Generac 150kW QT15068GVNNA Standby Generator Manual

Generac 150kW QT15068GVNNA Standby Generator Manual
Serial Number
Industrial QT
6.8L
150kW
Models
STANDBY GENERATOR
OWNER'S MANUAL
A new standard of reliability
This manual should remain with the unit.
Cover073 Rev. 0 05/06
Part No. 0G2034
Standby Generator Sets
Table of Contents
INTRODUCTION .....................................................1-3
Read this Manual Thoroughly ...................................1-3
Operation and Maintenance ......................................1-3
How to Obtain Service ..............................................1-3
IDENTIFICATION RECORD .....................................2-1
Data Label ................................................................2-1
EQUIPMENT DESCRIPTION ...................................3-1
Equipment Description ................................................3-1
Engine Oil Recommendations ......................................3-1
Coolant Recommendations...........................................3-1
ENGINE PROTECTIVE DEVICES ............................4-1
Coolant Temperature Sensing ...................................4-1
Low Coolant Level.....................................................4-1
Oil Pressure Sensing .................................................4-1
Overcrank Shutdown ................................................4-1
Overspeed Shutdown ................................................4-1
RPM Sensor Loss Shutdown.....................................4-1
DC Fuse ....................................................................4-1
FUEL SYSTEMS .....................................................5-1
Fuel Requirements ....................................................5-1
Natural Gas Fuel System ..........................................5-1
Propane Vapor Withdrawal Fuel System....................5-1
LP Fuel System .........................................................5-1
SPECIFICATIONS ...................................................6-1
Generator .................................................................6-1
Engine.......................................................................6-1
Cooling System .........................................................6-1
Fuel System ..............................................................6-1
Electrical System ......................................................6-1
5.4L & 6.8L Ignition Description .................................6-3
Ignition Power-up Input (“56 Line Input”) .................6-3
Ignition Enable (“14 Line Input”) ..............................6-3
Ignition Shutdown on Loss of Crank
or CAM Signals .........................................................6-3
Diagnostic Blink Patterns (Red LED Located
on the Ignition Control Board ...................................6-3
GENERAL INFORMATION.......................................7-1
Generator AC Lead Connections ..................................7-1
Alternator Power Winding Connections ........................7-1
Four-lead, Single-phase Stator ..................................7-1
3-phase Alternators ("Y" Configuration) ....................7-1
3-phase Alternators ("Delta" Configuration) ..............7-2
INSTALLATION.......................................................8-1
Installation ...................................................................8-1
Preparation Before Start-up .........................................8-1
Transfer Switch ........................................................8-1
Fuel System ..............................................................8-1
Generator Set Lubrication ........................................8-1
Prior to Initial Start-up .............................................8-1
Engine Coolant .........................................................8-1
Belt Tension ..............................................................8-1
Electrical System ......................................................8-1
Initial Inspection for QT Genset Start-up .....................8-1
Start-up Checklist ........................................................8-2
Preparation for Start-up............................................8-2
Start-up Inspection ...................................................8-2
OPERATION ...........................................................9-1
Generator Control and Operation ................................9-1
Operating Unit with Manual Transfer Switch ...............9-1
Engine Start-up and Transfer ...................................9-1
Retransfer and Shutdown .........................................9-1
Operating Unit with Automatic Transfer Switch ...........9-1
MAINTENANCE.....................................................10-1
Maintenance Performed by Authorized
Service Facilities .....................................................10-1
Every Three Months ...............................................10-1
Once Every Six Months ...........................................10-1
Once Annually.........................................................10-1
First 100 Operating Hours ......................................10-1
Every 500 Operating Hours ....................................10-1
Cooling System ..........................................................10-1
Checking Fluid Levels ................................................10-1
Check Engine Oil ....................................................10-1
Battery Fluid ...........................................................10-1
Engine Coolant .......................................................10-2
Maintenance Owner/Operator Can Perform ................10-2
Check Engine Oil Level ...........................................10-2
Check Battery .........................................................10-2
Exercise System ......................................................10-2
Inspect Cooling System ...........................................10-2
Check Engine Coolant Level....................................10-2
Perform Visual Inspection .......................................10-2
Inspect Exhaust System ..........................................10-2
Check Fan Belt........................................................10-2
Inspect Engine Governor ........................................10-2
Changing Engine Oil ...............................................10-2
Changing the Engine Air Cleaner ............................10-3
Spark Plugs ............................................................10-3
Coolant Change .......................................................10-3
Miscellaneous Maintenance ........................................10-3
Cleaning the Generator ...........................................10-3
Battery ....................................................................10-4
Battery Maintenance ...............................................10-4
Battery Replacement ...............................................10-4
SERVICE SCHEDULE ...........................................11-1
30 kW - 150 kW Standby Gas Engine
Driven Generator Sets ............................................11-1
TROUBLESHOOTING ...........................................12-1
Troubleshooting Guide...............................................12-1
NOTES
EXPLODED VIEWS & PARTS LISTS
WIRING DIAGRAMS & SCHEMATICS
WARRANTY
Content010 Rev. 0 04/06
SECTION
PAGE
SAFETY RULES ................................................ 1-1
Safety Rules
INTRODUCTION
shock hazard.
This symbol points out potential electrical
Thank you for purchasing this model of the Stationary Emergency
Generator set product line.
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.
Every effort was expended to make sure that the information and
instructions in this manual were both accurate and current at the
time the manual was written. However, the manufacturer reserves
the right to change, alter or otherwise improve this product(s) at
any time without prior notice.
READ THIS MANUAL THOROUGHLY
OPERATION AND MAINTENANCE
If any portion of this manual is not understood, contact the nearest Authorized Service Dealer for starting, operating and servicing
procedures.
It is the operator's responsibility to perform all safety checks, to
make sure that all maintenance for safe operation is performed
promptly, and to have the equipment checked periodically by
an Authorized Service Dealer. Normal maintenance service and
replacement of parts are the responsibility of the owner/operator
and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits
and usage contribute to the need for maintenance service.
Throughout this publication, and on tags and decals affixed to the
generator, DANGER, WARNING, CAUTION and NOTE blocks are
used to alert personnel to special instructions about a particular
service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are
as follows:
Proper maintenance and care of the generator ensure a minimum
number of problems and keep operating expenses at a minimum.
See an Authorized Service Dealer for service aids and accessories.
INDICATES A HAZARDOUS SITUATION OR
ACTION WHICH, IF NOT AVOIDED, WILL RESULT
IN DEATH OR SERIOUS INJURY.
Operating instructions presented in this manual assume that the
generator electric system has been installed by an Authorized
Service Dealer or other competent, qualified contractor. Installation
of this equipment is not a “do-it-yourself” project.
Indicates a hazardous situation or action which,
if not avoided, could result in death or serious
injury.
HOW TO OBTAIN SERVICE
Indicates a hazardous situation or action which,
if not avoided, could result in minor or moderate
injury.
NOTE:
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.
When the generator requires servicing or repairs, simply contact
an Authorized Service Dealer for assistance. Service technicians
are factory-trained and are capable of handling all service needs.
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 action or service are essential to
preventing accidents.
Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTION blocks. The type of information each
indicates is as follows:
AUTHORIZED SERVICE DEALER LOCATION
To locate the nearest AUTHORIZED
SERVICE DEALER, please call this number:
This symbol points out important safety
information that, if not followed, could
n
endanger personal safety and/or property of
1-800-333-1322
or locate us on the web at:
others.
www.generac.com
1-1
Safety 001 Rev. d 06/10

This symbol points out potential fire hazard.

This symbol points out potential explosion
hazard.
Safety Rules
Save These Instructions – The manufacturer suggests that these rules for safe operation be copied
n
and posted in potential hazard areas. Safety should be stressed to all operators, potential operators,
and service and repair technicians for this equipment.
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 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.
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.
Despite the safe design of this generator,
operating this equipment imprudently,
n
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.
Parts of the generator are rotating and/or
hot during operation. Exercise care near runn
ning generators.
GENERAL HAZARDS
• For safety reasons, the manufacturer recommends that this
equipment be installed, serviced and repaired by an Authorized
Service Dealer or other competent, qualified electrician or installation technician who is familiar with applicable codes, standards
and regulations. The operator also must comply with all such
codes, standards and regulations.
• Installation, operation, servicing and repair of this (and related)
equipment must always comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and
national electrical and building codes. Comply with regulations
the Occupational Safety and Health Administration (OSHA) has
established. Also, ensure that the generator is installed, operated and serviced in accordance with the manufacturer’s instructions and recommendations. Following installation, do nothing
that might render the unit unsafe or in noncompliance with the
aforementioned codes, standards, laws and regulations.
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
Safety 001 Rev. d 06/10
Safety Rules
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.
Safety 001 Rev. d 06/10
1-3
General Information
IDENTIFICATION RECORD
Identification Code
Use this code to obtain important information about the generator.
For example, if the code is:
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.
M Q
QT
100
5.4
A
MADE IN USA
SERIAL
MODEL
RATED KVA
RATED KW
POWER FACTOR
PHASE
RATED AMPS
RATED VOLTAGE
HERTZ
ALT RPM
PRODUCTION DATE
ENGINE RPM
ALTERNATOR SUBTRANSIENT REACTANCE
N —
S —
ALTERNATOR TRANSIENT REACTANCE
CLASS
—
—
—
—
ROTOR
STATOR WINDING INSULATION AT 25°C AMBIENT
GENERAC POWER SYSTEMS, INC.
N —
WAUKESHA, WI
A —
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.
T
1
0
0
5
4
A
N
S
N A
able for this configuration.
Quiet Test Generator Series
kw Rating
Engine Size in Liters
Voltage Code: A = 120/240, Single-phase; G =
120/208, Three-phase; K = 277/480, Three-phase; J
= 120/240, Three-phase;
L = 346/600, Three-phase
Fuel: N = Natural Gas; V = Vapor Propane
Enclosure Material: A = Aluminum; S = Steel
(Corrosion Resistant Aluminum Enclosure Material,
Steel is Standard)
Emission Equipment: N = No Equipment; Y =
Catalytic Converter and Air/Fuel Ratio Controller
Industrial Dealer Product
Voltage Codes
The identification code letter following the unit’s engine size is the
generator’s “voltage code.”
Stationary Emergency Generator Model and Serial
Number
Groups and Assembly Numbers
The manual drawing listing lists the groups and corresponding
assembly numbers for each unit. The assembly numbers refer to
exploded view drawing numbers that are applicable to the specific
generator model. These drawings are located in the back half of
this manual.
This number is the key to numerous engineering and manufacturing details pertaining to your unit. Always supply this number
when requesting service, ordering parts or seeking information.
2-1
Identy001 Rev. E 06/10
GENERATOR SET DATA
M — Designates generators capable of paralleling. NOTE:
Only 100kW and 150kW, 6.8L units are currently avail-
Equipment Description
EQUIPMENT DESCRIPTION
COOLANT RECOMMENDATIONS
The Stationary Emergency Generator incorporates the following
alternator features:
not use any chromate base rust inhibitor
nDo
with ethylene glycol base anti-freeze or chromium hydroxide (“green slime”) forms and
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.
will cause overheating. Engines that have
been operated with a chromate base rust
inhibitor must be chemically cleaned before
adding ethylene glycol base anti-freeze.
Using any high silicate anti-freeze boosters or additives will also cause overheating.
The manufacturer also recommends that
any soluble oil inhibitor is NOT used for this
equipment.
• Rotor and Stator insulation is Class H rated as defined by NEMA
MG1-32.6, NEMA MG1-1.66. The generator is self ventilated
and drip-proof constructed.
• The voltage waveform deviation, total harmonic content of the
AC waveform and telephone influence factor have been evaluated and are acceptable according to NEMA MG1-32.
ENGINE OIL RECOMMENDATIONS
The unit has been filled with 15W-40 engine oil at the factory.
Use a high-quality detergent oil classified “For Service SJ or SH.”
Detergent oils keep the engine cleaner and reduce carbon deposits.
Use oil having the following SAE viscosity rating, based on the
ambient temperature range anticipated before the next oil change:
Temperature
Oil Grade (Recommended)
Above 80° F (27° C)
SAE 30W or 15W-40
32° to 80° F (0° to 27° C)
SAE 20W-20 or 15W-40
Below 32° F (0° C)
See Note
not remove the radiator pressure cap
nDo
while the engine is hot or serious burns from
boiling liquid or steam could result.
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
nAny
before it has been properly serviced with the
recommended oil may result in an engine
failure.
NOTE:
For temperatures below 32° F, it is strongly recommended to
use the optional Cold Weather Start Kit (part number listed in
the Specification Section). The oil grade for temperatures below
32° F is 5W-30 synthetic oil.
Equip005 Rev. C 06/10
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.
Required fuel pressure for natural gas is 11 inches to 14 inches
water column (0.4 to 0.5 psi); and for liquid propane, 11 inches
to 14 inches of water column (0.4 to 0.5 psi).
NOTE:
Any piping used to connect the generator to the fuel supply
should be of adequate size to ensure the fuel pressure NEVER
drops below 11 inches water column for natural gas or 11
inches water column for liquid propane for all load ranges. The
fuel supply piping shall be sized according to the installation
manual using the fuel consumption requirements identified in
the Specifications section of the Owner's Manual.
LP FUEL SYSTEM
LP is supplied as a liquid in pressure tanks. It is usually made up
of propane, butane, or a mixture of the two gases. Propane tends
to vaporize readily even at temperatures as low as -20° F (-29° C).
However, butane reverts to its liquid state when temperatures drop
below 32° F (0° C).
NOTE:
It is the responsibility of the installer to make sure that only
the correct recommended fuel is supplied to the generator fuel
system. Thereafter, the owner/operator must make certain that
only the proper fuel is supplied.
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.
NATURAL GAS FUEL SYSTEM
Natural gas is supplied in its vapor state. In most cases, the gas
distribution company provides piping from the main gas distribution line to the standby generator site. The following information
applies to natural gas fuel systems.
• Gas pressure in a building is usually regulated by national, state
and local codes.
• To reduce gas pressure to a safe level before the gas enters a
building, a primary regulator is needed. The natural gas supplier
may or may not supply such a regulator.
• It is the responsibility of the gas supplier to make sure sufficient
gas pressure is available to operate the primary regulator.
• Gas pressure at the inlet to the fuel shutoff solenoid should not
exceed approximately 14 inches water column (0.5 psi).
FuelSys002 Rev. E 06/10
5-1
Standby Generator Sets
Specifications
SPECIFICATIONS
Engine Lubrication System
Type of Oil Pump ...................................................................... Gear
Oil Filter .............................................................Full Flow, Cartridge
Crankcase Oil Capacity ....................................................5 U.S. qts.
‹ GENERATOR
Type ............................................................................. Synchronous
Rotor Insulation ................................Class F or H (see Data Label)
Stator Insulation .................................................................. Class H
Total Harmonic Distortion ......................................................< 3.5%
Telephone Interference Factor (TIF) ..........................................< 50
Alternator Output Leads 1-phase ........................................... 4-wire
Alternator Output Leads 3-phase ........................................... 6-wire
Bearings .........................................................................Sealed Ball
Coupling .......................................................................Flexible Disc
Load Capacity (Standby Rating) ..........................................150kW*
* NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349,
‹ COOLING SYSTEM
Type .......................................................................................Closed
Water Pump.................................................................... Belt Driven
Fan Speed ................................................................................ 2200
Fan Diameter .....................................................................26 inches
Fan Mode ................................................................................Puller
Air Flow (inlet air including alternator and
combustion air) .......................................................... 7800 ft3/min.
Coolant Capacity ........................................................ (4.5 U.S. gal.)
Heat Rejection to Coolant ..........................................568,000 Btu/h
Maximum Operating Air Temp. on Radiator ..............60° C (150° F)
Maximum Ambient Temperature................................50° C (140° F)
ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural
gas.
Excitation System ............................................................. Brushless
Generator Output Voltage/kW - 60 Hz
kW
Amp CB Size
120/240V, 1-phase, 1.0 pf
150
625
700
120/208V, 3-phase, 0.8 pf
150
520
600
120/240V, 3-phase, 0.8 pf
150
451
500
277/480V, 3-phase, 0.8 pf
150
226
250
600V, 3-phase, 0.8 pf
150
180
225
Generator Locked Rotor KVA Available @ Voltage Dip of 35%
Single-phase or 208 3-phase ........................................... 320 KVA
480V, 3-phase .................................................................. 350 KVA
‹ FUEL SYSTEM
Type of Fuel .............................................. Propane or Natural Gas*
Carburetor ...................................................................... Down Draft
Secondary Fuel Regulator .................................................Standard
Fuel Shut-off Solenoid ........................................................Standard
Operating Fuel Pressure .................... 11 in. - 14 in. Water Column
Fuel Consumption - ft3/hr (Natural Gas/LPV)
Exercise
25%
50%
75%
100%
Cycle
Load
Load
Load
Load
155/63
556/224
1070/431 1491/600 2061/830
‹ 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
* Engine is not field convertible between natural gas and propane. Jet size and ignition timing are
factory set for the specific fuel.
‹ ELECTRICAL SYSTEM
Battery Charge Alternator ............................................12V, 30 Amp
Static Battery Charger ..................................................12V, 10 Amp
Recommended Battery................................................ 24F 525CCA
System Voltage .....................................................................12 Volts
Voltage Regulator
Type ................................................................................. Full Digital
Sensing................................................................................ 3-phase
Regulation .............................................................................± 1/4%
Features ............................................Built into H-100 Control Panel
V/F Adjustable, Adjustable
Voltage and Gain
Engine Parameters
Rated Synchronous RPM ..............................................60 Hz, 3600
HP at rated kW ................................................................60 Hz, 254
Exhaust System
Exhaust Flow at Rated Output 60 Hz................................ 1535 cfm
Exhaust Temperature at Rated Output ................................ 1100° F
Power Adjustment for Ambient Conditions
Temperature Deration
3% for every 10° C above °C ..................................................... 25
1.65% for every 10° above °F .................................................... 77
Altitude Deration
1% for every 100 m above m ................................................... 183
3% for every 1000 ft. above ft. ................................................. 600
Combustion Air Requirements (Natural Gas)
Flow at rated power, 60 Hz ................................................. 410 cfm
Governor
Type .................................................................................. Electronic
Frequency Regulation ...................................................Isochronous
Steady State Regulation........................................................± 1/4%
Adjustments:
Speed ............................................................................ Selectable
Controller .............................................. H-panel
GenSpec029 Rev. 0 05/06
6-1
Standby Generator Sets
Specifications
Figure 1 — Interconnections
CIRCUIT BREAKER WIRE AND CONDUIT SIZE
KW
VOLTS
CB AMPS
LUG SIZE
100
240 1Ø
500
2 500-700 mcm
100
208 3Ø
400
#4 - 600 mcm
100
480 3Ø
175
#6 - 300 mcm
100
240 3Ø
400
#4 - 600 mcm
Figure 2 — AC Outlet for Block Heater and
Battery Charger (to be wired by installer)
6-2
GenSpec029 Rev. 0 05/06
Standby Generator Sets
Specifications
5.4L & 6.8L IGNITION DESCRIPTION
NOTE:
This single-fire Ignition is intended to operate with
a 10-cylinder, 6.8L engine and an 8-cylinder, 5.4L
engine.
The ignition cover does not need to be removed to
see the LED.
The 6.8L engine uses a 40-1 crank sensor, a magpickup CAM sensor and individual coil-on-plug coils
for each spark-plug.
‹ IGNITION SHUTDOWN ON LOSS OF CRANK
OR CAM SIGNALS
The ignition will stop firing the coils immediately following the loss of the crank signal. The ignition will
stop firing the coils after approx. 3 seconds following
the loss of the cam signal.
The 5.4L engine uses a 36-1 crank sensor, a magpick-up CAM sensor and individual coil-on-plug coils
for each spark-plug.
With a single-fire ignition, each high-voltage coil output is connected to one spark plug resulting in that
spark plug being fired only during the compression
cycle.
‹ DIAGNOSTIC BLINK PATTERNS (RED LED
LOCATED ON THE IGNITION CONTROL
BOARD)
Engine Timing versus Engine Speed for the 6.8L
engine is:
During normal ignition operation the RED LED
flashes at a 0.5 sec ON and a 0.5 sec OFF rate. This
is considered one (1) blink.
RPM
NG/LP Engine Timing (BTDC)
1800 rpm
22 degrees
3600 rpm
24 degrees
Engine Timing versus Engine Speed for the 5.4L
engine is:
RPM
1800 rpm
3600 rpm
LED Fault Code with Priority as shown:
1. No Crank Signal: LED blinks 2 times, is OFF for
3.0 seconds and then repeats
2. No CAM Signal: LED blinks 3 times, is OFF for
3.0 seconds and then repeats
Only one fault is displayed at a time. If multiple faults
exist then the highest priority fault must be resolved
prior to a lower priority fault being displayed. In the
event that an ignition fault has occurred the ignition
will wait 60 seconds before powering down.
NG/LP Engine Timing (BTDC)
26 degrees
26 degrees
‹ IGNITION POWER-UP INPUT ("56 LINE
INPUT")
When battery voltage is applied to this input the ignition will power-up. For the ignition to power itself
down, battery voltage must be removed from this
input.
NOTE:
The ignition cover does not need to be removed to
see the LED.
‹ IGNITION ENABLE ("14 LINE INPUT")
This input must be connected to the +12V battery for
the ignition to turn-on the coils. If this input is connected to battery ground the ignition will stop firing
the coils and will power down within approximately
2 seconds. In the event that an ignition fault has
occurred, however, the ignition will wait 60 seconds
before powering down. This allows time to view the
diagnostic LED located on the ignition board.
GenSpec029 Rev. 0 05/06
6-3
General Information
GENERATOR AC LEAD
CONNECTIONS
3-PHASE ALTERNATORS ("Y" CONFIGURATION)
The Stationary Emergency Generator is designed to supply
3-phase electrical loads. Electric power is produced in the alternator power windings. These windings were connected at the factory
to the main circuit breaker with a “Y” configuration as shown in
Figures 7.2, 7.3, and 7.4.
See “Voltage Codes”. This Stationary Emergency Generator may
be rated at any one of five voltages, either single-phase or threephase. The electrical wires in the unit’s AC connection (lower)
panel should be installed according to the number of leads and the
voltage/phase required for the application. If there are any questions regarding lead connection, refer to the wiring diagrams at the
back of this manual.
The rated voltage between circuit breaker terminals E1-E2, E1-E3
and E2-E3 is either 480V or 208V depending on the model.
The rated voltage between each circuit breaker terminal and the
neutral point 00 is either 277V or 120V depending on the model.
Voltage codes apply to the type of stator assembly installed on a
particular generator.
Figure 7.2 — Stator Power Winding
Connections - 3-phase, 120/208V (12 Lead)
ALTERNATOR POWER WINDING
CONNECTIONS
E1
FOUR-LEAD, SINGLE-PHASE STATOR
S7
S1
S10
S12
S4
S5
Four-lead generators are built to supply electrical loads with voltage code "A" (240V, 1-phase, 60Hz). Electrical power is produced
in the stator power windings. These windings were connected at
the factory to the main circuit breaker as shown in Figure 7.1.
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.
L-L
S9
Figure 7.1 — Four-lead, Single-phase Stator
S2
S6
S11
E3
E2
S3
S8
L-N
Figure 7.3 — Stator Power Winding
Connections - 3-phase, 277/480V (12 Lead)
E1
S1
S4
S7
L-L
S6
S3
E3
7-1
S9
S10
S11
S8
S5
L-N
S2
E2
ACConn005 Rev. B 06/10
S12
General Information
3-PHASE ALTERNATORS ("DELTA" CONFIGURATION)
Figure 7.1 — Stator Power Winding
Connections - 3-phase, 346/600V (6 Lead)
The Stationary Emergency Generator is designed to supply
3-phase electrical loads. Electric power is produced in the alternator power windings. These windings were connected at the factory
to the main circuit breaker with a “Delta” configuration as shown
in Figures 7.5.
S1 E1
The rated voltage between circuit breaker terminals E1-E2, E1-E3
and E2-E3 is 208V.
INTERNAL
CONNECTIONS
The rated voltage between E1 or E3 and the neutral point 00 is
120V.
L-L
S6
S4
Figure 7.5 — Stator Power Winding
Connections - 3-phase, 120/240V (12 Lead)
NEUTRAL
S5
E2
E3 S3
S2
E2
L-N
E1
7-2
E
ACConn005 Rev. B 06/10
Installation
INSTALLATION
PRIOR TO INITIAL START-UP
PREPARATION BEFORE START-UP
Prior to initially starting the generator, it
must be properly prepared for use. Any
n
attempt to crank or start the engine before
Refer to the separate “Installation Guide QT Product Line” supplied
with the unit.
The instructions in this section assume that the standby generator has been properly installed, serviced, tested, adjusted and
otherwise prepared for use by a competent, qualified installation
contractor. Be sure to read the “Safety Rules”, as well as all other
safety information in this manual, before attempting to operate this
(and related) equipment.
it has be en properly serviced with the recommended types and quantities of engine
fluids (oil, coolant, fuel, etc.) may result in an
engine failure.
ENGINE COOLANT
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”.
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
TRANSFER SWITCH
If this generator is used to supply power to any electrical system
normally powered by an electric utility, the National Electrical Code
requires that a transfer switch be installed. The transfer switch prevents electrical backfeed between two different electrical systems.
(For additional information, see the applicable transfer switch
manual for this unit.) The transfer switch, as well as the generator
and other electrical components, must be properly located and
mounted in strict compliance with applicable codes, standards
and regulations.
Check-the engine-fan belt tension and condition prior to placing
the unit into service and at recommended intervals. Belt tension is
correct when a force of approximately 22 pounds (10 kg), applied
midway between pulleys, deflects the belt about 3/8- to 5/8-inch
(10 to 16 mm).
FUEL SYSTEM
Make sure the generator battery is fully charged, properly installed
and interconnected, and ready for use.
ELECTRICAL SYSTEM
Make sure the generator is properly connected to an approved
earth ground.
Make sure the fuel supply system to the generator (a) delivers the
correct fuel at the correct pressure and (b) is properly purged and
leak tested according to code. No fuel leakage is permitted. See
“Specifications” for more information.
NOTE:
Battery charger must be connected to 120 VAC, 15 amp circuit
to operate.
Check to ensure that there are no loose electrical connections.
Restrain any loose wires to keep them clear of any moving generator set components.
GENERATOR SET LUBRICATION
Check the engine crankcase oil level before operating and add
oil to the proper level – the dipstick “FULL” mark. Never operate
the engine with the oil level below the dipstick “ADD” mark. See
“Specifications” and “Engine Oil Recommendations”.
INITIAL INSPECTION FOR QT
GENSET STARTUP
NOTE:
Inspect for the following.
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.
•
•
•
•
•
Also, if the engine is equipped with a mechanical governor, make
sure the governor is properly lubricated with clean engine oil.
•
•
•
•
•
8-1
Freight Damage.
Manuals present.
Fluid Levels (Oil, coolant, battery, Gear Drive).
Correct fuel piping.
Correct muffler installation for QT45, QT55, QT80, QT100 QT150.
Adequate air flow, clearances and ventilation per installation
drawings and applicable codes.
Correct AC and DC wire size, connections and grounding.
Control and communication wiring to/from the transfer switch
must be run in a separate conduit from the AC power leads.
AC outlet connection.
Communication wires connected between transfer switch and
generator (HTS only).
Unit secured to pad.
Install006 Rev. C 06/10
This engine is shipped from the manufacturer with “break-in”
oil. This oil should be changed after 30 hours of operation.
Installation
START-UP CHECKLIST
• 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.
Before working on the Stationary Emergency
n
Generator, ensure the following:
• The AUTO/OFF/MANUAL switch is in the OFF position.
• The power to the block heater and to the battery charger is
switched OFF.
PREPARATION FOR START-UP
• Remove the fuse from the the control panel. For the H-100 and
R-series: Open the front door of the control box and remove the
15 Amp ATO fuse in the lower left-hand corner of the control
box.
• Connect the battery cables to the battery. Attach negative battery cable last.
• Restore power to the GFCI outlet that provides power to the
battery charger.
• Measure the voltage at the battery before and after the charger
is turned on.
• Verify all AC electrical connections are tight at the circuit breaker
and transfer switch.
• Visually inspect entire area looking for loose paper, plastic
wrappings, leaves, etc.
• Check all hoses clamps fittings for leaks or damage.
• Check all electrical plugs throughout the generator. Ensure each
plug is seated correctly and fully inserted into its receptacle.
• Verify the AUTO/OFF/MANUAL switch is in OFF position.
• Open the valve to the engine fuel line.
• Bleed the fuel system of air. (necessary for long fuel lines).
• Open the generator main line circuit breaker.
• Connect a manometer to the gas line and record the static pressure. It must be as listed in the Specifications.
• Insert the fuse into the control panel.
• Move the AUTO/OFF/MANUAL switch to the MANUAL position.
The engine should now crank and start.
START-UP INSPECTION
When a start-up is performed by an Authorized Service Dealer, a
standard three-part form titled “Start-up Inspection for Standby
Power Systems” (part no. 067377), should be completed by the
installation technician or engineer. See page 1-3 for information on
locating the nearest Authorized Service Dealer. The installer should
complete the form and disseminate copies as follows:
• White copy: Mail to Generac Warranty Department, P.O. Box
340, 211 Murphy Dr., Eagle, WI 53119-2062.
• Pink Copy: For service file of installing dealer.
• Yellow Copy: For the customer’s records.
8-2
Install006 Rev. C 06/10
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
Maintenance
MAINTENANCE PERFORMED BY
AUTHORIZED SERVICE DEALERS
extremely hot and remain hot after shutget
down. High grass, weeds, brush, leaves, etc.
The exhaust system parts from this product
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.
The negative battery cable has been removed.
CHECKING FLUID LEVELS
CHECK ENGINE OIL
Check engine crankcase oil level (Figure 10.1) at least every 20
hours of operation, or prior to use.
EVERY THREE MONTHS
1.
2.
3.
4.
5.
6.
Check battery state of charge and condition.
Inspect and test fuel system.
Check transfer switch.
Inspect exhaust system.
Check engine ignition system.
Check fan belts.
•
•
•
•
ONCE EVERY SIX MONTHS
1.
Figure 10.1 - Oil Dipstick and Oil Fill Cap
Test Engine Safety Devices (low oil pressure, low coolant
level, high coolant temperature).
Oil Fill
ONCE ANNUALLY
1.
2.
3.
4.
Remove oil dipstick and wipe dry with a clean, lint-free cloth.
Install oil dipstick, then remove again.
Oil should be between FULL and ADD marks.
If oil level is below the dipstick ADD mark, remove oil fill cap.
Add the recommended oil to bring oil level up to the FULL
mark. DO NOT FILL ABOVE THE “FULL” MARK. See “Engine Oil
Recommendations” for recommended oils.
Test engine governor. Adjust or repair, if needed.
Clean, inspect generator.
Flush cooling system.
Clean/re-gap spark plugs or replace as necessary.
FIRST 30 OPERATING HOURS
1.
Change engine "break-in" oil and oil filter.
FIRST 100 OPERATING HOURS
1.
Oil
Dipstick
Change engine oil and oil filter. (After initial change, service
engine oil and filter at 150 operating hours or 6 months,
whichever comes first.)
EVERY 500 OPERATING HOURS
1.
2.
3.
Oil Filter
Service air cleaner.
Check starter.
Check engine DC alternator.
BATTERY FLUID
Check battery electrolyte fluid at least once weekly. Fluid should
cover separators in all battery cells. If fluid level is low, add distilled
water to cover tops of separators. DO NOT USE TAP WATER IN
BATTERY.
COOLING SYSTEM
Air intake and outlet openings in the generator compartment must
be open and unobstructed for continued proper operation. This
includes such obstructions as high grass, weeds, brush, leaves
and snow.
Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down.
Maint013 Rev. F 07/10
10-1
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.
following:
Before working on the generator, ensure the
•
•
•
•
not attempt to adjust the governor. Only
qualified service facilities should adjust
nDo
the governor. Excessively high operating
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.
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
nHot
cool before draining oil. Avoid prolonged
or repeated skin exposure with used oil.
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.
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
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.
5.
10-2
Remove OIL DRAIN HOSE from its retaining clip.
Loosen and remove OIL DRAIN HOSE CAP. Drain oil completely into suitable container.
When all oil has drained, install and tighten OIL DRAIN HOSE
CAP, and re-install into its retaining clip.
Turn OIL FILTER (Figure 10.2) counterclockwise and remove.
Dispose of old filter.
Apply light coating of new engine oil to seal of new oil
filter.-Install FILTER and tighten by hand only. DO NOT
OVERTIGHTEN.
Maint013 Rev. F 07/10
Maintenance
6.
SPARK PLUGS
Remove OIL FILL CAP. Add recommended oil (see
SPECIFICATIONS). DO NOT FILL ABOVE THE DIPSTICK
“FULL” MARK. Crankcase oil capacity is listed in the
“Specifications”.
Reset the spark plug gap or replace the spark plugs as necessary.
1.
refilling the crankcase with oil, always
nAfter
check oil level on dipstick. NEVER OPERATE
ENGINE WITH OIL BELOW THE DIPSTICK
2.
7.
8.
3.
9.
“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.
Clean the area around the base of the spark plugs to keep dirt
and debris out of the engine. Clean by scraping or washing
using a wire brush and commercial solvent. Do not blast the
spark plugs to clean.
Remove the spark plugs and check the condition. Replace
the spark plugs if worn or if reuse is questionable. See the
“Service Schedule” section for recommended inspection.
Check the spark plug gap using a wire feeler gauge. Adjust
the gap to 0.94 - 1.07 mm (0.037 - 0.042 inch) by carefully
bending the ground electrode (Figure 10.4).
Figure 10.4 – Setting the Spark Plug Gap
Figure 10.2 - Oil Filter
Oil
Dipstick
COOLANT CHANGE
Every year, have an Authorized Service Facility drain, flush and
refill the cooling system. See the “Specifications” section for cooling system recommendations.
Oil Filter
CHANGING THE ENGINE AIR CLEANER
MISCELLANEOUS MAINTENANCE
To replace the engine air cleaner, (part number 0A4637), remove
the air cleaner cover and replace the air filter making sure it is
positioned properly before reattaching the cover.
CLEANING THE STATIONARY EMERGENCY GENERATOR
Keep the generator as clean and as dry as possible. Dirt and
moisture that accumulates on internal generator windings have an
adverse effect on insulation resistance.
Figure 10.3 — Engine Air Filter
Periodically clean generator exterior surfaces. A soft brush may be
used to loosen caked on dirt. Use a vacuum system or dry, low
pressure air to remove any accumulations of dirt. The generator is
housed inside an all-weather enclosure, clean the enclosure with a
soft, damp cloth or sponge and water.
Air Filter
Once each year, have the generator cleaned and inspected by an
Authorized Service Dealer. That dealer will use dry, low pressure air
to clean internal windings. Parts inside the control console should
be cleaned and inspected at this time as well.
Finally, have the insulation resistance of stator and rotor windings
checked. If insulation resistances are excessively low, the generator may require drying.
See the “Service Schedule” section for air cleaner maintenance.
Maint013 Rev. F 07/10
10-3
Maintenance
BATTERY
electrolyte fluid is an extremely
caustic sulfuric acid solution that can cause
nBattery
severe burns. Do not permit fluid to contact
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:
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
nDo
battery to crank and start the generator
engine. If the battery has completely dis-
charged, remove it from the generator for
recharging.
sure the AUTO/OFF/MANUAL switch is set
nBe
to the OFF position before connecting the
battery cables. If the switch is set to AUTO
or MANUAL, the generator can crank and
start as soon as the battery cables are connected.
tery is turned OFF, or sparking may occur at
Be sure the 120VAC power supply to the batthe battery posts as the cables are attached
and cause an explosion.
BATTERY MAINTENANCE
The battery should be inspected per the “Service Schedule” section. The following procedure should be followed for inspection:
1.
2.
3.
BATTERY REPLACEMENT
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.
When replacing batteries, use the same number and type of battery
that was supplied with the unit, and is listed in the parts list in the
back of this manual.
NOTE:
The BCI number should be located directly on the battery.
gas. This gas can form an explosive mixture
Storage batteries give off explosive hydrogen
around the battery for several hours after
charging. The slightest spark can ignite the
gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a
storage battery must be properly ventilated.
Do not allow smoking, open flame, sparks or
any spark producing tools or equipment near
the battery.
10-4
Maint013 Rev. F 07/10
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. G 06/10
11-1
Service Schedule
Maintenance
Tasks
Level 1
Recommended
to be done
monthly/
10 hrs.
Level 2
Task
Comp.
(DateInitials)
Required
to be done
3 months/
Break-in
30 hrs.
Level 3
Task
Comp.
(DateInitials)
Required
to be done
Semiannually/
50 hrs.
1. Disable the unit
from operating
per the first page
warning.
2. Check the engine
oil level. Adjust
as necessary.
3. Check the engine
coolant level.
Adjust as
necessary.
4. Check the engine
coolant thermal
protection level.
Correct as
necessary.
5. Check the natural
gas delivery
system for leaks
and correct
pressure on gas
engine driven
units. Tighten
connections as
necessary.
6. Check the air
inlets and outlets
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.
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. G 06/10
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. G 06/10
Maintenance
Tasks
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. G 06/10
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.
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.
Engine starts then shuts down.
1.
2.
3.
4.
5.
6.
7.
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
1. Replace switch.*
2. Reconnect/close wire.
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
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
Check main line circuit breaker.
Check circuit breaker & fuses.
Transfer switch set to NORMAL position
Generator internal failure.
Thermal circuit breaker open.
2. Unclog fuel line.
3. Clean, regap or replace plugs.
4. Confirm fuel pressure to regulator is as
recommended in SPECIFICATIONS.
Check oil and add oil as needed.
Check cooling system for leaks.
Replace switch.*
Replace switch.*
Replace board.*
Repair leak - Add coolant.
Replace Switch.*
3. Replace board.*
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. B 06/10
Engine starts hard, runs rough.
4. Clean, regap or replace plugs.
5. Close door on tank.
Notes
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
0F9952
0F3417
0F2984
0F9949
0F3418
0F2985
0F9950
0F9951
0G6319
0F6183
0F6187
0F6184
0F6212
0G2023
0F8757
068405C
0F3013
072878
0C9708
0F3726B
0F2689
023454
059980
046526
0A2601
072879
022473
022097
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
REF
1
1
1
4
4
1
1
8/12
4/6
ASSY ROTOR 2390 80KB3 CPL
ASSY ROTOR 390 2P 100K BRSHLS
ASSY ROTOR 390 2P 150K BRSHLS
ASSY STATOR 80KW 1PH 2P BRSHLS
ASSY STATOR 390 2P 100K BRSHLS
ASSY STATOR 390 2P 150K BRSHLS UL
STATOR 2390 80 GB3 CPL
STATOR 2390 80 KB3 CPL
STR 2390 80 JB3 CPL
ASSY STR 390 100KW 2P 3PH 208V
ASSY STR 100KW 1PH 2P BRSHLS
ASSY STR 390 150KW 2P 3PH 208V
ASSY STR 150KW 1PH 2P BRSHLS
ASSY STR 390 150KW 2P 3PH 240V
STR-2390-150LB4 CPL
EXITER FIELD 2" LG SPD CONN
ASSY EXCITER 2.0" STACK 2P
KEY SQ 3/8 X 3-1/4 STEEL
HYPOT TEST PROCEDURE (NOT SHOWN)
ASSY FLYWHEEL CPL
RING PRESSURE 390 STATOR CAN
KEY WOODRUFF #E
SCREW HHC M10-1.5 X 25 C10.9
WASHER LOCK M10
SCREW HHC M16-2.0 X 45 G8.8
SPACER .69 X 2.75 X .37 ST/ZNC
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
16
17
18
19
20
21
22
23
24
25
26
44
45
46
47
48
49
50 *
51
52
53
0C2454
092950
04576100CF
052646
043123
051779
022392
052259
051769
0E7230
0F3033
0F9492
0F2722
077043F
020151
023365
033133
033143
086032
090063
090064
090152
022661L
028739A
085662D
068113
068406
0F7272
023484N
023484N
0F6819
REF.
0C2428
022155
042568
049813
052624
0F7030
0F7047
0F7029
11
1
4
4
4
4
2
2
3
3
1
1
1
1
1
3
1
2
2
1
1
1
1
2
1
1
1
6
1
2
1
2/3
2
2
4/6
4/6
1
1
1
1
60
0F3834
1
61
62
63
64
65
66
67
68
69
KIT PARTS
0F3846B
0F3892
0A2496A
056326
022097
022473
045757
047411
0A2110
2
2
2
8.4 FT.
6
6
2
4
12
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
SCREW THF M6-1 X 16 N WA Z/JS
COLLAR SLIP FIT 390 MM
STUD M14-2.0 X 760 G5 ZINC
WASHER FLAT M14
WASHER LOCK M14
NUT HEX M14-2.0 G8 YEL CHR
PIN DOWEL 1/2 X 1-1/4
WASHER FLAT M12
WASHER LOCK M12
SCREW HHC M12-1.75 X 80 G10.9
SHIELD ALT EXCITER 390
SHIELD ALT EXCITER 5.4/6.8 (1 PHASE)
COVER EXCITER SHIELD
CONDUIT FLEX 1.25” ID
CLAMP VINYL .312 X .203 Z
WASHER SHAKEPROOF INT #8
SCREW HHM #8-32 X 3/8
SCREW HHM #8-32 X 7/8
LUG RT-ANG #10/10-12
BRIDGE SUPPORT DIODE 15"
CAP END ROTOR 390MM
ASSY BRIDGE RECTIFIER
SLEEVING UL #0 .330 ID (3” LG)
TIE WRAP UL 3.9" X .10" BLK
TIE WRAP UL 17.7 X .35 BLK HT
REAR BEARING CARRIER
SCREW HHC M12-1.75 X 60 G10.9
SCREW 1/4-20 X 5/8" TAPTITE SS
BUSHING SNAP SB-2.5-31
BUSHING SNAP SB-2.5-31 (FOR 5.4/6.8 1 PHASE)
MOUNT CT'S 5.4L 100KW
TRANSFORMER
SCREW PHTT #6-32 X 1/2 ZYC
WASHER LOCK #6
SCREW HHC M6-1.0 X 20 G8.8
NUT HEX M6 X 1.0 G8 YEL CHR
BEARING BALL 6212 SEALED
SHROUD UPPER ALTERNATOR EXCITR
SHROUD CENTER ALTERNATR EXCITR
SHROUD LOWER ALTERNATOR EXCITR
ASSY SCROLL 390 X 60MM CPL
I/N’S: 61 THRU 69
SHROUD ALT SHEET METAL CPL 2P
SCREEN, 390 SAE ALT 60MM WIDE
BRACKET SAE SCROLL TENSIONER
VINYL TRIM 1/8” GAP
WASHER, SPLIT 1/4”-M6
WASHER FLAT 1/4 ZINC
SCREW HHC M6-1.0 x 25 LONG
SCREW HHC M6-1.0 X 16 G8.8
SCREW SWAGE 1/4-20 X 1/2 Z/YC
* ROTOR REPLACEMENT PARTS.
** 1 PHASE UNITS REQUIRE SEPERATION OF LEADS.
QTY. REQ: 1 PHASE / 3 PHASE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
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
(2) 26
27
(2) 28
(2) 29
30
31
32
33
(1) 34
35
36
37
38
39
40
41
42
43
44
45
47
48
49
50
51
(1) 52
53
54
55
56
57
58
59
0F6479
0F6481
0D5582
0E2962
0F6505
0F6506
0F4677
023484N
0F6156
081008
077043J
022097
049813
047411
0D6029
022473
0C2266
049226
051713
057701
0F3618
022155
0C2428
0C9764
0G6962B
0D6682
057073
0A7822
0A8261
022241
022237
0F6507
0F6507A
0C4112B
0D6585
023645
024196
049226
0C2266
022127
0C2454
0F6640
043180
022264
0C3990
0F8926
0F8862
0F8863
051715
036943
023897
022152
022158
0F1733
0F8565
045764
023762
1
1
1
2
1
1
1
2
1
1
2
18
8
8
6
18
2
2
2
REF
1
4
4
6”
1
1
2
3
6
6
10
2
2
2
4
4
4
4
4
6
14
1
10
10
10
1
2
2
4
2
REF
3
2
2
1
1
1
1
PANEL CB CONNECTION
MOUNT CONTROL PANEL CPL
CB 0700A 3P 600V S LMD6 LL
INSULATOR (NOMEX)
COVER FIXED LMD CB
COVER SERVICE LMD CB
ASSY PCB INTERFACE 1PH 240V
BUSHING SNAP SB-2.5-31
PLATE WIRE SNGL GALV
GROMMET 1.25 X .25 X .75
CONDUIT FLEX 2.0" ID (36” LG)
WASHER LOCK M6-1/4
NUT HEX M6 X 1.0 G8 YEL CHR
SCREW HHC M6-1.0 X 16 G8.8
SCREW HHTT M6-1.0 X 16 ZYC
WASHER FLAT 1/4-M6 ZINC
SCREW PHTT M5-0.8 X 16 ZYC
WASHER LOCK M5
WASHER FLAT M5
BLOCK TERM 20A 8 X 6 X 1100V
DECAL CPL CUST CONN H CTRL
WASHER LOCK #6
SCREW PHTT #6-32 X 1/2 ZYC
RAIL SNAPTRACK PCB HOLDER BULK
ASSY RELAY PCB 12VDC
BUBAR NEUTRAL BLOCK (520/MAR)
JUNCTION BLOCK 3/8-16
LUG SLDLSS 600/250-1/0 X 1/4-28
SCREW HHC 1/4-28 X 5/8 .625TH
NUT HEX 3/8-16 STEEL
WASHER LOCK 3/8
BUS BAR 1/4 X 2 LMD L1
BUS BAR 1/4 X 2 LMD L2
LUG SIEMENS LMD/LD TA3K500
SCREW SHC 3/8-16 X 3.0 BLK OX
SCREW SHC 3/8-16 X 1.25 G8.8 Z
SCREW RHM 1/4-20 X 3-1/2
WASHER LOCK M5
SCREW PHTT M5-0.8 X 16 ZYC
NUT HEX 1/4-20 STEEL
SCREW THF M6-1 X 16 N WA Z/JS
CHAN ASSY CB SUPPORT
WASHER FLAT M4
WASHER LOCK #8-M4
SCREW PHTT M4-0.7 X 10 ZYC
INSUL CB COVER
CHANNEL SUPPORT
CHANNEL BRACE
NUT HEX M4-0.7 G8 YEL CHR
SCREW PPHM #10/32 X 2
CTRL IGN MODULE
WASHER FLAT #10 ZINC
WASHER LOCK #10
NUT HEX #10-32 STEEL
DECAL CUSTOMER CONNECT INSIDE
DECAL H-100 RB3 CUST CONN
SCREW HHTT M4-0.7 X 8 ZP
WASHER SHAKEPROOF EXT #10 STL
(1) SUPPLIED WITH BREAKER (0D5582)
(2) SUPPLIED IN ASM. KIT 0G0790.
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
0F6947
065852
052252
052257
052259
055597
052251A
052860
0F2895
045764
022447
061383
043107
022473
049813
057192
022131
046526
0536210410
042909
022261
022129
022145
045771
022097
0F2910
038750
090502
1
1
5
5
5
5
5
4
1
1
1
1
1
1
1
4
8
8
1
1
2
1
2
2
1
1
1
4
BASE CPL 150KW 2P
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
WASHER SHAKEPROOF INT 1/4
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
WASHER LOCK M6-1/4
SUPPORT, ENGINE 6.8L LH SIDE
SCREW HHC M6-1.0 X 30 G8.8
SCREW SHC M10-1.5 X 60 G12.9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
0F3408
0F3411
058208
022131
050331A
050331
038805U
038804U
045771
022129
027482
075763
0C2454
0F3409
1
1
1
1
1
1
1
1
1
1
1
1
8
1
TRAY BATTERY
STRAP BATTERY RETAINMENT
BATT 12VDC 24F 625
WASHER FLAT 3/8-M10 ZINC
BATT POST COVER RED +
BATT POST COVER BLK CABLE BATT BLK #1 X 18.00
CABLE BATT RED #1 X 28.00
NUT HEX M8-1.25 G8 YEL CHR
WASHER LOCK M8-5/16
WASHER SHAKEPROOF EXT 5/16 STL
BOOT BATTERY CABLE
SCREW THF M6-1X16 N WA Z/JS
SUPPORT BATTERY TRAY
1
2
4
5
6
7
8
9
10
11
12
13
18
19
20
21
22
23
24
26
27
28
29
30
0F2807C
0F2807E
0F9207
0F2807B
0F2807D
0F9208
0A6765
0F4710
0F7200
080762
0F2809
0F2981A
0F2962
0C2454
022097
0F2830
0F2773C
0F2773D
0D3159
088775
0F2808
0F5447
022473
0F6214
0F6803
049813
049721
088510
0C9748
1
1
1
1
1
1
2
6
6
8
1
2
2
4
8
2
2
2
1
6
2
1
12
2
4
4
8
6
1
PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5)
PIPE EXH MAN R/H 5.4L G/B & 2P (5.4L C5)
PIPE EXH MANIFOLD 4.6L RH
PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5)
PIPE EXH MAN L/H 5.4L G/B & 2P (5.4L C5)
PIPE EXH MANIFOLD 4.6L LH
RING GASKET 2.5 DIA
WASHER LOCK M10 SS
SCREW HHC M10-1.5 X 50 SS FTH
BOLT U 3/8-16 X 2.62
PIPE EXHAUST CROSSOVER
MFLR 7" X 9" X 25" (2) 2.5" IN/2.5" OUT
MUFFLER STRAP
SCREW THF M6-1 X 16 N WA Z/JS
WASHER LOCK M6-1/4
MUFFLER BRACKET STIFFENER
EXHAUST BLANKET 900MM LONG (6.8L C5)
EXHAUST BLANKET 850MM LONG (5.4L C5)
FLANGE EXHAUST
WASHER FLAT 3/8 SS
EXHUAST OUTLET PIPE CPL
BRKT MUFFLER
WASHER FLAT 1/4-M6 ZINC
PIPE ELBOW EXHAUST MUFFLER
MUFFLER STRAP UPPER/LOWER
NUT HEX M6 X 1.0 G8 YEL CHR
SCREW HHC M6-1.0 X 35 G8.8 BLK
NUT HEX M10-1.5 SS
PLUG M18-1.50
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
44
45
46
47
48
49
0F3017
039253
022129
022145
0D5419
0D7055
0D3488G
0D3488J
0D3488
0D3488K
057795A
059057
0F3287
0F5990
0H2595
0F4419
0H3081
0F9786
0H3080
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
047527
057823
0E0992A
078637
0G7519
0E8286
1
3
4
4
REF
1
1
1
1
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
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 6.8L H-100 (USE WITH PROBE P/N 0E2507)
HARN ENG G6.8L G3 H-100 (USE WITH PROBE P/N 0H1827)
HARN ENG 6.8L G-100 (USE WITH PROBE P/N 0E2507)
HARN ENG G6.8L G3 MQT 480V (USE WITH PROBE P/N 0H1827)
HARN ENG 6.8L G-100 MQT 208V (USE WITH PROBE P/N 0E2507)
HARN ENG G6.8L G3 MQT 208V (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)
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
ELBOW 45D STREET 1/2NPT BRASS
(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
(3) 5
(3) 6
(1) 7
8
9
10
(2) 11
12
13
14
15
16
17
18
19
(3) 20
21
22
23
(3) 24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
40
43
44
0D5623
0D5418
022131
0F3514
022473
0F2776A
029333A
057772
0F2929
0F9965C
0F9965C
0D5417
057823
057765
034339
069860E
042909
022129
0D9913
055934M
022097
055596
077996
0C7649
047411
0G0321
0D3808
0D4255
070010
0D2244M
0F3844
052647
046526
039253
070008
070006
0D2608
0F5114
0F5454
0F6104
057823
062303
2
1
1
1
1/2
1/2
1
1
1
1
2
REF.
1
1
1
1
3
4
18
1
1/2
1
1
1
1/2
1
2
2
2
1
8
6
6
1
10
30
10
1
1
1
2
1
HEAT SHIELD EXHAUST
STARTER MOTOR FORD V-10 ENGINE
WASHER FLAT 3/8-M10 ZINC
SPACER FLEXPLATE 5.4L/6.8L (1800 RPM UNITS ONLY)
WASHER FLAT 1/4-M6 ZINC
BRACKET SIGNAL CONDITIONER
TIE WRAP UL 7.4" X .19" BLK (NOT SHOWN)
WASHER NYLON .565
ENGINE ADAPTER 5.4L/6.8L
FLEX PLATE 2 POLE (1800 RPM UNITS ONLY)
FLEX PLATE 2 POLE (3600 RPM UNITS ONLY)
SCREW HHC M10-1.0 X 25 G10.9
CLAMP HOSE #10 .56 - 1.06 (1800 RPM UNITS ONLY)
ADAPTER M14-1.50 X 3/8 NPT
BARBED EL 90 3/8NPT X 5/8
HOSE DRAIN ASSY 28"
SCREW HHC M8-1.25 X 30 G8.8
WASHER LOCK M8-5/16
SCREW SHC M8-1.25 X 35 SS
CLAMP VINYL .75 X .343 Z
WASHER LOCK M6-1/4
BARBED STR 3/8 NPT X 3/8
CAP HOSE (1800 RPM UNITS ONLY)
CLAMP HOSE .38-.87
SCREW HHC M6-1.0 X 16 G8.8
HOSE COOL 5/8" ID 250#WP (14”)
EXH MANIFOLD MACH 6.8L V-10
GASKET EXHAUST MANIFOLD
SCREW HHC M8-1.25 X 35 SS G8.8
ASSY MAGPICKUP (3/8-24 MALE)
WASHER FLAT .43 X 1.00
SCREW SHC M10-1.5 X 25 G12.9
WASHER LOCK M10
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT M8 SS
WASHER LOCK M8 SSTL
SCREW HHC 5/16-18 X 1/2 SSTL
DECAL REFER TO OWNERS MANUAL
PLATE MAG PICK-UP ADAPTOR
COVER STARTER 5.4 & 6.8 FORD CPL
CLAMP HOSE #10 .56-1.06
ADAPTOR 1/4" NPT TO 3/8" NPT
(1) NOTE: I/N 7 IS FOR HOLDING SENSORS TO I/N 6.
(2) NOTE: I/N 11 IS PART OF ENGINE P/N 0D3454.
(3) QTY. REQ. FOR NON-MQT / QTY REQ. FOR MQT EPA CERT. (NOT REQUIRED
FOR NEXUS CONTROL PANELS)
1
2
3
4
5
6
7
8
9
10
11
12
0D2513D
0D2513E
0F5419
0F4268
0F4270A
0F6977
037561
047411
022097
049811
0F4269
022473
0A4256
1
1
1
1
1
1
1
4
4
4
1
1
1
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
WASHER FLAT M6
GASKET MIXER BODY
WASHER FLAT 1/4-M6 ZINC
INDICATOR FILTER MINDER
1
2
3
4
5
6
(1)7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
(2) 23
0F2807C
0F2807G
0F2807B
0F2807D
088510
0A6765
0F4710
0F7200
080762
0F2809
0F2981A
0F2962
0C2454
022097
0F2830
049721
049813
0F6803
0F6214
0F2773C
0F2773D
0D3159
088775
022473
0F5447
0F2808
1
1
1
1
6
2
6
6
8/6
1
2
2
4
6
2
8
4
4
2
2
2
2
6
12
1
2
PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5)
PIPE EXH MAN R/H 5.4L D/D CPL (5.4L C5)
PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5)
PIPE EXH MAN L/H 5.4L G/B & 2P (5.4L C5)
NUT HEX M10-1.5 SS
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
MUFFLER 7" X 9" X 25" (2) 2.5" IN/2.5" OUT
MUFFLER STRAP
SCREW HWHT M6-1 X 16 N WA Z/JS
WASHER LOCK M6-1/4
MUFFLER BRACKET STIFFENER
SCREW HHC M6-1.0 X 35 G8.8 BLK
NUT HEX M6 X 1.0 G8 YEL CHR
MUFFLER STRAP UPPER/LOWER
PIPE ELBOW EXHAUST MUFFLER
EXHAUST BLANKET 900MM LONG (6.8L C5)
EXHAUST BLANKET 850MM LONG (5.4L C5)
FLANGE EXHAUST
WASHER FLAT 3/8 SS
WASHER FLAT 1/4-M6 ZINC
BRACKET MUFFLER
EXHAUST OUTLET PIPE CPL
(1) QTY. REQUIRED FOR ENCLOSED UNITS / QTY. REQUIRED FOR OPEN SETS.
(2) ENCLOSED SETS ONLY.
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
6
7
8
9
10
0J01150ST03
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
68
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
0D3700
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
8
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
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.
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
(1)31
(1)32
33
34
(1)35
(1)36
033212
065908
0G9191L
0G9191M
0G9190A
0G9239A
052617
022304
022129
045773
064346
0A8064
030131
031015
088963
026915
057823
059057
0D2698
0D1509
050280
0H2353
0F2756A
0E4390
0E4392
0F0960
0F3885
0G3167
0F3691E
0F3691F
0F3691J
0F3691B
022195
0G5989
026073A
0D2157
039294
022097
042568
049811
039130
066212
0G46350ST03
022097
4
1
1
1
1
1
2
2
4
2
1
2
1
1
1
2
4
2
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
4
1
4
2
2
1
1
1
2
SCREW HHC 5/16-18 X 1-1/4 G5
SUPPORT NAT GAS SOLENOID
REG ASSY 6.8L 130KW DUAL LP QT
REG ASSY 6.8L 150KW DUAL LP QT
REG ASSY 6.8L 100KW LPV CPL
REG ASSY 5.4L 80KW LPV CPL
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
MACHINING, INTAKE ADAPTOR 60MM
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)
VENTURI, THROTTLE 36MM (5.4L 80KW)
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
(1) G6.8L UNITS ONLY
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
033212
065908
0G9191A
0G9191B
052617
022304
022129
045773
022195
039130
030131
031015
088963
0G5989
057822
059057
0F4408
0D1509
050279
0H2353
0E4390
0E4392
0F0960
0F3885
0G3167
0F3691F
0F3691J
026915
0A8064
026073A
0D2157
039294
022097
049811
0D2698
042568
064346
059057
066212
0G46350ST03
059057
4
1
1
1
2
2
4
2
2
1
1
1
1
1
12
2
2
1
1
1
1
1
1
1
2
1
1
2
2
1
4
1
6
2
1
2
1
2
1
1
2
SCREW HHC 5/16-18 X 1-1/4 G5
SUPPORT NAT GAS SOLENOID
REG ASSY 6.8L 130KW DUAL NG QT
REG ASSY 6.8L 150KW DUAL NG QT
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 (130KW)
NIPPLE PIPE 1.25 NPT X 5.5 BL IRN (150KW)
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 44MM (130KW)
VENTURI THROTTLE 50MM (150KW)
NIPPLE CLOSE 3/4 X 1.375
BSHG RDCR HEX 1-1/4-3/4
PLUG STD PIPE 1/4 STEEL SQ HD
SCREW SHC M6-1.0 X 50 C8.8
CLAMP HOSE #44 2.31-3.25
WASHER LOCK M6-1/4
WASHER FLAT M6
GASKET ADAPTER THROT BODY
SCREW HHC M6-1.0 X 20 G8.8
PIPE TEE 1-1/4 NPT
HOSE 3/4 ID SAE-30R2 (12” LG)
CLAMP HOSE #52 2.81-3.75
BRACKET, HOSE RISER
HOSE 3/4 ID SAE-30R2 (9.5” LG)
(2) 1
(2) 2
(2) 3
(3) 4
(2) 5
(2) 6
(3) 7
0F58730ST01
0F58680ST01
0F58720ST01
0F58710AL01
0F58690ST01
0F58700ST01
0F58670AL01
1
4
2
2
2
1
1
REAR WRAP C5
DOOR C5
CENTER SUPPORT C5
DISCHARGE DUCT LH & RH SIDE C5
FRONT CORNERS C5
DISCHARGE CENTER DUCT C5
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
0C2634A
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
ASSEMBLY COVER ACCESS
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX 1/4-20 STEEL
INSULATION RETAINMENT HANGER
WASHER SELF LOCKING DOME #4-40
INSULATION SPLITTER
INSULATION SHORT LOUVER
VISE-ACTION LATCH SLOTTED CIR
GASKET EXTRUDED TRIM (566” LG)
TAB PULL
INSULATION SPLITTER SML
INSULATION ROOF TOP REAR
RETAINER INSULATION (740)
RIVET POP .1875 X .450 SS
INSULATION ROOF TOP
INSULATION DOOR
INSULATION DISCHARGE DUCT
INSULATION CENTER SUPPORT
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
0FXXXXALT13 = BISQUE / ALUMINUM
0FXXXX0ST08 = T- GRAY / STEEL
0FXXXX0ST14 = GRAY / STEEL
0FXXXX0AL08 = T- GRAY / ALUMINUM
0FXXXXALT14 = GRAY / ALUMINUM
0FXXXX0ST05 = WHITE / STEEL
0FXXXX0AL05 = WHITE / ALUMINUM
(3) PART NUMBER SHOWN IS FOR TAN. SEE GUIDE BELOW FOR AVAILABLE COLOR AND PART NUMBER
FORMAT.
0FXXXX0AL08 = T- GRAY / ALUMINUM
0FXXXXALT13 = BISQUE / ALUMINUM
0FXXXX0AL05 = WHITE / ALUMINUM
0FXXXXALT14 = GRAY / ALUMINUM
1
2
3
4
5
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
Notes
Notes
Warranty
GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR
COMMERCIAL STATIONARY EMERGENCY PRODUCT 50kW AND ABOVE
For a period of two (2) years from the date of sale, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part(s) which, upon
examination, inspection, and testing by Generac or an Authorized/Certified Generac Dealer, or branch thereof, is found to be defective under normal use and
service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be examined by
the nearest Authorized/ Certified Generac Dealer, or branch thereof. This warranty applies only to Generac generators used in "Stationary Emergency" applications, as Generac has defined Stationary Emergency, provided said generator has been properly installed and inspected on-site by appropriate personnel.
It is highly recommended that scheduled maintenance, as outlined by the generator Owner's Manual, be performed by an Authorized/Certified Generac
Servie Dealer, or branch thereof. This will verify service has been performed on the unit throughout the warranty period.
*** This warranty only applies to units sold for use in the US and Canada.***
WARRANTY SCHEDULE
YEAR ONE — Limited comprehensive coverage on mileage, labor, and parts listed.
• - ALL COMPONENTS
YEAR TWO — Limited comprehensive coverage on parts listed.
• - ALL COMPONENTS
*Start-up and/or On-line Activation, or Registration Card, along with Proof of Purchase, must be performed and/or sent in.
GUIDELINES:
• Any and all warranty repairs and/or concerns, must be performed and/or addressed by an Authorized/Certified Generac Service Dealer, or branch thereof.
• A Generac Transfer Switch is highly recommended to be used in conjunction with the genset. If a Non - Generac Transfer Switch is substituted for use and directly causes
damage to the genset, no warranty coverage shall apply.
• All warranty expense allowances are subject to the conditions defined in Generac's General Service Policy Manual.
• Units that have been resold are not covered under the Generac Warranty, as this Warranty is not transferable except with change of ownership of original structure.
• Unit enclosure is only covered against rust or corrosion the first year of the warranty provision.
• Use of Non-Generac replacement part(s) will void the warranty in its entirety.
• Engine coolant heaters (block-heaters), heater controls and circulating pumps are only covered during the first year of the warranty provision (If applicable).
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Any unit built/manufactured prior to March 1, 2005.
Costs of normal maintenance (i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up).
Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze.
Units sold, rated or used for "Prime Power", "Trailer Mounted" or "Rental Unit" applications as Generac has defined Prime Power, Trailer Mounted or Rental Unit. Contact a
Generac Dealer for Prime Power, Trailer Mounted or Rental Unit definition.
Units used for prime power in place of existing utility power where utility is present or in place of utility power where utility power service does not normally exist.
Failures caused by any act of God and other force majeure events beyond the manufacture's control.
Products that are modified or altered in a manner not authorized by Generac in writing.
Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing.
Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the defective part(s).
Failure due to misapplication, misrepresentation, or bi-fuel conversion.
Telephone, facsimile, cell phone, satellite, internet, or any other communication expenses.
Rental equipment used while warranty repairs are being performed (i.e. rental generators, cranes, etc.).
Overtime, holiday, or emergency labor.
Planes, ferries, railroad, busses, helicopters, snowmobiles, snow-cats, off-road vehicle or any other mode of transportation deemed abnormal.
Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct cause of the problem.
Starting batteries, fuses, light bulbs, engine fluids, and overnight freight cost for replacement part(s).
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES AS
TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Any implied warranties which are allowed by law, shall be limited in duration to
the terms of the express warranty provided herein. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may
not apply to purchaser/owner.
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC BE LIABLE FOR
ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC'S NEGLIGENCE.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/ owner.
Purchaser/owner agrees to make no claims against Generac based on negligence. This warranty gives purchaser/owner specific legal rights. Purchaser/
owner also may have other rights that vary from state to state.
Generac Power Systems, Inc. • P.O. Box 8 • Waukesha, WI 53187
Ph: (262) 544-4811 • Fax: (262) 544-4851
1-888-GENERAC (1-888-436-3722)
Bulletin 0171370SVE / Rev. D 06.10 / Printed in U.S.A.
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
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
0F9952
0F3417
0F2984
0F9949
0F3418
0F2985
0F9950
0F9951
0G6319
0F6183
0F6187
0F6184
0F6212
0G2023
0F8757
068405C
0F3013
072878
0C9708
0F3726B
0F2689
023454
059980
046526
0A2601
072879
022473
022097
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
REF
1
1
1
4
4
1
1
8/12
4/6
ASSY ROTOR 2390 80KB3 CPL
ASSY ROTOR 390 2P 100K BRSHLS
ASSY ROTOR 390 2P 150K BRSHLS
ASSY STATOR 80KW 1PH 2P BRSHLS
ASSY STATOR 390 2P 100K BRSHLS
ASSY STATOR 390 2P 150K BRSHLS UL
STATOR 2390 80 GB3 CPL
STATOR 2390 80 KB3 CPL
STR 2390 80 JB3 CPL
ASSY STR 390 100KW 2P 3PH 208V
ASSY STR 100KW 1PH 2P BRSHLS
ASSY STR 390 150KW 2P 3PH 208V
ASSY STR 150KW 1PH 2P BRSHLS
ASSY STR 390 150KW 2P 3PH 240V
STR-2390-150LB4 CPL
EXITER FIELD 2" LG SPD CONN
ASSY EXCITER 2.0" STACK 2P
KEY SQ 3/8 X 3-1/4 STEEL
HYPOT TEST PROCEDURE (NOT SHOWN)
ASSY FLYWHEEL CPL
RING PRESSURE 390 STATOR CAN
KEY WOODRUFF #E
SCREW HHC M10-1.5 X 25 C10.9
WASHER LOCK M10
SCREW HHC M16-2.0 X 45 G8.8
SPACER .69 X 2.75 X .37 ST/ZNC
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
16
17
18
19
20
21
22
23
24
25
26
44
45
46
47
48
49
50 *
51
52
53
0C2454
092950
04576100CF
052646
043123
051779
022392
052259
051769
0E7230
0F3033
0F9492
0F2722
077043F
020151
023365
033133
033143
086032
090063
090064
090152
022661L
028739A
085662D
068113A
068406
0F7272
023484N
023484N
0F6819
REF.
0C2428
022155
042568
049813
052624
0F7030
0F7047
0F7029
11
1
4
4
4
4
2
2
3
3
1
1
1
1
1
3
1
2
2
1
1
1
1
2
1
1
1
6
1
2
1
2/3
2
2
4/6
4/6
1
1
1
1
60
0F3834
1
61
62
63
64
65
66
67
68
69
KIT PARTS
0F3846B
0F3892
0A2496A
056326
022097
022473
045757
047411
0A2110
2
2
2
8.4 FT.
6
6
2
4
12
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
SCREW THF M6-1 X 16 N WA Z/JS
COLLAR SLIP FIT 390 MM
STUD M14-2.0 X 760 G5 ZINC
WASHER FLAT M14
WASHER LOCK M14
NUT HEX M14-2.0 G8 YEL CHR
PIN DOWEL 1/2 X 1-1/4
WASHER FLAT M12
WASHER LOCK M12
SCREW HHC M12-1.75 X 80 G10.9
SHIELD ALT EXCITER 390
SHIELD ALT EXCITER 5.4/6.8 (1 PHASE)
COVER EXCITER SHIELD
CONDUIT FLEX 1.25” ID
CLAMP VINYL .312 X .203 Z
WASHER SHAKEPROOF INT #8
SCREW HHM #8-32 X 3/8
SCREW HHM #8-32 X 7/8
LUG RT-ANG #10/10-12
BRIDGE SUPPORT DIODE 15"
CAP END ROTOR 390MM
ASSY BRIDGE RECTIFIER
SLEEVING UL #0 .330 ID (3” LG)
TIE WRAP UL 3.9" X .10" BLK
TIE WRAP UL 17.7 X .35 BLK HT
REAR BEARING CARRIER CPL
SCREW HHC M12-1.75 X 60 G10.9
SCREW 1/4-20 X 5/8" TAPTITE SS
BUSHING SNAP SB-2.5-31
BUSHING SNAP SB-2.5-31 (FOR 5.4/6.8 1 PHASE)
MOUNT CT'S 5.4L 100KW
TRANSFORMER
SCREW PHTT #6-32 X 1/2 ZYC
WASHER LOCK #6
SCREW HHC M6-1.0 X 20 G8.8
NUT HEX M6 X 1.0 G8 YEL CHR
BEARING BALL 6212 SEALED
SHROUD UPPER ALTERNATOR EXCITR
SHROUD CENTER ALTERNATR EXCITR
SHROUD LOWER ALTERNATOR EXCITR
ASSY SCROLL 390 X 60MM CPL
I/N’S: 61 THRU 69
SHROUD ALT SHEET METAL CPL 2P
SCREEN, 390 SAE ALT 60MM WIDE
BRACKET SAE SCROLL TENSIONER
VINYL TRIM 1/8” GAP
WASHER, SPLIT 1/4”-M6
WASHER FLAT 1/4 ZINC
SCREW HHC M6-1.0 x 25 LONG
SCREW HHC M6-1.0 X 16 G8.8
SCREW SWAGE 1/4-20 X 1/2 Z/YC
* ROTOR REPLACEMENT PARTS.
** 1 PHASE UNITS REQUIRE SEPERATION OF LEADS.
QTY. REQ: 1 PHASE / 3 PHASE
EXPLODED VIEW: EV MTG BASE 6.8L 150KW CPL
GROUP C
DRAWING #: 0F2975
ITEM
(1)1
2
3
4
5
6
7
8
(1)9
10
11
12
13
14
15
(1)16
17
18
19
20
21
22
23
24
25
(1)26
27
28
29
30
PART#
QTY.
0L05740ST0R
G065852
G052252
G052257
G052259
G055597
052251A
G052860
0L06890ST0R
G045764
0A4456
G061383
G043107
----0L01390ST0R
G022131
046526
0536210410
--0C3168
G022129
G022145
G045771
--0L01480ST0R
--G052243
G051735
0L0123
1
1
5
5
5
5
5
4
1
1
1
1
2
--1
7
7
1
-1
1
2
2
-1
-6
1
1
DESCRIPTION
MTG BASE C5 150KW
SPRING CLIP HOLDER .37-.62
DAMPENER VIBRATION
SPACER .49 X .62 X 1.87 PWDR/ZINC
WASHER FLAT M12
SCREW HHC M12-1.75 X 85 G8.8
DAMPENER VIBRATION 50 WHITE
NUT LOCKING M12-1.75
ENGINE SUPPORT 6.8L RH
SCREW HHTT M4-0.7 X 8 BP
WASHER LOCK SPECIAL 3/8
LUG SOLDERLESS 3/0-#4 X 13/32 CU
SCREW HHC M8-1.25 X 25 G8.8
--------------5.4L RH ENGINE MOUNT SPACER
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
ASSY WIRE 14.00”
-------WASHER LOCK SPECIAL 5/16-M8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
NUT HEX M8-1.25 G8 YEL CHR
-------ENGINE MOUNT 6.8L LH SIDE
-------SCREW HHC M10-1.5 X 60 C8.8
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-G
DATE: 10/11/2019
Page 2 of 2
EXPLODEDVIEW: EV BATTERY 4.6L, 80KW & 6.8L 150KW
GROUP C
DRAWING#: 0F3675
APPLICABLETO:
ITEM
PART#
QTY.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
0F3408
0F3411
G058208
G022131
050331A
G050331
038805U
038804U
G045771
G022129
G027482
G075763
0C2454
0F3409
0J3501
1
1
1
1
1
1
1
1
1
1
1
1
8
1
1
REVISION: CN-0021496
DATE: 11/9/18
DESCRIPTION
TRAY BATTERY
STRAP BATTERY RETAINMENT
BATT 12VDC 24F 625
WASHER FLAT 3/8-M10 ZINC
BATT POST COVER RED +
BATT POST COVER BLK CABLE BATT BLK #1 X 18.00
CABLE BATT RED #1 X 28.00
NUT HEX M8-1.25 G8 YEL CHR
WASHER LOCK M8-5/16
WASHER SHAKEPROOF EXT 5/16 STL
BOOT BATTERY CABLE
SCREW THF M6-1X16 N WA Z/JS
SUPPORT BATTERY TRAY
STRAP BATTERY 1.5X36
Page 2 of 2
(2) 1
(2) 2
(2) 3
(3) 4
(2) 5
(2) 6
(3) 7
0F58730ST01
0F58680ST01
0F58720ST01
0F58710AL01
0F58690ST01
0F58700ST01
0F58670AL01
1
4
2
2
2
1
1
REAR WRAP C5
DOOR C5
CENTER SUPPORT C5
DISCHARGE DUCT LH & RH SIDE C5
FRONT CORNERS C5
DISCHARGE CENTER DUCT C5
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
0C2634A
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
ASSEMBLY COVER ACCESS
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX 1/4-20 STEEL
INSULATION RETAINMENT HANGER
WASHER SELF LOCKING DOME #4-40
INSULATION SPLITTER
INSULATION SHORT LOUVER
VISE-ACTION LATCH SLOTTED CIR
GASKET EXTRUDED TRIM (566” LG)
TAB PULL
INSULATION SPLITTER SML
INSULATION ROOF TOP REAR
RETAINER INSULATION (740)
RIVET POP .1875 X .450 SS
INSULATION ROOF TOP
INSULATION DOOR
INSULATION DISCHARGE DUCT
INSULATION CENTER SUPPORT
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
0FXXXXALT13 = BISQUE / ALUMINUM
0FXXXX0ST08 = T- GRAY / STEEL
0FXXXX0ST14 = GRAY / STEEL
0FXXXX0AL08 = T- GRAY / ALUMINUM
0FXXXXALT14 = GRAY / ALUMINUM
0FXXXX0ST05 = WHITE / STEEL
0FXXXX0AL05 = WHITE / ALUMINUM
(3) PART NUMBER SHOWN IS FOR TAN. SEE GUIDE BELOW FOR AVAILABLE COLOR AND PART NUMBER
FORMAT.
0FXXXX0AL08 = T- GRAY / ALUMINUM
0FXXXXALT13 = BISQUE / ALUMINUM
0FXXXX0AL05 = WHITE / ALUMINUM
0FXXXXALT14 = GRAY / ALUMINUM
1
2
3
4
5
6
7
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
033212
065908
0F6261A
0F6261B
052617
022304
022129
045773
022195
039130
030131
031015
088963
0F6279
057822
059057
0F4408
0D1509
050279
0D2696B
0E4390
0E4392
0F0960
0F3885
0G3167
0F3691F
0F3691J
026915
0A8064
081017
046580
039294
022097
052223
0D2698
040173
064346
059057
066212
0G46350ST03
042568
049811
4
1
1
1
2
2
4
2
2
1
1
1
1
1
12
4
2
1
1
1
1
1
1
1
2
1
1
2
2
1
4
1
6
1
1
2
1
2
1
1
2
2
SCREW HHC 5/16-18 X 1-1/4 G5
SUPPORT NAT GAS SOLENOID
REGULATOR ASSM 6.8L 130KW NG
REGULATOR ASSM 6.8L 150KW NG
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
NIPPLE PIPE 1.25 NPT X 5.5 BL IRN (150KW ONLY)
HARNESS FUEL JUMPER DUAL REG
CLAMP HOSE #8 .53-1.00
HOSE 3/4 ID SAE-30R2 (42” LG)
Y CONNECTOR 500 SERIES BARBS
DECAL INLET PRESSURE
DECAL FUEL INLET NG
ADAPTOR THROTTLE BODY (BOSCH) (6.8L FORD GEARBOX)
GASKET GOVERNOR ACTUATOR
ACTUATOR BOSCH 60 GOVERNOR
REDUCER 3.0" TO 2.75" TURBO
MIXER 40/60MM ACTUATOR ASSY
O-RING 2-3/4 X 3/32 X 2-15/16
VENTURI THROTTLE 44MM (6.8L FORD GEARBOX 130KW)
VENTURI THROTTLE 50MM (6.8L FORD 2-POLE 150KW)
NIPPLE CLOSE 3/4 X 1.375
BSHG RDCR HEX 1-1/4-3/4
BARBED STR 1/4 NPT X 1/2
SCREW SHC M6-1.0 X 45 G12.9
CLAMP HOSE #44 2.31-3.25
WASHER LOCK M6-1/4
HOSE 1/2 ID SAE-30R2 FUEL/OIL (42” LG)
GASKET ADAPTER THROT BODY (6.8L FORD ONLY)
CLAMP HOSE #5.5 .62-.62
PIPE TEE 1-1/4 NPT
HOSE 3/4 ID SAE-30R2 (42” LG)
CLAMP HOSE #52 2.81-3.75
BRACKET, HOSE RISER
SCREW HHC M6-1.0 X 20 G8.8
WASHER FLAT M6
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
(1) 35
(1) 36
(1) 37
(1) 38
033212
065908
0F6261H
0F6261J
0F6261K
0F6261L
0F6261M
052617
022304
022129
045773
064346
0A8064
030131
031015
088963
026915
057823
059057
0D2698
0D1509
050280
0D2696B
0F2756A
0E4390
0E4392
0F0960
0F3885
0G3167
0F3691B
0F3691D
0F3691E
0F3691F
0F3691J
022195
0F6279
081017
046580
039294
022097
047290
040173
039130
066212
0G46350ST03
042568
022097
049811
4
1
1
1
1
1
1
2
2
4
2
1
2
1
1
1
2
4
2
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1
4
1
4
1
2
1
1
1
2
2
2
SCREW HHC 5/16-18 X 1-1/4 G5
SUPPORT NAT GAS SOLENOID
REGULATOR ASSM 5.4L 80KW LPV (5.4L 80KW)
REGULATOR ASSM 5.4L 100KW LPV (5.4L 100KW)
REGULATOR ASSM 6.8L 100KW LPG (6.8L 100KW)
REGULATOR ASSM 6.8L 130KW LPV (6.8L 130KW)
REGULATOR ASSM 6.8L 150KW LPV (6.8L 150KW)
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
NIPPLE PIPE 1.25 NPT X 5.5 BL IRN (6.8L 150KW ONLY)
NIPPLE CLOSE 3/4 X 1.375
CLAMP HOSE #10 .56-1.06
HOSE 3/4 ID SAE-30R2 (45” LG)
GASKET ADAPTER THROT BODY
DECAL INLET PRESSURE
DECAL FUEL INLET LPG (LP VAPOR APPLICATION)
ADAPTOR THROTTLE BODY (BOSCH) (6.8L)
MACHINING INTAKE ADAPTOR 60MM (5.4L)
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 36MM (5.4L 80KW)
VENTURI THROTTLE 40MM (5.4L 100KW)
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
BARBED STR 1/4 NPT X 1/2
SCREW SHC M6-1.0 X 45 G12.9
CLAMP HOSE #44 2.31-3.25
WASHER LOCK M6-1/4
HOSE 3/8 ID SINGLE BRAID (42” LG)
CLAMP HOSE #5.5 .62-.62
NIPPLE CLOSE 1.25 NPT X 1.625
CLAMP HOSE #52 2.81-3.75
BRACKET, HOSE RISER
SCREW HHC M6-1.0 X 20 G8.8
WASHER LOCK M6-1/4
WASHER FLAT M6
(1) G6.8L UNITS ONLY
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
44
45
46
47
48
49
0F3017
039253
022129
022145
0D5419
0D7055
0D3488G
0D3488J
0D3488
0D3488K
057795A
059057
0F3287
0F5990
0H2595
0F4419
0H3081
0F9786
0H3080
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
047527
057823
0E0992A
078637
0G7519
0E8286
1
3
4
4
REF
1
1
1
1
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
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 6.8L H-100 (USE WITH PROBE P/N 0E2507)
HARN ENG G6.8L G3 H-100 (USE WITH PROBE P/N 0H1827)
HARN ENG 6.8L G-100 (USE WITH PROBE P/N 0E2507)
HARN ENG G6.8L G3 MQT 480V (USE WITH PROBE P/N 0H1827)
HARN ENG 6.8L G-100 MQT 208V (USE WITH PROBE P/N 0E2507)
HARN ENG G6.8L G3 MQT 208V (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)
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
ELBOW 45D STREET 1/2NPT BRASS
(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)
EXPLODED VIEW: EV ENGCOMPRT R/H 6.8 (CPL)
GROUP D
DRAWING #: 0F3058
ITEM
1
2
3
4
(3) 5
(3) 6
(1) 7
8
9
10
(2) 11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
40
43
44
45
PART#
QTY.
0D5623
0D5418
G022131
0F3514
G022473
0F2776A
029333A
G057772
0F2929
0F9965C
0F9965C
0D5417
0K3440
G057765
G049340
069860E
G042909
G022129
0D9913
G047290
G022097
G055596
G077996
0C7649
G047411
0G0321
0D3808
0D4255
G070010
0D2244M
0F3844
G052647
G046526
G039253
G070008
G070006
0D2608
0F5114
0F5454
0F6104
048031P
048031J
0G1462
2
1
1
1
1/2
A/R
1
1
1
1
2
REF.
1
1
1
1
3
4
18
1
1
1
1
1
1
1
2
2
2
1
8
6
6
1
10
30
10
1
1
1
2
1
1
DESCRIPTION
HEAT SHIELD EXHAUST
STARTER MOTOR FORD V-10 ENGINE
WASHER FLAT 3/8-M10 ZINC
SPACER FLEXPLATE 5.4L/6.8L (1800 RPM UNITS ONLY)
WASHER FLAT 1/4-M6 ZINC
BRACKET SIGNAL CONDITIONER
TIE WRAP UL 7.4" X .19" BLK (NOT SHOWN)
WASHER NYLON .565
ENGINE ADAPTER 5.4L/6.8L
FLEX PLATE 2 POLE (1800 RPM UNITS ONLY)
FLEX PLATE 2 POLE (3600 RPM UNITS ONLY)
SCREW HHC M10-1.0 X 25 G10.9
CLAMP HOSE 1.062OD DOUBLEWIRE (1800 RPM UNITS ONLY)
ADAPTER M14-1.50 X 3/8 NPT
BARBED EL 90 1/4NPT X 3/8
HOSE DRAIN ASSY 28"
SCREW HHC M8-1.25 X 30 G8.8
WASHER LOCK M8-5/16
SCREW SHC M8-1.25 X 35 SS
HOSE 3/8 ID SINGLE BRAID
WASHER LOCK M6-1/4
BARBED STR 3/8 NPT X 3/8
CAP HOSE (1800 RPM UNITS ONLY)
CLAMP HOSE .38-.87
SCREW HHC M6-1.0 X 16 G8.8
HOSE COOL 5/8" ID 250#WP (14”)
EXH MANIFOLD MACH 6.8L V-10
GASKET EXHAUST MANIFOLD
SCREW HHC M8-1.25 X 35 SS G8.8
ASSY MAGPICKUP (3/8-24 MALE)
WASHER FLAT .43 X 1.00
SCREW SHC M10-1.5 X 25 G12.9
WASHER LOCK M10
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT M8 SS
WASHER LOCK M8 SSTL
SCREW HHC 5/16-18 X 1/2 SSTL
DECAL REFER TO OWNERS MANUAL
PLATE MAG PICK-UP ADAPTOR
COVER STARTER 5.4 & 6.8 FORD CPL
CLAMP HOSE BAND .88"
CLAMP HOSE BAND .63
HOSE BARB REDUCER 5/8"-3/8"ID
(1) NOTE: I/N 7 IS FOR HOLDING SENSORS TO I/N 6.
(2) NOTE: I/N 11 IS PART OF ENGINE P/N 0D3454.
(3) QTY. REQ. FOR NON-MQT / QTY REQ. FOR MQT EPA CERT. (NOT REQUIRED
FOR NEXUS CONTROL PANELS)
REVISION: CN-0016489-M
DATE: 5/29/18
Page 2 of 2
1
2
3
4
5
6
7
8
9
10
11
0F2687
0F2611
0F5254
0F5253
0F7077
046526
051756
0C2454
052250
076749
0F2573
0F2610
0G56820ST03
1
1
1
1
1
12
8
2
2
1
1
1
1
WELDMENT RADIATOR SUPPORT150
RADIATOR 680 X 680 X 70 CPL
V-BELT 31/64" X 62-3/8"
V-BELT 31/64" X 61-3/8" (5.4L 100KW ONLY)
V-BELT 1/2" X 63-3/8" (6.8L 100 130KW)
WASHER LOCK M10
SCREW HHC M10-1.5 X 20 G8.8
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
FLAT TENSIONER ARM
12
13
14
15
(2) 16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
39
40
42
43
44
45
46
47
(1) 48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
0G2990
0F2862
0F2560
022131
039287
052625
0F2561
0C8165
0D6795
0C7043
0E8909
0E8909A
048031C
0C8146
082774
0F2686
0F5463
0F8695
0F4028
0F4030
0F4032
1
1
1
15
1
3
1
5
1
12
1
1
1
4
2
1
1
1
1
1
1
0F4496
042911
0F2872
022304
022195
022196
049813
070015
022145
022129
035685
045764
065852
0C7649
055596
069860E
069811
080713
022473
022097
042568
0F5050
039253
051769
0C8145
0E2507
090283
0C8566
0F2776A
052644
0G4376
0G56830ST03
051698
049820
022145
0G6151
1
1
1
2
1
1
8
1
1
1
4
1
1
1
1
1
REF
1
16
16
8
1
1
1
8
1
1
8
1
1
1
1
1
1
2
1
SHOULDER BOLT 3/8 X 1/2"
SPRING TENSION CPL
PULLEY V-BELT 4" FLANGED
WASHER FLAT 3/8-M10 ZINC
SCREW HHC M8-1.25 X 45 C8.8
SCREW SHC M10-1.5 X 35 G12.9
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)
PULLEY 4.5" DIA MACHINED (5.4L 100KW)
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
NUT HEX LOCK 5/16-18 NY INS SS
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
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 C5
SCREW HHC M8-1.25 X 20 G8.8
WASHER LOCK M12
WASHER FLEX (THIN)
PROBE, COOLANT LEVEL 3/8 NPTF
CAP RADIATOR 13 PSI
SCREW HHFC M6-1.0 X 20 G8.8
BRACKET, SIGNAL CONDITIONER
SPACER .5 X 1.5 X .25 STL/ZINC
WASHER BELLEVILLE .75X.38X.028
BENT 90 TENSIONER ARM SUPPORT
SCREW HHC M8-1.25 X 75 C8.8
NUT HEX LOCK M8-1.25 NY INS
WASHER FLAT 5/16-M8 ZINC
EYEBOLT 3/8-16 X 3.5" TURNED
(1) ITEM 48 IS INCLUDED WITH 47.
(2) APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THREADS.
EXPLODED VIEW: EV MUFFLER 4.6/5.4/6.8L CPL C5
GROUP D
DRAWING #: 0F2969
ITEM
PART#
QTY.
0F2807C
0F2807E
0F9207
0F2807B
0F2807D
0F9208
0A6765
0F4710
0F7200
080762
0F2809
0F2981A
0F2962
0C2454
022097
0F2830
0F2773C
0F2773D
0D3159
088775
0F2808
0F5447
022473
0F6214
0L1789
049813
049721
088510
0C9748
1
1
1
1
1
1
2
6
6
8
1
2
2
4
12
2
2
2
1
6
2
1
20
2
8
8
12
6
1
1
2
4
5
6
7
8
9
10
11
12
13
18
19
20
21
22
23
24
26
27
28
29
30
REVISION: K-1591-J
DATE: 1/29/15
DESCRIPTION
PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5)
PIPE EXH MAN R/H 5.4L G/B & 2P (5.4L C5)
PIPE EXH MANIFOLD 4.6L RH
PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5)
PIPE EXH MAN L/H 5.4L G/B & 2P (5.4L C5)
PIPE EXH MANIFOLD 4.6L LH
RING GASKET 2.5 DIA
WASHER LOCK M10 SS
SCREW HHC M10-1.5 X 50 SS FTH
BOLT U 3/8-16 X 2.62
PIPE EXHAUST CROSSOVER
MFLR 7" X 9" X 25" (2) 2.5" IN/2.5" OUT
MUFFLER STRAP
SCREW THF M6-1 X 16 N WA Z/JS
WASHER LOCK M6-1/4
MUFFLER BRACKET STIFFENER
EXHAUST BLANKET 900MM LONG (6.8L C5)
EXHAUST BLANKET 850MM LONG (5.4L C5)
FLANGE EXHAUST
WASHER FLAT 3/8 SS
EXHUAST OUTLET PIPE CPL
BRKT MUFFLER
WASHER FLAT 1/4-M6 ZINC
PIPE ELBOW EXHAUST MUFFLER
MUFFLER STRAP UPPER/LOWER
NUT HEX M6 X 1.0 G8 YEL CHR
SCREW HHC M6-1.0 X 35 G8.8 BLK
NUT HEX M10-1.5 SS
PLUG M18-1.50
Page 2 of 2
1
2
4
5
6
7
8
9
10
11
12
13
18
19
20
21
22
23
24
26
27
28
29
30
0F2807C
0F2807E
0F9207
0F2807B
0F2807D
0F9208
0A6765
0F4710
0F7200
080762
0F2809
0F2981A
0F2962
0C2454
022097
0F2830
0F2773C
0F2773D
0D3159
088775
0F2808
0F5447
022473
0F6214
0F6803
049813
049721
088510
0C9748
1
1
1
1
1
1
2
6
6
8
1
2
2
4
8
2
2
2
1
6
2
1
12
2
4
4
8
6
1
PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5)
PIPE EXH MAN R/H 5.4L G/B & 2P (5.4L C5)
PIPE EXH MANIFOLD 4.6L RH
PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5)
PIPE EXH MAN L/H 5.4L G/B & 2P (5.4L C5)
PIPE EXH MANIFOLD 4.6L LH
RING GASKET 2.5 DIA
WASHER LOCK M10 SS
SCREW HHC M10-1.5 X 50 SS FTH
BOLT U 3/8-16 X 2.62
PIPE EXHAUST CROSSOVER
MFLR 7" X 9" X 25" (2) 2.5" IN/2.5" OUT
MUFFLER STRAP
SCREW THF M6-1 X 16 N WA Z/JS
WASHER LOCK M6-1/4
MUFFLER BRACKET STIFFENER
EXHAUST BLANKET 900MM LONG (6.8L C5)
EXHAUST BLANKET 850MM LONG (5.4L C5)
FLANGE EXHAUST
WASHER FLAT 3/8 SS
EXHUAST OUTLET PIPE CPL
BRKT MUFFLER
WASHER FLAT 1/4-M6 ZINC
PIPE ELBOW EXHAUST MUFFLER
MUFFLER STRAP UPPER/LOWER
NUT HEX M6 X 1.0 G8 YEL CHR
SCREW HHC M6-1.0 X 35 G8.8 BLK
NUT HEX M10-1.5 SS
PLUG M18-1.50
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.
EXPLODED VIEW: EV EXHAUST 5.4L&6.8L O/S C5
GROUP D
DRAWING #: 0G1344
ITEM
PART#
QTY.
0F2807C
0F2807G
0F2807B
0F2807D
088510
0A6765
0F4710
0F7200
080762
0F2809
0F2981A
0F2962
0C2454
022097
0F2830
049721
049813
0L1789
0F6214
0F2773C
0F2773D
0D3159
088775
022473
0F5447
0F2808
1
1
1
1
6
2
6
6
8/6
1
2
2
4
12
2
12
8
8
2
2
2
2
6
20
1
2
1
2
3
4
5
6
(1)7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
(2) 23
DESCRIPTION
PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5)
PIPE EXH MAN R/H 5.4L D/D CPL (5.4L C5)
PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5)
PIPE EXH MAN L/H 5.4L G/B & 2P (5.4L C5)
NUT HEX M10-1.5 SS
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
MUFFLER 7" X 9" X 25" (2) 2.5" IN/2.5" OUT
MUFFLER STRAP
SCREW HWHT M6-1 X 16 N WA Z/JS
WASHER LOCK M6-1/4
MUFFLER BRACKET STIFFENER
SCREW HHC M6-1.0 X 35 G8.8 BLK
NUT HEX M6 X 1.0 G8 YEL CHR
MUFFLER STRAP UPPER/LOWER
PIPE ELBOW EXHAUST MUFFLER
EXHAUST BLANKET 900MM LONG (6.8L C5)
EXHAUST BLANKET 850MM LONG (5.4L C5)
FLANGE EXHAUST
WASHER FLAT 3/8 SS
WASHER FLAT 1/4-M6 ZINC
BRACKET MUFFLER
EXHAUST OUTLET PIPE CPL
(1) QTY. REQUIRED FOR ENCLOSED UNITS / QTY. REQUIRED FOR OPEN SETS.
(2) ENCLOSED SETS ONLY.
REVISION: K-1591-B
DATE: 1/29/15
Page 2 of 2
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
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
(2) 26
27
(2) 28
(2) 29
30
31
32
33
(1) 34
35
36
37
38
39
40
41
42
43
44
45
47
48
49
50
51
(1) 52
53
54
55
56
57
58
59
0F6479
0F6481
0D5582
0E2962
0F6505
0F6506
0F4677
023484N
0F6156
081008
077043J
022097
049813
047411
0D6029
022473
0C2266
049226
051713
057701
0F3618
022155
0C2428
0C9764
0G6962B
0D6682
057073
0A7822
0A8261
022241
022237
0F6507
0F6507A
0C4112B
0D6585
023645
024196
049226
0C2266
022127
0C2454
0F6640
043180
022264
0C3990
0F8926
0F8862
0F8863
051715
036943
023897
022152
022158
0F1733
0F8565
045764
023762
1
1
1
2
1
1
1
2
1
1
2
18
8
8
6
18
2
2
2
REF
1
4
4
6”
1
1
2
3
6
6
10
2
2
2
4
4
4
4
4
6
14
1
10
10
10
1
2
2
4
2
REF
3
2
2
1
1
1
1
PANEL CB CONNECTION
MOUNT CONTROL PANEL CPL
CB 0700A 3P 600V S LMD6 LL
INSULATOR (NOMEX)
COVER FIXED LMD CB
COVER SERVICE LMD CB
ASSY PCB INTERFACE 1PH 240V
BUSHING SNAP SB-2.5-31
PLATE WIRE SNGL GALV
GROMMET 1.25 X .25 X .75
CONDUIT FLEX 2.0" ID (36” LG)
WASHER LOCK M6-1/4
NUT HEX M6 X 1.0 G8 YEL CHR
SCREW HHC M6-1.0 X 16 G8.8
SCREW HHTT M6-1.0 X 16 ZYC
WASHER FLAT 1/4-M6 ZINC
SCREW PHTT M5-0.8 X 16 ZYC
WASHER LOCK M5
WASHER FLAT M5
BLOCK TERM 20A 8 X 6 X 1100V
DECAL CPL CUST CONN H CTRL
WASHER LOCK #6
SCREW PHTT #6-32 X 1/2 ZYC
RAIL SNAPTRACK PCB HOLDER BULK
ASSY RELAY PCB 12VDC
BUBAR NEUTRAL BLOCK (520/MAR)
JUNCTION BLOCK 3/8-16
LUG SLDLSS 600/250-1/0 X 1/4-28
SCREW HHC 1/4-28 X 5/8 .625TH
NUT HEX 3/8-16 STEEL
WASHER LOCK 3/8
BUS BAR 1/4 X 2 LMD L1
BUS BAR 1/4 X 2 LMD L2
LUG SIEMENS LMD/LD TA3K500
SCREW SHC 3/8-16 X 3.0 BLK OX
SCREW SHC 3/8-16 X 1.25 G8.8 Z
SCREW RHM 1/4-20 X 3-1/2
WASHER LOCK M5
SCREW PHTT M5-0.8 X 16 ZYC
NUT HEX 1/4-20 STEEL
SCREW THF M6-1 X 16 N WA Z/JS
CHAN ASSY CB SUPPORT
WASHER FLAT M4
WASHER LOCK #8-M4
SCREW PHTT M4-0.7 X 10 ZYC
INSUL CB COVER
CHANNEL SUPPORT
CHANNEL BRACE
NUT HEX M4-0.7 G8 YEL CHR
SCREW PPHM #10/32 X 2
CTRL IGN MODULE
WASHER FLAT #10 ZINC
WASHER LOCK #10
NUT HEX #10-32 STEEL
DECAL CUSTOMER CONNECT INSIDE
DECAL H-100 RB3 CUST CONN
SCREW HHTT M4-0.7 X 8 ZP
WASHER SHAKEPROOF EXT #10 STL
(1) SUPPLIED WITH BREAKER (0D5582)
(2) SUPPLIED IN ASM. KIT 0G0790.
Stationary Emergency Generator
Warranty
GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR
COMMERCIAL STATIONARY EMERGENCY PRODUCT 50kW AND ABOVE
For a period of two (2) years from the date of sale, Generac Power Systems, Inc. will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or an Authorized/Certified Generac Power Systems Dealer, or branch thereof, is found to be
defective under normal use and service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims
to be defective must be examined by the nearest Authorized/ Certified Generac Power Systems Dealer, or branch thereof. This warranty applies
only to Generac Power Systems Generators used in "Stationary Emergency" applications, as Generac Power Systems, Inc. has defined Stationary
Emergency, provided said generator has been properly installed and inspected on-site by appropriate personnel. Scheduled maintenance, as outlined
by the generator owner's manual, is highly recommended. This should be performed by an Authorized/Certified Generac Power Systems Dealer, or
branch thereof. This will verify service has been performed on the unit throughout the warranty period.
WARRANTY SCHEDULE
YEAR ONE — Limited comprehensive coverage on mileage, labor, and parts listed.
• - ALL COMPONENTS
YEAR TWO — Limited comprehensive coverage on parts listed.
• - ALL COMPONENTS
*Start-up and/or On-line Registration, or Registration Card, along with Proof of Purchase, must be performed and/or sent in.
Guidelines:
• Any and all warranty repairs and/or concerns, must be performed and/or addressed by an Authorized/Certified Generac Power Systems Dealer, or
branch thereof.
• A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a Non - Generac Power
Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the genset, no warranty coverage shall apply.
• All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty, Policies, and Procedures Flat Rate
Manual.
• Units that have been resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable except with change of
ownership of original structure.
• Unit enclosure is only covered against rust or corrosion the first year of the warranty provision.
• Use of Non-Generac replacement part(s) will void the warranty in its entirety.
• Engine coolant heaters (block-heaters), heater controls and circulating pumps are only covered during the first year of the warranty provision (If
applicable).
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Any unit built/manufactured prior to March 1, 2005.
Costs of normal maintenance (i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up).
Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze.
Units sold, rated or used for "Prime Power", "Trailer Mounted" or "Rental Unit" applications as Generac Power Systems have defined Prime Power,
Trailer Mounted or Rental Unit. Contact a Generac Power Systems Distributor for Prime Power, Trailer Mounted or Rental Unit definition.
Units used for prime power in place of existing utility power where utility is present or in place of utility power where utility power service does not
normally exist.
Failures caused by any act of God and other force majeure events beyond the manufactures control.
Products that are modified or altered in a manner not authorized by Generac Power Systems in writing.
Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing.
Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the
defective part(s).
Failure due to misapplication, misrepresentation, or bi-fuel conversion.
Telephone, facsimile, cell phone, satellite, internet, or any other communication expenses.
Rental equipment used while warranty repairs are being performed (i.e. rental generators, cranes, etc.).
Overtime, holiday, or emergency labor.
Planes, ferries, railroad, busses, helicopters, snowmobiles, snow-cats, off-road vehicle or any other mode of transportation deemed abnormal.
Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct
cause of the problem.
Starting batteries, fuses, light bulbs, engine fluids, and overnight freight cost for replacement part(s).
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC POWER SYSTEMS
MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Any implied warranties which
are allowed by law, shall be limited in duration to the terms of the express warranty provided herein. Some states do not allow limitations on how long
an implied warranty lasts, so the above limitation may not apply to purchaser/owner.
GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT
SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A
DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/
owner. Purchaser/owner agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gives purchaser/owner
specific legal rights. Purchaser/owner also may have other rights that vary from state to state
Generac Power Systems, Inc. • P.O. Box 8 • Waukesha, WI 53187
Ph: (262) 544-4811 • Fax: (262) 544-4851
1-888-GENERAC (1-888-436-3722)
Bulletin 0171370SVE / Rev. C 12.08 / Printed in U.S.A.
Printed in U.S.A.
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement