/4 (150KW ONLY) (SEE SPECIAL NOTE)
1
2
3
4
5
0F6207
0E3573
0C9275
025393
0G0896
0G0897
070208
1
1
1
2
REF
REF
1
OUTLET 20A GFCI
COVER,BLANK 4X2 1/8 HNDY BX
BOX HANDY 2-1/8 X 4
SCREW HHTT #10-24 X 3/8 CZ
HARN ALT CON BOX 1PH QT
HARN ALT CON BOX 3PH QT
GROMMET .87 X .25 X .62
1
2
3
4
5
6
7
8
9*
10
11
12
13
14
15 **
16 **
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37 ***
38
39
40
41
42
43
44
45
0F2885
0F2883
0F3685
023484N
023484N
086961
067617030A
067617030B
072158
043180
022264
0C3990
057701
022155
0C2428
0F3618
0A9457
057073
0D5466
0A7822
022237
022241
049226
0C2266
0C2454
042568
022473
022097
049813
0E9764
0G6962B
025433
024469
067210A
0D6029
051713
081008
077043J
077043J
0F6156
029289
0F3113
047411
036943
023897
022152
022158
0F8565
045764
023762
1
1
1
1
2
1
4
6
6
REF.
2
2
1
1
2
REF.
REF.
4
4
6
6
10
4
12
8
4
6”
1
1
1
1
4
2
1
3
4
1
1
REF
4
2
3
2
2
1
1
1
PANEL CB CONN BOX
STAND RH CONTROL
STAND LH CONTROL C5 GRBX
BUSHING SNAP SB-2.5-31
BUSHING SNAP SB-2.5-31 (FOR 5.4L 1000KW 1PHASE)
INTERFACE 1PH 240V
INTERFACE 3PHS 416/480V
INTERFACE 3PHS 208/240V
ASSY INTFC 3PH 600V
WASHER FLAT M4
WASHER LOCK #8-M4
SCREW PHTT M4-0.7 X 10 ZYC
BLOCK TERM 20A 8 X 6 X 1100V
WASHER LOCK #6
SCREW PHTT #6-32 X 1/2 ZYC
DECAL CPL CUST CONN H CTRL
DECAL NEUTRAL
JUNCTION BLOCK 3/8-16
BUS BAR NEUTRAL BLOCK 390
LUG SLDLSS 600/250-1/0 X 1/4-28
WASHER LOCK 3/8
NUT HEX 3/8-16 STEEL
WASHER LOCK M5
SCREW PHTT M5-0.8 X 16 ZYC
SCREW THF M6-1 X 16 N WA Z/JS
SCREW HHC M6-1.0 X 20 G8.8
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX M6 X 1.0 G8 YEL CHR
RAIL SNAPTRACK PCB HOLDER BULK
ASSY RELAY PCB 12VDC
LUG SLDLSS #6-14 X 13/64 CU
SCREW HHTT #10-32 X 3/8 CZ
DECAL GROUND LUG
SCREW HHTT M6-1.0 X 16 ZYC
WASHER FLAT M5
GROMMET 1.25 X .25 X .75
CONDUIT FLEX 2.0" ID
CONDUIT FLEX 2.0" ID (FOR 5.4L/100KW 1 PHASE)
PLATE WIRE SNGL GALV
TAPE ELEC 1/2 FOAM (AS REQ’D)
ASSY PCB HSB CTRL IGN MODULE
SCREW HHC M6-1.0 X 16 G8.8
SCREW PPHM #10/32 X 2
WASHER FLAT #10 ZINC
WASHER LOCK #10
NUT HEX #10-32 STEEL
DECAL H-100 RB3 CUST CONN
SCREW HHTT M4-0.7 X 8 ZP
WASHER SHAKEPROOF EXT #10 STL
1.)
A
C
D
E
F
G
H
J
K
L
2.)
A
C
D
E
F
G
H
J
K
L
0F2887
0D5572
0D5573
0D5574
0D5575
0D5576
0F0199
065960
022473
022097
022127
0C2454
029289
0F1733
UL CIRCUIT BREAKER (FD)
1
COVER FD FRM CB
CB 0150A 3P 600V S FD6 LL
CB 0175A 3P 600V S FD6 LL
CB 0200A 3P 600V S FD6 LL
CB 0225A 3P 600V S FD6 LL
CB 0250A 3P 600V S FD6 LL
1
INSULATOR CB FD FRAME 30MIL
4
SCREW SHC 1/4-20 X 4 G8.8 NZ
4
WASHER FLAT 1/4-M6 ZINC
4
WASHER LOCK M6-1/4
4
NUT HEX 1/4-20 STEEL
4
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
0F2721
0D5577
0D5578
0D5579
0D5581
0D5585
0F2353
022770
022473
022097
022127
0C2454
029289
0F1733
UL CIRCUIT BREAKER (JD+LD)
1
COVER CIR BRKR JD/LD
CB 0300A 3P 600V S JD6 LL
CB 0350A 3P 600V S JD6 LL
CB 0400A 3P 600V S JD6 LL
CB 0600A 3P 600V S LD6
CB 0450A 3P 600V S LD6 LL
2
INSULATOR CIRCUIT BR. JD/LD
4
SCREW RHM 1/4-20 X 3
4
WASHER FLAT 1/4-M6 ZINC
4
WASHER LOCK M6-1/4
4
NUT HEX 1/4-20 STEEL
7
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
0F3327
0D5556
0D5566
0D5568
0D5570
0D9693
0F0492
048927
023897
022152
022158
0C2454
029289
0F1733
UL CIRCUIT BREAKER (ED)
1
COVER,ED CB TALL
1
CB 0090A 3P 480V S ED4 LL
CB 0060A 3P 600V S ED6 LL
CB 0080A 3P 600V S ED6 LL
CB 0100A 3P 600V S ED6 LL
CB 0125A 3P 480V S ED4 LL
1
INSULATOR CB S (ED-3P)
4
SCREW RHM #10-32 X 4-1/2
4
WASHER FLAT #10 ZINC
4
WASHER LOCK #10
4
NUT HEX #10-32 STEEL
7
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE
3)
A
C
D
E
F
G
H
J
K
L
* ITEM INCLUDED WITH HARNESS.
** ITEM INCLUDED WITH 0D5464B.
*** ITEM IS PART OF 9R.
3.)
A
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W*
X
Y
4.)
A
C
D
E
F
G
H
J
K
L
M
N
P
R
S*
T
U
V
0F4173
0F4165$
0F4186
036261
053640
038150
022264
022471
029289
0F1733
022129
0F8432
0C2454
0F8451
049897
022145
045771
0F8843
W/CB
0G3259
058306
0F4175
0F4166$
0F1733
042419
023897
022152
022158
0C2454
029289
052647
046526
W/CB
0A7822
022131
W/CB
023334
022097
0G3259
1
REF
1
4
4
4
4
4
2
1
9
1
7
3
6
6
3
3
2
1
3
UL CIRCUIT BREAKER (225AF)
COVER CB C5 225AF
CIRCUIT BREAKERS 200A FRAME
COVER CB DISH 225AF
RIVET POP .125 X .275 SS
SCREW RHM #8-32 X 3-1/4
WASHER FLAT #8 ZINC
WASHER LOCK #8-M4
NUT HEX #8-32 STEEL
TAPE ELEC 1/2 FOAM
DECAL CUSTOMER CONNECT INSIDE
WASHER LOCK M8-5/16
INSULATOR CB 225AF
SCREW THF M6-1 X 16 N WA Z/JS
LUG SLDLSS 300 MCM-6 AL/CU
SCREW SHC M8-1.25 X 20 G8
WASHER FLAT 5/16-M8 ZINC
NUT HEX M8-1.25 G8 CLEAR ZINC
BUS BAR 200A LUG ADAPTOR
TERMINAL COVER CB
DECAL TERMINAL SHOCK HZD BI
SCREW SHC M8-1.25 X 25 G12.9
1
REF
1
4
8
4
4
7
1
6
6
3
3
3
2
6
6
1
UL CIRCUIT BREAKER (400AF)
COVER CB C5 400AF
CIRCUIT BREAKERS 400A FRAME
DECAL CUSTOMER CONNECT INSIDE
SCREW RHM 10-32 X 4
WASHER FLAT #10 ZINC
WASHER LOCK #10
NUT HEX #10-32 STEEL
SCREW THF M6-1 X 16 N WA Z/JS
TAPE ELEC 1/2 FOAM
SCREW SHC M10-1.5 X 25 G12.9
WASHER LOCK M10
BUS BAR CB ADAPTER 225-400 A
LUG SLDLSS 600/250-1/0 X 1/4-28
WASHER FLAT 3/8-M10 ZINC
TERM COVER CB
SCREW HHC 1/4-28 X 1/2 G5
WASHER LOCK M6-1/4
DECAL TERMINAL SHOCK HZD BI
5.)
A
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U*
V
W
0F4176
0F4167$
0F8433
024196
022473
022097
022127
0C2454
029289
060619
022131
022237
045772
0F9721
0D2157
0F1733
W/CB
0G3259
022097
1
REF
2
4
4
4
4
7
2
2/3
2/3
2/3
2/3
2/3
4/6
1
2
1
4/6
UL CIRCUIT BREAKER (800AF)
COVER CB C5 800AF
CIRCUIT BREAKERS 800A FRAME
INSULATOR CB 800AF
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
SCREW THF M6-1X16 N WA Z/JS
TAPE ELEC 1/2 FOAM
SCREW SHC M10-1.50 X 40 G12.9
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK 3/8
NUT HEX M10-1.5 G8 YEL CHR
LUG SLDLSS 3/0-400X3 MCM AL/CU
SCREW SHC M6-1.0 X 50 G8.8
DECAL CUSTOMER CONNECT INSIDE
TERM COVER VITZROTECH 400AF CB
DECAL TERMINAL SHOCK HZD BI
WASHER LOCK M6-1/4
6.)
A
B
C
D
E
F
G
H
0D5466
039287
022145
022129
045771
045335
022097
0A7822
2
1
1
1
1
2
2
1
NEUTRAL BLOCK 390 / 200-400A
BUS BAR NEUTRAL BLOCK 390
SCREW HHC M8-1.25 X 45 G8.8 FT
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
SCREW HHC 1/4-28 X 3/4 G5
WASHER LOCK M6-1/4
LUG SLDLSS 600/250-1/0X1/4-28
* HARDWARE FOR MTG. CB TERMINAL COVERS IS
SUPPLIED WITH CIRCUIT BREAKERS.
1
2
3
4
5
6
7
8
9*
10
11
12
13
14
15 **
16 **
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
0F2885
0G0171
0G0171A
0G0172
023484N
086961
067617030A
067617030B
043180
022264
0C3990
057701
022158
0F8565
0F3618
0A9457
057073
0D5466
0A7822
022237
022241
049226
0C2266
0C2454
042568
022473
022097
049813
0E9764
0G6962B
025433
024469
067210A
0D6029
051713
081008
077043J
0F6156
1
1
1
1
1
1
4
6
6
REF.
2
1
1
1
2
REF.
REF.
4
4
6
6
10
4
12
8
4
6”
1
1
1
1
4
2
1
3
1
PANEL CB CONN BOX
STAND RH CONTROL CPL C5
STAND RH CONTROL CPL C5 2 HOLE
STAND LH CONTROL CPL C5
BUSHING SNAP SB-2.5-31
INTERFACE 1PH 240V
INTERFACE 3PHS 416/480V
INTERFACE 3PHS 208/240V
WASHER FLAT M4
WASHER LOCK #8-M4
SCREW PHTT M4-0.7 X 10 ZYC
BLOCK TERM 20A 8 X 6 X 1100V
NUT HEX #10-32 STEEL
DECAL H-100 RB3 CUST CONN
DECAL CPL CUST CONN H CTRL
DECAL NEUTRAL
JUNCTION BLOCK 3/8-16
BUS BAR NEUTRAL BLOCK 390
LUG SLDLSS 600/250-1/0 X 1/4-28
WASHER LOCK 3/8
NUT HEX 3/8-16 STEEL
WASHER LOCK M5
SCREW PHTT M5-0.8 X 16 ZYC
SCREW THF M6-1 X 16 N WA Z/JS
SCREW HHC M6-1.0 X 20 G8.8
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX M6 X 1.0 G8 YEL CHR
RAIL SNAPTRACK PCB HOLDER BULK
ASSY RELAY PCB 12VDC
LUG SLDLSS #6-14 X 13/64 CU
SCREW HHTT #10-32 X 3/8 CZ
DECAL GROUND LUG
SCREW HHTT M6-1.0 X 16 ZYC
WASHER FLAT M5
GROMMET 1.25 X .25 X .75
CONDUIT FLEX 2.0" ID
PLATE WIRE SNGL GALV
36
37 ***
38
39
40
41
42
43
029289
0F3113
047411
036943
023897
022152
045764
023762
1.)
A
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T ****
U
V
0G0173
0F4167$
0F8433
022477
022473
022097
022127
0F1733
029289
060619
022131
022237
045772
0F9721
0D2157
W/CB
0G3259
022097
UL CIRCUIT BREAKER (800AF)
1
COVER, CB 803 C5
REF
CIRCUIT BREAKERS 800A FRAME
2
INSUL CB 800AF
4
SCREW RHM 1/4-20 X 1-1/2
8
WASHER FLAT 1/4-M6 ZINC
4
WASHER LOCK M6-1/4
4
NUT HEX 1/4-20 STEEL
1
DECAL CUSTOMER CONNECT INSIDE
2
TAPE ELEC 1/2 FOAM
2/3
SCREW SHC M10-1.50 X 40 G12.9
2/3
WASHER FLAT 3/8-M10 ZINC
2/3
WASHER LOCK 3/8
2/3
NUT HEX M10-1.5 G8 YEL CHR
2/3
LUG SLDLSS 3/0-400X3 MCM AL/CU
4/6
SCREW SHC M6-1.0 X 50 G8.8
2
TERM. COVER VITZROTECH 400AF CB
1
DECAL TERMINAL SHOCK HZD BI
4/6
WASHER LOCK M6-1/4
0D5466
039287
022145
022129
045771
045335
083896
0A7822
NEUTRAL BLOCK 390 / 200-400A
1
BUS BAR NEUTRAL BLOCK 390
1
SCREW HHC M8-1.25 X 45 G8.8 FT
1
WASHER FLAT 5/16-M8 ZINC
1
WASHER LOCK M8-5/16
1
NUT HEX M8-1.25 G8 YEL CHR
2
SCREW HHC 1/4-28 X 3/4 G5
2
WASHER LOCK 1/4-M6 SS
1
LUG SLDLSS 600/250-1/0 X 1/4-28
2.)
A
B
C
D
E
F
G
H
1
REF
4
2
3
2
1
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
ASSY PCB HSB CTRL IGN MODULE
SCREW HHC M6-1.0 X 16 G8.8
SCREW PPHM #10/32 X 2
WASHER FLAT #10 ZINC
WASHER LOCK #10
SCREW HHTT M4-0.7 X 8 ZP
WASHER SHAKEPROOF EXT #10 STL
* ITEM INCLUDED WITH HARNESS
** ITEM INCLUDED WITH 0D5464B
*** ITEM IS PART OF 9R.
**** HARDWARE FOR MTG. CB TERMINAL COVERS IS SUPPLIED WITH
CIRCUIT BREAKERS.
1
2
3
4
5
6
7
8
9
10
0G17730GS0R
0G17710GS0R
0G17720GS0R
0G17740GS0R
056326
0C2454
022131
046526
051756
081008B
1
1
1
1
1
10
4
4
4
1
GUARD BELT RIGHT HAND C5
GUARD BELT TOP C5
GUARD BELT BOTTOM C5
GUARD BELT LEFT HAND C5
TRIM VINYL BLACK 1/8GP
SCREW THF M6-1 X 16 N WA Z/JS
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
SCREW HHC M10-1.5 X 20 G8.8
GROMMET 1.25 X .25 X 1.00
EXPLODED VIEW: EV MFL 6.8 CPL C5 EMSN
GROUP D
DRAWING #: 0H2814
ITEM
PART#
QTY.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
0F2807F
0F2807B
0F9071
0A6765
0F4710
0F7200
080762
0F2809
0F2981A
0F2962
0C2454
022097
0F2830
088510
049721
049813
0L1789
0F2773C
0D3159
088775
0F2808
0F2808C
0F5447
022473
0F6214
0G3163A
0H4445
0F5512
1
1
1
2
6
6
8
1
2
2
4
12
2
6
12
8
8
2
2
6
2
2
1
20
1
2
1
1
22
23
24
25
26
27
REVISION: K-1591-D
DATE: 1/2/15
DESCRIPTION
PIPE EXH MAN R/H 6/8 G/BCPLEPA
PIPE EXH MAN L/H 6.8L G/B 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 2.62
PIPE EXHAUST CROSSOVER
MFLR 7" X 9" X 25" (2) 2.5" IN/2.5" OUT
MUFFLER STRAP
SCREW THF M6-1 X 16 N WA Z/JS
WASHER LOCK M6-1/4
MUFFLER BRACKET STIFFENER
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
EXHUAST OUTLET PIPE CPL
EXHAUST OUTLET PIPE CPL (OPEN SET ONLY)
BRKT MUFFLER
WASHER FLAT 1/4-M6 ZINC
PIPE ELBOW EXHAUST MUFFLER
BLANKET EXHAUST MUFFLER 584MM
PIPE ELBOW EXHAUST O2 SENSOR
REFLEX WRAP 13MM 13 X 460 (12”LG)
Page 2 of 2
EXPLODED VIEW:
GROUP
DRAWING #:
ITEM
PART#
QTY.
DESCRIPTION
PAGE 1
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
42
43
44
45
46
47
(1) 48
49
50
51
52
53
54
55
56
57
58
59
60
REVISION: -ADATE: 2/13/17
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
0F2776A
022145
022129
052644
035685
045764
065852
0C7649
055596
069860E
069811
080713
022473
022097
042568
0F5050B
039253
051769
0C8145
0H1827
0H23980ST03
029032
049820
1
1
1
1
12
4
2
2
1
1
1
1
1
1
1
15
1
8
1
4
1
12
1
1
1
4
2
1
1
1
1
1
1
1
1
1
1
1
8
1
1
1
4
2
1
4
1
1
1
1
1
REF
1
24
16
8
1
3
1
8
1
1
1
2
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
BRACKET, SIGNAL CONDITIONER
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
SPACER .5 X 1.5 X .25 STL/ZINC
CLAMP HOSE #28 1.32-2.25
SCREW HHTT M4-0.7 X 8 BP
SPRING CLIP HOLDER .37-.62
CLAMP HOSE .38-.87
BARBED 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
SCREW HHC M6-1.0 X 20 G8.8
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
Page 2 of 2
EXPLODED VIEW:
GROUP
DRAWING #:
ITEM
PART#
QTY.
(3) 61
62
(4) 63
64
(4) 65
66
67
68
0H2844
0G53150AL0R
051756
052625
055934H
072252
0D6029
0D3700
2 (REF)
1
4/5
3
1/2
1
1
8
DESCRIPTION
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 35 G12.9
CLAMP STL/VNL .62 X .406 Z
GROMMET 1.37 X .06 X 1.00
SCREW HHTT M6-1.0 X 16 ZYC
NUT FLANGE M6-1.0 NYLOK
(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) QTY REQ. FOR OPEN SETS. / QTY REQ. FOR ENCLOSED SETS.
PAGE 2
1
2
3
4
5
6
(1) 7
(1) 8
0G15310GS0R
0G15320GS0R
0G15300GS0R
0G15290GS0R
0H30010GS0R
0G15330GS0R
0C2454
0D3215B
0C2454
2
2
1
1
1
1
20
2
8
PANEL C5 FRONT SIDES
PANEL C5 REAR SIDES
PANEL LOWER FRONT
PANEL C5 TOP
PANEL C5 TOP
PANEL C5 TOP MOUNT
SCREW THF M6-1 X 16 N WA Z/JS
ACCESS COVER 160 X 170 GALV
SCREW THF M6-1 X 16 N WA Z/JS
(1) NOT REQUIRED FOR UNITS WITH CATALYST.
REVISION: -ADATE: 2/13/17
Page 3 of 2
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