Generac 80kW QT08054ANAN Standby Generator Owner's Manual

Serial Number

STANDBY GENERATOR

OWNER'S MANUAL

QT

5.4L

80kW

Models

A new standard of reliability

This manual should remain with the unit.

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Standby Generator Sets

Table of Contents

SECTION PAGE

SAFETY RULES ................................................

1-1

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

Read this Manual Thoroughly ...................................1-3

Operation and Maintenance ......................................1-3

How to Obtain Service ..............................................1-3

IDENTIFICATION RECORD .....................................2-1

EQUIPMENT DESCRIPTION ...................................3-1

Equipment Description ................................................3-1

Engine Oil Recommendations ......................................3-1

Coolant Recommendations...........................................3-1

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

Coolant Temperature Sensing ...................................4-1

Low Coolant Level .....................................................4-1

Oil Pressure Sensing .................................................4-1

RPM Sensor Loss Shutdown .....................................4-1

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

Natural Gas Fuel System ..........................................5-1

Propane Vapor Withdrawal Fuel System....................5-1

LP Fuel System .........................................................5-1

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

Engine.......................................................................6-1

Generator Set Lubrication ........................................8-1

Prior to Initial Start-up .............................................8-1

Initial Inspection for QT Genset Start-up .....................8-2

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

Generator Control and Operation ................................9-1

Operating Unit with Automatic Transfer Switch ...........9-1

Operating Unit with Manual Transfer Switch ...............9-1

Engine Start-up and Transfer ...................................9-1

Retransfer and Shutdown .........................................9-1

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

Maintenance Performed by Authorized

Service Facilities .....................................................10-1

Cooling System ..........................................................10-1

Checking Fluid Levels ................................................10-1

Check Engine Oil ....................................................10-1

Maintenance Owner/Operator Can Perform ................10-2

Check Engine Oil Level ...........................................10-2

Inspect Cooling System ...........................................10-2

Check Engine Coolant Level....................................10-2

Perform Visual Inspection .......................................10-2

Inspect Exhaust System ..........................................10-2

Check Fan Belt ........................................................10-2

Inspect Engine Governor ........................................10-2

Changing Engine Oil ...............................................10-2

Changing the Engine Air Cleaner ............................10-3

Miscellaneous Maintenance ........................................10-3

Cleaning the Generator ...........................................10-3

Cold Weather Kit .......................................................6-2

5.4L & 6.8L Ignition Description .................................6-3

Ignition Power-up Input (“56 Line Input”) .................6-3

Ignition Enable (“14 Line Input”) ..............................6-3

Ignition Shutdown on Loss of Crank or CAM Signals .........................................................6-3

Diagnostic Blink Patterns (Red LED Located on the Ignition Control Board ...................................6-3

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

Generator AC Lead Connections ..................................7-1

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

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

Installation ...................................................................8-1

Preparation Before Start-up .........................................8-1

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

30 kW - 150 kW Standby Gas Engine

Driven Generator Sets ............................................11-1

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

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

NOTES

EXPLODED VIEWS & PARTS LISTS

WIRING DIAGRAMS & SCHEMATICS

WARRANTY

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Important Safety Instructions

 SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all

 operators, potential operators, and service and repair technicians for this equipment.





WARNING:

The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

WARNING:





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

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.

DANGER



Despite the safe design of this generator, 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.



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



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

1-1



GENERAL HAZARDS



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

• Installation, operation, servicing and repair of this

(and related) equipment must always comply with applicable codes, standards, laws and regulations.

Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration

(OSHA) has established. Also, ensure that the generator is installed, operated and serviced in accordance with the manufacturer’s instructions and recommendations. Following installation, do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes, standards, laws and regulations.

• 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. Exhaust gases must be piped safely away from any building or enclosure that houses the generator to an area where people, animals, etc., will not be harmed.

This exhaust system must be installed properly, 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 factory-approved parts.

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• 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.



ELECTRICAL HAZARDS



• All 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 standby 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.

• 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 set 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.

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1-2

• 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.



FIRE HAZARDS



• Keep a fire extinguisher near the generator at all times. Do NOT use any carbon tetra-chloride type extinguisher. Its fumes are toxic, and the liquid can deteriorate wiring insulation. Keep the extinguisher properly charged and be familiar with its use. If there are any questions pertaining to fire extinguishers, consult the local fire department.



EXPLOSION HAZARDS



• Properly ventilate any room or building housing the generator to prevent build-up of explosive gas.

• Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or

EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.

• These generator sets 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.



INTRODUCTION

Thank you for purchasing this model of the standby generator set product line.

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

READ THIS MANUAL THOROUGHLY

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

Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING,

CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.

Their definitions are as follows:

DANGER

After this heading, read instructions that, if not strictly complied with, will result in personal injury or property damage.

After this heading, read instructions that, if not strictly complied with, may result in personal injury or property damage.

After this heading, read instructions that, if not strictly complied with, could result in damage to equipment and/or property.

NOTE:

After this heading, read explanatory statements that require special emphasis.

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.

Four commonly used safety symbols accompany the

DANGER, WARNING and CAUTION blocks. The type of information each indicates is as follows:



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



This symbol points out potential explosion hazard.

1-3



This symbol points out potential fire hazard.



This symbol points out potential electrical shock hazard.

The operator is responsible for proper and safe use of the 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.

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 an Authorized

Service Dealer. Normal maintenance service and replacement of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.

Proper maintenance and care of the generator ensure a minimum number of problems and keep operating expenses at a minimum. See an Authorized Service

Dealer for service aids and accessories.

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

HOW TO OBTAIN SERVICE

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

When contacting an Authorized Service Dealer or the factory about parts and service, always supply the complete model number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit.

AUTHORIZED SERVICE DEALER LOCATION

To locate the nearest AUTHORIZED

SERVICE DEALER, please call this number:

1-800-333-1322

or locate us on the web at:

www.generac.com

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General Information

IDENTIFICATION RECORD

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, etc.

GENERATOR SET DATA

MADE IN USA

MODEL

RATED KW

RATED VOLTAGE

POWER FACTOR

ENGINE RPM

HERTZ

SERIAL

RATED KVA

RATED AMPS

PHASE

PRODUCTION DATE

ALT RPM

ALTERNATOR SUBTRANSIENT REACTANCE

ALTERNATOR TRANSIENT REACTANCE

CLASS ROTOR STATOR WINDING INSULATION AT 25

°

C AMBIENT

GENERAC POWER SYSTEMS, INC.

WAUKESHA, WI

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.

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.

Identification Code

Use this code to obtain important information about the generator. For example, if the code is:

M Q T 1 0 0 5 4 A N S N A

M — Designates generators capable of paralleling.

NOTE: Only 100kW and 150kW, 6.8L units are currently available for this configuration.

QT — Quiet Test Generator Series

100 — kw Rating

5.4

— Engine Size in Liters

A — Voltage Code: A = 120/240, Single-phase;

G = 120/208, Three-phase; K = 277/480,

Three-phase; J = 120/240, Three-phase;

L = 346/600, Three-phase

N — Fuel: N = Natural Gas; V = Vapor Propane

S — Enclosure Material: A = Aluminum; S

= Steel (Corrosion Resistant Aluminum

Enclosure Material, Steel is Standard)

N — Emission Equipment: N = No Equipment;

Y = Catalytic Converter and Air/Fuel Ratio

Controller

A — Industrial Dealer Product

Voltage Codes

The identification code letter following the unit’s engine size is the generator’s “voltage code.”

Groups and Assembly Numbers

The manual drawing listing lists the groups and corresponding assembly numbers for each unit. The assembly numbers refer to exploded view drawing numbers that are applicable to the specific generator model. These drawings are located in the back half of this manual.

2-1

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Equipment Description

EQUIPMENT DESCRIPTION

This equipment is a revolving field, alternating current generator set. It is powered by a gaseous fueled engine operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for 2-pole direct drive units and

2300 - 3000 rpm for quiet drive gear units. See the

Specifications section for exact numbers. The unit comes complete with a sound attenuated enclosure, internally mounted muffler, control console, mainline circuit breaker, battery charger, and protective alarms as explained in the following paragraph.

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

The generator incorporates the following generator features:

• Rotor and Stator insulation is Class H rated as defined by NEMA MG1-32.6, NEMA MG1-1.66.

The generator is self ventilated and drip-proof constructed.

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

ENGINE OIL RECOMMENDATIONS

The unit has been filled with 15W-40 engine oil at the factory. Use a high-quality detergent oil classified “For Service SJ or SH.” Detergent oils keep the engine cleaner and reduce carbon deposits. Use oil having the following SAE viscosity rating, based on the ambient temperature range anticipated before the next oil change:

Temperature (Recommended)

Above 80° F (27° C)

32° to 80° F (0° to 27° C)

Below 32° F (0° C)

SAE 30W or 15W-40

SAE 20W-20 or 15W-40

See Note

COOLANT RECOMMENDATIONS

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



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

DANGER



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



Ethylene glycol base antifreeze is poisonous.

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



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

NOTE:

For temperatures below 32° F, it is strongly recommended to use the optional Cold Weather Start Kit

(part number listed in the Specification Section).

The oil grade for temperatures below 32° F is 5W-

30 synthetic oil.

A 08/06 Equip001 Rev.

3-1


Engine Protective Devices

ENGINE PROTECTIVE DEVICES

The standby generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant temperature, oil pressure or rpm. For that reason, the engine has several devices designed to protect it against potentially damaging conditions by automatically shutting down the unit when the oil pressure is too low, the coolant temperature is too high, the coolant level is too low, or the engine is running too fast.

NOTE:

Engine protective switches and sensors are mentioned here for the reader's convenience. Also refer to the applicable control panel manual for additional automatic engine shutdown information.

COOLANT TEMPERATURE SENSING

An analog Water Temperature Sender (WTS) is located in the engine's cooling system. This sender is connected to the panel and allows the panel to monitor and display the temperature of the coolant system.

The WTS is a resistive device whose resistance changes based on coolant temperature. The resistance of the sender results in a voltage being developed across the sender. As the Coolant temperature increases, the resistance will decrease, causing the voltage to decrease. This changing voltage is converted to 4-

20mA signal by a signal conditioner module. The corresponding 4-20mA signal is read by the control panel and displayed as the coolant temperature.

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

If the temperature exceeds approximately 140° C

(284° F), the engine shutdown will be initiated. The generator will automatically restart and the display will reset once the temperature has returned to an operating level.

LOW COOLANT LEVEL

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

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

The resistance of the LCL results in a voltage being developed across the LCL. This voltage changes as the resistance changes. This changing voltage is converted to 4-20mA signal by a signal conditioner module. The corresponding 4-20mA signal is read by the control panel and displayed as the low coolant level.

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

4-1

OIL PRESSURE SENSING

An analog Oil Pressure Sender (OPS) is used for monitoring the engine oil pressure. This sender allows the control panel to measure and display the

Engine oil pressure.

The OPS is a resistive device, whose resistance changes based on engine oil pressure. The resistance of the sender results in a voltage being developed across the sender. As the oil pressure increases, the resistance will decrease, causing the voltage to decrease. This changing voltage is converted to 4-

20mA signal by a signal conditioner module. The corresponding 4-20mA signal is read by the control panel and displayed as the oil pressure.

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

Should the oil pressure drop below the 8 psi range, the engine shutdown is initiated. The unit should not be restarted until oil is added. Turn the AUTO/OFF/

MANUAL switch to the OFF position, then back to

AUTO to restart.

OVERCRANK SHUTDOWN

When the control panel receives a start signal, it initiates the programmed starting sequence. The start sequence consists of the number of crank attempts, the length of each crank attempt, and the rest time between each crank attempt. If the engine has not started by the end of the final crank attempt, an

Overcrank alarm is generated, the control panel will sound the alarm and display the message "Failed to start".

OVERSPEED SHUTDOWN

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

Dealer if this failure occurs.

RPM SENSOR LOSS SHUTDOWN

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

DC FUSE

This fuse is located inside of the control panel. It protects the panel wiring and components from damaging overload. Always remove this fuse before commencing work on the generator. The unit will not start or crank if the fuse is blown. Replace the fuse with one of the same size, type, and rating. (See the exploded views and parts lists at the end of this manual for replacement part number.)

B 10/05 EngProt002 Rev.


Fuel Systems

FUEL SYSTEM

FUEL REQUIREMENTS

The standby generator may be equipped with one of the following fuel systems:

• Natural gas fuel system

• Propane vapor (PV) fuel system

• Liquid propane (LP) fuel system

The Manual Drawing Listing that is affixed to the unit includes the “Identification Code,” which may be used to identify the type of fuel system installed on the unit.

Recommended fuels should have a Btu content of at least 1,000 Btu's per cubic foot for natural gas; or at least 2,520 Btu's per cubic foot for LP gas. Ask the fuel supplier for the Btu content of the fuel.

Required fuel pressure for natural gas is 11 inches to 14 inches water column (0.4 to 0.5 psi); and for liquid propane, 11 inches to 14 inches of water column (0.4 to 0.5 psi).

NOTE:

Any piping used to connect the generator to the fuel supply should be of adequate size to ensure the fuel pressure NEVER drops below 11 inches water column for natural gas or 11 inches water column for liquid propane for all load ranges.

NOTE:

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

NATURAL GAS FUEL SYSTEM

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

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

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

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

• Gas pressure at the inlet to the fuel shutoff solenoid should not exceed approximately 14 inches water column (0.5 psi). Optimum pressure at the fuel shutoff solenoid is 11 inches water column

(0.4 psi).

5-1

PROPANE VAPOR WITHDRAWAL FUEL SYSTEM

This type of system utilizes the vapors formed above the liquid fuel in the supply tank. Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor state. The vapor withdrawal system is generally best suited for smaller engines that require less fuel. The installer should be aware of the following:

• The natural gas and LP gas systems are similar.

However, the natural gas system delivers gas at a pressure of approximately five inches water column to the carburetor.

• When ambient temperatures are low and engine fuel 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.

LP FUEL SYSTEM

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

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

A 05/06 FuelSys002 Rev.


Specifications

SPECIFICATIONS

GENERATOR

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

Rotor Insulation ................................................................... Class H

Stator Insulation .................................................................. Class H

Total Harmonic Distortion ......................................................< 3.5%

Telephone Interference Factor (TIF) ..........................................< 50

Alternator Output Leads 3-phase ........................................... 4-wire

Bearings .........................................................................Sealed Ball

Coupling ..........................................................................Gear Drive

Load Capacity (Standby Rating) ............................................80kW*

*

NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349,

ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural gas.

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

Generator Output Voltage/kW - 60 Hz kW Amp CB Size

120/240V, 1-phase, 1.0 pf 80 333 350

120/208V, 3-phase, 0.8 pf

277/480V, 3-phase, 0.8 pf

80 278 300

80 120 150

Generator Locked Rotor KVA Available @ Voltage Dip of 35%

Single-phase or 208 3-phase ...........................................160 Amp

480V, 3-phase ..................................................................185 Amp

ENGINE

Make ................................................................................... Generac

Model ...................................................................................... V-type

Cylinders and Arrangement ............................................................ 8

Displacement ....................................................................... 5.4 Liter

Bore ...................................................................................... 3.55 in.

Stroke ................................................................................... 4.17 in.

Compression Ratio ..................................................................9-to-1

Air Intake System ...............................................Naturally Aspirated

Valve Seats ....................................................................... Hardened

Lifter Type .......................................................................... Hydraulic

Engine Parameters

Rated Synchronous RPM ..............................................60 Hz, 2650

HP at rated kW ................................................................60 Hz, 138

Exhaust System

Exhaust Flow at Rated Output 60 Hz .................................. 649 cfm

Exhaust Temperature at Rated Output .................................. 800° F

Combustion Air Requirements (Natural Gas)

Flow at rated power, 60 Hz ................................................. 240 cfm

Governor

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

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

Steady State Regulation ........................................................± 1/2%

Adjustments:

Speed ............................................................................ Selectable

Engine Lubrication System

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

Oil Filter .............................................................Full Flow, Cartridge

Crankcase Oil Capacity ....................................................5 U.S. qts.

COOLING SYSTEM

Type ....................................................................................... Closed

Water Pump .................................................................... Belt Driven

Fan Speed ................................................................................ 1600

Fan Diameter .....................................................................26 inches

Fan Mode ................................................................................ Puller

Air Flow (inlet air including alternator and

combustion air) .......................................................... 5300 ft3/min.

Coolant Capacity ........................................................ (4.0 U.S. gal.)

Heat Rejection to Coolant ..........................................301,000 Btu/h

Maximum Operating Air Temp. on Radiator ..............60° C (150° F)

Maximum Ambient Temperature ................................50° C (140° F)

FUEL SYSTEM

Type of Fuel .........................................Natural Gas/Propane Vapor*

Carburetor ...................................................................... Down Draft

Secondary Fuel Regulator .................................................Standard

Fuel Shut-off Solenoid ........................................................Standard

Operating Fuel Pressure .................... 11 in. - 14 in. Water Column

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

Exercise 25% 50% 75% 100%

Cycle Load Load Load Load

125/50.4 297/119 571/230 795/320 1100/442

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

ELECTRICAL SYSTEM

Battery Charge Alternator ............................................12V, 30 Amp

Static Battery Charger ....................................................12V, 2 Amp

Recommended Battery ................................................ 24F 525CCA

System Voltage .....................................................................12 Volts

Voltage Regulator

Type ................................................................................. Full Digital

Sensing ................................................................................ 3-phase

Regulation .............................................................................± 1/4%

Features ............................................ Built into H-100 Control Panel

V/F Adjustable, Adjustable

Voltage and Gain

Power Adjustment for Ambient Conditions

Temperature Deration

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

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

Altitude Deration

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

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

6-1

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

C 11/05 GenSpec006 Rev.


Specifications

Figure 1 — Interconnections

C 11/05

COLD WEATHER KIT

For cold climates, optional cold weather kit (part number 0F6148A) is recommended. The kit includes:

• Battery Warmer

• 4” Junction Box with hardware

• 700 Cold Cranking Amp Battery

• 6 qt. pack 5W-60 synthetic oil (engine)

• 1 qt. 75W90 synthetic gear oil (gear drive)

GenSpec006 Rev.

6-2


Specifications

5.4L & 6.8L IGNITION DESCRIPTION

This single-fire Ignition is intended to operate with a 10-cylinder, 6.8L engine and an 8-cylinder, 5.4L engine.

The 6.8L engine uses a 40-1 crank sensor, a magpickup CAM sensor and individual coil-on-plug coils for each spark-plug.

The 5.4L engine uses a 36-1 crank sensor, a magpick-up CAM sensor and individual coil-on-plug coils for each spark-plug.

With a single-fire ignition, each high-voltage coil output is connected to one spark plug resulting in that spark plug being fired only during the compression cycle.

Engine Timing versus Engine Speed for the 6.8L engine is:

RPM

1800 rpm

NG/LP Engine Timing (BTDC)

22 degrees

3600 rpm 24 degrees

Engine Timing versus Engine Speed for the 5.4L engine is:

RPM

1800 rpm

3600 rpm

NG/LP Engine Timing (BTDC)

26 degrees

26 degrees

IGNITION POWER-UP INPUT ("56 LINE

INPUT")

When battery voltage is applied to this input the ignition will power-up. For the ignition to power itself down, battery voltage must be removed from this input.

IGNITION ENABLE ("14 LINE INPUT")

This input must be connected to the +12V battery for the ignition to turn-on the coils. If this input is connected to battery ground the ignition will stop firing the coils and will power down within approximately

2 seconds. In the event that an ignition fault has occurred, however, the ignition will wait 60 seconds before powering down. This allows time to view the diagnostic LED located on the ignition board.

NOTE:

The ignition cover does not need to be removed to see the LED.

IGNITION SHUTDOWN ON LOSS OF CRANK

OR CAM SIGNALS

The ignition will stop firing the coils immediately following the loss of the crank signal. The ignition will stop firing the coils after approx. 3 seconds following the loss of the cam signal.

DIAGNOSTIC BLINK PATTERNS (RED LED

LOCATED ON THE IGNITION CONTROL

BOARD)

During normal ignition operation the RED LED flashes at a 0.5 sec ON and a 0.5 sec OFF rate. This is considered one (1) blink.

LED Fault Code with Priority as shown:

1. No Crank Signal: LED blinks 2 times, is OFF for

3.0 seconds and then repeats

2. No CAM Signal: LED blinks 3 times, is OFF for

3.0 seconds and then repeats

Only one fault is displayed at a time. If multiple faults exist then the highest priority fault must be resolved prior to a lower priority fault being displayed. In the event that an ignition fault has occurred the ignition will wait 60 seconds before powering down.

NOTE:

The ignition cover does not need to be removed to see the LED.

C 11/05 GenSpec006 Rev.

6-3


General Information

GENERATOR AC LEAD CONNECTIONS

See “Voltage Codes”. This generator may be rated at any one of three voltages, either single-phase or three-phase. 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.

Voltage codes apply to the type of stator assembly installed on a particular generator.

FOUR-LEAD, SINGLE-PHASE STATOR

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.

Figure 7.1 — Four-lead, Single-phase Stator

ALTERNATOR POWER WINDING

CONNECTIONS

3-PHASE ALTERNATORS

The 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 and 7.3.

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.

Figure 7.2 — Stator Power Winding

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

S1

E1

S4

S7

L - L

S12

S10

S11

S6

S9 S8

S5

S3

E3 L - N S2

E2

Figure 7.3 — Stator Power Winding

Connections - 3-phase, 120/208V (12 Lead)

E1

S7 S1

7-1

S9

E3

S3

S10

S12

S4

S5

S6 S11

L - N

S8

S2

E2

L - L v. 0 08/05 ACConn002 Re


Installation

INSTALLATION

Refer to the separate “Installation Guide QT Product

Line” supplied with the unit.

PREPARATION BEFORE START-UP

The instructions in this section assume that the standby generator has been properly installed, serviced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor.

Be sure to read the “Safety Rules”, as well as all other safety information in this manual, before attempting to operate this (and related) equipment.

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”.

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 standby components, must be properly located and mounted in strict compliance with applicable codes, standards and regulations.

FUEL SYSTEM

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

“Specifications” for more information.

GENERATOR SET LUBRICATION

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

NOTE:

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

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

Also, if the engine is equipped with a mechanical governor, make sure the governor is properly lubricated with clean engine oil.

8-1

PRIOR TO INITIAL START-UP



Prior to initially starting the generator, it must 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.

ENGINE COOLANT

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

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 5/8inch (10 to 16 mm).

ELECTRICAL SYSTEM

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

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

NOTE:

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

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

INITIAL INSPECTION FOR QT GENSET

STARTUP

Inspect for the following.

• Freight Damage.

• Manuals present.

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

• Correct fuel piping.

• Correct muffler installation for external application.

• 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.

D 01/07 Install001 Rev.


Installation

• Battery charger connection to 120 VAC.

• Communication wires connected between transfer switch and generator (HTS only).

• Unit secured to pad.

START-UP CHECKLIST



Before working on the generator, ensure the following:

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

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

PREPARATION FOR START-UP

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

• Remove the fuse from the the control panel. For the H-100 and R-series: Open the front door of the control box and remove the 15 Amp ATO fuse in the lower left-hand corner of the control box.

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

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

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

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

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

• Check all hoses clamps fittings for leaks or damage.

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

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

• Open the valve to the engine fuel line.

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

• Open the generator main line circuit breaker.

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

Specifications.

• Insert the fuse into the control panel.

• Move the AUTO/OFF/MANUAL switch to the MAN-

UAL 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.

START-UP INSPECTION

When a start-up is performed by an Authorized

Service Dealer, a standard three-part form titled

“Start-up Inspection for Standby Power Systems”

(part no. 067377), should be completed by the installation technician or engineer. See page 1-3 for information on locating the nearest Authorized Service

Dealer. The installer should complete the form and disseminate copies as follows:

• White copy: Mail to Generac Warranty Department,

P.O. Box 340, 211 Murphy Dr., Eagle, WI 53119-

2062.

• Pink Copy: For service file of installing dealer.

• Yellow Copy: For the customer’s records.

D 01/07 Install001 Rev.

8-2


Operation

GENERATOR CONTROL AND

OPERATION

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

OPERATING UNIT WITH MANUAL

TRANSFER SWITCH

If the 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.

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.

DANGER



The Maintenance Disconnect Switch and the

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



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

UTILITY.



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



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

In order to transfer load from the utility source to the generator, follow these directions:

• Turn OFF or disconnect the utility power circuit to the transfer switch, using the means provided

(such as the utility source main line circuit breaker).

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

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

• Start the generator.

9-1



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

• Let engine stabilize and warm up.

• Check all applicable instrument and gauge readings. When certain that all readings are correct, move the transfer switch manual handle to its

STANDBY (GENERATOR) position, i.e., load circuits supplied by the generator.

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

• Load circuits are now powered by the standby generator.

RETRANSFER AND SHUTDOWN

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

To transfer the load back to the utility power source and shut down the generator, follow these directions:

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

• Manually move the transfer switch handle to its

UTILITY (NORMAL) position, i.e., load circuits connected to the utility.

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

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

• Shut down the generator.

OPERATING UNIT WITH AUTOMATIC

TRANSFER SWITCH

If the generator has been installed with an automatic transfer switch, such as an RTS, HTS, or GTS-type transfer switch, the engine may be started and stopped automatically or manually.

NOTE:

Refer to the applicable manual for your transfer switch and to “Transfer Switch Start Signal

Connections”. In addition, please note the dangers under “Engine Start-up and Transfer.”

0 08/05 Oper001 Rev.


Maintenance

MAINTENANCE PERFORMED BY

AUTHORIZED SERVICE FACILITIES



Before working on the generator, ensure the following:

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

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

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

EVERY THREE MONTHS

1. Check battery state of charge and condition.

2. Inspect and test fuel system.

5. Check engine ignition system.

ONCE EVERY SIX MONTHS

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

ONCE ANNUALLY

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



The exhaust system parts from this product get extremely hot and remain hot after shutdown.

High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such materials may ignite and burn from the heat of the exhaust system.

CHECKING FLUID LEVELS

CHECK ENGINE OIL

Check engine crankcase oil level (Figure 10.1) at least every 20 hours of operation, or prior to use.

• Remove oil dipstick and wipe dry with a clean, lintfree cloth.

• Install oil dipstick, then remove again.

• Oil should be between FULL and ADD marks.

• If oil level is below the dipstick ADD mark, remove oil fill cap. Add the recommended oil to bring oil level up to the FULL mark. DO NOT

FILL ABOVE THE “FULL” MARK. See “Engine Oil

Recommendations” for recommended oils.

Figure 10.1 - Oil Dipstick and Oil Fill Cap

Oil Fill

FIRST 30 OPERATING HOURS

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

FIRST 100 OPERATING HOURS

1. Change engine oil and oil filter. (After initial change, service engine oil and filter at 150 operating hours or 6 months, whichever comes first.)

EVERY 500 OPERATING HOURS

Oil

Dipstick

Oil Filter

3. Check engine DC alternator.

COOLING SYSTEM

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

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

10-1

BATTERY FLUID

Check battery electrolyte fluid at least once weekly.

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

A 10/06 Maint003 Rev.


Maintenance

A 10/06

ENGINE COOLANT

Check coolant level in coolant recovery bottle. See the

“Specifications” section.

• Add recommended coolant mixture as necessary.

• Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly. Coolant should be at bottom of radiator filler neck. If coolant level is low, inspect gasket in radiator pressure cap. Replace cap, if necessary.

To have pressure cap tested, contact an Authorized

Service Dealer. Inspect cooling system and coolant recovery system for leaks.

MAINTENANCE OWNER/

OPERATOR CAN PERFORM

CHECK ENGINE OIL LEVEL

Refer to the “Checking Fluid Levels” section.

CHECK BATTERY

• Check battery fluid level each week as outlined under “Check Fluid Levels”.

• Check battery cables for condition, tightness, corrosion or damage. Clean, tighten or replace as necessary.

EXERCISE SYSTEM

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

INSPECT COOLING SYSTEM

• Inspect engine cooling system at least once each month.

• Check hoses for damage, deterioration, leaks, etc.

Correct any discrepancies found.

• Check hose clamps for tightness.

CHECK ENGINE COOLANT LEVEL

See the “Checking Fluid Levels” section.

PERFORM VISUAL INSPECTION

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

Maint003 Rev.

10-2

INSPECT EXHAUST SYSTEM

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

CHECK FAN BELT

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

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

INSPECT ENGINE GOVERNOR

Visually inspect electronic governor.

DANGER

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

CHANGING ENGINE OIL

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

Drain the oil while the engine is still warm from running. This means warm up the engine, shut it down and drain immediately as follows:

1. Remove OIL DRAIN HOSE from its retaining clip.

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

3. When all oil has drained, install and tighten OIL

DRAIN HOSE CAP, and re-install into its retaining clip.

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

5. Apply light coating of new engine oil to seal of new oil filter.-Install FILTER and tighten by hand only.

DO NOT OVERTIGHTEN.

SPECIFICATIONS). DO NOT FILL ABOVE THE

DIPSTICK “FULL” MARK. Crankcase oil capacity is listed in the “Specifications”.


Maintenance



After refilling the crankcase with oil, always check oil level on dipstick. NEVER OPERATE

ENGINE WITH OIL BELOW THE DIPSTICK “ADD”

MARK.

7. Start engine and check for oil leaks.

Figure 10.2 - Oil Filter

Oil

Dipstick

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

SPARK PLUGS

Reset the spark plug gap or replace the spark plugs as necessary.

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

2. Remove the spark plugs and check the condition.

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

3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 1.14 mm (0.045 inch) by carefully bending the ground electrode (Figure

10.4).

Figure 10.4 – Setting the Spark Plug Gap

SET PLUG GAP AT 1.14 mm

(0.045 inch)

Oil Filter

CHANGING THE ENGINE AIR CLEANER

To replace the engine air cleaner, (part number

0A4637), remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover.

Figure 10.3 — Engine Air Filter

Air Filter

10-3

COOLANT CHANGE

Every year, have an Authorized Service Facility drain, flush and refill the cooling system. See the

“Specifications” section for cooling system recommendations.

MISCELLANEOUS MAINTENANCE

CLEANING THE GENERATOR

Keep the generator as clean and as dry as possible.

Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation resistance.

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

A 10/06 Maint003 Rev.


Maintenance

A 10/06

Once each year, have the generator cleaned and inspected by an Authorized Service Dealer. That dealer will use dry, low pressure air to clean internal windings. Parts inside the control console should be cleaned and inspected at this time as well.

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

BATTERY

All lead-acid storage batteries discharge when not in use. Refer to specific instructions and warnings that accompany the battery. If such information is not available, observe the following precautions when handling a battery:

• DO NOT use jumper cables and a booster battery to crank or start the generator engine.

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

• Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns. DO

NOT permit fluid to contact eyes, skin, clothing, painted surfaces, wiring insulation, etc. If any battery fluid is spilled, flush the affected area with clear water immediately.

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

• Batteries give off explosive hydrogen gas while charging. The gas can form an explosive mixture around the battery for 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.

BATTERY MAINTENANCE

The battery should be inspected per the “Service

Schedule” section. The following procedure should be followed for inspection:

1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary.

2. Check the battery fluid level of unsealed batteries and, if necessary, fill with DISTILLED WATER

ONLY. DO NOT USE TAP WATER IN BATTER-

IES.

3. Have the state of charge and condition checked.

This should be done with an automotive-type battery hydrometer.

DANGER



Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an 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.



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



Do not use any jumper cables or booster battery to crank and start the generator engine. If the battery has completely discharged, remove it from the generator for recharging.



Be sure the AUTO/OFF/MANUAL switch is set to the OFF position before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected.



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

BATTERY REPLACEMENT

When replacing batteries, use the same number and type of battery that was supplied with the unit, and is listed in the parts list in the back of this manual.

NOTE:

The BCI number should be located directly on the battery.

REPAIR PARTS

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

Maint003 Rev.

10-4


Service Schedule

SERVICE SCHEDULE

30 KW - 150 KW STANDBY GAS ENGINE DRIVEN GENERATOR SETS

The following is a recommended maintenance schedule for standby gas engine driven generator sets from 30kW to

150 kW in size. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need to be decreased (performed more frequently) if the unit is used in a severe application. Use calendar time, from the previous maintenance interval to determine the next required maintenance interval.

Service Maintenance Interval Information:

The various service maintenance intervals are designated by interval numbers as follows:

1 An early inspection of the generator set to insure it is ready to operate when required and to identify any potential problem areas.

This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning:

To prevent injury, perform the following steps in the order indicated before starting any maintenance:

Disable the generator set from starting and/or connecting to the load by setting the control panel Auto/Off/

Manual switch to the “OFF” position.

• Remove the 15 amp control panel fuse.

• Turn off the battery charger.

• Remove the negative battery cable.

The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition from burning out sensitive control panel components and circuits.

Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal operation when required.

2 A wear-in service inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas.

Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of the unit.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Dealer.

3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas.

Performed semi-annually or following each 50 hours of operation of the unit.


4 A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas.

Performed annually or following each 100 hours of operation of the unit.


5 A comprehensive inspection of the generator set to insure it is properly serviced and ready to operate and carry the load when required, and to identify any potential problem areas.

Performed annually or following each 250 hours of operation of the unit.


v. B 03/07 SrvSchd001 Re

11-1



Maintenance Level 1 Level 2 Level 3 Level 4 Level5

Tasks

RecomTask Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.

to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Datemonthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) annually/ Initials)

10 hrs. 30 hrs. 50 hrs. 100 hrs. 250 hrs.

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

Check the engine oil level. Adjust as necessary.

Check the engine coolant level.

Adjust as necessary.

4. coolant thermal protection level.

Correct as necessary.

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

Check the air inlets and outlets for debris. Clean as necessary.

electrolyte level and specific gravity if accessible. Adjust as necessary.

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


wiring for loose connections, corrosion, and damage. Correct as necessary.


11-2




Tasks




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

11. Check the engine valve clearance/ lash. Adjust as necessary.

12. Visually inspect the unit looking for leaks, wear or damage, loose connections or components, and corrosion. Correct as necessary.

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

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


15. Replace the engine accessory drive belts.

16. Check gearbox oil level (if equipped).

17. Change gearbox oil (if equipped).

v. B 03/07

11-3

SrvSchd001 Re




Tasks




18. Start and exercise the unit at full rated load

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


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

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

20. Change the engine oil.

21. Replace the engine oil filter(s).

22. Replace engine spark plugs.

Clean and re-gap or replace as necessary.

23. Replace the engine air filter(s).

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

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


11-4


Troubleshooting

TROUBLESHOOTING GUIDE

PROBLEM CAUSE

Engine won’t crank.

Engine cranks but won't start

Engine starts hard, runs rough.

1. 15 amp fuse blown.

2. Loose or corroded or defective battery cables.

3. Defective starter contactor.

4. Defective starter motor.

5. Dead or Defective Battery.

6. 5 amp fuse blown.

1. Out of fuel.

2. Fuel solenoid (FS) is defective

3. Open Wire #14A from Engine Control circuit board.

4. Spark plugs defective.

5. Door on tank not closed.

1. Flame arrestor (air cleaner) plugged or damaged.

2. Plugged fuel line.

3. Defective spark plugs.

4. Fuel pressure incorrect.

Engine starts then shuts down. 1. Engine oil level is low.

2. Engine is overheated.

3. Defective Low Oil Pressure Switch

4. Defective Coolant Temperature Switch

5. Defective Control Module circuit board.

6. Coolant Level is Low.

7. Defective Low Coolant Level Switch

AUTO/OFF/MANUAL Switch at OFF, 1. Defective AUTO/OFF/MANUAL switch engine continues to run 2. Open/disconnected wire #15A between

AUTO/OFF/MANUAL switch and Control

Module circuit board.

3. Defective Control Module circuit board

No AC output from generator.

CORRECTION

1. Replace fuse.

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

3. Replace contactor.*

4. Replace starter motor.*

5. Remove, change or replace battery.

6. Replace fuse.*

1. Replenish fuel.

2. Replace solenoid.*

3. Reconnect wire.

4. Clean, regap or replace plugs.

5. Close door on tank.

1. Clean or replace as needed.

2. Unclog fuel line.

3. Clean, regap or replace plugs.

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

1. Check oil and add oil as needed.

2. Check cooling system for leaks.

3. Replace switch.*

4. Replace switch.*

5. Replace board.*

6. Repair leak - Add coolant.

7. Replace Switch.*

1. Replace switch.*

2. Reconnect/close wire.

1. Check main line circuit breaker.

2. Check circuit breaker & fuses.

3. Transfer switch set to NORMAL position

3. Replace board.*

1. Reset to ON or CLOSED.

2. Reset and replace, if necessary.

3. Set to GENERATOR position.

5. Thermal circuit breaker open. 5. Auto-reset - Wait 5 min. and attempt restart.

*Contact the nearest Authorized Dealer for assistance.

0 08/05 lsht001 Rev.

T rb

12-1


Notes


Notes


Notes


Notes

25

(1) 26

27

28

29

30

31

32

33

34

17

18

19

20

21

22

23

24

(1) 9

10

11

12

13

14

(2) 15

(2) 16

6

7

8

5

35

36

(3) 37

3

4

1

2

38

39

40

41

42

0F2885

0F2883

0F9637 (4)

0F3685

023484N

023484N

022237

022241

049226

0C2266

0C2454

042568

022473

022097

049813

0D4698

0F4464

025433

024469

067210A

0D6029

051713

081008

077043J

077043J

086961

067617030A

067617030B

043180

022264

0C3990

057701

022155

0C2428

0F3618

0A9457

057073

0D5466

0A7822

0F6156

029289

0F8656

0F3113

047411

036943

023897

022152

022158

1

1

1

4

1

1

6

10

4

12

8

4

4

6

1

1

1

1

1

2

4

4

4

1

-

-

PANEL CB CONN BOX

STAND RH CONTROL

STAND RH CONTROL, TWO HOLE (FOR 5.4L 100KW &

4.6L 80KW 1PHASE)

STAND LH CONTROL C5 GRBX

BUSHING SNAP SB-2.5-31

BUSHING SNAP SB-2.5-31 (FOR 5.4L 100KW & 4.6L

80KW 1PHASE)

INTERFACE 1PH 240V

INTERFACE 3PHS 416/480V

INTERFACE 3PHS 208/240V

WASHER FLAT M4

WASHER LOCK #8-M4

SCREW PHTT M4-0.7 X 10 ZYC

REF. BLOCK TERM 20A 8 X 6 X 1100V

2 WASHER LOCK #6

2

1

1

SCREW PHTT #6-32 X 1/2 ZYC

DECAL CPL CUST CONN H CTRL

DECAL NEUTRAL

2 JUNCTION BLOCK 3/8-16

REF. BUS BAR NEUTRAL BLOCK 390

REF. LUG SLDLSS 600/250-1/0 X 1/4-28

WASHER LOCK 3/8

NUT HEX 3/8-16 STEEL

WASHER LOCK M5


SCREW THF M6-1 X 16 N WA Z/JS

SCREW HHC M6-1.0 X 20 G8.8

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

NUT HEX M6 X 1.0 G8 YEL CHR

BLOCK TERM 20A 6 X 3 X 1100V

DECAL CUST CONN 120V UTILITY

LUG SLDLSS #6-14 X 13/64 CU

SCREW HHTT #10-32 X 3/8 CZ

DECAL GROUND LUG

2

2

4

2

2

4

2

1

3

4

1

1

SCREW HHTT M6-1.0 X 16 ZYC

WASHER FLAT M5

GROMMET 1.25 X .25 X .75

CONDUIT FLEX 2.0" ID

CONDUIT FLEX 2.0" ID (FOR 5.4L 100KW & 4.6L 80KW

1 PHASE)

PLATE WIRE SNGL GALV

TAPE ELEC 1/2 FOAM (AS REQ’D)

REF ASSY PCB 4.6L IGNITION MODULE

REF ASSY PCB HSB CTRL IGN MODULE (ALL OTHER

APPLICATIONS EXCEPT 4.6L G3)


SCREW PPHM #10/32 X 2

WASHER FLAT #10 ZINC

WASHER LOCK #10

NUT HEX #10-32 STEEL

G

H

J

K

L

D

E

F

2.)

A

C

J

K

L

D

E

F

G

H

1.)

A

C

0F2721

0D5577

0D5578

0D5579

0D5581

0D5585

0F2353

022770

022473

022097

022127

0C2454

029289

0F1733

0F2887

0D5572

0D5573

0D5575

0D5576

0F0199

065960

022473

022097

022127

0C2454

029289

0F1733

UL CIRCUIT BREAKER (FD)

1 COVER FD FRM CB

- CB 0150A 3P 600V S FD6 LL

-

-

-

CB 0175A 3P 600V S FD6 LL



1

4

4

4

4

INSULATOR CB FD FRAME 30MIL

SCREW SHC 1/4-20 X 4 G8.8 NZ


WASHER LOCK M6-1/4


4

1



1 DECAL CUSTOMER CONNECT INSIDE

UL CIRCUIT BREAKER (JD+LD)

4

4

7

1

1

2

4

4

-

-

-

1

-

-

COVER CIR BRKR JD/LD

CB 0300A 3P 600V S JD6 LL



CB 0600A 3P 600V S LD6

CB 0450A 3P 600V S LD6 LL

INSULATOR CIRCUIT BR. JD/LD

SCREW RHM 1/4-20 X 3


WASHER LOCK M6-1/4




DECAL CUSTOMER CONNECT INSIDE

(1) ITEM INCLUDED WITH HARNESS.

(2) ITEM INCLUDED WITH 0D5464B.

(3) ITEM IS PART OF 9R.

(4) ROUTE ONE SET (11, 22, 33, 44) THROUGH ONE HOLE; AND

ROUTE THE SECOND SET (11, 22, 33, 44) THROUGH THE OTHER

HOLE.

(2) X

Y

P

R

(1) S

T

U

V

(2) W

G

H

J

K

(2) L

(2) M

N

4.)

A

C

D

E

F

R

S

T

U

V

(1) W

X

L

M

N

P

H

J

K

3.)

A

C

D

E

F

G

W/CB

0G3259

022152

022158

0C2454

029289

052647

046526

W/CB

0A7822

022131

W/CB

023334

022097

022473

W/CB

0F8451

049897

022145

045771

0F8843

W/CB

0G3259

0F4175

0F4166$

0F1733

042419

023897

0F4173

0F4165$

0F4186

036261

053640

038150

022264

022471

029289

0F1733

022129

0F8432

0C2454

2/3

1

3

3

2

6

6

6

2/3

1

9

1

7

4

4

2

1

UL CIRCUIT BREAKER (225AF)

COVER CB C5 225AF

REF CIRCUIT BREAKERS 200A FRAME

1

4

4

4

COVER CB DISH 225AF

RIVET POP .125 X .275 SS

SCREW RHM #8-32 X 3-1/4

WASHER FLAT #8 ZINC

WASHER LOCK #8-M4

NUT HEX #8-32 STEEL

TAPE ELEC 1/2 FOAM


WASHER LOCK M8-5/16

INSULATOR CB 225AF


1

2/3

2/3

3

4

4

4

4

7

3

9

6

LUG SLDLSS 300 MCM-6 AL/CU

SCREW SHC M8-1.25 X 20 G8


3

3

2

1

NUT HEX M8-1.25 G8 CLEAR ZINC

BUS BAR 200A LUG ADAPTOR

TERMINAL COVER CB

DECAL TERMINAL SHOCK HZD BI

1


COVER CB C5 400AF


1 DECAL CUSTOMER CONNECT INSIDE

SCREW RHM 10-32 X 4

WASHER FLAT #10 ZINC

WASHER LOCK #10

NUT HEX #10-32 STEEL


TAPE ELEC 1/2 FOAM

SCREW SHC M10-1.5 X 25 G12.9

WASHER LOCK M10

BUS BAR CB ADAPTER 225-400 A

LUG SLDLSS 600/250-1/0 X 1/4-28


TERM COVER CB

SCREW HHC 1/4-28 X 1/2 G5

WASHER LOCK M6-1/4


SCREW SHC M10-1.5 X 25 G12.9

WASHER LOCK M10


H

D

E

F

G

A

B

C

R

S

T

(1) U

V

6.)

L

M

N

P

H

J

K

5.)

A

C

D

E

F

G

0A7822

0F8452

097950

0F1733

W/CB

0G3259

0D5466

039287

022145

022129

045771

045335

022097

0F4176

0F4167$

0F8433

024196

022473

022097

022127

0C2454

029289

060619

022131

022237

045772

3

9

6

6

4

7

2

1


COVER CB C5 800AF


2

4

4

4

INSULATOR CB 800AF

SCREW RHM 1/4-20 X 3-1/2


WASHER LOCK M6-1/4


SCREW THF M6-1X16 N WA Z/JS

TAPE ELEC 1/2 FOAM

SCREW SHC M10-1.50 X 40 G12.9


WASHER LOCK 3/8

NUT HEX M10-1.5 G8 YEL CHR

2

1

3

3

1

1

1

2

2

2

1

1

LUG SLDLSS 500-750 X 2 MCM AL/CU

SCREW SHC M10-1.25 X 70 G8.8


TERM COVER VITZROTECH 400AF CB


NEUTRAL BLOCK 390 / 200-400A

BUS BAR NEUTRAL BLOCK 390

SCREW HHC M8-1.25 X 45 G8.8 FT


WASHER LOCK M8-5/16



WASHER LOCK M6-1/4

1 LUG SLDLSS 600/250-1/0X1/4-28

(1) HARDWARE FOR MTG. CB TERMINAL COVERS IS SUPPLIED

WITH CIRCUIT BREAKERS.

(2) 2/3 QTY. 2POLE & 3 POLE CB.

6

7

8 *

9

10

1 055173 6 SCREW HHC M8-1.25 X 20 G10.9

2 022129 6

4

5

0E2747A

0A3870

1

1

FAN SAE ALTERNATOR (G/B)

KEY SQ 3/8 X 1-9/16 STEEL

0A3009

0F5564D

0F5563D

0A3881D

0A3881B

0A3882B

0A3883B

052624

0A5580

0A1633

1

1

1

1

1

1

1

1

4

4

HUB DRIVE 390 SAE GB

RTR 390 100KB3 GB SAE TECHUM

RTR 390 130KB4 GB SAE TECHUM

RTR 390 80GB BR BRLSS

RTR 390 80GB 1P BRLSS



BEARING BALL 6212 SEALED

SCREW HHC M14-2.0 X 140 G8.8

WASHER 390 SAE ALT.

11 0F7351

0F7349

0F7348

0F7350

0F7024D

1

1

1

1

1

STR 390 130 GB4 CPL

STR 390 80 AB3 CPL

STR 390 100 AB3 CPL

STR 390 130 AB4 CPL

ASSY STR 390 80KB3 SAE

13 022392 2

CARRIER 15"

PIN DOWEL 1/2 X 1-1/4

14 043123 4

15 051779 4 NUT HEX M14-2.0 G8 YEL CHR

16

17 051769 3

18

052259

068406

2

3

WASHER FLAT M12

LOCK

SCREW HHC M12-1.75 X 60 G10.9

19 072878 1 KEY SQ 3/8 X 3-1/4 STEEL

20 087272 1

21

22

068405C

092950

1

1

EXITER FIELD 2" LG SPD CONN

COLLAR SLIP FIT 390 MM

25 090063 1 BRIDGE SUPPORT DIODE 15"

26 090152 1

27 023365 3

28

29

033143

090064

2

1

SCREW HHM #8-32 X 7/8

CAP END ROTOR 390MM

30 083485 2

31 031980 2 TIE WRAP UL 14.6 X .14 NATL

32 083401 1

33

34

042561

033212

1

2

CLAMP HOSE #36 1.88-2.7

SCREW HHC 5/16-18 X 1-1/4 G5

SLEEVE

40 0A4089 1

41

KIT PARTS

0A2491 2

I/N’S: 41 THRU 49

SHROUD ALT SHEET METAL

42 0A2497 2

43 0A2496 2 BRKT TENSIONER SAE SCROLL

44 056326 8.4 FT. TRIM VINYL BLACK 1/8 GP

45 022307 6

46 022473 6

47 045757 2 SCREW HHC M6-1.0 X 25 G8.8

48

49

047411

0A2110

4

12

SCREW HHC M6-1.0 X 16 G8.8

SCREW SWAGE 1/4-20 X 1/2 ZYC

* ROTOR REPLACEMENT PART

57

58

59

60

52

53

54

55

56

44

45

46

47

48 *

49

50

51

61

62

30

31

32

33

34

35

36

39

40

42

43

26

27

28

29

18

19

20

21

22

23

24

25

12

13

14

15

16

17

9

10

11

4

5

6

7

8

1

2

3

065852

0C7649

055596

069860E

069811

080713

022473

022097

042568

0F5050

039253

051769

0C8145

0E2507

090283

0C8566

0F2776A

052644

0G4376

0F2686

0F5463

0F8695

0F4028

0F4030

0F4032

0F4496

042911

0F2872

022304

022195

022196

049813

070015

022145

022129

035685

045764

0F2687

0F2611

0F5254

0F5253

0F7077

046526

051756

0C2454

052250

076749

0F2573

0F2610

0G51580ST03

0G2990

0F2862

0F2560

022131

039414

052625

0F2561

0C8165

0D6795

0C7043

0E8909

048031C

0C8146

082774

12

1

1

4

2

1

5

1

15

1

3

1

1

1

1

1

1

12

8

2

2

1

1

1

1

1

1

WELDMENT RADIATOR SUPPORT150

RADIATOR 680 X 680 X 70 CPL

V-BELT 31/64" X 62-3/8"

V-BELT 31/64" X 61-3/8" (5.4L 100KW ONLY)

V-BELT 1/2" X 63-3/8" (6.8L 100 130KW)

WASHER LOCK M10



TAPE FOAM 1 X 1 (26.75” LG)

TANK COOLANT RECOVERY

PULLEY FAN V-GROOVE 9"

FAN 26" LH ROTATION

TENSIONER ARM, PULLER SYSTEM

SHOULDER BOLT 3/8 X 1/2"

SPRING TENSION CPL

PULLEY V-BELT 4" FLANGED



SCREW SHC M10-1.5 X 35 G12.9

HUB FLEX PLATE

NUT HEX LOCK 5/16-24 NY INS


DISK FLEX

COUPLING HUB FLEX (MACH)

CLAMP HOSE BAND 1/4

SCREW HHC 5/16-24 X 1.124

KEY WOODRUFF 4 X 19D

2

1

1

8

1

1

1

1

1

1

4

1

1

1

1

1

1

1

HOSE RADIATOR UPPER CPL

HOSE LOWER RAD CPL C5 6.8L

ASSY BRG/SHAFT CPL FANDRIVE

PULLEY 6.5" DIA MACHINED (6.8L 100KW)

PULLEY 6" DIA MACHINED (6.8L 130KW)

PULLEY 5.5" DIA MACHINED (5.4L 80KW & 6.8L 150KW)

PULLEY 4.5" DIA MACHINED (5.4L 100KW)


SCREW HHC 1/2-13 X 2" G8

WASHER FLAT 1/2 ZINC

WASHER LOCK 1/2



NUT HEX LOCK 5/16-18 NY INS SS


WASHER LOCK M8-5/16

CLAMP HOSE #28 1.32-2.25

SCREW HHTT M4-0.7 X 8 BP

1

1

8

1

8

1

1

1

8

1

1

1

1

REF

1

16

16

SPRING CLIP HOLDER .37-.62

CLAMP HOSE .38-.87

BARBED STR 3/8 NPT X 3/8

HOSE DRAIN ASSY 28"

CAP HEX 1/4 NPT BRASS

BRACKET COOLANT TANK


WASHER LOCK M6-1/4


SHIELD RADIATOR C5


WASHER LOCK M12

WASHER FLEX (THIN)

PROBE, COOLANT LEVEL 3/8 NPTF

CAP RADIATOR 13 PSI

SCREW HHFC M6-1.0 X 20 G8.8

BRACKET, SIGNAL CONDITIONER

1

1

SPACER .5 X 1.5 X .25 STL/ZINC

WASHER BELLEVILLE .75X.38X.028

* ITEM 48 IS INCLUDED WITH 47.

022131

046526

0536210360

042909

022261

022129

022145

045771

053557

0F2591

038750

022097

0F2586

065852

052252

052257

052259

055597

052251A

052860

0F2895

045764

022447

061383

043107

022473

049813

057192

21

22

23

24

17

18

19

20

25

26

27

28

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

2

2

2

1

1

1

8

8

1

1

4

2

1

8

1

1

1

1

2

1

4

4

8

4

4

4

1

1

BASE CP 80KW GB-150KW 2P

SPRING CLIP HOLDER .37-.62

DAMPENER VIBRATION

SPACER .49 X .62 X 1.87 PWDR/ZINC

WASHER FLAT M12

SCREW HHC M12-1.75 X 85 G8.8

DAMPENER VIBRATION 50 WHITE

NUT LOCKING M12-1.75

SUPPORT ENG 5.4L LH/RH 6.8L RH

SCREW HHTT M4-0.7 X 8 BP

WASHER SHAKEPROOF INT 1/4

LUG SOLDERLESS 3/0-#4 X 13/32 CU

SCREW HHC M8-1.25 X 25 G8.8

WASHER FLAT 1/4-M6 ZINC

NUT HEX M6 X 1.0 G8 YEL CHR

SCREW SHC M10-1.5 X 30 G12.9


WASHER LOCK M10

WIRE ASSEM #4GA GRD

SCREW HHC M8-1.25 X 30 G8.8

WASHER SHAKEPROOF INT 3/8

WASHER LOCK M8-5/16


NUT HEX M8-1.25 G8 YEL CHR

SCREW HHC M12-1.75 X 40 G8.8

TOWER GB COMPROD C5

SCREW HHC M6-1.0 X 30 G8.8


13

14

15

16

17

8

9

10

11

12

6

7

4

5

1

2

3

0F3408A

0F3411A

058665

022131

050331A

050331

038805U

038804U

045771

022129

027482

075763

0C2454

0F3409A

022097

049813

042568

4

4

4

1

4

1

1

1

1

1

1

1

1

1

1

1

1

TRAY BATTERY 27F

STRAP BATTERY RETAINMENT 27F

BATTERY 12VDC 90-AH 27F


BATTERY POST COVER RED +

BATTERY POST COVER BLK -

CABLE BATTERY BLK #1 X 18.00

CABLE BATTERY RED #1 X 28.00



WASHER SHAKEPROOF EXT 5/16 STL

BOOT BATTERY CABLE

SCREW THF M6-1 X 16 N WA Z/JS

SUPPORT BATTERY TRAY



SCREW HHC M6-1.0 X 20 G8.8

GEAR MACHINED

GEAR

3 095613 1

4 051756 2

5 046526 44

OIL

SCREW HHC M10-1.5 X 20 G8.8

8

9

6

7

049814

051735

0F2097

072879

1

1

4

8

LOCK

SCREW HHC M10-1.5 X 25 G8.8

SCREW HHC M10-1.5 X 70 G8.8

GASKET 390 GEARBOX

10 097557B 1

SPACER .69 X 2.75 X .37 ST/ZNC

KEY 10 X 16 X 46

11 097785 1

12

13

0E6866

070263

057019

1

2

2

GEAR

095970 1

095968 1 OUT

GEAR OUTPUT 2:1 50HZ 390

SCREW HHC M16-2.0 X 35 G10.9

BALL BRG 65 X 120 X 23

14 026847 1

15 097784 1 1

GEAR 25T

GEAR 27T

0E6865 1

16 095966 1 SHAFT 390 INPUT GEAR

17 095976 1

096777

057019S

COLLAR

18 095971 1 OIL

SNAP RING INT 120MM 19

20

1

1 BEARING #6213 SEALED

22 096379 1

23 048189 2

24 095979 1

INTRNL

PIN DOWEL M8 X 24

PLATE

25 021159 1 STRESSPROOF

KEY 10 X 16 X 40

51

47

48

49

50

41

44

45

46

38

39

40

26

27

28

30

31

32

33

34

35

097557A

057163

0F6518

020443

094666A

099828

099828A

026925

097557C

1

1

4

8

8

1

1

2

1

PLUG PIPE 3/8" MAGNETIC

SCREW HHFC M10-1.5 X 25 G10.9

29 0F3201 1 GUARD

COUPLING INNER DRAWN

COUPLING OUTER MACHN

DAMPER GB CPLR VIBRA

DAMPER GB CPLR VIBRA

PLUG STD PIPE 3/8 STEEL SQ HD

KEY 10 X 16 X 50

36 038591 1 NIPPLE PIPE 3/8 NPT X 3-1/2

37 025066 1

031578

052625

049814

0A1786

027175

045772

052243

057642

0F6487

0F6355

0F6477

0F6557

026924

6

REF.

10

FULL

SCREW HHC 3/8-16 X 1-1/2 G8

SCREW SHC M10-1.5 X 35 G12.9 (FORD ENGINES)

SCREW HHC M10-1.5 X 25 G8.8

2.5cc RETAINING COMPOUND

.200 GAL LUBE GREASE SAE #90 80W90 (NOT SHOWN)

10

10

2

4

1


SCREW HHC M10-1.5 X 60 G8.8

SCREW HHC M10-1.5 X 40 G10.9

WASHER FLAT M10 SEALING COPPER

GASKET SEAL PLATE 390 GB

.050 GAL ENHANCER GEAR OIL (NOT SHOWN)

0.4cc THREADLOCK AND SEALANT

1 ELBOW 90D STREET 3/8

A

B

26

27

28

29

C

D

E

22

23

24

25

18

19

20

21

50

1

14

15

16

17

10

11

12

13

6

7

8

9

2

3

4

5

70

71

72

73

65

66

67

68

69

59

60

61

62

63

64

55

56

57

58

51

52

53

54

0C3990

043280

055014

043184

0F2557

0F5884

0C2265

0F4333

0F5883

0F6305

0F6305A

0F6277

0F1263

0F1262

0F1264

0E9049B

055911

056739

0F1823

0F1824

0F2606

036261

0F5763

0F1732

0E9764

0F1725C

0F1958

0F2256

0E3161

029673

049226

079224

051713

0F5886

051716

0E7403C

0E7403B

0F6145

091526

0C2699

051713

049226

0G3546

0F1732

-

-

0F2627A

022287

022473

022097

043182

051714

052777

0C2323

0F5459

0F5461

022127

0F5460

4

4

1

1

1

2

A/R

4

2

3

2

1

1

2

1

4

2

3

3

1

1

1

2

COMPONENTS INCLUDED IN 0F1826E

1 ENCL H CONTROL PANEL

4

8

3

5

1

1

1

8

1

1

1

1

1

1

6

1

COVER CONTROL PANEL

HINGE CONTINUOUS H-PNL


ASSY PROGRAMMED PM H-100

DECAL FUSES LOCATED INSIDE

RAIL SNAPTRACK PCB HOLDER BULK (12” LG)

ASSY PCB 2AMP 12V UL BATT CHGR

PLATE HARNESS CLAMP

ASSY PCB PWR AVR W/AMP HEADER

ASSY PCB BOSCH GOV DRIVER

DIO BRIDGE 25A 600V

WASHER LOCK M5

SCREW PPHM M5-0.8 X 30 SS

WASHER FLAT M5

SCREW HHPM M5-0.8 X 12

NUT HEX M5-0.8 G8 CLEAR ZINC

1

1

4

1

3

3

10

10


WASHER FLAT M4

SCREW PPHM M4-0.7 X 8 BLK OX

WASHER LOCK M4

DECAL WARNING BATT CHRG 12/24V

SCREW PHTT M3.5-0.6 X 10


CONN DUST CAP W/CHAIN DB9

1

2

1

1

WASHER FLAT M3.5

SEAL COVER 3.18 X 12.7 X 382

SEAL COVER 3.18 X 12.7 X 283

ASSY HARNESS H-PNL SW (NOT SHOWN)

COMPONENTS INCLUDED IN WIRE HARNESS

1

4

ADPTR RH SIDE WICKMAN 178.6191

HOLDER FUSE WICKMANN 178.6150

1

1

1

ADPTR LH SIDE WICKMAN 178.6192

ASSY PCB G-PANEL RELAY 12VDC

BLOCK TERM 20A 12 X 6 X 1100V

COMPONENTS NOT INCLUDED IN 0F1826E OR WIRE HARNESS

1 RELAY SOLENOID 12VDC PNL MNT

DPE BREAKER SEE DRAWING 0F9280

BOOST RESISTOR SEE DRAWING 0F9280

COVER CONTROL PANEL SIDE



WASHER LOCK M6-1/4

WASHER LOCK M3


WASHER FLAT M3


DECAL CPL CONTROL PANEL FUSES

DECAL 5.4/6.8L TB3


DECAL CPL 5.4/6.8L RELAY BOARD

FUSE ATO TYPE 15 AMP (BLUE)

FUSE ATO TYPE 10 AMP (RED)

SEAL WEATHER .45" DIA

SCREW PPHM M5-0.8 X 12 ZNC


WASHER FLAT M5

WASHER LOCK M5

DECAL WRN BATT CHRG 12/24V BI

DECAL FUSES LOCATED INSIDE

24

(1) 25

0F6214

080762

049813

049721

088510

2

REF

26 0F6803 4

27

28

29

(1) 3

4

2

1 0F2807C

0F2807E

0F9207

0F2807B

0F2807D

0F9208

0F4505

0A6765

1

1

REF

2

1

1

1

1

PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5)

PIPE EXH MAN R/H 5.4L G/B & 2P (5.4L C5)

PIPE EXH MANIFOLD 4.6L RH

PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5)

PIPE EXH MAN L/H 5.4L G/B & 2P (5.4L C5)

PIPE EXH MANIFOLD 4.6L LH

GLASS PACK 23.5" LG 2.5" IN/OUT

RING GASKET 2.5 DIA

5

6

7

0F4710

0F7200

080762

6

6

8

WASHER LOCK M10 SS

SCREW HHC M10-1.5 X 50 SS FTH

BOLT U 3/8-16 X 2.62

8 0F2809 1

9 0F2981A 2

10 0F2962 2

EXHAUST

MFLR 7" X 9" X 25" (2) 2.5" IN/2.5" OUT

11

13

(1) 14

(1) 15

(1) 16

(1) 17

18

0C2454

0F2830

0F4462

0C2454

0F4367

0F4368

0F2773C

0F2773D

4

2

REF

REF

REF

REF

2

2


12 022097 8

19 0D3159 2

STRAP

LOCK

MUFFLER BRACKET STIFFENER

RAIN CAP ALUM FOR 2-1/2" PIPE


HEAT SHIELD EXHAUST STACK

CAP HEAT SHIELD EXHAUST STACK

EXHAUST BLANKET 900MM LONG (6.8L C5)

EXHAUST BLANKET 850MM LONG (5.4L C5)

20

21

088775

0F2808

6

2

EXHAUST

WASHER FLAT 3/8 SS

EXHUAST OUTLET PIPE CPL

22 0F5447 1

4

8

6

(1) PARTS INCLUDED IN 0F6332 KIT (TAN) OR 0F6332B KIT (TELECOM GRAY) GLASS PACK

SHIP LOOSE.

BRKT

23 022473 12 FLAT

PIPE ELBOW EXHAUST MUFFLER

BOLT U 3/8-16 X 2.62

STRAP


SCREW HHC M6-1.0 X 35 G8.8 BLK

NUT HEX M10-1.5 SS

7

8

5

6

1

2

3

4

039253

0E9747

052625

047411

0F3534

0D2608

070006

070008

2

8

24

8

1

1

11

1

SCREW HHC M8-1.25 X 20 G8.8

STARTER 12 VOLT

SCREW SHC M10-1.5 X 35 G12.9

SCREW HHC M6-1.0 X 16 G8.8

HEAT SHLD EXHAUST MANIFOLD

SCREW HHC 5/16-18 X 1/2 SSTL

WASHER LOCK M8 SSTL

WASHER FLAT M8 SS

9

10

055934M

047290

1

1

2

1

CLAMP VINYL .75 X .343 Z

HOSE 3/8 ID SINGLE BRAID (15” LG)

11 046526 23

12

13

057823

057765

CLAMP HOSE #10 .56 - 1.06

ADAPTER M14-1.50 X 3/8 NPT

14 0D6742 1 6.8L)

15

16

18

0D5417

049821

8

3

SCREW HHC M10-1.0 X 25 G10.9

SCREW SHC M8-1.25 X 30 G12.9

17 022129 4

0F1820 2 MACHINED MANIFOLD EXHAUST 5.4L

19 0F2776A 1

20 022097 1

21

22

23 *

24

25

26 069860E 1

27

28

30

31

32

35

36

048191

022473

029333A

0D9913

055596

0F1818

057772

0F3131

0D3805

021113

048031J

052647

2

1

1

16

1

2

1

1

1

1

1

9

LOCK

DOWEL PIN M10 X 24

WASHER FLAT 1/4 ZINC

TIE WRAP UL 7.4" X .19" BLK (NOT SHOWN)

SCREW SHC M8-1.25 X 35 SS

BARBED STR 3/8 NPT X 3/8

33 077996 2

34 022131 7

DRAIN

GASKET EXHAUST MANIFOLD

WASHER NYLON .565

29 0D6686 1 6.8L

HOUSING FLYWHEEL 6.8L FORD MCH

COVER FLYWHEEL MACH 6.8L V-10

PLATE DAMPNER RETNR

FLAT

HOSE CLAMP BAND 5/8"

SCREW SHC M10-1.5 X 25 G12.9

ASSY

38 0F5114 1

39

40

0F5454

079121

1

2

41 049340 1

42 040173 1

REFER

PLATE MAG PICK-UP ADAPTOR

SCREW SHC M10-1.50 X 100 G10.9

BARBED EL 90 1/4 NPT X 3/8

CLAMP .62-.62

* NOTE: I/N 23 IS FOR HOLDING SENSOR TO I/N 19.

7

8

5

6

3

4

1

2

9

10

11

0D2513D

0F5419

0F4268

0F4270A

0F6977

037561

047411

022097

049811

0F4269

022473

4

4

1

1

1

1

1

1

4

1

1

AIR CLNR BTM PLT W/CPLR 8.1L

ELEMENT AIR FILTER

TOP PLATE VENTURI

HOLD DOWN AIR CLEANER PLATED

PLATE AIR CLEAN TOP 5.4L/6.8L

NUT WING 1/4-20 NYLK

SCREW HHC M6-1.0 X 16 G8.8


WASHER FLAT M6

GASKET MIXER BODY


3

1

2

049721

065908

0F6261G

0F6261C

1

1

4

1

SCREW HHC M6-1.0 X 35 G8.8 BLK

SUPPORT NAT GAS SOLENOID

REGULATOR ASSM 5.4L 80KW NG


4

0F6261D

052617

1

2


SCREW HHC M12-1.75 X 20 G8.8

WASHER

6 022129 4

7 045773 2

8 022195 2

LOCK


9 040173

0C7649

2

2

LOCK

CLAMP HOSE #5.5 .62-.62 (5.4L)

CLAMP HOSE .38-.87 (6.8L 100KW)

10 030131 1

11

12

031015

039130

1

1

90D

NIPPLE PIPE 1-1/4 NPT X 3

NIPPLE CLOSE 1.25 NPT X 1.625

13 057822 9

14 059057 2

15 0A8064 2

HOSE

HOSE 3/4 ID SAE-30R2 (42” LG)

17

BSHG 1-1/4-3/4

16 0D1509 1

18

050279

0F2756A

1

1

DECAL FUEL INLET NG

MACHINING INTAKE ADAPTOR 60MM (5.4L FORD)

0D2696B 1 ADAPTOR THROTTLE BODY (BOSCH) (6.8L FORD GEARBOX)

19 0E4390 1

24

25

20

21

22

23

0E4392

0F0960

0F3885

0G3167

0F3691C

0F3691D

0F3691E

026915

1

2

1

1

1

2

1

1

GOVERNOR

ACTUATOR BOSCH 60 GOVERNOR

REDUCER 3.0" TO 2.75" TURBO

MIXER 40/60MM ACTUATOR ASSY

O-RING 2-3/4 X 3/32 X 2-15/16

VENTURI THROTTLE 38MM (5.4L 80KW)

VENTURI THROTTLE 40MM (5.4L FORD 2-POLE 100KW)

VENTURI THROTTLE 42MM (6.8L FORD GEARBOX 100KW)

26

27

28

059057

035461

081017

046580

1

4

1

1

NIPPLE CLOSE 3/4 X 1.375

HOSE 3/4 ID SAE-30R2 (42” LG)

BARBED STR 1/4 NPT X 3/8 (5.4L 80KW & 100KW NG)

BARBED STR 1/4 NPT X 1/2 (6.8L 100KW NG)

29 039294 1

SCREW SHC M6-1.0 X 45 G12.9

CLAMP HOSE #44 2.31-3.25

30 022097 4

37

(1) 38

(1) 39

(1) 40

(1) 41

31

32

33

047290

052223

0D2698

059057

1

1

1

1

LOCK


HOSE 1/2 ID SAE-30R2 FUELOIL (42” LG) (6.8L 100KW)

GASKET ADAPTER THROT BODY (6.8L FORD ONLY)

34

35

064346

0F4408

1

1

HOSE 3/4 ID SAE-30R2 (42” LG)

PIPE TEE 1-1/4 NPT

Y CONNECTOR 500 SERIES BARBS

36 0F6279 1

066212

0G46350ST03

042568

022097

049811

1

1

2

2

2

FUEL

CLAMP HOSE #52 2.81-3.75

BRACKET, HOSE RISER

SCREW HHC M6-1.0 X 20 G8.8


WASHER FLAT M6

(1) G6.8L UNITS ONLY

4

3

1

2

033212

065908

0F6261H

0F6261J

0F6261K

0F6261L

0F6261M

052617

1

2

1

1

1

1

4

1

SCREW HHC 5/16-18 X 1-1/4 G5

SUPPORT NAT GAS SOLENOID

REGULATOR ASSM 5.4L 80KW LPV (5.4L 80KW)


REGULATOR ASSM 6.8L 100KW LPG (6.8L 100KW)



SCREW HHC M12-1.75 X 20 G8.8

2

1

WASHER

6 022129 4 LOCK

NUT HEX M12-1.75 G8 YEL CHR 7

8

045773

064346 PIPE TEE 1-1/4 NPT

9 0A8064 2

10 030131 1

11

1-1/4-3/4

12

13

14

031015

088963

026915

057823

2

4

1

1

NIPPLE PIPE 1-1/4 NPT X 3

NIPPLE PIPE 1.25 NPT X 5.5 BL IRN (6.8L 150KW ONLY)

NIPPLE CLOSE 3/4 X 1.375

CLAMP HOSE #10 .56-1.06

059057 2 HOSE 3/4 ID SAE-30R2 (45” LG)

15 0D2698 1

16 0D1509 1

17

18

0F2756A 1

19 0E4390 1

24

20

21

22

23

050280

0D2696B

0E4392

0F0960

0F3885

0G3167

0F3691B

0F3691D

0F3691E

0F3691F

1

1

1

1

1

2

1

1

1

1

INLET

DECAL FUEL INLET LPG (LP VAPOR APPLICATION)

ADAPTOR THROTTLE BODY (BOSCH) (6.8L)

MACHINING INTAKE ADAPTOR 60MM (5.4L)

GOVERNOR

ACTUATOR BOSCH 60 GOVERNOR

REDUCER 3.0" TO 2.75" TURBO

MIXER 40/60MM ACTUATOR ASSY

O-RING 2-3/4 X 3/32 X 2-15/16




0F3691J 1



25 022195 2

26 0F6279 1 FUEL

BARBED STR 1/4 NPT X 1/2 27

28

29

31

081017

046580

039294

047290

1

4

1

1

SCREW SHC M6-1.0 X 45 G12.9

CLAMP HOSE #44 2.31-3.25

30 022097 4

32 040173 2

LOCK


CLAMP

33

34

(1) 35

(1) 36

039130

066212

0G46350ST03

042568

1

2

1

1

(1) 37

(1) 38

022097

049811

2

2

(1)

.62-.62

NIPPLE CLOSE 1.25 NPT X 1.625

CLAMP HOSE #52 2.81-3.75

BRACKET, HOSE RISER

SCREW HHC M6-1.0 X 20 G8.8


WASHER FLAT M6

36

37

38

39

40

42

43

(1) 44

30

31

32

33

34

35

45

46

47

48

49

50

22

23

24

25

26

27

28

29

16

17

18

19

20

21

(2) 1

(2) 2

(2) 3

(2) 4

(2) 5

(2) 6

(2) 7

11

12

13

14

15

0F3890A

087233

0F3949C

0F3949D

0F3949G

0F3949J

0F3949K

0F3949F

0F3890B

0F3890

042568

022447

049813

077992

0912970094

0F2766A

0F3949M

0F8869D

0E3257

078115A

0F3949

0C2634A

022473

022097

022127

0F3072

078115

0F3949B

0F3949A

0F5048D

0E5968

0F5049

0F3949L

0F3949E

0F5873

0F5868

0F5872

0F5871

0F5869

0F5870

0F5867

0C2454

0F2766

0F3181

0F3185

0F3416

4

1

4

2

1

58

3

4

1

1

20

2

1

5

4

2

2

1

1

86

2

1

4

2

2

2

REAR WRAP C5

DOOR C5

CENTER SUPPORT C5

DISCHARGE DUCT LH & RH SIDE C5

FRONT CORNERS C5

DISCHARGE CENTER DUCT C5

ROOF C5 ALUM


SPLITTER

SPLITTER SHORT

STRINGER SPLITTER C3

SUPPORT SPLITTER C5 130KW

INSULATION CORNER POST

ASSEMBLY COVER ACCESS


WASHER LOCK M6-1/4


INSULATION RETAINMENT HANGER

WASHER SELF LOCKING DOME #4-40

INSULATION SPLITTER

INSULATION SHORT LOUVER

VISE-ACTION LATCH SLOTTED CIR

GASKET EXTRUDED TRIM (566” LG)

TAB PULL

INSULATION SPLITTER SML

INSULATION ROOF TOP REAR

14

4

4

4

28

1

2

4

4

1

2

8

2

1

RETAINER INSULATION (740)


INSULATION ROOF TOP

INSULATION DOOR

INSULATION DISCHARGE DUCT

INSULATION CENTER SUPPORT

INSULATION DISCHARGE DUCT TOP

INSULATION INNER DUCT SIDE




WASHER SHAKEPROOF INT 1/4


NUT HEX LOCK M6-1.0 SS NY INS

1

6

12

4

1

1

ASSY WIRE 14 AWG 34.8" GRN/YEL

SPLITTER C5

INSULATION SPLITTER SHRT MPS

KEY VISE-ACTION LATCH SLOT CIR

SCREW TH-FRM M6 W/CAP SHKPRF W

WASHER SELF LOCKING DOME #8-32

(1) ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO

THE BASE FRAME MUST BE SECURED USING ITEM 11 & 49 THREAD FORMING

FASTENER AND ITEM 44 LOCK NUT. LOCK NUT IS TO BE INSTALLED AFTER THREAD

FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS.

ALL ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER.

(2) I/N’S 1 THRU 7, REFER TO CHART BELOW FOR ENCLOSURE COLOR & MATERIAL TYPE.


Warranty

GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR

COMMERCIAL PRODUCT 50kW AND ABOVE

For a period of two (2) years from the date of sale, or start-up by Authorized/Certified Generac Power Systems Dealer, or branch thereof, Generac

Power Systems, Inc. will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or an Authorized/Certified Generac Power Systems Dealer, or branch thereof, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Authorized/

Certified Generac Power Systems Dealer, or branch thereof. This warranty applies only to Generac Power Systems Generators used in "Standby" applications, as Generac Power Systems, Inc. has defined Standby, provided said generator has been properly installed and inspected on-site by appropriate personnel. Scheduled maintenance, as outlined by the generator owner's manual, is highly recommended. This should be performed by an Authorized/ Certified Generac Power Systems Dealer, or branch thereof. This will verify service has been performed on the unit throughout the warranty period.

WARRANTY SCHEDULE

YEAR ONE — Limited comprehensive coverage on mileage, labor, and parts listed.

• - ALL COMPONENTS

YEAR TWO — Limited comprehensive coverage on parts listed.

• - ALL COMPONENTS

*Start-up and/or On-line Registration, or Registration Card, along with Proof of Purchase, must be performed and/or sent in.

Guidelines: branch thereof.

Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the genset, no warranty coverage shall apply.

Manual.

• Units that have been resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable.

• Unit enclosure is only covered against rust or corrosion the first year of the warranty provision.

• Use of Non-Generac replacement part(s) will void the warranty in its entirety.

applicable).

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

1. Any unit built/manufactured prior to March 1, 2005.

2. Costs of normal maintenance (i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up).

3. Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze.

Trailer Mounted or Rental Unit. Contact a Generac Power Systems Distributor for Prime Power, Trailer Mounted or Rental Unit definition and warranty.

normally exist.

earthquake, windstorm, hail, volcanic eruption, water or flood, tornado, hurricane, terrorist acts or nuclear holocaust.

7. Products that are modified or altered in a manner not authorized by Generac Power Systems in writing.

8. Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing.

defective part(s).

10. Failure due to misapplication, misrepresentation, or bi-fuel conversion.

11. Telephone, facsimile, cell phone, satellite, internet, or any other communication expenses.

12. Rental equipment used while warranty repairs are being performed (i.e. rental generators, cranes, etc.).

13. Overtime, holiday, or emergency labor.

14. Planes, ferries, railroad, busses, helicopters, snowmobiles, snow-cats, off-road vehicle or any other mode of transportation deemed abnormal.

15. Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct cause of the problem.

16. Starting batteries, fuses, light bulbs, engine fluids, and overnight freight cost for replacement part(s).

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC POWER SYSTEMS

MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to purchaser/owner.

GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT

SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A

DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.

Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/ owner. Purchaser/owner agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gives purchaser/owner specific legal rights. Purchaser/owner also may have other rights that vary from state to state

Generac Power Systems, Inc. • P.O. Box 8 • Waukesha, WI 53187

Ph: (262) 544-4811 • Fax: (262) 544-4851

Bulletin 0171370SVE / Printed in U.S.A. 7.05

Printed in U.S.A.

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