Generac 20 kW 0053373 Standby Generator Manual

Generac 20 kW 0053373 Standby Generator Manual
1.6L
20/25/30 kW
Models
Serial Number
STANDBY GENERATOR
OWNER'S MANUAL
A new standard of reliability
Not intended for use in critical life support applications. 
—CAUTION—
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
This manual should remain with the unit.
Cover113 Rev. C 09/07
Catalog Number OMASPES025-2
Part No. 0G5244
Standby Generator Sets
Table of Contents
SECTION
PAGE
SAFETY RULES ................................................ 1-1
OPERATION ...........................................................9-1
INTRODUCTION .....................................................1-3
Read this Manual Thoroughly ...................................1-3
Operation and Maintenance ......................................1-3
How to Obtain Service ..............................................1-3
IDENTIFICATION RECORD .....................................2-1
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
High Coolant Temperature Switch ............................4-1
Low Coolant Level Sensor.........................................4-1
Low Oil Pressure Switch ...........................................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
Cold Weather Kit .......................................................6-2
Reconfiguring the Fuel System ..................................6-2
GENERAL INFORMATION.......................................7-1
Generator AC Lead Connections ..................................7-1
Four-lead, Single-phase Stator ..................................7-1
Alternator Power Winding Connections ........................7-1
3-phase Alternators ..................................................7-1
INSTALLATION.......................................................8-1
Installation ...................................................................8-1
Preparation Before Start-up .........................................8-1
Transfer Switch ........................................................8-1
Fuel System ..............................................................8-1
Generator Set Lubrication ........................................8-1
Prior to Initial Start-up .............................................8-1
Engine Coolant .........................................................8-1
Belt Tension ..............................................................8-1
Electrical System ......................................................8-1
Initial Inspection for Genset Start-up ...........................8-1
Start-up Checklist ........................................................8-2
Preparation for Start-up............................................8-2
Operating Unit with Manual Transfer Switch ...............9-1
Generator Control and Operation ................................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 Service Facilities ..............10-1
Every Three Months ...............................................10-1
Once Every Six Months ...........................................10-1
Once Annually.........................................................10-1
First 30 Operating Hours ........................................10-1
First 100 Operating Hours ......................................10-1
Every 500 Operating Hours ....................................10-1
Every 800 Operating Hours ....................................10-1
Cooling System ..........................................................10-1
Overload Protection for Engine DC
Electrical System ....................................................10-1
Checking Fluid Levels ................................................10-1
Check Engine Oil ....................................................10-1
Battery Fluid ...........................................................10-2
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 ...............................................10-3
Changing the Engine Air Cleaner ............................10-3
Spark Plugs ............................................................10-3
Coolant Change .......................................................10-3
Miscellaneous Maintenance ........................................10-4
Cleaning the Generator ...........................................10-4
Battery ....................................................................10-4
Battery Maintenance ...............................................10-4
Battery Replacement ...............................................10-4
Repair Parts ............................................................10-4
SERVICE SCHEDULE ...........................................11-1
TROUBLESHOOTING ...........................................12-1
Troubleshooting Guide...............................................12-1
NOTES
EXPLODED VIEWS & PARTS LISTS
WIRING DIAGRAMS & SCHEMATICS
Content014 Rev. A 04/07
Safety Instructions
THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential
nSAVE
hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this
equipment.
INTRODUCTION

This symbol points out potential electrical shock hazard.

This symbol points out potential fire hazard.
Thank you for purchasing this model of the stationary emergency
generator product line.
Every effort was expended to make sure that the information and
instructions in this manual were both accurate and current at the
time the manual was written. However, the manufacturer reserves
the right to change, alter or otherwise improve this product(s) at
any time without prior notice.
The operator is responsible for proper and safe use of the equipment. The manufacturer strongly recommends that the operator
read this Owner's Manual and thoroughly understand all instructions before using this equipment. The manufacturer also strongly
recommends instructing other users to properly start and operate
the unit. This prepares them if they need to operate the equipment
in an emergency.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest
Service Dealer for starting, operating and servicing procedures.
For safety reasons, the manufacturer recommends that this
equipment be installed, serviced and repaired by a Service
Dealer or other competent, qualified electrician or installation
technician who is familiar with applicable codes, standards and
regulations. The operator also must comply with all such codes,
standards and regulations.
Throughout this publication, and on tags and decals affixed to the
generator, DANGER, WARNING, CAUTION and NOTE blocks are
used to alert personnel to special instructions about a particular
service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are
as follows:
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety checks, to
make sure that all maintenance for safe operation is performed
promptly, and to have the equipment checked periodically by a
Service Dealer. Normal maintenance service and replacement of
parts are the responsibility of the owner/operator and, as such,
are not considered defects in materials or workmanship within the
terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.
INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF
NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.
Indicates a hazardous situation or action which, if not
avoided, could result in death or serious injury.
Proper maintenance and care of the generator ensure a minimum
number of problems and keep operating expenses at a minimum.
See a Service Dealer for service aids and accessories.
Indicates a hazardous situation or action which, if not
avoided, could result in minor or moderate injury.
NOTE:
Operating instructions presented in this manual assume that the
generator electric system has been installed by a Service Dealer or
other competent, qualified contractor. Installation of this equipment
is not a “do-it-yourself” project.
Notes contain additional information important to a procedure
and will be found within the regular text body of this manual.
These safety warnings cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the special
instructions while performing the service are essential to preventing accidents.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs, simply contact
a Service Dealer for assistance. Service technicians are factorytrained and are capable of handling all service needs.
Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTION blocks. The type of information each
indicates is as follows:
When contacting a dealer about parts and service, always supply
the complete Model Number, Serial Number and Type Code (where
applicable) from the DATA LABEL that is affixed to the unit.
This symbol points out important safety information that,
if not followed, could endanger personal safety and/or
property of others.
n


This symbol points out potential explosion hazard.
Safety004 Rev. F 05/10
1-1
Safety Instructions
SAFETY RULES
• The engine exhaust fumes contain carbon monoxide gas, which
can be DEADLY. This dangerous gas, if breathed in sufficient
concentrations, can cause unconsciousness or even death. For
that reason, adequate ventilation must be provided. This should
be considered prior to installing the generator. The unit should
be positioned to direct exhaust gasses safely away from any
building where people, animals, etc., will not be harmed. Any
exhaust stacks that ship loose with the unit must be installed
properly per the manufacturer's instruction, and in strict compliance with applicable codes and standards.
• Keep hands, feet, clothing, etc., away from drive belts, fans,
and other moving or hot parts. Never remove any drive belt or
fan guard while the unit is operating.
• Adequate, unobstructed flow of cooling and ventilating air is
critical in any room or building housing the generator to prevent
buildup of explosive gases and to ensure correct generator
operation. Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seriously affect
safe operation of the generator.
• Keep the area around the generator clean and uncluttered.
Remove any materials that could become hazardous.
• When working on this equipment, remain alert at all times.
Never work on the equipment when physically or mentally
fatigued.
• Inspect the generator regularly, and promptly repair or replace
all worn, damaged or defective parts using only factoryapproved parts.
• Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start-up. Disconnect
the cable from the battery post indicated by a NEGATIVE, NEG
or (–) first. Reconnect that cable last.
• Never use the generator or any of its parts as a step. Stepping
on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel
leakage, oil leakage, etc.
Study these SAFETY RULES carefully before installing, operating
or servicing this equipment. Become familiar with this Owner’s
Manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and
maintained. Many accidents are caused by failing to follow simple
and fundamental rules or precautions.
The manufacturer cannot anticipate every possible circumstance
that might involve a hazard. The warnings in this manual, and on
tags and decals affixed to the unit are, therefore, not all inclusive.
If a procedure, work method or operating technique is used that
the manufacturer does not specifically recommend, ensure that it
is safe for others. Also make sure the procedure, work method or
operating technique utilized does not render the generator unsafe.
the safe design of this generator,
nDespite
operating this equipment imprudently, neglecting its maintenance or being careless can cause
possible injury or death. Permit only responsible and capable persons to install, operate or
maintain this equipment.
these machines. Ensure all steps are taken to
Potentially lethal voltages are generated by
render the machine safe before attempting to
work on the generator.
of the generator are rotating and/or hot
nParts
during operation. Exercise care near running
generators.
GENERAL HAZARDS
• For safety reasons, the manufacturer recommends that this
equipment be installed, serviced and repaired by a Service
Dealer or other competent, qualified electrician or installation
technician who is familiar with applicable codes, standards
and regulations. The operator also must comply with all such
codes, standards and regulations.
• Installation, operation, servicing and repair of this (and related)
equipment must always comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and
national electrical and building codes. Comply with regulations
the Occupational Safety and Health Administration (OSHA) has
established. Also, ensure that the generator is installed, operated and serviced in accordance with the manufacturer’s instructions and recommendations. Following installation, do nothing
that might render the unit unsafe or in noncompliance with the
aforementioned codes, standards, laws and regulations.
ELECTRICAL HAZARDS
• All stationary emergency generators covered by this manual
produce dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely high and dangerous voltages to the transfer switch as well as the generator.
Avoid contact with bare wires, terminals, connections, etc.,
on the generator as well as the transfer switch, if applicable.
Ensure all appropriate covers, guards and barriers are in place
before operating the generator. If work must be done around
an operating unit, stand on an insulated, dry surface to reduce
shock hazard.
• Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
1-2
Safety004 Rev. F 05/10
Safety Instructions
FIRE HAZARDS
• If personnel must stand on metal or concrete while installing,
operating, servicing, adjusting or repairing this equipment,
place insulative mats over a dry wooden platform. Work on the
equipment only while standing on such insulative mats.
• The National Electrical Code (NEC) requires the frame and
external electrically conductive parts of the generator to be connected to an approved earth ground. This grounding will help
prevent dangerous electrical shock that might be caused by a
ground fault condition in the generator or by static electricity.
Never disconnect the ground wire.
• Wire gauge sizes of electrical wiring, cables and cord sets must
be adequate to handle the maximum electrical current (ampacity) to which they will be subjected.
• Before installing or servicing this (and related) equipment, make
sure that all power voltage supplies are positively turned off at
their source. Failure to do so will result in hazardous and possibly fatal electrical shock.
• Connecting this unit to an electrical system normally supplied
by an electric utility shall be by means of a transfer switch so as
to isolate the generator electric system from the electric utility
distribution system when the generator is operating. Failure to
isolate the two electric system power sources from each other
by such means will result in damage to the generator and may
also result in injury or death to utility power workers due to
backfeed of electrical energy.
• Stationary emergency generators installed with an automatic
transfer switch will crank and start automatically when normal
(utility) source voltage is removed or is below an acceptable
preset level. To prevent such automatic start-up and possible
injury to personnel, disable the generator’s automatic start circuit (battery cables, etc.) before working on or around the unit.
Then, place a “Do Not Operate” tag on the generator control
panel and on the transfer switch.
• In case of accident caused by electric shock, immediately
shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID
DIRECT CONTACT WITH THE VICTIM. Use a nonconducting
implement, such as a dry rope or board, to free the victim from
the live conductor. If the victim is unconscious, apply first aid
and get immediate medical help.
• Never wear jewelry when working on this equipment. Jewelry
can conduct electricity resulting in electric shock, or may get
caught in moving components causing injury.
• Keep a fire extinguisher near the generator at all times. Do NOT
use any carbon tetra-chloride type extinguisher. Its fumes are
toxic, and the liquid can deteriorate wiring insulation. Keep the
extinguisher properly charged and be familiar with its use. If
there are any questions pertaining to fire extinguishers, consult
the local fire department.
EXPLOSION HAZARDS
• Properly ventilate any room or building housing the generator to
prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any fuel or oil
spills immediately. Ensure that no combustible materials are left
in the generator compartment, or on or near the generator, as
FIRE or EXPLOSION may result. Keep the area surrounding the
generator clean and free from debris.
• These generators may operate using one of several types
of fuels. All fuel types are potentially FLAMMABLE and/or
EXPLOSIVE and should be handled with care. Comply with all
laws regulating the storage and handling of fuels. Inspect the
unit’s fuel system frequently and correct any leaks immediately.
Fuel supply lines must be properly installed, purged and leak
tested according to applicable fuel-gas codes before placing
this equipment into service.
• Diesel fuels are highly FLAMMABLE. Gaseous fluids such
as natural gas and liquid propane (LP) gas are extremely
EXPLOSIVE. Natural gas is lighter than air, and LP gas is heavier
than air; install leak detectors accordingly.
CALIFORNIA PROPOSITION 65 WARNING
Engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects
and other reproductive harm.
CALIFORNIA PROPOSITION 65 WARNING
This product contains or emits chemicals known to the
State of California to cause cancer, birth defects and
other reproductive harm.
Safety004 Rev. F 05/10
1-3
General Information
IDENTIFICATION RECORD
NOTE:
For actual information related to this particular model, please
refer to the Manual Drawing Listing located at the end of this
manual, or to the data label affixed to the unit.
DATA LABEL
Every generator set has a DATA LABEL that contains important
information pertinent to the generator. The data label, which can be
found attached to the generator’s lower connection box, lists the
unit’s serial number and its rated voltage, amps, wattage capacity,
phase, frequency, rpm, power factor, production date, etc.
Stationary Emergency Generator Model and Serial
Number
This number is the key to numerous engineering and manufacturing details pertaining to your unit. Always supply this number
when requesting service, ordering parts or seeking information.
Data Label
Identy005 Rev. D 05/10
2-1
Equipment Description
EQUIPMENT DESCRIPTION
COOLANT RECOMMENDATIONS
This equipment is a revolving field, alternating current Stationary
Emergency Generator. It is powered by a gaseous fueled engine
operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for
2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear
units. See the Specifications section for exact numbers. The unit
comes complete with a sound attenuated enclosure, internally
mounted muffler, control console, mainline circuit breaker, battery charger, and protective alarms as explained in the following
paragraph.
Use a mixture of half low silicate ethylene glycol base anti-freeze
and deionized water. Cooling system capacity is listed in the
specifications. Use only deionized water and only low silicate
anti-freeze. If desired, add a high quality rust inhibitor to the recommended coolant mixture. When adding coolant, always add the
recommended 50-50 mixture.
not use any chromate base rust inhibitor
Do
with ethylene glycol base anti-freeze or chromium hydroxide (“green slime”) forms and will
All AC connections, including the power leads from the alternator, 120 volt battery charger input and control connections to the
transfer switch are available in the main connection box.
cause overheating. Engines that have been
operated with a chromate base rust inhibitor
must be chemically cleaned before adding ethylene glycol base anti-freeze. Using any high
silicate anti-freeze boosters or additives will
also cause overheating. The manufacturer also
recommends that any soluble oil inhibitor is
NOT used for this equipment.
The Stationary Emergency Generator incorporates the following
alternator features:
• Rotor and Stator insulation is Class F 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
not remove the radiator pressure cap while
Do
the engine is hot or serious burns from boiling
liquid or steam could result.
The unit has been filled with 5W-20 engine oil at the factory. Use
a high-quality detergent oil classified “For Service SJ or SH.”
Detergent oils keep the engine cleaner and reduce carbon deposits.
When changing the engine oil, be sure to use 5W-30 engine oil
(synthetic oil is recommended).
glycol base antifreeze is poisonous.
Ethylene
Do not use mouth to siphon coolant from the
radiator, recovery bottle or any container. Wash
hands thoroughly after handling. Never store
used antifreeze in an open container because
animals are attracted to the smell and taste of
antifreeze even though it is poisonous to them.
attempt to crank or start the engine before
Any
it has been properly serviced with the recommended oil may result in an engine failure.
NOTE:
For temperatures below 32° F, it is strongly recommended to
use the optional Cold Weather Start Kit. The oil grade for temperatures below 32° F is 5W-30 synthetic oil.
Equip007 Rev. D 07/11
3-1
Engine Protective Devices
ENGINE PROTECTIVE DEVICES
OVERCRANK SHUTDOWN
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.
After a prespecified duration of cranking, this function ends the
cranking if the engine has failed to start. The overcrank LED will
turn ON. Turn OFF the AUTO/OFF/MANUAL switch, then turn switch
back to AUTO to reset the generator control board.
NOTE:
If the fault is not corrected, the overcrank feature will continue
to activate.
NOTE:
Approximate Crank Cycle Times
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.
•
•
•
•
•
HIGH COOLANT TEMPERATURE SWITCH
The switch will close if the temperature should exceed approximately 140° C (284° F), initiating an engine shutdown. The generator will automatically restart and the LED will reset once the
temperature has returned to a safe operating level.
15 seconds ON
7 seconds OFF
7 seconds ON
7 seconds OFF
Repeat for 45 seconds
Approximately 90 seconds total.
OVERSPEED SHUTDOWN
A speed circuit controls engine cranking, start-up, operation and
shutdown. Engine speed signals are delivered to the circuit board
whenever the unit is running. Should the engine overspeed above
a safe, preset value, the circuit board initiates an automatic engine
shutdown. Contact the nearest Authorized Dealer if this failure
occurs.
LOW COOLANT LEVEL SENSOR
To prevent overheating, the engine has a low coolant level sensor.
If the level of engine coolant drops below the level of the low coolant level sensor, the engine automatically shuts down.
RPM SENSOR LOSS SHUTDOWN
LOW OIL PRESSURE SWITCH
If the speed signal to the control panel is lost, engine shutdown
will occur.
This switch has normally closed contacts that are held open by
engine oil pressure during cranking and operating. Should oil pressure drop below the 8 psi range, switch contacts close, and the
engine shuts down. The unit should not be restarted until oil is
added, and the AUTO/OFF/MANUAL switch must be turned to OFF
and then back to AUTO.
DC FUSES
Fuse F1 (15 amp) 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.
Fuse F2 (25 amp) is located in the engine wire harness adjacent
to the DC alternator. It is used to prevent circuit failure due to DC
alternator falure. If this fuse is blown, battery charging will not
occur while the engine is running. Replace these fuses with the
same size, type, and rating. (See the exploded views and parts
lists at the end of this manual for replacement part number.)
EngProt001 Rev. C 06/10
4-1
Fuel System
FUEL SYSTEM
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.
FUEL REQUIREMENTS
The Stationary Emergency Generator may be equipped with one of
the following fuel systems:
• Gas pressure in a building is usually regulated by national, state
and local codes.
• To reduce gas pressure to a safe level before the gas enters a
building, a primary regulator is needed. The natural gas supplier
may or may not supply such a regulator.
• It is the responsibility of the gas supplier to make sure sufficient
gas pressure is available to operate the primary regulator.
• Gas pressure at the inlet to the fuel shutoff solenoid must never
exceed approximately 14 inches water column (0.5 psi).
• Natural gas fuel system
• Propane vapor (LPV) fuel system
Recommended fuels should have a Btu content of at least 1,000
Btu's per cubic foot for natural gas; or at least 2,520 Btu's per
cubic foot for LP gas. Ask the fuel supplier for the Btu content of
the fuel.
NOTE:
The fuel consumption requirements are identified in the
Specifications section of the Owner's Manual. Refer to the
Installation Manual if assistance is required for the sizing of
the pipe diameter for the generator. Any piping used to connect
the generator to the fuel supply should be of adequate size to
achieve the 100% load fuel consumption requirements identified in the Specifications section regardless of actual load.
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:
NOTE:
The recommended fuel pressure is identified in the Specifications
section this manual.
• 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.
5-1
FuelSys001 Rev. F 04/11
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.
Standby Generator Sets
Specifications
SPECIFICATIONS
Engine Lubrication System
Type of Oil Pump ...................................................................... Gear
Oil Filter .............................................................Full Flow, Cartridge
Crankcase Oil Capacity ....................................................4 U.S. qts.
‹ GENERATOR
Type ............................................................................. Synchronous
Rotor Insulation ....................................................................Class F
Stator Insulation ...................................................................Class F
Total Harmonic Distortion .........................................................< 5%
Alternator Output Leads 3-phase ........................................... 4-wire
Bearings .........................................................................Sealed Ball
Coupling .......................................................................Flexible Disc
Load Capacity (Standby Rating) ................................ 20/25/30 kW*
‹ COOLING SYSTEM
Type .......................................................................................Closed
Water Pump.................................................................... Belt Driven
Fan Speed ................................................................................ 2450
Fan Diameter ..................................................................17.7 inches
Fan Mode ..............................................................................Pusher
Air Flow (inlet air including alternator and
combustion air) ........................................................... 2490 ft3/min.
Coolant Capacity ...........................................................2.0 U.S. gal.
Heat Rejection to Coolant ..........................................117,000 Btu/h
Maximum Operating Air Temp. on Radiator ..............60° C (150° F)
Maximum Ambient Temperature................................50° C (140° F)
* NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349,
ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural
gas.
Excitation System ....................................................................Direct
Generator Output Voltage/kW - 60 Hz
kW
Amp
CB Size
120/240V, 1-phase, 1.0 pf 20/25/30 83/104/125 100/125/150
120/208V, 3-phase, 0.8 pf 20/25/30
69/87/104 80/100/125
277/480V, 3-phase, 0.8 pf 20/25/30
30/38/45
35/45/50
‹ FUEL SYSTEM
Type of Fuel .........................................Natural Gas, Propane Vapor
Carburetor ...................................................................... Down Draft
Secondary Fuel Regulator .................................................Standard
Fuel Shut-off Solenoid ........................................................Standard
Operating Fuel Pressure ...................... 5 in. - 14 in. Water Column
Generator Locked Rotor KVA Available @ Voltage Dip of 35%
Single-phase or 208 3-phase:
20kW
25kW
30kW
34 KVA 38 KVA 56 KVA
‹ ENGINE
Make ................................................................................... Generac
Model ..................................................................................... In Line
Cylinders and Arrangement............................................................ 4
Displacement ....................................................................... 1.6 Liter
Bore ...................................................................................... 3.15 in.
Stroke ................................................................................... 3.13 in.
Compression Ratio .............................................................9.75-to-1
Air Intake System ...............................................Naturally Aspirated
Valve Seats................................................................... Replaceable
Lifter Type .......................................................................... Hydraulic
Fuel Consumption - ft3/hr
Exercise
25%
Cycle
Load
20kW
56/24
124/49
25kW
56/24
161/64
30kW
56/24
209/82
(Natural Gas/LPV)
50%
75%
100%
Load
Load
Load
188/75
250/99 315/125
253/101 345/138 430/175
281/117 360/147 437/185
‹ ELECTRICAL SYSTEM
Battery Charge Alternator ............................................12V, 15 Amp
Static Battery Charger ............................................................2 Amp
Recommended Battery...................................... Group 26, 525CCA
System Voltage .....................................................................12 Volts
Engine Parameters
Rated Synchronous RPM ..............................................60 Hz, 3600
HP at rated:
20kW
25kW
30kW
35 HP
45 HP
48 HP
Voltage Regulator
Type .................................................................................. Electronic
Sensing........................................................................ Single-phase
Regulation ................................................................................± 1%
Features ................................................. V/F Adjustable, Adjustable
Voltage and Gain LED Indicators
Exhaust System
Exhaust Flow at Rated Output 60 Hz: 20kW
25kW
30kW
209 cfm 235 cfm 240 cfm
Exhaust Temp. at Rated Output:
910°F 1015°F 1022°F
Power Adjustment for Ambient Conditions
Temperature Deration:
3% for every 10° C above °C
20kW
25kW
40
40
1.65% for every 10° above °F
104
104
Altitude Deration:
1% for every 100 m above m
20kW
25kW
1220
915
3% for every 1000 ft. above ft.
4000
3000
Combustion Air Requirements (Natural Gas)
Flow at rated power, 60 Hz:
20kW
25kW
30kW
80 cfm 90 cfm 92 cfm
Governor
Type .................................................................................. Electronic
Frequency Regulation ...................................................Isochronous
Steady State Regulation........................................................± .25%
Adjustments:
Speed ............................................................................ Selectable
30kW
25
77
30kW
182
600
Controller .................................................R-200
GenSpec037 Rev. A 04/07
6-1
Standby Generator Sets
Specifications
Figure 6.1 — Interconnections
Utility In
Transfer Switch
CONTROL PANEL
NEUTRAL
TO
ALTERNATOR
Gen
N1
N2
23
194
GENERATOR
CONNECTION
BOX
183
178
NEUTRAL
N1
N2
23
194
4- # 14 GA
WIRES TO
GENERATOR
CONNECTION
BOX
CIRCUIT
BREAKER
Battery
Charger
Input
186
178
Load
Out
TO GENERATOR
CONNECTION BOX
GROUND
120 Volt +
Neutral
Grd
To Generator Control Panel
FRAME RAIL
Ground Level
Concrete Slab
KW
25
25
STUB-UP AREA
See Install Dwg for
Dimensions
‹ COLD WEATHER KIT
CIRCUIT BREAKER SIZE
VOLTS / AMPS
LUG SIZE
240 1 Ø
125
#4 to 1/0
208 3 Ø
100
#4 to 1/0
NOTE:
For cold climates, optional cold weather kit (part
number 0F6148) is recommended. The kit includes:
The jet sizes are stamped on the individual jets.
The larger jet size is used for running on NG.
• Battery Warmer
• 4” Junction Box with hardware
• 6 qt. pack 5W-30 synthetic oil (engine)
8. Install the previously removed NG jet into the jet
keeper port on the side of the regulator housing.
9. Install the previously removed black pipe onto
the outlet port of the demand regulator.
10. Reverse steps 1-4 in this procedure to reactivate
the demand regulator.
‹ RECONFIGURING THE FUEL SYSTEM
NOTE:
Figure 6.2 — Reconfigure the Fuel System
All models are configured to run on natural gas
from the factory.
To reconfigure the fuel system from NG to LP, follow
these steps:
1. Turn the main gas supply off.
2. Remove the carburetor fuel hose from the outlet
port of the demand regulator (see Figure 6.2).
3. Disconnect the power wires from the fuel solenoid located on top of the regulator assembly.
4. Loosen the spring clamp on the small fuel enrichment line and remove the hose from the hose
barb.
5. Remove the black pipe assembly from the outlet
port of the demand regulator.
6. Remove the NG fuel jet (loosen counter clockwise) from the outlet port.
7. Remove the LP fuel jet (loosen counter clockwise)
from the jet keeper port on the side of the regulator housing. Install this jet into the outlet port in
the regulator casting.
DANGER
injury or damage may occur if not con Serious
figured properly. Please consult an Authorized
Dealer with any questions.
6-2
GenSpec037 Rev. A 04/07
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
Refer to the separate “Installation Guide” supplied with the unit.
For safety reasons, the manufacturer recommends that this equipment be installed, serviced and repaired by a Service Dealer or
other competent, qualified electrician or installation technician who
is familiar with applicable codes, standards and regulations. The
operator also must comply with all such codes, standards and
regulations.
Prior to initially starting the generator, it must
n
be properly prepared for use. Any attempt to
crank or start the engine before it has been
properly serviced with the recommended types
and quantities of engine fluids (oil, coolant,
fuel, etc.) may result in an engine failure.
PREPARATION BEFORE START-UP
ENGINE COOLANT
The instructions in this section assume that the Stationary
Emergency Generator has been properly installed, serviced, tested,
adjusted and otherwise prepared for use by a competent, qualified
installation contractor. Be sure to read the “Safety Rules”, as well
as all other safety information in this manual, before attempting to
operate this (and related) equipment.
Have the engine cooling system properly filled with the recommended coolant mixture. Check the system for leaks and other
problems. See “Specifications” and “Coolant” sections.
BELT TENSION
Before starting the generator for the first time, the installer
must complete the following procedures. For follow-up maintenance information and/or service intervals, please refer to the
“Maintenance” section and the “Service Schedule”.
Check-the engine-fan belt tension and condition prior to placing
the unit into service and at recommended intervals. Belt tension is
correct when a force of approximately 22 pounds (10 kg), applied
midway between pulleys, deflects the belt about 3/8- to 5/8-inch
(10 to 16 mm).
TRANSFER SWITCH
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.
ELECTRICAL SYSTEM
FUEL SYSTEM
Check to ensure that there are no loose electrical connections.
Restrain any loose wires to keep them clear of any moving generator set components.
Make sure the generator is properly connected to an approved
earth ground.
Make sure the generator battery is fully charged, properly installed
and interconnected, and ready for use.
NOTE:
Battery charger must be connected to 120 VAC, 15 amp circuit
to operate.
Make sure the fuel supply system to the generator (a) delivers the
correct fuel at the correct pressure and (b) is properly purged and
leak tested according to code. No fuel leakage is permitted. See
“Specifications” for more information.
INITIAL INSPECTION FOR GENSET
STARTUP
GENERATOR SET LUBRICATION
Inspect for the following.
Check the engine crankcase oil level before operating and add
oil to the proper level – the dipstick “FULL” mark. Never operate
the engine with the oil level below the dipstick “ADD” mark. See
“Specifications” and “Engine Oil Recommendations”.
•
•
•
•
•
Freight Damage.
Manuals present.
Fluid Levels (Oil, coolant, battery, Gear Drive).
Correct fuel piping.
Correct muffler installation for external applications (open units
only).
• Adequate air flow, clearances and ventilation per installation
drawings and applicable codes.
• Correct AC and DC wire size, connections and grounding.
Control and communication wiring to/from the transfer switch
must be run in a separate conduit from the AC power leads.
Check the oil level in the generator gearbox (if so equipped) prior to
initial use and at the intervals indicated by the “Service Schedule.”
The recommended oil is SAE 90 gear lubricant.
NOTE:
This engine is shipped from the manufacturer with “break-in”
oil. This oil should be changed after 30 hours of operation.
• Battery charger connection to 120 VAC.
• Unit secured to pad.
Install002 Rev. G 06/10
8-1
Installation
START-UP CHECKLIST
• Connect a manometer to the gas line and record the static pressure. It must be as listed in the Specifications.
• Insert the fuse into the control panel.
• Move the AUTO/OFF/MANUAL switch to the manual position.
The engine should now crank and start.
• Check voltage at the generator terminals.
• For 3-phase units, check phase rotation at the transfer switch
terminals. The generator phase rotation must match the utility
phase rotation.
• Check for coolant, fuel, oil, and exhaust leaks.
• Close the generators main line circuit breaker.
• Turn the generator set off.
• Connect the UTILITY supply to the transfer switch.
• Set the AUTO/OFF/MANUAL switch to AUTO.
• Disconnect utility power before the transfer switch.
Engine should start, transfer to load.
Run at least 15 minutes on generator power. Make certain all
3-phase loads are functioning correctly (correct phase rotation).
• Reconnect Utility power
Transfer switch will transfer back to Utility and engine will
shut down within the given time parameters set up for the
specific transfer switch and controller.
• Install all covers, access plates and door panels.
• Put the Owners Manual in a safe and accessible place.
• Make certain the AUTO/OFF/MANUAL switch is in the AUTO
position.
Before working on the Stationary Emergency
Generator, ensure the following:
n
• The AUTO/OFF/MANUAL switch is in the OFF position.
• The 120VAC supply to the battery charger is switched OFF.
PREPARATION FOR START-UP
• Ensure that the 120VAC circuit breaker to the battery charger is
open.
• Remove the fuse from the the control panel. Open the front door
of the control box and remove the 15 Amp ATO fuse in the lower
left-hand corner of the control box.
• Connect the battery cables to the battery. Attach negative battery cable last.
• Close the 120VAC circuit breaker to the battery charger.
• Measure the voltage at the battery before and after the charger
is turned on.
• Verify all AC electrical connections are tight at the circuit breaker
and transfer switch.
• Visually inspect entire area looking for loose paper, plastic
wrappings, leaves, etc.
• Check all hoses clamps fittings for leaks or damage.
• Check all electrical plugs throughout the generator. Ensure each
plug is seated correctly and fully inserted into its receptacle.
• Verify the AUTO/OFF/MANUAL switch is in OFF position.
• Open the valve to the engine fuel line.
• Bleed the fuel system of air. (necessary for long fuel lines).
• Open the generator main line circuit breaker.
8-2
Install002 Rev. G 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
SERVICE DEALERS
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.
Generator, ensure the following:
Before working on the Stationary Emergency
Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down. (See the
installation diagram.)
• 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.
get
extremely hot and remains hot after shutdown. High grass, weeds, brush, leaves, etc.
The exhaust system parts from this product
EVERY THREE MONTHS
Check battery condition.
Inspect and test fuel system.
Check transfer switch.
Inspect exhaust system.
Check engine ignition system.
Check fan belts.
must remain clear of the exhaust. Such materials may ignite and burn from the heat of the
exhaust system.
OVERLOAD PROTECTION FOR
ENGINE DC ELECTRICAL SYSTEM
ONCE EVERY SIX MONTHS
1.
Engine cranking, start up and running are controlled by a solid
state Engine Controller circuit board. Battery voltage is delivered to
that circuit board via a 15 amp fuse. These overcurrent protection
devices will open if the circuit is overloaded.
Test Engine Safety Devices (low oil pressure, low coolant
level, high coolant temperature).
ONCE ANNUALLY
1.
2.
3.
Test engine governor; adjust or repair, if needed.
Clean, inspect generator.
Flush cooling system.
a circuit breaker opens or a fuse element
nIfmelts,
find the cause of the overload before
resetting the circuit breaker or replacing the
FIRST 30 OPERATING HOURS
1.
fuse.
Change engine "break-in" oil and filter.
CHECKING FLUID LEVELS
FIRST 100 OPERATING HOURS
1.
2.
3.
CHECK ENGINE OIL
Change engine oil and oil filter. After initial change, service
engine oil and filter at 100 operating hours or six months,
whichever comes first.
Retorque cylinder head.
Retorque intake and exhaust manifold.
Check engine crankcase oil level (Figure 10.1) at least every 20
hours of operation, or prior to use.
•
•
•
•
EVERY 500 OPERATING HOURS
1.
2.
3.
Service air cleaner.
Check starter.
Check engine DC alternator.
10-1
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
Recommen-dations” for recommended oils.
Maint011 Rev. G 07/10
1.
2.
3.
4.
5.
6.
Maintenance
EXERCISE SYSTEM
Figure 10.1 - Oil Dipstick and Oil Fill Cap
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.
OIL FILL CAP
INSPECT COOLING SYSTEM
• Inspect engine cooling system. See “Maintenance Schedule”.
• Check hoses for damage, deterioration, leaks, etc. Correct any
discrepancies found.
• Check hose clamps for tightness.
CHECK ENGINE COOLANT LEVEL
OIL
DIPSTICK
See “Checking Fluid Levels”.
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.
BATTERY FLUID
INSPECT EXHAUST SYSTEM
Check battery electrolyte fluid based on the Maintenance Schedule.
Fluid should cover separators in all battery cells. If fluid level is low,
add distilled water to cover tops of separators. DO NOT USE TAP
WATER IN BATTERY.
Inspect the exhaust system at least once every three months.
Check all exhaust system pipes, mufflers, clamps, etc. for condition, tightness, leaks, security, damage.
ENGINE COOLANT
CHECK FAN BELT
Check coolant level in coolant recovery bottle. See Specifications.
• 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 of an inch.
Adjust belt tension as required.
• Add recommended coolant mixture as necessary.
• Periodically remove radiator pressure cap (only when engine
has cooled down) to make sure the coolant recovery system
is functioning properly. Coolant should be at bottom of radiator filler neck. If coolant level is low, inspect gasket in radiator
pressure cap. Replace cap, if necessary. To have pressure cap
tested, contact a Service Dealer. Inspect cooling system and
coolant recovery system for leaks.
INSPECT ENGINE GOVERNOR
Visually inspect electronic governor.
MAINTENANCE OWNER/OPERATOR
CAN PERFORM
not attempt to adjust the governor. Only
qualified service facilities should adjust
nDo
the governor. Excessively high operating
speeds are dangerous and increase the
risk of personal injury. Low speeds impose
a heavy load on the engine when adequate
engine power is not available and may
shorten engine life. Correct rated frequency
and voltage are supplied only at the proper
governed speed. Some connected electrical
load devices may be damaged by incorrect
frequency and/or voltage. Only qualified service technicians should adjust the governed
speed.
CHECK ENGINE OIL LEVEL
Refer to “Checking Fluid Levels”.
CHECK BATTERY
• See “Checking Fluid Levels”.
• Check battery cables for condition, tightness, corrosion or damage. Clean, tighten or replace as necessary.
10-2
Maint011 Rev. G 07/10
Maintenance
CHANGING ENGINE OIL
Figure 10.3 – Engine Air Cleaner
Refer to maintenance performed by service facilities for engine oil
and filter change frequencies.
Air Cleaner
Drain the oil while the engine is still warm from running. This
means warm up the engine, shut it down and drain immediately
as follows:
1.
2.
3.
4.
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.
Properly dispose of old filter.
Figure 10.2 – Oil Filter
(Doors Removed for Clarity)
SPARK PLUGS
Reset the spark plug gap or replace the spark plugs as necessary
(Figure 10.4).
OIL
DIPSTICK
1.
2.
OIL
FILTER
3.
5.
6.
Apply light coating of new engine oil to seal of new oil
filter.-Install FILTER and tighten by hand only. DO NOT OVER
TIGHTEN.
Remove OIL FILL CAP. Add recommended oil (see
SPECIFICATIONS). DO NOT FILL ABOVE THE DIPSTICK
“FULL” MARK. Crankcase oil capacity is 4.0 U.S. quarts (3.8
liters).
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 0.76 mm (0.030 inch) by carefully bending the ground
electrode (Figure 10.4).
Figure 10.4 – Setting the Spark Plug Gap
SET PLUG GAP AT 0.76 mm
(0.030 inch)
refilling the crankcase with oil, always
nAfter
check oil level on dipstick. NEVER OPERATE
ENGINE WITH OIL BELOW THE DIPSTICK
7.
“ADD” MARK.
Start engine and check for oil leaks.
COOLANT CHANGE
CHANGING THE ENGINE AIR CLEANER
Every year, have a service facility drain, flush and refill the cooling
system. See “Specifications” for cooling system recommendations.
To replace the engine air cleaner, simply remove the air cleaner
cover and replace the air filter making sure it is positioned properly
before reattaching the cover (Figure 10.3).
See the “Service Schedule,” for air cleaner maintenance.
Maint011 Rev. G 07/10
10-3
Maintenance
MISCELLANEOUS MAINTENANCE
gas. This gas can form an explosive mixture
Storage batteries give off explosive hydrogen
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.
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.
Periodically clean generator exterior surfaces. A soft brush may be
used to loosen caked on dirt. Use a vacuum system or dry, low
pressure air to remove any accumulations of dirt. The generator is
housed inside an all-weather enclosure, clean the enclosure with a
soft, damp cloth or sponge and water.
Once each year have the generator cleaned and inspected by a
Service Dealer. That dealer will use dry, low pressure air to clean
internal windings. Parts inside the control console should be
cleaned and inspected at this time as well.
electrolyte fluid is an extremely cornBattery
rosive sulfuric acid solution that can cause
severe burns. Do not permit fluid to contact
eyes, skin, clothing, painted surfaces, etc.
Wear protective goggles, protective clothing
and gloves when handling a battery. If fluid
is spilled, flush the affected area immediately with clear water.
Finally, have the insulation resistance of stator and rotor windings
checked. If insulation resistances are excessively low, the generator may require drying.
BATTERY
not use any jumper cables or booster
nDo
battery to crank and start the generator
engine. If the battery has completely dis-
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:
charged, remove it from the generator for
recharging.
• 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.
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 REPLACEMENT
NOTE:
BATTERY MAINTENANCE
Unit DOES NOT include battery.
The battery should be inspected per the Scheduled Maintenance
section. The following procedure should be followed for inspection:
When supplying or replacing the battery, the recommended number and type of battery is listed in the Specifications Section.
1.
2.
3.
NOTE:
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.
The BCI number should be located directly on the battery.
REPAIR PARTS
The latter portion of this manual consists of exploded views,
parts lists and electrical data pertaining to this generator set. The
parts lists consist of (a) an item number, (b) a part number, (c)
the quantity required, and (d) a description of the part. The item
number corresponds to an identical number on the exploded view
drawing.
10-4
Maint011 Rev. G 07/10
Service Schedule
SERVICE SCHEDULE
The following is a recommended maintenance schedule for Stationary Emergency Generator sets. 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 or accumulated run 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.
Performed monthly this requires approximately .5 man-hours per unit to complete.
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 5 amp and 15 amp control panel fuses.
• Turn off the battery charger (turn OFF utility supply to ATS).
• 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 break-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 30 run time hours of operation after purchase of the unit and requires approximately 2.5 man-hours per unit to complete.
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 this requires approximately 1.5 man-hours per unit to complete.
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 this requires approximately 4.0 man-hours per unit to complete.
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.
SrvSchd002 Rev. F 06/10
11-1
Service Schedule
Maintenance
Tasks
1. Disable the unit from
operating per the first page
warning.
2. Check the engine oil level.
Adjust as necessary.
3. Check the engine coolant
level. Adjust as necessary.
4. Check the engine coolant
thermal protection level.
Correct as necessary.
5. Check the natural gas
delivery system 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 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.
10. Check the engine
accessory drive belts for
wear, weather cracking,
and damage. Replace as
necessary.
11. Visually inspect the unit
looking for leaks, wear or
damage, loose connections
or components, and
corrosion. Correct as
necessary.
12. Test the engine and
transfer switch safety
devices. Correct and/or
adjust as necessary.
Level 1
Recommended
to be done
monthly
10 Hrs.
Level 2
Task
Comp.
(DateInitials)
Required
to be done
3 months/
Break-in
30 Hrs.
11-2
Level 3
Task
Comp.
(DateInitials)
Required
to be done
Semiannually
50 Hrs.
Level 4
Task
Comp.
(DateInitials)
Required
to be done
Annually
100 Hrs.
Task
Comp.
(DateInitials)
SrvSchd002 Rev. F 06/10
Service Schedule
13. 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.
14. 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.
15. Change the engine oil.
16. Replace the engine oil
filter(s).
17. Replace the engine air
filter(s).
18. Replace the engine fuel
filter(s) on diesel engine
driven units and re-prime
the fuel system.
19. Check the engine spark
plugs on gas engine driven
units. Clean and re-gap or
replace as necessary.
20. Perform a 5 minute no-load
operational run of the unit
looking for any post service
problems.
21. Return the unit to standby
setup for operation when
required.
Level 1
Recommended
to be done
monthly
10 Hrs.
Level 2
Task
Comp.
(DateIn itials)
Required
to be done
3 months/
Break-in
30 Hrs.
11-3
Level 3
Task
Comp.
(DateInitials)
Required
to be done
Semiannually
50 Hrs.
Level 4
Task
Comp.
(DateInitials)
Required
to be done
Annually
100 Hrs.
Task
Comp.
(DateInitials)
SrvSchd002 Rev. F 06/10
Maintenance
Tasks
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 batter 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 Dealer for assistance.
12-1
Trblsht002 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
16
17
18
19
20
21
22
(1) 23
24
25
26
27
28
29
30
(2)31
(2)32
(2)33
(2)34
0G4827
0G2927
0G2827
0G3451
0G0820A
0G4452
020746
049226
051713
022129
0G4825
0G4826
0G2926
0G3682
0G5584
0G3685
0G2826
0G3683
0G6573
0G3686
0G3684
0G3687
0G5909
0G6103
0A5382A
075591
051787
0A5601A
0G8827
0G8827A
0A9375
022152
0G4196
042558
0J6102
0G0965B
053607
051769
023365
0F3353
072578
0G3787
0A8830
077043E
0G2070
0G2070A
045771
0D8427
0J6853A
0J6853B
0J6853C
0C2454
1
1
1
1
1
1
4
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
4
4
4
4
1
1
4
1
1
1
4
6
1
6
4
1
1
1
4
4
1
1
1
6
ASSY RTR 104 KD1 HI EFF (18KW)
RTR-102-20.0AD1 CPL (2006) (20KW)
ASSY RTR 25KW 2P (2006) (25KW)
ASSY RTR 30KW 2P 10"(2006)
HOUSING BLOWER LG PILOT
BLOWER HOUSING SCREEN
SCREW PPHM M5-0.8 X 8 ZINC
WASHER LOCK M5
WASHER FLAT M5
WASHER LOCK M8-5/16
ASSY STR 104-18AD1 HI EFF (18KW)
ASSY STR 104 18GD1 HI EFF (18KW)
STR-102-20.0AD1 CPL (2006) (20KW)
STR-102-20.0GD1 CPL (2006) (20KW)
STR-102-20.0JD1 CPL (2006) (20KW)
STR-102-20.0KD1 CPL (2006) (20KW)
ASSY STR 102 25AD1 (2006) (25KW)
STR-102-25.0GD1 CPL (2006) (25KW)
STR-102-25.0-JD1 CPL (2006) (25KW)
STR-102-25.0KD1 CPL (2006) (25KW)
STR-102-30.0GD2 CPL (30KW)
STR-102-30.0KD2 CPL (30KW)
ASSY STR 102 30AD2 10" (30KW)
STR-102-30.0JD2
BEARING CARRIER REAR LG PILOT
ASSY HOLDER BRUSH
SCREW HHC M4-0.7 X 16 G8.8
COVER REAR BEARING
STUD M8-1.25 475 LONG
STUD M8-1.25 418 LONG
SCREW RHM #10-24 X 2
WASHER LOCK #10
FLYWHEEL & RINGGEAR ASSY 1.6L
KEY SQ 3/8 X 1 STEEL
SCREW HHFC M10-1.5 X 16 C10.9
PLATE FLEX 1.6L R12.7
SCREW HHC M12-1.75 X 35 G8.8
WASHER LOCK M12
WASHER SHAKEPROOF INT #8
SCREW HHC M10-1.0 X 20 G10.9
SPACER ROTOR SHAFT
WASHER .41 ID .94 OD .12 THK
WASHER FLAT .34 ID X .75 OD
FLEX CONDUIT 1" BLACK (NOT SHOWN)
PLATE SPACER 14GA 1.6L (TO BE USED WITH ENGINE PLATE P/N 0G0834.)
PLATE SPACER 16GA 1.6L (TO BE USED WITH ENGINE PLATE P/N 0G0834A.)
NUT HEX M8-1.25 G8 CLEAR ZINC
WASHER LOCK M10 RIBBED ZINC
SUPPORT LH ALT COVER
SUPPORT RH ALT COVER
COVER REAR 10" ALT
SCREW HWHT M6-1 X 16 N WA Z/JS
(1) APPLY LOCTITE 242 BEFORE THREADING SCREW INTO CRANKSHAFT.
(2) ALTERNATE CONFIGURATION REQUIRES ALL NOTED PARTS.
1
A
B
C
D
E
F
G
H
J
K
L
2
A
B
C
D
E
F
G
H
J
K
L
N/A
0D5543
0D5544
0A2077
0G4499
0C2265
0C2264
0E7890
0G4497
052619
023897
049226
051716
0E3257
N/A
1
1
1
1
2
2
1
1
2
4
2
2
7
UL BREAKER BQ2
CB 0090A 2P 240V S BQ2 LL
CB 0100A 2P 240V S BQ2 LL
CB 0125A 2P 240V S BQ2 LL
CB COVER 20-25K 1P (BQ2)
SCREW PHTT M4-0.7 X 12 ZYC
WASHER LOCK #8-M4
BRKT CB MTG BACK
CIRCUIT BREAKER SUPPORT (BQ)
SCREW HHC M5-0.8 X 20 G8.8
WASHER FLAT #10 ZINC
WASHER LOCK M5
NUT HEX M5-0.8 G8 CLEAR ZINC
SCREW HWHTF M6-1.0 X 16
N/A
049135
062812
040532
0G4500
0C2265
0C2264
0E6002
0G4497
052619
023897
049226
051716
0E3257
N/A
1
1
1
1
2
2
1
1
3
6
3
3
7
UL BREAKER BQ3
CB 0070A 3P 240V S BQ3 LL
CB 0080A 3P 240V S BQ3 LL
CB 0100A 3P 240V S BQ3 LL
CB COVER 20-25K 3P (BQ3)
SCREW PHTT M4-0.7 X 12 ZYC
WASHER LOCK #8-M4
BRKT CB MTG BACK
CIRCUIT BREAKER SUPPORT (BQ)
SCREW HHC M5-0.8 X 20 G8.8
WASHER FLAT #10 ZINC
WASHER LOCK M5
NUT HEX M5-0.8 G8 CLEAR ZINC
SCREW HWHTF M6-1.0 X 16
3
A
B
C
D
E
F
G
H
J
K
L
N/A
0D5548
0D5549
0D5551
0D5552
0D5556
0D5557
0D9693
0G4502
066715
038150
022264
022471
0A8278
022097
0D5621
0G4498
0E3257
N/A
1
1
1
1
1
1
1
1
4
4
4
4
3
3
3
1
7
UL BREAKER ED
CB 0030A 3P 480V S ED4 LL
CB 0035A 3P 480V S ED4 LL
CB 0045A 3P 480V S ED4 LL
CB 0050A 3P 480V S ED4 LL
CB 0090A 3P 480V S ED4 LL
CB 0100A 3P 480V S ED4 LL
CB 0125A 3P 480V S ED4 LL
CB COVER 20-30K 3P (ED)
SCREW RHM #8-32 X 4-1/2
WASHER FLAT #8 ZINC
WASHER LOCK #8-M4
NUT HEX #8-32 STEEL
SCREW SHC 1/4-28 X 3/4 G8.8 NZ
WASHER LOCK M6-1/4
WASHER-STEP 1/2ODX9/32ID BRASS
CIRCUIT BREAKER SUPPORT (ED)
SCREW HWHTF M6-1.0 X 16
4
A
B
C
D
E
F
N/A
0E7283
0G3474
074908
0E3257
0E3664
0G4112
N/A
1
1
2
7
1
1
UL BREAKER QN
CB 0150A 2P 240V S QN2 LL
CONBOX FRONT COVER 1.6L QN 2P
SCREW HHTT M5-0.8 X 10 BP
SCREW HWHTF M6-1.0 X 16
BASE, QN CIRCUIT BREAKER
BREAKER SUPPORT BRACKET 30KW
5
6
7
26
27
28
0A1354A
0G3473
0F6366A
0F6366B
0G3524
057701
0F3824
057073
057329
0D4698
0F4464
025433
0G3472
0E3257
0C2212
022264
022241
022237
0C2265
023762
0A9457
0G4577E
0G4578E
047411
022097
049813
1
1
1
1
1
1
1
1
1
1
1
1
1
22
4
9
1
1
5
1
1
REF
REF
1
1
1
REGULATOR - DC ALT
CONBOX TOP PANEL SUPPORT
XFMR 208 TO 16V 6VA (208V. ONLY)
XFMR 240 TO 16V 6VA (240 / 480V.)
COVER BELL HOUSING CONBOX
BLOCK TERM 20A 8 X 6 X 1100V
DECAL UTIL SENSE/CUST CONN
JUNCTION BLOCK 3/8-16
LUG SLDLSS 350-#6X13/32 AL/CU
BLOCK TERM 20A 6 X 3 X 1100V
DECAL CUST CONN 120V UTILITY
LUG SLDLSS #6-14 X 13/64 CU
CONBOX BACK & SIDES 1.6L
SCREW HWHTF M6-1.0 X 16
SCREW PHTT M4-0.7 X 16 ZYC
WASHER LOCK #8-M4
NUT HEX 3/8-16 STEEL
WASHER LOCK 3/8
SCREW PHTT M4-0.7 X 12 ZYC
WASHER SHAKEPROOF EXT #10 STL
DECAL NEUTRAL
ASSY R-200 3600 1.6L
ASSY R-200 1800 1.6L
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
NUT HEX M6 X 1.0 G8 YEL CHR
5
A
*
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
N/A
0G5249
W/CB
0G5735
053640
038150
022264
022471
0F8432A
0G5734
0E3257
049897
022129
022145
058306
045771
0F8451
0F8843
N/A
1
2
1
2
2
2
2
1
1
8
4
4
6
2
2
2
2
UL BREAKER
CB 150A 2 POLE 240V 225AF
TERMINAL COVER CB
CB COVER 30K G 225AF
SCREW RHM #8-32 X 3-1/4
WASHER FLAT #8 ZINC
WASHER LOCK #8-M4
NUT HEX #8-32 STEEL
INSULATOR CB 2P 225AF
CIRCUIT BREAKER SPPRT G 225AF
SCREW HWHTF M6-1.0 X 16
SCREW SHC M8-1.25 X 20 G8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
SCREW SHC M8-1.25 X 25 G12.9
NUT HEX M8-1.25 G8 CLEAR ZINC
LUG SLDLSS 300 MCM-6 AL/CU
BUS BAR 200A LUG ADAPTOR
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
35
36
37
42
43
44
45
46
47
48
0F1823A
0F3078CST03
0F2606
036261
0E7358
052777
0G3958D
0F1262
0F1263
0F1264
0G8023D
067680
0E6875A
055911
0F5459
0F5462
0A5062J
029673
0C1457A
0F1958
082573
0E4494
0G9372
0F6305
0F6305A
0F5886
051713
049226
0F5752F
0F5884
0F5896
0C3990
091526
051716
074076
043182
051714
0F3192
0E7403C
0G4583
0F2627
A
B
C
D
E
F
G
H
J
K
L
056739
022287
022473
022097
022127
0F6145
0G3545
SEE TABLE
052777
043182
051714
COMPONENTS INCLUDED IN 0G4577E
1
ENCL HSB CONTROL PANEL
1
COVER CONTROL PNL W/HOUR METER
1
HINGE CONTINUOUS H-PANEL
7
RIVET POP .125 X .275 SS
4
SCREW PPPH HI-LO #4-24 X 3/8
3
WASHER FLAT M3
1
ASSY PCB R-200A CNTRL 3600
REF
HOLDER FUSE WICKMANN 178.6150
REF
ADPTR RH SIDE WICKMAN 178.6191
REF
ADPTR LH SIDE WICKMAN 178.6192
1
BATC 13.4VDC 2.5A W/8POS PLUG
1
ASSY VOLTAGE REGULATOR 60HZ
2
RELAY 12VD C C FORM W/DIODE
REF
BLOCK TERM 20A 12 X 6 X 1100V
1
DECAL CPL CONTROL PANEL FUSES
1
DECAL CPL 3.9L TB1
4
SPACER 9.5H 3.2 ID
1
DIO BRIDGE 25A 600V
1
HOUR METER 10-80VDC
1
PLATE HARNESS CLAMP
1
SWITCH RKR DPST 125V SPD
1
SWITCH RKR DPDT ON-OFF-ON
1
DECAL CONTROL PNL W/HOUR METER
2
SEAL COVER 3.18 X 12.7 X 382
1
SEAL COVER 3.18 X 12.7 X 283
3
SCREW HHPM M5-0.8 X 12
14
WASHER FLAT M5
14
WASHER LOCK M5
1
RES WW 15R 5% 25W QK CONN
2
SCREW PHTT M3.5-0.6 X 10
2
SCREW PHTT M3.5-0.6 X 16
2
SCREW PHTT M4-0.7 X 10 ZYC
8
SCREW PPHM M5-0.8 X 12 ZNC
7
NUT HEX M5-0.8 G8 CLEAR ZI NC
2
SCREW PHM M3-0.5 X 10 BLA CK
7
WASHER LOCK M3
7
NUT HEX M3-0.5 G8 YEL CHR
1
SUPPORT ANGLE PCB
1
FUSE ATO TYPE 15 AMP (BLUE)
1
HARN CTRL PNL R-200 LOW KW (NOT SHOWN)
1
PLATE COVER H PANEL
COMPONENTS INSTALLED PER THIS DRAWING
1
RELAY SOLENOID 12VDC PNL MNT
2
SCREW HHC 1/4-20 X 3/4 G5
4
WASHER FLAT 1/4-M6 ZINC
2
WASHER LOCK M6-1/4
2
NUT HEX 1/4-20 STEEL
A/R
SEAL WEATHER .45"DIA
1
DANGER HIGH VOLTAGE (SPANISH)
1
CIRCUIT BREAKER
2
WASHER FLAT M3
2
WASHER LOCK M3
2
NUT HEX M3-0.5 G8 YEL CHR
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
23
24
25
26
27
28
29
30
31
32
33
34
35
(1) 36
37
38
39
(2) 40
0G3418
0G3421
0G3419
0E9837B
0G3553
0E3257
0G4080
099502
0G4070
0G4072
0G4071
046627
052250
022473
022097
0C8566
045771
0C2454A
042568
0G3573
0G3574
0G3420
080713
076749
048031C
029032
0G4451
055934N
0F9504
0G0568
0G3433
0E2507
0H1827
0A2628
029333A
042907
027482
022129
039253
0H1851
1
1
1
1
1
2
1
6
1
1
1
1
2
8
8
4
4
28
4
1
1
1
1
1
2
1
REF
2
1
1
1
1
1
1
10
4
4
4
4
1
RADIATOR SUPPORT LH SIDE 1.6L
VENTURI 1.6L
RADIATOR SUPPORT RH SIDE 1.6L
RADIATOR 1.6L CHY
FAN COOL 450MM DIA 7 BLADE
SCREW HWHTF M6-1.0 X 16
HOSE LOWER RADIATOR 1.6L
CLAMP HOSE #24 B1.06-2.00
HOSE REAR COOLANT 1.6L
TUBE ENGINE COOLANT 1.6L
HOSE UPPER RADIATOR 1.6L
CAP RADIATOR
TAPE FOAM 1 X 1 (24” LG)
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
SCREW HHFC M6-1.0 X 20 G8.8
NUT HEX M8-1.25 G8 CLEAR ZINC
SCREW THF M6-1 X 12 N WA Z/JS
SCREW HHC M6-1.0 X 20 G8.8
GUARD FAN LH C1
GUARD FAN RH C1
RADIATOR BLOCK-OFF
BRACKET COOLANT TANK
TANK COOLANT RECOVERY
CLAMP HOSE BAND 1/4
HOSE 9/32 ID (43” LG)
BRACKET STEPPER MOTOR COOLANT
CLAMP VINYL 1.31 X .281 Z
GROMMET 5/8"X 1 1/8"X 5/16"
ASSY FAN BEARING SUPPORT
BRACKET FAN ALT ADAPTER 1.6L
PROBE COOLANT LEVEL 3/8NPTF
PROBE COOLANT LEVEL 3/8-18NPTF (USE WITH I/N 40, P/N 0H1851)
PULLEY - FAN 95 DIA
TIE WRAP UL 7.4" X .19" BLK (NOT SHOWN)
SCREW HHC M8-1.25 X 16 G8.8
WASHER SHAKEPROOF EXT 5/16 STL
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 20 G8.8
ASSY PCB LCL SENSOR (USE WITH I/N 33, P/N 0H1827 ONLY)
(1) APPLY LOCTITE 242 TO I/N 36 BEFORE THREADING INTO I/N 31.
(2) USE WITH R-200 CONTROL PANEL ONLY.
EXPLODED VIEW: MOUNTING BASE 1.6L
GROUP C
DRAWING #: 0G3531
APPLICABLE TO:
ITEM
PART#
QTY.
1
2
3
4
5
6
7
8
9
10
11
13
14
15
16
17
18
19
0G3343
027482
070936
070936C
039253
022145
022129
045771
071956
051730
021991
026850
0G3461
055414
047411
022097
022473
025507
1
1
2
2
12
16
16
4
4
4
1
1
2
1
1
1
5
1
REVISION: H-5975-B
DATE: 2/5/10
DESCRIPTION
MOUNTING BASE 1.6L 2007 C1
WASHER SHAKEPROOF EXT 5/16 STL
DAMPENER VIBRATION
VIB. ISO. 70-75 DURO
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
WASHER FLAT M8
SCREW HHC M8-1.25 X 60 G8.8
EARTH STRAP
WASHER SHAKEPROOF EXT 1/4 STL
ALTERNATOR SUPPORT BLOCK OFF
LUG SLDLSS #2-#8 X 17/64 CU
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK EXT 7/16 STL
Page 2 of 2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
0F3408C
0F3411
025507
059980
046526
077483
050331A
050331
038805J
038804M
045771
022131
027482
0F3976
0C2454
022145
1
1
1
1
1
REF
REF
REF
1
1
REF
1
1
1
4
REF
BATTERY TRAY, C1 & C2
STRAP BATTERY RETAINMENT
WASHER SHAKEPROOF EXT 7/16 STL
SCREW HHC M10-1.5 X 25 G10.9
WASHER LOCK M10
BATTERY 12VDC 75-AH 26
BATTERY POST COVER RED +
BATTERY POST COVER BLK CABLE BATTERY BLACK #1 X 30.00
CABLE BATTERY RED #1 X 21.00
NUT HEX M8-1.25 G8 YEL CHR
WASHER FLAT 3/8-M10 ZINC
WASHER SHAKEPROOF EXT 5/16 STL
BOOT CONTACTOR CABLES
SCREW THF M6-1 X 16 N WA Z/JS
WASHER FLAT 5/16-M8 ZINC
NOTE: WHEN INSTALLING BATTERY, TUCK BATTERY’S LIFTING STRAP ALONG
THE LEFT SIDE OF BATTERY ( SIDE OPPOSITE RADIATOR) BEFORE
CONNECTING THE BATTERY CABLES.
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
46
47
48
49
50
51
52
53
54
55
56
57
58
59
61
62
63
0H1734
0G0834
0G0834A
0G0820
0G7461
0G0839
0G0781
0G0722
0G4059
0G4604
0G3424
0G4863
0G0786
0G4605
0F9617A
0A1354B
0G0823
0G4949
0G3900
0D2244M
036710
0C5479
059980
046526
022131
0G3922
0G0464
0G0465
052858
051735
0G3920
0A7387
039414
022129
022145
029333A
057821
045771
022507
022097
022473
090388
0A5768
0A6751
035579
0A8584
0C1852
069860C
069811
0G38580ST03
025065
027738A
0E3257
0A8830
0G4582
0G4581
0G02070100
077043H
0G38620ST03
055596
0C7649
0H2250
0G3433
049541
0G7311
REF
1
1
REF
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
13
22
18
9
1
1
14
1
4
4
1
4
3
1
3
3
2
2
5
3
5
1
1
1
1
1
1
1
1
1
3
29
1
1
1
1
1
1
3
1
REF
1
REF
ENGINE GENERAC 1.6L G11 CERT
ENGINE PLATE 1.6L (TO BE USED WITH PLATE SPACER P/N 0G2070.)
ENGINE PLATE 1.6L 6MM (TO BE USED WITH PLATE SPACER P/N 0G2070A.)
HOUSING BLOWER MACHINED 1.6L
STARTER MOTOR 12V
ENGINE MOUNTING FOOT STAMPING
EXHAUST MANIFOLD 1.6L MACHINED
INTAKE MANIFOLD MACHINED 1.6L
SHIELD 1.6L EXHAUST HEAT
DC ALTERNATOR ADAPTER MACHINED
PULLEY CRANKSHAFT MACHINED (3600RPM)
PULLEY CRANKSHAFT CASTING (1800RPM)
WASHER PULLEY
BRACKET TENSIONER DC ALT
SPACER ALTERNATOR
DC ALTERNATR HAN-KOK
V-BELT 3/8 X 30.6 (3600RPM)
V-BELT 3/8 X 31.6 (1800RPM)
CAP, 1.5" HOLE SHALLOW
ASSY MAGPICKUP (3/8-24 MALE)
PIN SPRING 1/4 X 3/4
SCREW HHC M12-1.5 X 40 G10.9
SCREW HHC M10-1.5 X 25 G10.9
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
NUT HEX M10-1.5 CLASS 10 ZINC
GASKET INTAKE MANIFOLD 1.6L
GASKET EXHAUST MANIFOLD 1.6L
NUT TOP LOCK FL M8-1.25
SCREW HHC M10-1.5 X 70 G8.8
SCREW HHC M10-1.5 X 110 G10.9
SCREW HHC M10-1.5 X 40 G10.9
SCREW HHC M8-1.25 X 35 G8.8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
TIE WRAP UL 7.4" X .19" BLK
SCREW HHC M8-1.25 X 40 G8.8
NUT HEX M8-1.25 G8 CLEAR ZINC
SCREW HHC 1/4-20 X 1/2 G5
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
SCREW HHTT M6-1.0 X 12 ZINC
WASHER FLAT M10 HEAVY DUTY
SWITCH HI-TEMP 245 D X 3/8 NPT
BSHG RDCR HEX 1/4 TO 1/8
SWITCH OIL PRESSURE 10PSI 2POL
ADAPTER DRAIN OIL
HOSE OIL DRAIN ASSY 21"
CAP HEX 1/4 NPT BRASS
STRUT LH 1.6L ENG ADAPT PLATE
NIPPLE PIPE 3/8 NPT X 1-1/2
PIPE TEE 3/8 NPT
SCREW HWHTF M6-1.0 X 16
WASHER FLAT .34 ID X .75 OD
HARN ENG 1.6L R200 3600RPM G11 (NOT SHOWN) (3600RPM)
HARN ENG 1.6L R200 1800RPM G11 (NOT SHOWN) (1800RPM)
OIL FILTER 1.6L
CONDUIT FLEX .25"ID (6” LG)
STRUT RH 1.6L ENG ADAPT PLATE
BARBED STR 3/8 NPT X 3/8
CLAMP HOSE .38-.87
HOSE COOLANT 3/8 ID 20R3 (11” LG)
BRACKET FAN ALT ADAPTER 1.6L
SCREW HHC M10-1.5 X 35 G8.8
DECAL EMISSION CTRL INFO 1.6L
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
098290
098941A
098958A
098942A
098225
043146
022097
084543A
098783
037398
0E1326
0G4451
064526
029333A
022507
0E1694
1
1
REF
1
2
3
5
1
1
2
1
1
1
10
2
1
ASM MOTOR STEPPER
HOUSING GOVERNOR CONNECTOR
CONNECTOR INTERFACE ASSEMBLY
COVER CONNECTOR HOUSING
SCREW FHM #2 X 5/8 SELF TAP
SCREW HHC M6-1.0 X 10 G8.8
WASHER LOCK M6-1/4
SCREW PHM M3-0.5 X 12MM
LEVER STEPPER MOTOR
NUT LOCK HEX #10-32 NYL INS
ASSY. CARBURETOR LINKAGE ROD
BRACKET STEPPER MOTOR COOLANT
SCREW TAP HWH #6-25 X 3/8 ZINC
TIE WRAP 7.4"X.19" BLK UL
SCREW HHC 1/4-20 X 1/2 G5
SPRING ANTI LASH
EXPLODED VIEW: FUEL SYSTEM NG/LPV
GROUP E
DRAWING #: 0G4970
APPLICABLE TO:
ITEM
PART#
QTY.
1
2
3
026812
075580
0G1397A
0G1397B
039253
022145
022129
045771
0F1570
0A6344
047290
025424
047290
0A5547
0G3178
0D1509
0E0591
059402
037561
0E1028F
0E1028E
059401
091526
049226
026915
062522
022127
0E1339
050279
050280
030795
0F6155
0E1104
0E0668
0E0590A
0E0590
0C5133
0E0665
0E1108
033138
022152
0E0645
034339
059194
057823
026073A
048031L
048031J
0G1985
0F3994
0E0568
0E0527
025105
0E0991
048031P
022097
2
1
1
1
2
2
4
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
4
4
1
1
1
1
1
1
1
1
4
5
6
7
(1) 8
9
10
11
12
13
14
15
(1) 16
17
18
19
20
(1) 21
(1) 22
23
24
25
(1) 26
(3) 27
28
29
(1) 30
(1) 31
(1) 32
(1) 33
(1) 34
(1) 35
(1) 36
(1) 37
(1) 38
(1) 39
40
41
42
43
44
46
47
(1) 49
(1) 50
(1)(2) 51
(1) 52
53
54
DESCRIPTION
ELBOW 90D 3/4 NPT
FLANGE FUEL INLET
FUEL REG. REWORK 1.6L 3600 '07 (3600RPM)
FUEL REG. REWORK 1.6L 1800 '07 (1800RPM)
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
BODY CARBURETOR ASSEMBLY
BARBED EL 90 1/8 NPT X 3/8
HOSE 3/8 ID SINGLE BRAID (16” LG)
NIPPLE PIPE 3/4 NPT X 6
HOSE 3/8 ID SINGLE BRAID (12” LG)
COVER AIR CLEANER
HOSE BREATHER 1.6L
DECAL INLET PRESSUR
ADAPTER CARB. TO AIR CLNR
FILTER ELEMENT
NUT WING 1/4-20 NYLK
ASSY CARBURETOR 1.6L 3600RPM
ASSY CARBURETOR 1.6L 1800RPM
CARBURETOR GASKET
SCREW PPHM M5-0.8 X 12 ZNC
WASHER LOCK M5
NIPPLE CLOSE 3/4 X 1.375
STUD TH 1/4-20 X 3 G2 ZNC FULL
NUT HEX 1/4-20 STEEL
PIN SPRING 3/16 X 5/8
DECAL FUEL INLET NG
DECAL FUEL INLET LPG
SCREW HHC 5/16-18 X 1 G5
HARNESS FUEL JUMPER SINGLE REG
GASKET AIR CLEANER ADAPTER
O-RING 2-028 1.38 X 1.50 X .06
VENTURI 20MM (3600RPM)
VENTURI 18MM (1800RPM)
O-RING 29.82 X 2.62
SCREW THROTTLE PIN STOP
THROTTLE ARM REWORK
SCREW HHM #10-32 X 5/8
WASHER LOCK #10
LEVER THROTTLE STOP
BARBED EL 90 3/8 NPT X 5/8
HOSE 5/8 ID LPG & NG (12” LG)
CLAMP HOSE #10 .56 - 1.06
PLUG STD PIPE 1/4 STEEL SQ HD
CLAMP HOSE BAND 1.0"
CLAMP HOSE BAND .63
HOSE BARB REDUCR TEE 3/4"-3/8"
PCV VALVE 2.5L FORD
SHAFT THROTTLE 1.5L
THROTTLE VALVE PLATE 27MM
SCREW RHMS 6-32 X 1/4 ZINC
SEAL SHAFT COVER
CLAMP HOSE BAND .88"
WASHER LOCK M6-1/4
(1) INCLUDED IN ITEM 19 (CARBURETOR ASSY )
(2) APPLY LOCTITE TO I/N 51 BEFORE THREADING INTO I/N 49.
(3) FOR LP VAPOR APPLICATION SUBSTITUE LPG FUEL INLET DECAL P/N 050280 FOR NG FUEL INLET DECAL P/N 050279 (ITEM 27).
NOTES:
1. REGULATOR (I/N 3) AS SHOWN IN ILLUSTRATION IS SET UP FOR NATURAL GAS APPLICATION.
2. TO CONFIGURE REGULATOR FOR LP VAPOR, REFER TO THE “RECONFIGURING THE FUEL SYSTEM” SECTION OF THIS MANUAL.
REVISION: H-5975-D
DATE: 2/5/10
Page 2 of 2
EXPLODED VIEW: EV ENCLOSURE C1 CPL
GROUP F
DRAWING #: 0G3534
ITEM
PART#
QTY.
(2) 1
(2) 2
(1) 3
(2) 4
6
7
8
9
(1)10
11
12
13
14
15
16
17
(1)19
20
21
23
24
25
(3) 26
27
0G33370AL0R
0J14640AL0R
077992
0J14630AL0R
0F4487A
022127
022097
022473
0C2454
0F5048D
0F5049B
0F8869D
089961
078115
0H7518
0H7518A
0E3257
0912970090
0H7518B
0C8566
0H0412
022097
0H7529
0H1208A
0H1208B
0G33350AL0R
0A1658
1
1
10
2
1
1
1
10
8
2
2
1
1
8
2
1
6
2
1
10
10
8
1
1
1
1
2
(2) 28
(1)29
DESCRIPTION
ROOF 1.6L C1
REAR INTAKE WRAP C1
NUT HEX LOCK M6-1.0 SS NY INS
DOOR LEFT/RIGHT SIDE C1
ASSY ACCESS COVER
NUT HEX 1/4-20 STEEL
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
SCREW THF M6-1 X 16 N WA Z/JS
VISE-ACTION LATCH, SLOTTED CIR
PULL TAB DOOR LOCK SS
KEY VISE-ACTION LATCH,SLOT CIR
FOAM STRIP 3/4"WIDE X 3/16"THK (294”LG)
WASHER SELF LOCKING DOME
INSULATION SIDE DOOR C1
INSULATION ROOF C1
SCREW HWHTF M6-1.0 X 16
ASSY WIRE 14AWG GRN/YEL (32.25”LG)
INSULATION REAR C1
SCREW HHFC M6-1.0 X 20 G8.8
NUT SPRINGCLIP M6-1.0
WASHER LOCK M6-1/4
FOIL ALUMINUM WITH ADHESIVE
RF COVER PLATE-PLASTIC-BISQUE
RF COVER PLATE-PLASTIC-GREY
FRONT DISCHARGE WRAP 1.6L C1
WASHER LOCK SPECIAL 1/4"
(1)ENCLOSURE NOTE: ALL PANELS THAT FASTEN TO THE ROOF MUST BE SECURED USING I/N 10 (THREAD FORMING FASTENER) AND I/N 3 (LOCK NUT) AND
TO INCLUDE AT LEAST ONE CONNECTION POINT USING I/N 19 (THREAD FORMING FASTENER) WITH I/N 3 (LOCK NUT) TO EACH PANEL. LOCK NUT IS TO BE
INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSION IN ENCLOSURE PANELS. ALL PANEL TO BASEFRAME
CONNECTIONS TO INCLUDE AT LEAST ONE CONNECTION POINT USING I/N 29 (WASHER SPECIAL).
(2) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
•
MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
•
CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR CORRECT MATERIAL
AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
(3) USED ON 1.5L / 1.6L UNITS ONLY.1
REVISION: J-1720-K
DATE: 3/23/12
Page 2 of 2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
0F7366
0F7647
0F8095
0G3576
0E3257
0F7644
0C6119
036434
036449
022129
022259
038750
0G3575
0F3794A
022097
049813
022473
1
1
1
1
4
2
1
3
3
6
6
1
1
1
1
1
6
MUFFLER C1
MUFFLER SADDLE
PIPE EXHAUST OUTLET
EXHAUST PIPE LOWER 1.6L
SCREW HWHTF M6-1.0 X 16
MUFFLER STRAP
BOLT U 5/16-18 X 2-1/4
BOLT U 5/16-18 X 2.09
SADDLE 2 INCH
WASHER LOCK M8-5/16
NUT HEX 5/16-18 STEEL
SCREW HHC M6-1.0 X 30 G8.8
EXHAUST PIPE UPPER 1.6L SS
EXHAUST BLANKET 500MM LONG
WASHER LOCK M6-1/4
NUT HEX M6 X 1.0 G8 YEL CHR
WASHER FLAT 1/4-M6 ZINC
BackPg001 Rev. A 04/07
EXPLODED VIEW: MOUNTING BASE 1.6L
GROUP C
DRAWING #: 0G3531
APPLICABLE TO:
ITEM
PART#
QTY.
1
2
3
4
5
6
7
8
9
10
11
13
14
15
16
17
18
19
0G3343
027482
070936
070936C
039253
022145
022129
045771
071956
051730
021991
026850
0G3461
055414
042568
022097
022473
025507
1
1
2
2
12
16
16
4
4
4
1
1
2
1
1
1
5
1
REVISION: J-8330-C
DATE: 4/8/14
DESCRIPTION
MOUNTING BASE 1.6L 2007 C1
WASHER SHAKEPROOF EXT 5/16 STL
DAMPENER VIBRATION
VIB. ISO. 70-75 DURO
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
WASHER FLAT M8
SCREW HHC M8-1.25 X 60 G8.8
EARTH STRAP
WASHER SHAKEPROOF EXT 1/4 STL
ALTERNATOR SUPPORT BLOCK OFF
LUG SLDLSS #2-#8 X 17/64 CU
SCREW HHC M6-1.0 X 20 C8.8
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK EXT 7/16 STL
Page 2 of 2
EXPLODED VIEW: EV BATTERY C1 1.6L
GROUP C
DRAWING #: 0G4067
ITEM
PART#
QTY.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
0F3408C
0F3411
025507
059980
046526
077483
050331A
050331
038805J
038804M
045771
022131
027482
0F3976
0C2454
022145
055934H
1
1
2
2
2
REF
REF
REF
1
1
REF
2
1
1
4
REF
1
DESCRIPTION
BATTERY TRAY, C1 & C2
STRAP BATTERY RETAINMENT
WASHER SHAKEPROOF EXT 7/16 STL
SCREW HHC M10-1.5 X 25 G10.9
WASHER LOCK M10
BATTERY 12VDC 75-AH 26
BATTERY POST COVER RED +
BATTERY POST COVER BLK CABLE BATTERY BLACK #1 X 30.00
CABLE BATTERY RED #1 X 21.00
NUT HEX M8-1.25 G8 YEL CHR
WASHER FLAT 3/8-M10 ZINC
WASHER SHAKEPROOF EXT 5/16 STL
BOOT CONTACTOR CABLES
SCREW THF M6-1 X 16 N WA Z/JS
WASHER FLAT 5/16-M8 ZINC
CLAMP STL/VNL .62 X .406 Z
NOTE: WHEN INSTALLING BATTERY, TUCK BATTERY’S LIFTING STRAP ALONG THE LEFT SIDE OF BATTERY ( SIDE OPPOSITE RADIATOR) BEFORE
CONNECTING THE BATTERY CABLES.
REVISION: K-1287-B
DATE: 11/20/14
Page 2 of 2
EXPLODED VIEW: EV ENCLOSURE C1 CPL
GROUP F
DRAWING #: 0G3534
ITEM
PART#
QTY.
(2) 1
(2) 2
(1) 3
(2) 4
6
7
8
9
(1)10
11
12
13
14
15
16
17
(1)19
20
21
23
24
25
(3) 26
27
0G33370AL0R
0J14640AL0R
077992
0J14630AL0R
0F4487A
022127
022097
022473
0C2454
0F5048D
0F5049B
0F8869D
089961
078115
0H7518
0H7518A
0E3257
0912970090
0H7518B
0C8566
0H0412
022097
0H7529
0H1208A
0H1208B
0G33350AL0R
0A1658
1
1
10
2
1
1
1
10
8
2
2
1
1
8
2
1
6
2
1
10
10
8
1
1
1
1
2
(2) 28
(1)29
DESCRIPTION
ROOF 1.6L C1
REAR INTAKE WRAP C1
NUT HEX LOCK M6-1.0 SS NY INS
DOOR LEFT/RIGHT SIDE C1
ASSY ACCESS COVER
NUT HEX 1/4-20 STEEL
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
SCREW THF M6-1 X 16 N WA Z/JS
VISE-ACTION LATCH, SLOTTED CIR
PULL TAB DOOR LOCK SS
KEY VISE-ACTION LATCH,SLOT CIR
FOAM STRIP 3/4"WIDE X 3/16"THK (294”LG)
WASHER SELF LOCKING DOME
INSULATION SIDE DOOR C1
INSULATION ROOF C1
SCREW HWHTF M6-1.0 X 16
ASSY WIRE 14AWG GRN/YEL (32.25”LG)
INSULATION REAR C1
SCREW HHFC M6-1.0 X 20 G8.8
NUT SPRINGCLIP M6-1.0
WASHER LOCK M6-1/4
FOIL ALUMINUM WITH ADHESIVE
RF COVER PLATE-PLASTIC-BISQUE
RF COVER PLATE-PLASTIC-GREY
FRONT DISCHARGE WRAP 1.6L C1
WASHER LOCK SPECIAL 1/4"
(1)ENCLOSURE NOTE: ALL PANELS THAT FASTEN TO THE ROOF MUST BE SECURED USING I/N 10 (THREAD FORMING FASTENER) AND I/N 3 (LOCK NUT) AND
TO INCLUDE AT LEAST ONE CONNECTION POINT USING I/N 19 (THREAD FORMING FASTENER) WITH I/N 3 (LOCK NUT) TO EACH PANEL. LOCK NUT IS TO BE
INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSION IN ENCLOSURE PANELS. ALL PANEL TO BASEFRAME
CONNECTIONS TO INCLUDE AT LEAST ONE CONNECTION POINT USING I/N 29 (WASHER SPECIAL).
(2) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
•
MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
•
CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR CORRECT MATERIAL
AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
(3) USED ON 1.5L / 1.6L UNITS ONLY.1
REVISION: J-1720-K
DATE: 3/23/12
Page 2 of 2
EXPLODED VIEW: FUEL SYSTEM NG/LPV
GROUP E
DRAWING #: 0G4970
APPLICABLE TO:
ITEM
PART#
QTY.
1
2
3
026812
075580
0G1397A
0G1397B
039253
022145
022129
045771
0F1570
0A6344
047290
025424
047290
0A5547
0G3178
0D1509
0E0591
059402
037561
0E1028F
0E1028E
059401
091526
049226
026915
062522
022127
0E1339
050279
050280
030795
0F6155
0E1104
0E0668
0E0590A
0E0590
0C5133
0E0665
0E1108
033138
022152
0E0645
034339
059194
057823
026073A
048031L
048031J
0G1985
0F3994
0E0568
0E0527
025105
0E0991
048031P
022097
2
1
1
1
2
2
4
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
4
4
1
1
1
1
1
1
1
1
4
5
6
7
(1) 8
9
10
11
12
13
14
15
(1) 16
17
18
19
20
(1) 21
(1) 22
23
24
25
(1) 26
(3) 27
28
29
(1) 30
(1) 31
(1) 32
(1) 33
(1) 34
(1) 35
(1) 36
(1) 37
(1) 38
(1) 39
40
41
42
43
44
46
47
(1) 49
(1) 50
(1)(2) 51
(1) 52
53
54
DESCRIPTION
ELBOW 90D 3/4 NPT
FLANGE FUEL INLET
FUEL REG. REWORK 1.6L 3600 '07 (3600RPM)
FUEL REG. REWORK 1.6L 1800 '07 (1800RPM)
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
BODY CARBURETOR ASSEMBLY
BARBED EL 90 1/8 NPT X 3/8
HOSE 3/8 ID SINGLE BRAID (16” LG)
NIPPLE PIPE 3/4 NPT X 6
HOSE 3/8 ID SINGLE BRAID (12” LG)
COVER AIR CLEANER
HOSE BREATHER 1.6L
DECAL INLET PRESSUR
ADAPTER CARB. TO AIR CLNR
FILTER ELEMENT
NUT WING 1/4-20 NYLK
ASSY CARBURETOR 1.6L 3600RPM
ASSY CARBURETOR 1.6L 1800RPM
CARBURETOR GASKET
SCREW PPHM M5-0.8 X 12 ZNC
WASHER LOCK M5
NIPPLE CLOSE 3/4 X 1.375
STUD TH 1/4-20 X 3 G2 ZNC FULL
NUT HEX 1/4-20 STEEL
PIN SPRING 3/16 X 5/8
DECAL FUEL INLET NG
DECAL FUEL INLET LPG
SCREW HHC 5/16-18 X 1 G5
HARNESS FUEL JUMPER SINGLE REG
GASKET AIR CLEANER ADAPTER
O-RING 2-028 1.38 X 1.50 X .06
VENTURI 20MM (3600RPM)
VENTURI 18MM (1800RPM)
O-RING 29.82 X 2.62
SCREW THROTTLE PIN STOP
THROTTLE ARM REWORK
SCREW HHM #10-32 X 5/8
WASHER LOCK #10
LEVER THROTTLE STOP
BARBED EL 90 3/8 NPT X 5/8
HOSE 5/8 ID LPG & NG (12” LG)
CLAMP HOSE #10 .56 - 1.06
PLUG STD PIPE 1/4 STEEL SQ HD
CLAMP HOSE BAND 1.0"
CLAMP HOSE BAND .63
HOSE BARB REDUCR TEE 3/4"-3/8"
PCV VALVE 2.5L FORD
SHAFT THROTTLE 1.5L
THROTTLE VALVE PLATE 27MM
SCREW RHMS 6-32 X 1/4 ZINC
SEAL SHAFT COVER
CLAMP HOSE BAND .88"
WASHER LOCK M6-1/4
(1) INCLUDED IN ITEM 19 (CARBURETOR ASSY )
(2) APPLY LOCTITE TO I/N 51 BEFORE THREADING INTO I/N 49.
(3) FOR LP VAPOR APPLICATION SUBSTITUE LPG FUEL INLET DECAL P/N 050280 FOR NG FUEL INLET DECAL P/N 050279 (ITEM 27).
NOTES:
1. REGULATOR (I/N 3) AS SHOWN IN ILLUSTRATION IS SET UP FOR NATURAL GAS APPLICATION.
2. TO CONFIGURE REGULATOR FOR LP VAPOR, REFER TO THE “RECONFIGURING THE FUEL SYSTEM” SECTION OF THIS MANUAL.
REVISION: H-5975-D
DATE: 2/5/10
Page 2 of 2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
35
36
37
42
43
44
45
46
47
48
0F1823A
0F3078CST06
0F2606
036261
0E7358
052777
0G3958D
0F1262
0F1263
0F1264
0G8023D
067680
0E6875A
055911
0F5459
0F5462
0A5062J
029673
0C1457A
0F1958
082573
0E4494
0G9372
0F6305
0F6305A
0F5886
051713
049226
0F5752F
0F5884
0F5896
0C3990
091526
051716
074076
043182
051714
0F3192
0E7403C
0G4583
0F2627
A
B
C
D
E
F
G
H
J
K
L
056739
022287
022473
022097
022127
0F6145
0G3545
SEE TABLE
052777
043182
051714
COMPONENTS INCLUDED IN 0G4577E
1
ENCL HSB CONTROL PANEL
1
COVER CONTROL PNL W/HOUR METER
1
HINGE CONTINUOUS H-PANEL
7
RIVET POP .125 X .275 SS
4
SCREW PPPH HI-LO #4-24 X 3/8
3
WASHER FLAT M3
1
ASSY PCB R-200A CNTRL 3600
REF
HOLDER FUSE WICKMANN 178.6150
REF
ADPTR RH SIDE WICKMAN 178.6191
REF
ADPTR LH SIDE WICKMAN 178.6192
1
BATC 13.4VDC 2.5A W/8POS PLUG
1
ASSY VOLTAGE REGULATOR 60HZ
2
RELAY 12VDC C FORM W/DIODE
REF
BLOCK TERM 20A 12 X 6 X 1100V
1
DECAL CPL CONTROL PANEL FUSES
1
DECAL CPL 3.9L TB1
4
SPACER 9.5H 3.2 ID
1
DIO BRIDGE 25A 600V
1
HOUR METER 10-80VDC
1
PLATE HARNESS CLAMP
1
SWITCH RKR DPST 125V SPD
1
SWITCH RKR DPDT ON-OFF-ON
1
DECAL CONTROL PNL W/HOUR METER
2
SEAL COVER 3.18 X 12.7 X 382
1
SEAL COVER 3.18 X 12.7 X 283
3
SCREW HHPM M5-0.8 X 12
14
WASHER FLAT M5
14
WASHER LOCK M5
1
RES WW 15R 5% 25W QK CONN
2
SCREW PHTT M3.5-0.6 X 10
2
SCREW PHTT M3.5-0.6 X 16
2
SCREW PHTT M4-0.7 X 10 ZYC
8
SCREW PPHM M5-0.8 X 12 ZNC
7
NUT HEX M5-0.8 G8 CLEAR ZINC
2
SCREW PHM M3-0.5 X 10 BLACK
7
WASHER LOCK M3
7
NUT HEX M3-0.5 G8 YEL CHR
1
SUPPORT ANGLE PCB
1
FUSE ATO TYPE 15 AMP (BLUE)
1
HARN CTRL PNL R-200 LOW KW (NOT SHOWN)
1
PLATE COVER H PANEL
COMPONENTS INSTALLED PER THIS DRAWING
1
RELAY SOLENOID 12VDC PNL MNT
2
SCREW HHC 1/4-20 X 3/4 G5
4
WASHER FLAT 1/4-M6 ZINC
2
WASHER LOCK M6-1/4
2
NUT HEX 1/4-20 STEEL
A/R
SEAL WEATHER .45"DIA
1
DANGER HIGH VOLTAGE (SPANISH)
1
CIRCUIT BREAKER
2
WASHER FLAT M3
2
WASHER LOCK M3
2
NUT HEX M3-0.5 G8 YEL CHR
EXPLODED VIEW: EV ENG COMPRT 1.6L
GROUP D
DRAWING #: 0G3425
APPLICABLE TO:
ITEM
PART#
QTY.
1
2
0H1734
0G0834
0G0834A
0G0820
0G7461
0G0839
0G0781
0G0722
0G4059
0G4604
0G3424
0G4863
0G0786
0G4605
0F9617A
0A1354B
0G0823
0G4949
0G3900
0D2244M
G036710
0C5479
G059980
G046526
G022131
0G3922
0G0464
0G0465
G052858
G051735
0G3920
0A7387
G039414
G022129
G022145
029333A
G057821
G045771
G022507
G022097
G022473
G090388
0A5768
0A6751
035579
0A8584
0C1852
069860C
G069811
0G38580ST03
G025065
027738A
0E3257
0A8830
0G4582
0G4581
0E7080
077043H
0G38620ST03
G055596
0C7649
0H2250
0G3433
G049541
0G7311
REF
1
1
REF
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
13
22
18
9
1
1
14
1
4
4
1
4
3
1
3
3
2
2
5
3
5
1
1
1
1
1
1
1
1
1
3
29
1
1
1
1
1
1
3
1
REF
1
REF
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
46
47
48
49
50
51
52
53
54
55
56
57
58
59
61
62
63
REVISION: CN-0009252-K
DATE: 8/30/17
DESCRIPTION
ENGINE GENERAC 1.6L G11 CERT
ENGINE PLATE 1.6L (TO BE USED WITH PLATE SPACER P/N 0G2070.)
ENGINE PLATE 1.6L 6MM (TO BE USED WITH PLATE SPACER P/N 0G2070A.)
HOUSING BLOWER MACHINED 1.6L
STARTER MOTOR 12V
ENGINE MOUNTING FOOT STAMPING
EXHAUST MANIFOLD 1.6L MACHINED
INTAKE MANIFOLD MACHINED 1.6L
SHIELD 1.6L EXHAUST HEAT
DC ALTERNATOR ADAPTER MACHINED
PULLEY CRANKSHAFT MACHINED (3600RPM)
PULLEY CRANKSHAFT CASTING (1800RPM)
WASHER PULLEY
BRACKET TENSIONER DC ALT
SPACER ALTERNATOR
DC ALTERNATR HAN-KOK
V-BELT 3/8 X 30.6 (3600RPM)
V-BELT 3/8 X 31.6 (1800RPM)
CAP, 1.5" HOLE SHALLOW
ASSY MAGPICKUP (3/8-24 MALE)
PIN SPRING 1/4 X 3/4
SCREW HHC M12-1.5 X 40 G10.9
SCREW HHC M10-1.5 X 25 G10.9
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
NUT HEX M10-1.5 CLASS 10 ZINC
GASKET INTAKE MANIFOLD 1.6L
GASKET EXHAUST MANIFOLD 1.6L
NUT TOP LOCK FL M8-1.25
SCREW HHC M10-1.5 X 70 G8.8
SCREW HHC M10-1.5 X 110 G10.9
SCREW HHC M10-1.5 X 40 G10.9
SCREW HHC M8-1.25 X 35 G8.8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
TIE WRAP UL 7.4" X .19" BLK
SCREW HHC M8-1.25 X 40 G8.8
NUT HEX M8-1.25 G8 CLEAR ZINC
SCREW HHC 1/4-20 X 1/2 G5
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
SCREW HHTT M6-1.0 X 12 ZINC
WASHER FLAT M10 HEAVY DUTY
SWITCH HI-TEMP 245 D X 3/8 NPT
BSHG RDCR HEX 1/4 TO 1/8
SWITCH OIL PRESSURE 10PSI 2POL
ADAPTER DRAIN OIL
HOSE OIL DRAIN ASSY 21"
CAP HEX 1/4 NPT BRASS
STRUT LH 1.6L ENG ADAPT PLATE
NIPPLE PIPE 3/8 NPT X 1-1/2
PIPE TEE 3/8 NPT
SCREW HWHTF M6-1.0 X 16
WASHER FLAT .34 ID X .75 OD
HARN ENG 1.6L R200 3600RPM G11 (NOT SHOWN) (3600RPM)
HARN ENG 1.6L R200 1800RPM G11 (NOT SHOWN) (1800RPM)
OIL FILTER 1.6,2.5,3.0,4.2L G3
CONDUIT FLEX .25"ID (6” LG)
STRUT RH 1.6L ENG ADAPT PLATE
BARBED STR 3/8 NPT X 3/8
CLAMP HOSE .38-.87
HOSE COOLANT 3/8 ID 20R3 (11” LG)
BRACKET FAN ALT ADAPTER 1.6L
SCREW HHC M10-1.5 X 35 G8.8
DECAL EMISSION CTRL INFO 1.6L
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
23
24
25
26
27
28
29
30
31
32
33
34
35
(1) 36
37
38
39
(2) 40
0G3418
0G3421
0G3419
0E9837B
0G3553
0E3257
0G4080
099502
0G4070
0G4072
0G4071
046627
052250
022473
022097
0C8566
045771
0C2454A
042568
0G3573
0G3574
0G3420
080713
076749
048031C
029032
0G4451
055934N
0F9504
0G0568
0G3433
0E2507
0H1827
0A2628
029333A
042907
027482
022129
039253
0H1851
1
1
1
1
1
2
1
6
1
1
1
1
2
8
8
4
4
28
4
1
1
1
1
1
2
1
REF
2
1
1
1
1
1
1
10
4
4
4
4
1
RADIATOR SUPPORT LH SIDE 1.6L
VENTURI 1.6L
RADIATOR SUPPORT RH SIDE 1.6L
RADIATOR 1.6L CHY
FAN COOL 450MM DIA 7 BLADE
SCREW HWHTF M6-1.0 X 16
HOSE LOWER RADIATOR 1.6L
CLAMP HOSE #24 B1.06-2.00
HOSE REAR COOLANT 1.6L
TUBE ENGINE COOLANT 1.6L
HOSE UPPER RADIATOR 1.6L
CAP RADIATOR
TAPE FOAM 1 X 1 (24” LG)
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
SCREW HHFC M6-1.0 X 20 G8.8
NUT HEX M8-1.25 G8 CLEAR ZINC
SCREW THF M6-1 X 12 N WA Z/JS
SCREW HHC M6-1.0 X 20 G8.8
GUARD FAN LH C1
GUARD FAN RH C1
RADIATOR BLOCK-OFF
BRACKET COOLANT TANK
TANK COOLANT RECOVERY
CLAMP HOSE BAND 1/4
HOSE 9/32 ID (43” LG)
BRACKET STEPPER MOTOR COOLANT
CLAMP VINYL 1.31 X .281 Z
GROMMET 5/8"X 1 1/8"X 5/16"
ASSY FAN BEARING SUPPORT
BRACKET FAN ALT ADAPTER 1.6L
PROBE COOLANT LEVEL 3/8NPTF
PROBE COOLANT LEVEL 3/8-18NPTF (USE WITH I/N 40, P/N 0H1851)
PULLEY - FAN 95 DIA
TIE WRAP UL 7.4" X .19" BLK (NOT SHOWN)
SCREW HHC M8-1.25 X 16 G8.8
WASHER SHAKEPROOF EXT 5/16 STL
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 20 G8.8
ASSY PCB LCL SENSOR (USE WITH I/N 33, P/N 0H1827 ONLY)
(1) APPLY LOCTITE 242 TO I/N 36 BEFORE THREADING INTO I/N 31.
(2) USE WITH R-200 CONTROL PANEL ONLY.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
0F7366
0F7647
0F8095
0G3576
0E3257
0F7644
0C6119
036434
036449
022129
022259
038750
0G3575
0F3794A
022097
049813
022473
1
1
1
1
4
2
1
3
3
6
6
1
1
1
1
1
6
MUFFLER C1
MUFFLER SADDLE
PIPE EXHAUST OUTLET
EXHAUST PIPE LOWER 1.6L
SCREW HWHTF M6-1.0 X 16
MUFFLER STRAP
BOLT U 5/16-18 X 2-1/4
BOLT U 5/16-18 X 2.09
SADDLE 2 INCH
WASHER LOCK M8-5/16
NUT HEX 5/16-18 STEEL
SCREW HHC M6-1.0 X 30 G8.8
EXHAUST PIPE UPPER 1.6L SS
EXHAUST BLANKET 500MM LONG
WASHER LOCK M6-1/4
NUT HEX M6 X 1.0 G8 YEL CHR
WASHER FLAT 1/4-M6 ZINC
EXPLODED VIEW: EV ALT COMMON PARTS
GROUP A
DRAWING #: 0G4008
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
(1) 23
24
25
26
27
28
29
30
(2)31
(2)32
(2)33
(2)34
PART#
QTY.
0G4827
0G2927
0G2827
0G3451
0G0820A
0G4452
020746
049226
051713
022129
0G4825
0G4826
0G2926
0G3682
0G5584
0G3685
0G2826
0G3683
0G6573
0G3686
0G3684
0G3687
0G5909
0G6103
0A5382A
075591
051787
0A5601A
0G8827
0G8827A
0A9375
022152
0G4196
042558
0J6102
0G0965B
053607
051769
023365
0F3353
072578
0G3787
0A8830
077043E
0G2070
0G2070A
045771
0D8427
0J6853A
0J6853B
0J6853C
0C2454
1
1
1
1
1
1
4
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
4
4
4
4
1
1
4
1
1
1
4
6
1
6
4
1
1
1
4
4
1
1
1
6
DESCRIPTION
ASSY RTR 104 KD1 HI EFF (18KW)
RTR-102-20.0AD1 CPL (2006) (20KW)
ASSY RTR 25KW 2P (2006) (25KW)
ASSY RTR 30KW 2P 10"(2006)
HOUSING BLOWER LG PILOT
BLOWER HOUSING SCREEN
SCREW PPHM M5-0.8 X 8 ZINC
WASHER LOCK M5
WASHER FLAT M5
WASHER LOCK M8-5/16
ASSY STR 104-18AD1 HI EFF (18KW)
ASSY STR 104 18GD1 HI EFF (18KW)
STR-102-20.0AD1 CPL (2006) (20KW)
STR-102-20.0GD1 CPL (2006) (20KW)
STR-102-20.0JD1 CPL (2006) (20KW)
STR-102-20.0KD1 CPL (2006) (20KW)
ASSY STR 102 25AD1 (2006) (25KW)
STR-102-25.0GD1 CPL (2006) (25KW)
STR-102-25.0-JD1 CPL (2006) (25KW)
STR-102-25.0KD1 CPL (2006) (25KW)
STR-102-30.0GD2 CPL (30KW)
STR-102-30.0KD2 CPL (30KW)
ASSY STR 102 30AD2 10" (30KW)
STR-102-30.0JD2
BEARING CARRIER REAR LG PILOT
ASSY HOLDER BRUSH
SCREW HHC M4-0.7 X 16 G8.8
COVER REAR BEARING
STUD M8-1.25 475 LONG
STUD M8-1.25 418 LONG
SCREW RHM #10-24 X 2
WASHER LOCK #10
FLYWHEEL & RINGGEAR ASSY 1.6L
KEY SQ 3/8 X 1 STEEL
SCREW HHFC M10-1.5 X 16 C8.8
PLATE FLEX 1.6L R12.7
SCREW HHC M12-1.75 X 35 G8.8
WASHER LOCK M12
WASHER SHAKEPROOF INT #8
SCREW HHC M10-1.0 X 20 G10.9
SPACER ROTOR SHAFT
WASHER .41 ID .94 OD .12 THK
WASHER FLAT .34 ID X .75 OD
FLEX CONDUIT 1" BLACK (NOT SHOWN)
PLATE SPACER 14GA 1.6L (TO BE USED WITH ENGINE PLATE P/N 0G0834.)
PLATE SPACER 16GA 1.6L (TO BE USED WITH ENGINE PLATE P/N 0G0834A.)
NUT HEX M8-1.25 G8 CLEAR ZINC
WASHER LOCK M10 RIBBED ZINC
SUPPORT LH ALT COVER
SUPPORT RH ALT COVER
COVER REAR 10" ALT
SCREW HWHT M6-1 X 16 N WA Z/JS
(1) APPLY LOCTITE 242 BEFORE THREADING SCREW INTO CRANKSHAFT.
(2) ALTERNATE CONFIGURATION REQUIRES ALL NOTED PARTS.
REVISION: -ADATE:
Page 2 of 2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
098290
098941A
098958A
098942A
098225
043146
022097
084543A
098783
037398
0E1326
0G4451
064526
029333A
022507
0E1694
1
1
REF
1
2
3
5
1
1
2
1
1
1
10
2
1
ASM MOTOR STEPPER
HOUSING GOVERNOR CONNECTOR
CONNECTOR INTERFACE ASSEMBLY
COVER CONNECTOR HOUSING
SCREW FHM #2 X 5/8 SELF TAP
SCREW HHC M6-1.0 X 10 G8.8
WASHER LOCK M6-1/4
SCREW PHM M3-0.5 X 12MM
LEVER STEPPER MOTOR
NUT LOCK HEX #10-32 NYL INS
ASSY. CARBURETOR LINKAGE ROD
BRACKET STEPPER MOTOR COOLANT
SCREW TAP HWH #6-25 X 3/8 ZINC
TIE WRAP 7.4"X.19" BLK UL
SCREW HHC 1/4-20 X 1/2 G5
SPRING ANTI LASH
1
A
B
C
D
E
F
G
H
J
K
L
2
A
B
C
D
E
F
G
H
J
K
L
N/A
0D5543
0D5544
0A2077
0G4499
0C2265
0C2264
0E7890
0G4497
052619
023897
049226
051716
0E3257
N/A
1
1
1
1
2
2
1
1
2
4
2
2
7
UL BREAKER BQ2
CB 0090A 2P 240V S BQ2 LL
CB 0100A 2P 240V S BQ2 LL
CB 0125A 2P 240V S BQ2 LL
CB COVER 20-25K 1P (BQ2)
SCREW PHTT M4-0.7 X 12 ZYC
WASHER LOCK #8-M4
BRKT CB MTG BACK
CIRCUIT BREAKER SUPPORT (BQ)
SCREW HHC M5-0.8 X 20 G8.8
WASHER FLAT #10 ZINC
WASHER LOCK M5
NUT HEX M5-0.8 G8 CLEAR ZINC
SCREW HWHTF M6-1.0 X 16
N/A
049135
062812
040532
0G4500
0C2265
0C2264
0E6002
0G4497
052619
023897
049226
051716
0E3257
N/A
1
1
1
1
2
2
1
1
3
6
3
3
7
UL BREAKER BQ3
CB 0070A 3P 240V S BQ3 LL
CB 0080A 3P 240V S BQ3 LL
CB 0100A 3P 240V S BQ3 LL
CB COVER 20-25K 3P (BQ3)
SCREW PHTT M4-0.7 X 12 ZYC
WASHER LOCK #8-M4
BRKT CB MTG BACK
CIRCUIT BREAKER SUPPORT (BQ)
SCREW HHC M5-0.8 X 20 G8.8
WASHER FLAT #10 ZINC
WASHER LOCK M5
NUT HEX M5-0.8 G8 CLEAR ZINC
SCREW HWHTF M6-1.0 X 16
3
A
B
C
D
E
F
G
H
J
K
L
N/A
0D5548
0D5549
0D5551
0D5552
0D5556
0D5557
0D9693
0G4502
066715
038150
022264
022471
0A8278
022097
0D5621
0G4498
0E3257
N/A
1
1
1
1
1
1
1
1
4
4
4
4
3
3
3
1
7
UL BREAKER ED
CB 0030A 3P 480V S ED4 LL
CB 0035A 3P 480V S ED4 LL
CB 0045A 3P 480V S ED4 LL
CB 0050A 3P 480V S ED4 LL
CB 0090A 3P 480V S ED4 LL
CB 0100A 3P 480V S ED4 LL
CB 0125A 3P 480V S ED4 LL
CB COVER 20-30K 3P (ED)
SCREW RHM #8-32 X 4-1/2
WASHER FLAT #8 ZINC
WASHER LOCK #8-M4
NUT HEX #8-32 STEEL
SCREW SHC 1/4-28 X 3/4 G8.8 NZ
WASHER LOCK M6-1/4
WASHER-STEP 1/2ODX9/32ID BRASS
CIRCUIT BREAKER SUPPORT (ED)
SCREW HWHTF M6-1.0 X 16
4
A
B
C
D
E
F
N/A
0E7283
0G3474
074908
0E3257
0E3664
0G4112
N/A
1
1
2
7
1
1
UL BREAKER QN
CB 0150A 2P 240V S QN2 LL
CONBOX FRONT COVER 1.6L QN 2P
SCREW HHTT M5-0.8 X 10 BP
SCREW HWHTF M6-1.0 X 16
BASE, QN CIRCUIT BREAKER
BREAKER SUPPORT BRACKET 30KW
5
6
7
26
27
28
0A1354A
0G3473
0F6366A
0F6366B
0G3524
057701
0F3824
057073
057329
0D4698
0F4464
025433
0G3472
0E3257
0C2212
022264
022241
022237
0C2265
023762
0A9457
0G4577E
0G4578E
047411
022097
049813
1
1
1
1
1
1
1
1
1
1
1
1
1
22
4
9
1
1
5
1
1
REF
REF
1
1
1
REGULATOR - DC ALT
CONBOX TOP PANEL SUPPORT
XFMR 208 TO 16V 6VA (208V. ONLY)
XFMR 240 TO 16V 6VA (240 / 480V.)
COVER BELL HOUSING CONBOX
BLOCK TERM 20A 8 X 6 X 1100V
DECAL UTIL SENSE/CUST CONN
JUNCTION BLOCK 3/8-16
LUG SLDLSS 350-#6X13/32 AL/CU
BLOCK TERM 20A 6 X 3 X 1100V
DECAL CUST CONN 120V UTILITY
LUG SLDLSS #6-14 X 13/64 CU
CONBOX BACK & SIDES 1.6L
SCREW HWHTF M6-1.0 X 16
SCREW PHTT M4-0.7 X 16 ZYC
WASHER LOCK #8-M4
NUT HEX 3/8-16 STEEL
WASHER LOCK 3/8
SCREW PHTT M4-0.7 X 12 ZYC
WASHER SHAKEPROOF EXT #10 STL
DECAL NEUTRAL
ASSY R-200 3600 1.6L
ASSY R-200 1800 1.6L
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
NUT HEX M6 X 1.0 G8 YEL CHR
5
A
*
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
N/A
0G5249
W/CB
0G5735
053640
038150
022264
022471
0F8432A
0G5734
0E3257
049897
022129
022145
058306
045771
0F8451
0F8843
N/A
1
2
1
2
2
2
2
1
1
8
4
4
6
2
2
2
2
UL BREAKER
CB 150A 2 POLE 240V 225AF
TERMINAL COVER CB
CB COVER 30K G 225AF
SCREW RHM #8-32 X 3-1/4
WASHER FLAT #8 ZINC
WASHER LOCK #8-M4
NUT HEX #8-32 STEEL
INSULATOR CB 2P 225AF
CIRCUIT BREAKER SPPRT G 225AF
SCREW HWHTF M6-1.0 X 16
SCREW SHC M8-1.25 X 20 G8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
SCREW SHC M8-1.25 X 25 G12.9
NUT HEX M8-1.25 G8 CLEAR ZINC
LUG SLDLSS 300 MCM-6 AL/CU
BUS BAR 200A LUG ADAPTOR
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
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