Generac QT13068ANANA Manual (149 Sider)

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

Data Label ................................................................2-1

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

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

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

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

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

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

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

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

Overcrank Shutdown ................................................4-1

Overspeed Shutdown ................................................4-1

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

DC Fuse ....................................................................4-1

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

Fuel Requirements ....................................................5-1

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

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

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

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

Generator .................................................................6-1

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

Cooling System .........................................................6-1

Fuel System ..............................................................6-1

Electrical System ......................................................6-1

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

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

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

Ignition Shutdown on Loss of Crank

or CAM Signals .........................................................6-3

Diagnostic Blink Patterns (Red LED Located

on the Ignition Control Board ...................................6-3

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

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

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

Four-lead, Single-phase Stator ..................................7-1

3-phase Alternators ("Y" Configuration) ....................7-1

3-phase Alternators ("Delta" Configuration) ..............7-2

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

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

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

Transfer Switch ........................................................8-1

Fuel System ..............................................................8-1

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

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

Engine Coolant .........................................................8-1

Belt Tension ..............................................................8-1

Electrical System ......................................................8-1

Initial Inspection for QT Genset Start-up .....................8-1

Start-up Checklist ........................................................8-2

Preparation for Start-up............................................8-2

Start-up Inspection ...................................................8-2

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

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

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

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

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

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

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

Maintenance Performed by Authorized

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

Every Three Months ...............................................10-1

Once Every Six Months ...........................................10-1

Once Annually .........................................................10-1

First 100 Operating Hours ......................................10-1

Every 500 Operating Hours ....................................10-1

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

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

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

Battery Fluid ...........................................................10-1

Engine Coolant .......................................................10-2

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

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

Check Battery .........................................................10-2

Exercise System ......................................................10-2

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

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

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

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

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

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

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

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

Spark Plugs ............................................................10-3

Coolant Change .......................................................10-3

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

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

Battery ....................................................................10-4

Battery Maintenance ...............................................10-4

Battery Replacement ...............................................10-4

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

30 kW - 150 kW Standby Gas Engine

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

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

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

NOTES

EXPLODED VIEWS & PARTS LISTS

WIRING DIAGRAMS & SCHEMATICS

WARRANTY

Content010 Rev. 0 04/06

1-1

INTRODUCTION

Thank you for purchasing this model of the Stationary

Emergency 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, con-

tact the nearest Authorized Service Dealer for start-

ing, 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 person-

nel 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 serious person-

al injury, including death, 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 compli-

ance 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 infor-

mation that, if not followed, could endanger

personal safety and/or property of others.

 This symbol points out potential explosion

hazard.

 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 recom-

mends that the operator read this Owner's Manual

and thoroughly understand all instructions before

using this equipment. The manufacturer also strong-

ly 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 generator electric system has been

installed by an Authorized Service Dealer or other

competent, qualified contractor. Installation of this

equipment is not a “do-it-yourself” project.

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

Stationary Emergency Generator

Important Safety Instructions

Safety 001 Rev. B 10/08

Study these SAFETY RULES carefully before install-

ing, operating or servicing this equipment. Become

familiar with this Owner’s Manual and with the unit.

The generator can operate safely, efficiently and reli-

ably 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 warn-

ings in this manual, and on tags and decals affixed

to the unit are, therefore, not all inclusive. If a pro-

cedure, work method or operating technique is used

that the manufacturer does not specifically recom-

mend, ensure that it is safe for others. Also make

sure the procedure, work method or operating tech-

nique utilized does not render the generator unsafe.

DANGER

 Despite the safe design of this generator,

operating this equipment imprudently, neglect-

ing its maintenance or being careless can cause

possible injury or death. Permit only responsible

and capable persons to install, operate or main-

tain 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.

 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 tech-

nician who is familiar with applicable codes, stan-

dards and regulations. The operator also must

comply with all such codes, standards and regula-

tions.

• 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 electri-

cal 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 mon-

oxide gas, which can be DEADLY. This dangerous

gas, if breathed in sufficient concentrations, can

cause unconsciousness or even death. For that

reason, adequate ventilation must be provided.

This should be considered prior to installing the

generator. The unit should be positioned to direct

exhaust gasses safely away from any building

where people, animals, etc., will not be harmed.

Any exhaust stacks that ship loose with the unit

must be installed properly per the manufacturer's

instruction, and in strict compliance with appli-

cable 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 venti-

lating air is critical in any room or building hous-

ing 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 seri-

ously 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.

 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.

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.

WARNING:

 

1-2

Stationary Emergency Generator

Important Safety Instructions



Safety 001 Rev. B 10/08

• Before performing any maintenance on the gen-

erator, 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 con-

ditions from leaking exhaust gases, fuel leakage,

oil leakage, etc.

 ELECTRICAL HAZARDS 

• All Stationary Emergency Generators covered by

this manual produce dangerous electrical voltages

and can cause fatal electrical shock. Utility power

delivers extremely high and dangerous voltages

to the transfer switch as well as the generator.

Avoid contact with bare wires, terminals, connec-

tions, etc., on the generator as well as the transfer

switch, if applicable. Ensure all appropriate cov-

ers, guards and barriers are in place before operat-

ing 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 repair-

ing 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 danger-

ous electrical shock that might be caused by a

ground fault condition in the generator or by static

electricity. Never disconnect the ground wire.

• Wire gauge sizes of electrical wiring, cables and

cord sets must be adequate to handle the maxi-

mum 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 pos-

sibly fatal electrical shock.

• Connecting this unit to an electrical system nor-

mally 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 operat-

ing. Failure to isolate the two electric system power

sources from each other by such means will result

in damage to the generator and may also result

in injury or death to utility power workers due to

backfeed of electrical energy.

• Stationary Emergency Generators installed with

an automatic transfer switch will crank and start

automatically when normal (utility) source volt-

age is removed or is below an acceptable preset

level. To prevent such automatic start-up and pos-

sible 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, imme-

diately 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 imple-

ment, such as a dry rope or board, to free the vic-

tim from the live conductor. If the victim is uncon-

scious, apply first aid and get immediate medical

help.

• Never wear jewelry when working on this equip-

ment. Jewelry can conduct electricity resulting in

electric shock, or may get caught in moving com-

ponents 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 extin-

guisher 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 com-

bustible materials are left in the generator com-

partment, or on or near the generator, as FIRE or

EXPLOSION may result. Keep the area surround-

ing the generator clean and free from debris.

• These generators may operate using one of sev-

eral types of fuels. All fuel types are potentially

FLAMMABLE and/or EXPLOSIVE and should be

handled with care. Comply with all laws regulat-

ing the storage and handling of fuels. Inspect the

unit’s fuel system frequently and correct any leaks

immediately. Fuel supply lines must be prop-

erly installed, purged and leak tested according to

applicable fuel-gas codes before placing this equip-

ment 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.

1-3

Stationary Emergency Generator

Important Safety Instructions

Safety 001 Rev. B 10/08

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 gen-

erator’s lower connection box, lists the unit’s serial

number and its rated voltage, amps, wattage capac-

ity, phase, frequency, rpm, power factor, production

date, etc.

WAUKESHA, WI

RATED KW

RATED VOLTAGE

POWER FACTOR

ENGINE RPM

ALTERNATOR SUBTRANSIENT REACTANCE

ALTERNATOR TRANSIENT REACTANCE

CLASS

MODEL

MADE IN USA

PRODUCTION DATE

GENERAC POWER SYSTEMS, INC.

HERTZ

RATED KVA

GENERATOR SET DATA

RATED AMPS

ALT RPM

PHASE

SERIAL

ROTOR STATOR WINDING INSULATION AT 25 C AMBIENT°

NOTE:

For actual information related to this particular

model, please refer to the Manual Drawing Listing

located at the end of this manual, or to the data

label affixed to the unit.

Stationary Emergency Generator Model and 

Serial Number

This number is the key to numerous engineering and

manufacturing details pertaining to your unit. Always

supply this number when requesting service, order-

ing parts or seeking information.

Identification Code 

Use this code to obtain important information about

the generator. For example, if the code is:

M — Designates generators capable of paralleling.

NOTE: Only 100kW and 150kW, 6.8L units

are currently available for this configura-

tion.

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 cor-

responding 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

Stationary Emergency Generator

General Information

Identy001 Rev. D 10/08

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

EQUIPMENT DESCRIPTION

This equipment is a revolving field, alternating cur-

rent Stationary Emergency Generator. It is powered

by a gaseous fueled engine operating at 1800 rpm for

4-pole direct drive units, 3600 rpm for 2-pole direct

drive units and 2300 - 3000 rpm for quiet drive gear

units. See the Specifications section for exact num-

bers. The unit comes complete with a sound attenu-

ated enclosure, internally mounted muffler, control

console, mainline circuit breaker, battery charger,

and protective alarms as explained in the following

paragraph.

The Stationary Emergency Generator incorporates

the following alternator 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 con-

structed.

• The voltage waveform deviation, total harmonic

content of the AC waveform and telephone influ-

ence 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 classi-

fied “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:

 Any attempt to crank or start the engine before

it has been properly serviced with the recom-

mended oil may result in an engine failure.

NOTE:

For temperatures below 32° F, it is strongly recom-

mended 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.

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 deion-

ized 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 chro-

mium hydroxide (“green slime”) forms and will

cause overheating. Engines that have been oper-

ated 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.

Temperature Oil Grade (Recommended)

Above 80° F (27° C) SAE 30W or 15W-40

32° to 80° F (0° to 27° C) SAE 20W-20 or 15W-40

Below 32° F (0° C) See Note

3-1

Stationary Emergency Generator

Equipment Description

Equip005 Rev. B 10/08

ENGINE PROTECTIVE DEVICES

The Stationary Emergency Generator may be required

to operate for long periods of time without an opera-

tor 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 run-

ning too fast.

NOTE:

Engine protective switches and sensors are men-

tioned here for the reader's convenience. Also refer

to the applicable control panel manual for addi-

tional automatic engine shutdown information.

COOLANT TEMPERATURE SENSING 

An analog Water Temperature Sender (WTS) is locat-

ed in the engine's cooling system. This sender is con-

nected 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 chang-

es 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 cool-

ant 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 con-

verted to 4-20mA signal by a signal conditioner mod-

ule. 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.

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 pres-

sure 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 ini-

tiates 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.)

4-1

Stationary Emergency Generator

Engine Protective Devices

EngProt002 Rev. C 10/08

FUEL SYSTEM

FUEL REQUIREMENTS 

The Stationary Emergency Generator may be equipped

with one of the following fuel systems:

• Natural gas fuel system

• Propane vapor (PV) fuel system

• Liquid propane (LP) fuel system

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 sup-

plied 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 sole-

noid 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).

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 col-

umn 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 vaporiza-

tion, 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.

5-1

Stationary Emergency Generator

Fuel Systems

FuelSys002 Rev. B 10/08

SPECIFICATIONS

GENERATOR

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

Rotor Insulation ................................Class F or H (see Data Label)

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

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

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

Alternator Output Leads 1-phase ........................................... 4-wire

Alternator Output Leads 3-phase ........................................... 6-wire

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

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

Load Capacity (Standby Rating) ..........................................130kW*

* 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 130 542 600

120/208V, 3-phase, 0.8 pf 130 451 500

120/240V, 3-phase, 0.8 pf 130 391 500

277/480V, 3-phase, 0.8 pf 130 195 225

Generator Locked Rotor KVA Available @ Voltage Dip of 35%

Single-phase or 208 3-phase ........................................... 305 KVA

480V, 3-phase .................................................................. 406 KVA

240V, 3-phase .................................................................. 305 KVA

ENGINE

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

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

Cylinders and Arrangement .......................................................... 10

Displacement ....................................................................... 6.8 Liter

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

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

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

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

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

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

Engine Parameters

Rated Synchronous RPM ..............................................60 Hz, 3000

HP at rated kW ................................................................60 Hz, 210

Exhaust System

Exhaust Flow at Rated Output 60 Hz ................................ 1119 cfm

Exhaust Temperature at Rated Output .................................. 970° F

Combustion Air Requirements (Natural Gas)

Flow at rated power, 60 Hz ................................................. 336 cfm

Governor

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

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

Steady State Regulation .......................................................± 1/4 %



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 ................................................................................ 1950

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

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

Air Flow (inlet air including alternator and

combustion air) .......................................................... 6450 ft3/min.

Coolant Capacity ........................................................ (4.5 U.S. gal.)

Heat Rejection to Coolant ..........................................496,000 Btu/h

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

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

FUEL SYSTEM

Type of Fuel ....................................Liquid Propane or Natural Gas*

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

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

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

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

Fuel Consumption - ft3/hr (Natural Gas/LPV)

Exercise 25% 50% 75% 100%

Cycle Load Load Load Load

135/54.5 482/193 927/373 1292/520 1786/719

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

factory set for the specific fuel.

ELECTRICAL SYSTEM

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

Static Battery Charger ..................................................12V, 10 Amp

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

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

Voltage Regulator

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

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

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

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

V/F Adjustable, Adjustable

Voltage and Gain

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

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



6-1

Standby Generator Sets

Specifications

GenSpec027 Rev. 0 04/06

Figure 2 — AC Outlet for Block Heater and

Battery Charger (to be wired by installer)

Figure 1 — Interconnections

6-2

Standby Generator Sets

Specifications

TO

ALTERNATOR

NEUTRAL

GROUND

CIRCUIT

BREAKER

NEUTRAL

Ground Level

Concrete Slab

STUB-UP AREA

See Install Dwg for

Dimensions

GENERATOR

CONNECTION

BOX

FRAME RAIL

H100 CONTROL

PANEL

RS485 +

RS485 -

Sig B4 Xfer

TO GENERATOR

CONNECTION BOX

Utility In

Load

Out

Gen

RS485 +

RS485 -

Grd.

Remot e St art

Transfer Switch

CIRCUIT BREAKER WIRE AND CONDUIT SIZE

KW VOLTS CB AMPS LUG SIZE

130 240 1 Ø 600 2-500 to 750 mcm

130 208 3 Ø 500 2-500 to 750 mcm

130 480 3 Ø 225 #6 to 300 mcm

130 240 3 Ø 500 2-500 to 750 mcm

2 WIRE

SHIELDED

CABLE

W/GROUND

TO

GENERATOR

CONNECTION

BOX

2 WIRE SHIELDED

CABLE W/GROUND

TO TRANSFER SW

GROUND AT GEN

CONNECTION BOX

ONLY

GenSpec027 Rev. 0 04/06

5.4L & 6.8L IGNITION DESCRIPTION

This single-fire Ignition is intended to operate with

a 10-cylinder, 6.8L engine and an 8-cylinder, 5.4L

engine.

The 6.8L engine uses a 40-1 crank sensor, a mag-

pickup CAM sensor and individual coil-on-plug coils

for each spark-plug.

The 5.4L engine uses a 36-1 crank sensor, a mag-

pick-up CAM sensor and individual coil-on-plug coils

for each spark-plug.

With a single-fire ignition, each high-voltage coil out-

put 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 NG/LP Engine Timing (BTDC)

1800 rpm 22 degrees

3600 rpm 24 degrees

Engine Timing versus Engine Speed for the 5.4L

engine is:

RPM NG/LP Engine Timing (BTDC)

1800 rpm 26 degrees

3600 rpm 26 degrees

IGNITION POWER-UP INPUT ("56 LINE

INPUT")

When battery voltage is applied to this input the igni-

tion 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 con-

nected 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 fol-

lowing 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.



6-3

Standby Generator Sets

Specifications

GenSpec027 Rev. 0 04/06

GENERATOR AC LEAD CONNECTIONS

See “Voltage Codes”. This Stationary Emergency

Generator may be rated at any one of five 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.

ALTERNATOR POWER WINDING

CONNECTIONS

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 fac-

tory to the main circuit breaker as shown in Figure

7.1.

The rated voltage between each circuit breaker ter-

minal 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

3-PHASE ALTERNATORS ("Y" CONFIGURATION) 

The Stationary Emergency Generator is designed

to supply 3-phase electrical loads. Electric power is

produced in the alternator power windings. These

windings were connected at the factory to the main

circuit breaker with a “Y” configuration as shown in

Figures 7.2, 7.3, and 7.4.

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 termi-

nal and the neutral point 00 is either 277V or 120V

depending on the model.

Figure 7.2 — Stator Power Winding

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

E1

S10

S12

S4

S5

S2

S8

S11

S6

S3

S9

S7 S1

E2

E3

L - N

L - L

Figure 7.3 — Stator Power Winding

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

E1

S1

S4

S7

S12 S11

S10

S8

S5

S2

E2

S9

S6

S3

E3 L - N

L - L

7-1

Stationary Emergency Generator

General Information

ACConn005 Rev. A 09/08

Figure 7.1 — Stator Power Winding

Connections - 3-phase, 346/600V (6 Lead)

S6

E

3

S3

INTERNAL

CO

NNE

C

TI

O

N

S

L-

N

L

-

L

S4

E2

S2

S5

S1

E1

NE

U

TRA

L

3-PHASE ALTERNATORS 

("DELTA" CONFIGURATION)

The Stationary Emergency Generator is designed

to supply 3-phase electrical loads. Electric power is

produced in the alternator power windings. These

windings were connected at the factory to the main

circuit breaker with a “Delta” configuration as shown

in Figures 7.5.

The rated voltage between circuit breaker terminals

E1-E2, E1-E3 and E2-E3 is 208V.

The rated voltage between E1 or E3 and the neutral

point 00 is 120V.

Figure 7.5 — Stator Power Winding

Connections - 3-phase, 120/240V (12 Lead)

E2

E1

E

7-2

Stationary Emergency Generator

General Information

ACConn005 Rev. A 09/08

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 con-

tractor. 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 elec-

trical system normally powered by an electric utility,

the National Electrical Code requires that a transfer

switch be installed. The transfer switch prevents elec-

trical backfeed between two different electrical sys-

tems. (For additional information, see the applicable

transfer switch manual for this unit.) The transfer

switch, as well as the generator and other electrical

components, must be properly located and mounted

in strict compliance with applicable codes, standards

and regulations.

FUEL SYSTEM 

Make sure the fuel supply system to the genera-

tor (a) delivers the correct fuel at the correct pres-

sure 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 recom-

mended oil is SAE 90 gear lubricant.

Also, if the engine is equipped with a mechanical gov-

ernor, make sure the governor is properly lubricated

with clean engine oil.

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 5/8-

inch (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 con-

nections. 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 QT45, QT55, QT80,

QT100 - QT150.

• Adequate air flow, clearances and ventilation per

installation drawings and applicable codes.

8-1

Stationary Emergency Generator

Installation

Install006 Rev. B 10/08

• Correct AC and DC wire size, connections and

grounding. Control and communication wiring to/

from the transfer switch must be run in a separate

conduit from the AC power leads.

• AC outlet connection.

• Communication wires connected between transfer

switch and generator (HTS only).

• Unit secured to pad.

START-UP CHECKLIST

 Before working on the Stationary Emergency

Generator, ensure the following:

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

position.

• The power to the block heater and to the battery

charger is switched OFF.

PREPARATION FOR START-UP 

• Remove the fuse from the the control panel. For

the H-100 and R-series: Open the front door of the

control box and remove the 15 Amp ATO fuse in

the lower left-hand corner of the control box.

• Connect the battery cables to the battery. Attach

negative battery cable last.

• Restore power to the GFCI outlet that provides

power to the battery charger.

• Measure the voltage at the battery before and after

the charger is turned on.

• Verify all AC electrical connections are tight at the

circuit breaker and transfer switch.

• Visually inspect entire area looking for loose paper,

plastic wrappings, leaves, etc.

• Check all hoses clamps fittings for leaks or dam-

age.

• Check all electrical plugs throughout the genera-

tor. 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 instal-

lation technician or engineer. See page 1-3 for infor-

mation on locating the nearest Authorized Service

Dealer. The installer should complete the form and

disseminate copies as follows:

• White copy: Mail to Generac Warranty Department,

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

2062.

• Pink Copy: For service file of installing dealer.

• Yellow Copy: For the customer’s records.

8-2

Stationary Emergency Generator

Installation

Install006 Rev. B 10/08

STATIONARY EMERGENCY GENERATOR

CONTROL AND OPERATION

Refer to the appropriate control panel operator’s

manual for this unit.

OPERATING UNIT WITH MANUAL

TRANSFER SWITCH

If the Stationary Emergency Generator was installed

in conjunction with a transfer switch capable of man-

ual 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 lit-

erature 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 posi-

tively turned off, or extremely dangerous - pos-

sibly 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 break-

er).

• Set the transfer handle to its UTILITY (NORMAL)

position with load circuits connected to the utility

power supply.

• Set the generator’s main line circuit breaker to its

OFF (or OPEN) position.

• Start the generator.

 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 read-

ings. When certain that all readings are correct,

move the transfer switch manual handle to the

STANDBY position, i.e., load circuits supplied by

the generator.

• Set the generator’s main line circuit breaker to its

ON (or CLOSED) position.

• Load circuits are now powered by the generator.

RETRANSFER AND SHUTDOWN 

For additional information, refer to the applicable

control panel manual for this unit, as well as any lit-

erature pertaining to the specific transfer switch.

To transfer the load back to the utility power source

and shut down the generator, follow these direc-

tions:

• Set the generator’s main line circuit breaker to its

OFF (or OPEN) position.

• Manually move the transfer switch handle to its

UTILITY (NORMAL) position, i.e., load circuits

connected to the utility.

• Turn ON the utility power supply to the transfer

switch, using the means provided (such as the util-

ity power source main line circuit breaker).

• Let the generator run at no-load for a few minutes

to stabilize internal temperatures.

• Shut down the generator.

OPERATING UNIT WITH AUTOMATIC

TRANSFER SWITCH

If the Stationary Emergency Generator has been

installed with an automatic transfer switch, 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 trans-

fer switch and to “Transfer Switch Start Signal

Connections”. In addition, please note the dangers

under “Engine Start-up and Transfer.”

9-1

Stationary Emergency Generator

Operation

Oper001 Rev. A 09/08









Figure 10.1 - Oil Dipstick and Oil Fill Cap

Oil Fill

Oil

Dipstic

k

Oil Filter



10-1

ENGINE COOLANT 



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

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

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

• The negative battery cable has been removed.

CHECK ENGINE OIL LEVEL 

CHECK BATTERY 

EXERCISE SYSTEM 

INSPECT COOLING SYSTEM 

CHECK ENGINE COOLANT LEVEL 

PERFORM VISUAL INSPECTION 

INSPECT EXHAUST SYSTEM 

CHECK FAN BELT 

INSPECT ENGINE GOVERNOR 

DANGER



CHANGING ENGINE OIL 

Stationary Emergency Generator

Maintenance

10-2



After refilling the crankcase with oil, always

check oil level on dipstick. NEVER OPERATE

ENGINE WITH OIL BELOW THE DIPSTICK

“ADD” MARK.

7. Start engine and check for oil leaks.

8. Shut OFF engine and wait 10 minutes for the oil

into the oil pan. R

above the dipstick

9. Dispose of used oil at a proper collection center.

Figure 10.2 - Oil Filter

CHANGING THE ENGIN

To replace the engine air cleaner, (part number 0A46the air cleaner cover and replace the air filter makingpositioned properly before reattaching the cover.

Figure 10.3

See the “Service Schedule” section for air cleaner m

SPARK PLUGS 

Reset the spark plug gap or replace the spark plugs as nsary.1. Clean the area around the base of the spark plugs to and debris out of the engine. Clean by scraping or washusing a wire brush and commercial solvent. Do not blasspark plugs to clean.2. Remove the spark plugs and check the condition. Rethe spark plugs if worn or if reuse is questionable. See t“Service Schedule” section for recommended inspection3. Check the spark plug gap using a wire feeler gauge. gap to 1.14 mm (0.045 inch) by carefully bending the gelectrode (Figure 10.4).

Figure 10.4 – Setting the Spark Plug Gap

COOLANT CHANGE 

Every year, have an Authorized Service Facility drain, frefill the cooling system. See the “Specifications” sectioing system recommendations.

Keep the generator as clean and as dry as possible. Dirt moisture that accumulates on internal generator windingadverse effect on insulation resistance.Periodically clean generator exterior surfaces. A soft bruused to loosen caked on dirt. Use a vacuum system or dpressure air to remove any accumulations of dirt. The ghoused inside an all-weather enclosure, clean the enclossoft, damp cloth or sponge and water.Once each year, have the generator cleaned and inspecteAuthorized Service Dealer. That dealer will use dry, lowto clean internal windings. Parts inside the control consbe cleaned and inspected at this time as well.Finally, have the insulation resistance of stator and rotochecked. If insulation resistances are excessively low, thtor may require drying.

SET PLUG GAP AT 1.14 mm(0.045 inch)

Stationary Emergency GeneratorMaintenance

10-3

a t0 3 ev. C 03/09



DANGER









10-4

SERVICE SCHEDULE

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.

Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal opera-

tion when required.

11-1

SrvSchd001 Rev. E 02/09

11-2

SrvSchd001 Rev. E 02/09

11-3

SrvSchd001 Rev. E 02/09

Maintenance Level 1 Level 2 Level 3 Level 4 Level5

Tasks

11-4

SrvSchd001 Rev. E 02/09

TROUBLESHOOTING GUIDE

PROBLEM CAUSE CORRECTION

Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse.

2. Loose or corroded or defective 2. Tighten, clean or replace

battery cables. battery cables as necessary.

3. Defective starter contactor. 3. Replace contactor.*

4. Defective starter motor. 4. Replace starter motor.*

5. Dead or Defective Battery. 5. Remove, change or replace battery.

6. 5 amp fuse blown. 6. Replace fuse.*

Engine cranks but won't start 1. Out of fuel. 1. Replenish fuel.

2. Fuel solenoid (FS) is defective 2. Replace solenoid.*

3. Open Wire #14A from Engine Control 3. Reconnect wire.

circuit board.

4. Spark plugs defective. 4. Clean, regap or replace plugs.

5. Door on tank not closed. 5. Close door on tank.

Engine starts hard, runs rough. 1. Flame arrestor (air cleaner) plugged or 1. Clean or replace as needed.

damaged.

2. Plugged fuel line. 2. Unclog fuel line.

3. Defective spark plugs. 3. Clean, regap or replace plugs.

4. Fuel pressure incorrect. 4. Confirm fuel pressure to regulator is as

recommended in SPECIFICATIONS.

Engine starts then shuts down. 1. Engine oil level is low. 1. Check oil and add oil as needed.

2. Engine is overheated. 2. Check cooling system for leaks.

3. Defective Low Oil Pressure Switch 3. Replace switch.*

4. Defective Coolant Temperature Switch 4. Replace switch.*

5. Defective Control Module circuit board. 5. Replace board.*

6. Coolant Level is Low. 6. Repair leak - Add coolant.

7. Defective Low Coolant Level Switch 7. Replace Switch.*

AUTO/OFF/MANUAL Switch at OFF, 1. Defective AUTO/OFF/MANUAL switch 1. Replace switch.*

engine continues to run 2. Open/disconnected wire #15A between 2. Reconnect/close wire.

AUTO/OFF/MANUAL switch and Control

Module circuit board.

3. Defective Control Module circuit board 3. Replace board.*

No AC output from generator. 1. Check main line circuit breaker. 1. Reset to ON or CLOSED.

2. Check circuit breaker & fuses. 2. Reset and replace, if necessary.

3. Transfer switch set to NORMAL position 3. Set to GENERATOR position.

4. Generator internal failure. 4. *

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

attempt restart.

*Contact the nearest Authorized Dealer for assistance.

12-1

Stationary Emergency Generator

Troubleshooting

Trblsht001 Rev. A 10/08

Stationary Emergency Generator

Notes

Stationary Emergency Generator

Notes

Stationary Emergency Generator

Notes

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

2 022129 6 WASHER LOCK M8-5/16

4 0E2747A 1 FAN SAE ALTERNATOR (G/B)

5 0A3870 1 KEY SQ 3/8 X 1-9/16 STEEL

6 0A3009 1 HUB DRIVE 390 SAE GB

7 0F5564D 1 RTR 390 100KB3 GB SAE TECHUM

0F5563D 1 RTR 390 130KB4 GB SAE TECHUM

0A3881D 1 RTR 390 80GB BR BRLSS

0A3881B 1 RTR 390 80GB 1P BRLSS

0A3882B 1 RTR 390 100GB 1P BRLSS

0A3883B 1 RTR 390 125GB 1P BRLSS

8 * 052624 1 BEARING BALL 6212 SEALED

9 0A5580 4 SCREW HHC M14-2.0 X 140 G8.8

10 0A1633 4 WASHER 390 SAE ALT.

11 0F7024J 1 STR-390-80LB3 SAE

0F7351 1 STR 390 130 GB4 CPL

0F7349 1 STR 390 80 AB3 CPL

0F7348 1 STR 390 100 AB3 CPL

0F7350 1 STR 390 130 AB4 CPL

0F7024D 1 ASSY STR 390 80KB3 SAE

12 068113 1 CARRIER REAR BRG 15"

13 022392 2 PIN DOWEL 1/2 X 1-1/4

14 043123 4 WASHER LOCK M14

15 051779 4 NUT HEX M14-2.0 G8 YEL CHR

16 052259 2 WASHER FLAT M12

17 051769 3 WASHER LOCK M12

18 068406 3 SCREW HHC M12-1.75 X 60 G10.9

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

20 087272 1 ASSY EXCITER 2.00" STK

21 068405C 1 EXITER FIELD 2" LG SPD CONN

22 092950 1 COLLAR SLIP FIT 390 MM

25 090063 1 BRIDGE SUPPORT DIODE 15"

26 090152 1 ASSY BRIDGE RECTIFIER

27 023365 3 WASHER SHAKEPROOF INT #8

28 033143 2 SCREW HHM #8-32 X 7/8

29 090064 1 CAP END ROTOR 390MM

30 083485 2 PLATE NUT

31 031980 2 TIE WRAP UL 14.6 X .14 NATL

32 083401 1 BRACKET-STATOR WIRE

33 042561 1 CLAMP HOSE #36 1.88-2.7

34 033212 2 SCREW HHC 5/16-18 X 1-1/4 G5

35 083549 1 SLEEVE RUBBER

40 0A4089 1 ASSY SCROLL 390 SAE

KIT PARTS I/N’S: 41 THRU 49 (INCLUDED IN I/N 40)

41 0A2491 2 SHROUD ALT SHEET METAL

42 0A2497 2 SCREEN SHROUD SAE

43 0A2496 2 BRKT TENSIONER SAE SCROLL

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

45 022307 6 WASHER LOCK M6-1/4

46 022473 6 WASHER FLAT 1/4-M6 ZINC

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

48 047411 4 SCREW HHC M6-1.0 X 16 G8.8

49 0A2110 14 SCREW SWAGE 1/4-20 X 1/2 ZYC

* ROTOR REPLACEMENT PART

1 047411 2 SCREW HHC M6-1.0 X 16 G8.8

2 022097 4 WASHER LOCK M6-1/4

3 022473 4 WASHER FLAT 1/4 ZINC

4 084918G 1 HEATER ENG 1500W 120V

5 0G0015 4 CLAMP HOSE 7/8” OD DOUBLE WIRE

6 042568 2 SCREW HHC M6-1.0 X 20 G8.8

7 055934D 1 CLAMP VINYL 1.06 X .406 Z

8 084427 1 BRACKET HEATER

9 035467 1 NIPPLE CLOSE 3/8NPT X 1 VIBRA

10 049813 2 NUT HEX M6-1.0 G8 YEL CHR

11 050967 1 HOSE COOL 5/8 ID 20R3 (33”LG)

12 022129 1 WASHER LOCK M8-5/16

13 042907 1 SCREW HHC M8-1.25 X 16 G8.8

14 0C4905 2 BARBED EL 45 3/8NPT X 5/8OD

0C4905 1 BARBED EL 45 3/8NPT X 5/8OD (150KW ONLY)

15 0A6283 1 HOSE PREFORMED BLOCK HEATER

16 025066 1 COUPLING FULL 3/8-18

17 059057 1 HOSE 3/4 ID SAE-30R2 (8”LG) (150KW ONLY)

18 057823 2 CLAMP HOSE #10 .56-1.06 (150KW ONLY)

19 0G8847 1 BARB Y UNIVERSAL 5/8-3/4 HOSE (150KW ONLY)

20 050967 1 HOSE COOL 5/8 ID 20R3 (24”LG) (150KW ONLY)

21 0F4355 REF. ADAPTER 1/2”NPT X 3/8”NPT (150KW ONLY)

22 0G0153 REF. BARBED EL 90 1/2NPT X 3/4 HOSE (150KW ONLY)

23 057823 REF. CLAMP HOSE #10 .56-1.06 (150KW ONLY)

24 0G0866 REF. HOSE OIL COOLER PREFORMED 3/4 (150KW ONLY) (SEE SPECIAL NOTE)

1

0F2885

1

PANEL CB CONN BOX

2 0F2883 1 STAND RH CONTROL

3 0F3685 1 STAND LH CONTROL C5 GRBX

4 023484N 1 BUSHING SNAP SB-2.5-31

023484N 2 BUSHING SNAP SB-2.5-31 (FOR 5.4L 1000KW 1PHASE)

5 086961 1 INTERFACE 1PH 240V

067617030A - INTERFACE 3PHS 416/480V

067617030B - INTERFACE 3PHS 208/240V

072158 - ASSY INTFC 3PH 600V

6 043180 4 WASHER FLAT M4

7 022264 6 WASHER LOCK #8-M4

8 0C3990 6 SCREW PHTT M4-0.7 X 10 ZYC

9 * 057701 REF. BLOCK TERM 20A 8 X 6 X 1100V

10 022155 2 WASHER LOCK #6

11 0C2428 2 SCREW PHTT #6-32 X 1/2 ZYC

12 0F3618 1 DECAL CPL CUST CONN H CTRL

13 0A9457 1 DECAL NEUTRAL

14 057073 2 JUNCTION BLOCK 3/8-16

15 ** 0D5466 REF. BUS BAR NEUTRAL BLOCK 390

16 ** 0A7822 REF. LUG SLDLSS 600/250-1/0 X 1/4-28

17 022237 4 WASHER LOCK 3/8

18 022241 4 NUT HEX 3/8-16 STEEL

19 049226 6 WASHER LOCK M5

20 0C2266 6 SCREW PHTT M5-0.8 X 16 ZYC

21 0C2454 10 SCREW THF M6-1 X 16 N WA Z/JS

22 042568 4 SCREW HHC M6-1.0 X 20 G8.8

23 022473 12 WASHER FLAT 1/4-M6 ZINC

24 022097 8 WASHER LOCK M6-1/4

25 049813 4 NUT HEX M6 X 1.0 G8 YEL CHR

26 0E9764 6” RAIL SNAPTRACK PCB HOLDER BULK

27 0G6962B 1 ASSY RELAY PCB 12VDC

28 025433 1 LUG SLDLSS #6-14 X 13/64 CU

29 024469 1 SCREW HHTT #10-32 X 3/8 CZ

30 067210A 1 DECAL GROUND LUG

31 0D6029 4 SCREW HHTT M6-1.0 X 16 ZYC

32 051713 2 WASHER FLAT M5

33 081008 1 GROMMET 1.25 X .25 X .75

34 077043J 3 CONDUIT FLEX 2.0" ID

077043J 4 CONDUIT FLEX 2.0" ID (FOR 5.4L/100KW 1 PHASE)

35 0F6156 1 PLATE WIRE SNGL GALV

36 029289 1 TAPE ELEC 1/2 FOAM (AS REQ’D)

37 *** 0F3113 REF ASSY PCB HSB CTRL IGN MODULE

38 047411 4 SCREW HHC M6-1.0 X 16 G8.8

39 036943 2 SCREW PPHM #10/32 X 2

40 023897 3 WASHER FLAT #10 ZINC

41 022152 2 WASHER LOCK #10

42 022158 2 NUT HEX #10-32 STEEL

43 0F8565 1 DECAL H-100 RB3 CUST CONN

44 045764 1 SCREW HHTT M4-0.7 X 8 ZP

45 023762 1 WASHER SHAKEPROOF EXT #10 STL

1.) UL CIRCUIT BREAKER (FD)

A 0F2887 1 COVER FD FRM CB

C 0D5572 - CB 0150A 3P 600V S FD6 LL

0D5573 - CB 0175A 3P 600V S FD6 LL

0D5574 - CB 0200A 3P 600V S FD6 LL

0D5575 - CB 0225A 3P 600V S FD6 LL

0D5576 - CB 0250A 3P 600V S FD6 LL

D 0F0199 1 INSULATOR CB FD FRAME 30MIL

E 065960 4 SCREW SHC 1/4-20 X 4 G8.8 NZ

F 022473 4 WASHER FLAT 1/4-M6 ZINC

G 022097 4 WASHER LOCK M6-1/4

H 022127 4 NUT HEX 1/4-20 STEEL

J 0C2454 4 SCREW THF M6-1 X 16 N WA Z/JS

K 029289 1 TAPE ELEC 1/2 FOAM (AS REQ’D)

L 0F1733 1 DECAL CUSTOMER CONNECT INSIDE

2.) UL CIRCUIT BREAKER (JD+LD)

A 0F2721 1 COVER CIR BRKR JD/LD

C 0D5577 - CB 0300A 3P 600V S JD6 LL

0D5578 - CB 0350A 3P 600V S JD6 LL

0D5579 - CB 0400A 3P 600V S JD6 LL

0D5581 - CB 0600A 3P 600V S LD6

0D5585 - CB 0450A 3P 600V S LD6 LL

D 0F2353 2 INSULATOR CIRCUIT BR. JD/LD

E 022770 4 SCREW RHM 1/4-20 X 3

F 022473 4 WASHER FLAT 1/4-M6 ZINC

G 022097 4 WASHER LOCK M6-1/4

H 022127 4 NUT HEX 1/4-20 STEEL

J 0C2454 7 SCREW THF M6-1 X 16 N WA Z/JS

K 029289 1 TAPE ELEC 1/2 FOAM (AS REQ’D)

L 0F1733 1 DECAL CUSTOMER CONNECT INSIDE

3) UL CIRCUIT BREAKER (ED)

A 0F3327 1 COVER,ED CB TALL

C 0D5556 1 CB 0090A 3P 480V S ED4 LL

0D5566 - CB 0060A 3P 600V S ED6 LL

0D5568 - CB 0080A 3P 600V S ED6 LL

0D5570 - CB 0100A 3P 600V S ED6 LL

0D9693 - CB 0125A 3P 480V S ED4 LL

D 0F0492 1 INSULATOR CB S (ED-3P)

E 048927 4 SCREW RHM #10-32 X 4-1/2

F 023897 4 WASHER FLAT #10 ZINC

G 022152 4 WASHER LOCK #10

H 022158 4 NUT HEX #10-32 STEEL

J 0C2454 7 SCREW THF M6-1 X 16 N WA Z/JS

K 029289 1 TAPE ELEC 1/2 FOAM (AS REQ’D)

L 0F1733 1 DECAL CUSTOMER CONNECT INSIDE

* ITEM INCLUDED WITH HARNESS.

** ITEM INCLUDED WITH 0D5464B.

*** ITEM IS PART OF 9R.

3.) UL CIRCUIT BREAKER (225AF)

A 0F4173 1 COVER CB C5 225AF

C 0F4165$ REF CIRCUIT BREAKERS 200A FRAME

D 0F4186 1 COVER CB DISH 225AF

E 036261 4 RIVET POP .125 X .275 SS

F 053640 4 SCREW RHM #8-32 X 3-1/4

G 038150 4 WASHER FLAT #8 ZINC

H 022264 4 WASHER LOCK #8-M4

J 022471 4 NUT HEX #8-32 STEEL

K 029289 2 TAPE ELEC 1/2 FOAM

L 0F1733 1 DECAL CUSTOMER CONNECT INSIDE

M 022129 9 WASHER LOCK M8-5/16

N 0F8432 1 INSULATOR CB 225AF

P 0C2454 7 SCREW THF M6-1 X 16 N WA Z/JS

R 0F8451 3 LUG SLDLSS 300 MCM-6 AL/CU

S 049897 6 SCREW SHC M8-1.25 X 20 G8

T 022145 6 WASHER FLAT 5/16-M8 ZINC

U 045771 3 NUT HEX M8-1.25 G8 CLEAR ZINC

V 0F8843 3 BUS BAR 200A LUG ADAPTOR

W* W/CB 2 TERMINAL COVER CB

X 0G3259 1 DECAL TERMINAL SHOCK HZD BI

Y 058306 3 SCREW SHC M8-1.25 X 25 G12.9

4.) UL CIRCUIT BREAKER (400AF)

A 0F4175 1 COVER CB C5 400AF

C 0F4166$ REF CIRCUIT BREAKERS 400A FRAME

D 0F1733 1 DECAL CUSTOMER CONNECT INSIDE

E 042419 4 SCREW RHM 10-32 X 4

F 023897 8 WASHER FLAT #10 ZINC

G 022152 4 WASHER LOCK #10

H 022158 4 NUT HEX #10-32 STEEL

J 0C2454 7 SCREW THF M6-1 X 16 N WA Z/JS

K 029289 1 TAPE ELEC 1/2 FOAM

L 052647 6 SCREW SHC M10-1.5 X 25 G12.9

M 046526 6 WASHER LOCK M10

N W/CB 3 BUS BAR CB ADAPTER 225-400 A

P 0A7822 3 LUG SLDLSS 600/250-1/0 X 1/4-28

R 022131 3 WASHER FLAT 3/8-M10 ZINC

S* W/CB 2 TERM COVER CB

T 023334 6 SCREW HHC 1/4-28 X 1/2 G5

U 022097 6 WASHER LOCK M6-1/4

V 0G3259 1 DECAL TERMINAL SHOCK HZD BI

5.) UL CIRCUIT BREAKER (800AF)

A 0F4176 1 COVER CB C5 800AF

C 0F4167$ REF CIRCUIT BREAKERS 800A FRAME

D 0F8433 2 INSULATOR CB 800AF

E 024196 4 SCREW RHM 1/4-20 X 3-1/2

F 022473 4 WASHER FLAT 1/4-M6 ZINC

G 022097 4 WASHER LOCK M6-1/4

H 022127 4 NUT HEX 1/4-20 STEEL

J 0C2454 7 SCREW THF M6-1X16 N WA Z/JS

K 029289 2 TAPE ELEC 1/2 FOAM

L 060619 2/3 SCREW SHC M10-1.50 X 40 G12.9

M 022131 2/3 WASHER FLAT 3/8-M10 ZINC

N 022237 2/3 WASHER LOCK 3/8

P 045772 2/3 NUT HEX M10-1.5 G8 YEL CHR

R 0F9721 2/3 LUG SLDLSS 3/0-400X3 MCM AL/CU

S 0D2157 4/6 SCREW SHC M6-1.0 X 50 G8.8

T 0F1733 1 DECAL CUSTOMER CONNECT INSIDE

U* W/CB 2 TERM COVER VITZROTECH 400AF CB

V 0G3259 1 DECAL TERMINAL SHOCK HZD BI

W 022097 4/6 WASHER LOCK M6-1/4

6.) NEUTRAL BLOCK 390 / 200-400A

A 0D5466 2 BUS BAR NEUTRAL BLOCK 390

B 039287 1 SCREW HHC M8-1.25 X 45 G8.8 FT

C 022145 1 WASHER FLAT 5/16-M8 ZINC

D 022129 1 WASHER LOCK M8-5/16

E 045771 1 NUT HEX M8-1.25 G8 YEL CHR

F 045335 2 SCREW HHC 1/4-28 X 3/4 G5

G 022097 2 WASHER LOCK M6-1/4

H 0A7822 1 LUG SLDLSS 600/250-1/0X1/4-28

* HARDWARE FOR MTG. CB TERMINAL COVERS IS

SUPPLIED WITH CIRCUIT BREAKERS.

1

0F2885

1

PANEL CB CONN BOX

2 0G0171 1 STAND RH CONTROL CPL C5

0G0171A 1 STAND RH CONTROL CPL C5 2 HOLE

3 0G0172 1 STAND LH CONTROL CPL C5

4 023484N 1 BUSHING SNAP SB-2.5-31

5 086961 1 INTERFACE 1PH 240V

067617030A - INTERFACE 3PHS 416/480V

067617030B - INTERFACE 3PHS 208/240V

6 043180 4 WASHER FLAT M4

7 022264 6 WASHER LOCK #8-M4

8 0C3990 6 SCREW PHTT M4-0.7 X 10 ZYC

9 * 057701 REF. BLOCK TERM 20A 8 X 6 X 1100V

10 022158 2 NUT HEX #10-32 STEEL

11 0F8565 1 DECAL H-100 RB3 CUST CONN

12 0F3618 1 DECAL CPL CUST CONN H CTRL

13 0A9457 1 DECAL NEUTRAL

14 057073 2 JUNCTION BLOCK 3/8-16

15 ** 0D5466 REF. BUS BAR NEUTRAL BLOCK 390

16 ** 0A7822 REF. LUG SLDLSS 600/250-1/0 X 1/4-28

17 022237 4 WASHER LOCK 3/8

18 022241 4 NUT HEX 3/8-16 STEEL

19 049226 6 WASHER LOCK M5

20 0C2266 6 SCREW PHTT M5-0.8 X 16 ZYC

21 0C2454 10 SCREW THF M6-1 X 16 N WA Z/JS

22 042568 4 SCREW HHC M6-1.0 X 20 G8.8

23 022473 12 WASHER FLAT 1/4-M6 ZINC

24 022097 8 WASHER LOCK M6-1/4

25 049813 4 NUT HEX M6 X 1.0 G8 YEL CHR

26 0E9764 6” RAIL SNAPTRACK PCB HOLDER BULK

27 0G6962B 1 ASSY RELAY PCB 12VDC

28 025433 1 LUG SLDLSS #6-14 X 13/64 CU

29 024469 1 SCREW HHTT #10-32 X 3/8 CZ

30 067210A 1 DECAL GROUND LUG

31 0D6029 4 SCREW HHTT M6-1.0 X 16 ZYC

32 051713 2 WASHER FLAT M5

33 081008 1 GROMMET 1.25 X .25 X .75

34 077043J 3 CONDUIT FLEX 2.0" ID

35 0F6156 1 PLATE WIRE SNGL GALV

36

029289

1

TAPE ELEC 1/2 FOAM (AS REQ’D)

37 *** 0F3113 REF ASSY PCB HSB CTRL IGN MODULE

38 047411 4 SCREW HHC M6-1.0 X 16 G8.8

39 036943 2 SCREW PPHM #10/32 X 2

40 023897 3 WASHER FLAT #10 ZINC

41 022152 2 WASHER LOCK #10

42 045764 1 SCREW HHTT M4-0.7 X 8 ZP

43 023762 1 WASHER SHAKEPROOF EXT #10 STL

1.) UL CIRCUIT BREAKER (800AF)

A 0G0173 1 COVER, CB 803 C5

C 0F4167$ REF CIRCUIT BREAKERS 800A FRAME

D 0F8433 2 INSUL CB 800AF

E 022477 4 SCREW RHM 1/4-20 X 1-1/2

F 022473 8 WASHER FLAT 1/4-M6 ZINC

G 022097 4 WASHER LOCK M6-1/4

H 022127 4 NUT HEX 1/4-20 STEEL

J 0F1733 1 DECAL CUSTOMER CONNECT INSIDE

K 029289 2 TAPE ELEC 1/2 FOAM

L 060619 2/3 SCREW SHC M10-1.50 X 40 G12.9

M 022131 2/3 WASHER FLAT 3/8-M10 ZINC

N 022237 2/3 WASHER LOCK 3/8

P 045772 2/3 NUT HEX M10-1.5 G8 YEL CHR

R 0F9721 2/3 LUG SLDLSS 3/0-400X3 MCM AL/CU

S 0D2157 4/6 SCREW SHC M6-1.0 X 50 G8.8

T **** W/CB 2 TERM. COVER VITZROTECH 400AF CB

U 0G3259 1 DECAL TERMINAL SHOCK HZD BI

V 022097 4/6 WASHER LOCK M6-1/4

2.) NEUTRAL BLOCK 390 / 200-400A

A 0D5466 1 BUS BAR NEUTRAL BLOCK 390

B 039287 1 SCREW HHC M8-1.25 X 45 G8.8 FT

C 022145 1 WASHER FLAT 5/16-M8 ZINC

D 022129 1 WASHER LOCK M8-5/16

E 045771 1 NUT HEX M8-1.25 G8 YEL CHR

F 045335 2 SCREW HHC 1/4-28 X 3/4 G5

G 083896 2 WASHER LOCK 1/4-M6 SS

H 0A7822 1 LUG SLDLSS 600/250-1/0 X 1/4-28

* ITEM INCLUDED WITH HARNESS

** ITEM INCLUDED WITH 0D5464B

*** ITEM IS PART OF 9R.

**** HARDWARE FOR MTG. CB TERMINAL COVERS IS SUPPLIED WITH

CIRCUIT BREAKERS.

1 0F3384 1 BASE CPL 100-130KW 6.8L GB

2 065852 1 SPRING CLIP HOLDER .37-.62

3 052252 4 DAMPENER VIBRATION

4 052257 4 SPACER .49 X .62 X 1.87 PWDR/ZINC

5 052259 8 WASHER FLAT M12

6 055597 4 SCREW HHC M12-1.75 X 85 G8.8

7 052251A 4 DAMPENER VIBRATION 50 WHITE

8 052860 4 NUT LOCKING M12-1.75

9 0F2895 1 SUPPORT ENG 5.4L LH/RH 6.8L RH

10 045764 1 SCREW HHTT M4-0.7 X 8 BP

11 090502 4 SCREW SHC M10-1.5 X 60 G12.9

12 061383 1 LUG SOLDERLESS 3/0-#4 X 13/32 CU

13 043107 1 SCREW HHC M8-1.25 X 25 G8.8

14 022473 1 WASHER FLAT 1/4-M6 ZINC

15 049813 1 NUT HEX M6 X 1.0 G8 YEL CHR

16 057192 4 SCREW SHC M10-1.5 X 30 G12.9

17 022131 8 WASHER FLAT 3/8-M10 ZINC

18 046526 8 WASHER LOCK M10

19 0536210410 1 ASSY WIRE 14.00”

20 042909 1 SCREW HHC M8-1.25 X 30 G8.8

21 022261 2 WASHER SHAKEPROOF INT 3/8

22 022129 1 WASHER LOCK M8-5/16

23 022145 2 WASHER FLAT 5/16-M8 ZINC

24 045771 2 NUT HEX M8-1.25 G8 YEL CHR

25 053557 4 SCREW HHC M12-1.75 X 40 G8.8

26 0F2591 2 TOWER GB COMPROD C5

27 0F2910 1 SUPPORT ENGINE 6.8L LH SIDE

28 038750 1 SCREW HHC M6-1.0 X 30 G8.8

29 022097 1 WASHER LOCK M6-1/4

30 022447 1 WASHER SHAKEPROOF INT 1/4

1

0F2123

1

GEAR CASE ENG. MACHINED

2 0F2122 1 GEAR CASE ALT. MACHINED

3 095613 1 SEAL OIL

4 051756 2 SCREW HHC M10-1.5 X 20 G8.8

5 046526 44 WASHER LOCK M10

6 049814 4 SCREW HHC M10-1.5 X 25 G8.8

7 051735 8 SCREW HHC M10-1.5 X 70 G8.8

8 0F2097 1 GASKET 390 GEARBOX

9 072879 1 SPACER .69 X 2.75 X .37 ST/ZNC

10 097557B 1 KEY 10 X 16 X 46

11 0H3114 1 GEAR OUTPUT 1. 65:1

095970 1 GEAR OUT 390-50H 37T

095968 1 GEAR OUT 390-60H 35T

0E6866 1 GEAR OUTPUT 2:1 50HZ 390

12 070263 2 SCREW HHC M16-2.0 X 35 G10.9

13 057019 2 BALL BRG 65 X 120 X 23

14 026847 1 BREATHER

15 0H3113 1 GEAR INPUT 1.65: 1

095969 1 GEAR INPT 390-50 25T

095967 1 GEAR INPT 390-60 27T

0E6865 1 GEAR INPUT 2:1 50HZ 390

16 095966 1 SHAFT 390 INPUT GEAR

17 095976 1 COLLAR HARDENED

18 095971 1 SEAL OIL

19 096777 1 SNAP RING INT 120MM

20 057019S 1 BEARING #6213 SEALED

22 096379 1 PLATE INTRNL BRG RET

23 048189 2 PIN DOWEL M8 X 24

24 095979 1 PLATE BEARING THRST

25 021159 1 SPACER STRESSPROOF

26 097557A 1 KEY 10 X 16 X 40

27 057163 1 PLUG PIPE 3/8" MAGNETIC

28 0F6518 4 SCREW HHFC M10-1.5 X 25 G10.9

29 0F3201 1 COVER GEARBOX GUARD

30 020443 1 COUPLING INNER DRAWN

31 094666A 1 COUPLING OUTER MACHN

32 099828 8 DAMPER GB CPLR VIBRA

33 099828A 8 DAMPER GB CPLR VIBRA

34 026925 2 PLUG STD PIPE 3/8 STEEL SQ HD

35 097557C 1 KEY 10 X 16 X 50

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

37 025066 1 COUPLING FULL 3/8-18

38 031578 6 SCREW HHC 3/8-16 X 1-1/2 G8

052625 REF. SCREW SHC M10-1.5 X 35 G12.9 (FORD ENGINES)

39 049814 10 SCREW HHC M10-1.5 X 25 G8.8

40 0A1786 2.5cc RETAINING COMPOUND

41 027175 .200 GAL LUBE GREASE SAE #90 80W90 (NOT SHOWN)

44 045772 10 NUT HEX M10-1.5 G8 YEL CHR

45 052243 10 SCREW HHC M10-1.5 X 60 G8.8

46 057642 2 SCREW HHC M10-1.5 X 40 G10.9

47 0F6487 4 WASHER FLAT M10 SEALING COPPER

48 0F6355 1 GASKET SEAL PLATE 390 GB

49 0F6477 .050 GAL ENHANCER GEAR OIL (NOT SHOWN)

50 0F6557 0.4cc THREADLOCK AND SEALANT

51 026924 1 ELBOW 90D STREET 3/8

1 0F2807C 1 PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5)

0F2807E 1 PIPE EXH MAN R/H 5.4L G/B & 2P (5.4L C5)

0F9207 1 PIPE EXH MANIFOLD 4.6L RH

2 0F2807B 1 PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5)

0F2807D 1 PIPE EXH MAN L/H 5.4L G/B & 2P (5.4L C5)

0F9208 1 PIPE EXH MANIFOLD 4.6L LH

4 0A6765 2 RING GASKET 2.5 DIA

5 0F4710 6 WASHER LOCK M10 SS

6 0F7200 6 SCREW HHC M10-1.5 X 50 SS FTH

7 080762 8 BOLT U 3/8-16 X 2.62

8 0F2809 1 PIPE EXHAUST CROSSOVER

9 0F2981A 2 MFLR 7" X 9" X 25" (2) 2.5" IN/2.5" OUT

10 0F2962 2 MUFFLER STRAP

11 0C2454 4 SCREW THF M6-1 X 16 N WA Z/JS

12 022097 8 WASHER LOCK M6-1/4

13 0F2830 2 MUFFLER BRACKET STIFFENER

18 0F2773C 2 EXHAUST BLANKET 900MM LONG (6.8L C5)

0F2773D 2 EXHAUST BLANKET 850MM LONG (5.4L C5)

19 0D3159 1 FLANGE EXHAUST

20 088775 6 WASHER FLAT 3/8 SS

21 0F2808 2 EXHUAST OUTLET PIPE CPL

22 0F5447 1 BRKT MUFFLER

23 022473 12 WASHER FLAT 1/4-M6 ZINC

24 0F6214 2 PIPE ELBOW EXHAUST MUFFLER

26 0F6803 4 MUFFLER STRAP UPPER/LOWER

27 049813 4 NUT HEX M6 X 1.0 G8 YEL CHR

28 049721 8 SCREW HHC M6-1.0 X 35 G8.8 BLK

29 088510 6 NUT HEX M10-1.5 SS

30 0C9748 1 PLUG M18-1.50

1 0F3017 1 BRACKET,D.C. ALTERNATOR LOWER

2 039253 3 SCREW HHC M8-1.25 X 20 G 8.8

3 022129 4 W ASHER LOCK M8-5/16

4 022145 4 W ASHER FLAT 5/16-M8 ZINC

(2) 5 0D5419 REF OIL FILTER, F ORD V-10 ENG INE

6 0D7055 1 DIPSTICK TUBE, FO RD 6.8L

7 0D3488G 1 BELT SERPENTINE (65.0" LG) (1800 RPM)

0D3488J 1 BELT SERPENTINE (65.3" L G) (2300 RPM)

0D3488 1 BE LT S ERPENTINE (67.16" LG) ( 3000 RPM)

0D3488K 1 SERPENTINE BELT (68.3" L G) (3600 RPM)

8 057795A 1 BARBED EL 90 3/4 PLAST IC

9 059057 1 HOSE 3/4 ID SAE-30R2 (16.75” LG)

10 0F3287 1 BRACKET DC ALTERNATOR UP PER

(3) 11 0F5990 1 HARN ENG 6.8L H-100 (USE WITH PROBE P /N 0E2507)

0H2595 1 HARN ENG G6.8L G3 H-100 (USE WITH PROBE P/N 0H1827)

0F4419 1 HARN ENG 6.8L G-100 ( USE WIT H PROBE P/N 0E2507)

0H3081 1 HARN ENG G6.8L G3 MQT 480V (USE WITH PROBE P/N 0H1827)

0F9786 1 HARN ENG 6.8L G-100 MQT 208V (USE W ITH PROBE P/N 0E2507)

0H3080 1 HARN ENG G6.8L G3 MQT 208V (USE WITH PROBE P/N 0H1827)

12 0E9868A 1 ALTERNATOR DC W/OUT PULLEY

13 057796 1 GROMMET

14 0F3216 1 PULLEY 80 OD DC ALTERNATOR (1800 RPM)

0F3216A 1 PULLEY 102 O D DC ALTERNATOR (2300 RPM)

0F3216C 1 PULLEY 132 O D DC ALTERNATOR (3000 RPM)

0F3216D 1 PULLEY 160 O D DC ALTERNATOR (3600 RPM)

15 055476 1 BUSHING REDUCER 3/8 TO 1/8 G AL

16 0F4612 1 SENDER OIL PRESSURE 1/8" NPT

17 0D6658 1 DIPSTICK 6.8L FORD

(3) (1) 18 029333A 2 TIE W RAP UL 7.4" X .19" BL K

19 022097 3 WASHER LOCK M6-1/4

20 022473 3 WASHER FLAT 1/4 ZINC

21 042568 3 SCREW HHC M6-1.0 X 20 G8.8

22 0D8027 4 BOLT WATER P UMP PULLEY

23 0D8025 1 BOLT GRO OVED IDLE R P ULLEY

24 0D8026 3 BOLT BELT TENSIONER

25 0D8030 1 TENSIONER ENG. AUTOMATIC BELT

26 0F2846 1 PULLEY W ATER PUMP FORD (1800RPM UNITS)

0D8029 1 PULLEY ENGINE WATER PUMP (2-POLE & GEAR BOX)

27 0D8028 1 PULLEY G RO OVED ENGINE IDLER

28 045771 1 NUT HEX M8-1.25 G8 YEL CHR

29 0D3454A 1 ENGINE G6.8L G3 V-10

0H0923 1 ENGINE G6.8L G3 V-10 (2009)

30 022131 2 WASHER FLAT 3/8-M10 ZINC

31 046526 1 WASHER LOCK M10

32 064416 1 SCREW HHC M10-1.5 X 45 G 8.8 FT

33 045772 1 NUT HEX M10-1.5 G8 YEL CHR

34 0F3217 1 SPACER DC ALTERNAT OR PULLEY

35 0F2776A 1 BRACKET SIGNAL CONDIT IO NER

36 0F6151 1 CAP RUBBER

37 0F4308 1 BRACKET DC ALT STABILIZER

38 0F3158 1 OIL COOLER FORD (150KW 3600RPM)

39 057823 2 CLAMP HOSE #10 .56-1.06

40 0E0502 1 TEMPERATURE SENDER DELPHI

41 0G0866 1 HOS E OIL COOLER PREFORMED 3/4 ( 150KW 3600RPM)

42 0F4301 1 HOSE OIL COOLER (150KW 3600RPM)

44 0C4905A 1 BARBED EL 45 1/2NPT X 3/4OD

45 057823 4 CLAMP HOSE #10 .56-1.06 (150KW 3600RPM)

46 0E0992A 10 PLUG EXPANSION 14 OD

47 078637 A/R ADHES IVE LOCTITE 620

48 0G7519 1 DE CAL EMISSION CTRL INFO 6.8L

49 0F4355 1 ADAPTER 1/2"NPT X 3/8"NPT

(1) NOTE: I/N 18 IS FOR HOLDING SENSOR TO I/N 35.

(2) I/N 5 P ART OF I/N 29.

2 0D5418 1 STARTER MOTOR FORD V-10 ENGINE

3 052625 11 SCREW SHC M10-1.5 X 35 G12.9

4 047411 1 SCREW HHC M6-1.0 X 16 G8.8

5 0D5623 2 HEAT SHIELD EXHAUST

6 0D2608 10 SCREW HHC 5/16-18 X 1/2 SSTL

7 070006 30 WASHER LOCK M8 SSTL

8 070008 10 WASHER FLAT M8 SS

9 055934M 1 CLAMP VINYL .75 X .343 Z

10 0G0321 1 HOSE COOL 5/8" ID 250#WP (14”)

11 046526 23 WASHER LOCK M10

12 057823 1 CLAMP HOSE #10 .56 - 1.06 (2300 & 3000RPM UNITS ONLY)

13 057765 1 ADAPTER M14-1.50 X 3/8 NPT

14 046964 1 ELBOW 90D 1/4 NPT F-M BRASS

15 0D5417 REF. SCREW HHC M10-1.0 X 25 G10.9

16 049821 3 SCREW SHC M8-1.25 X 30 G12.9

17 022129 3 WASHER LOCK M8-5/16

18 070010 2 SCREW HHC M8-1.25 X 35 SS F-TH

19 0F2776A 1 BRACKET SIGNAL CONDITIONER

20 022097 1 WASHER LOCK M6-1/4

21 048191 2 DOWEL PIN M10 X 24

22 022473 1 WASHER FLAT 1/4 ZINC

23 * 029333A 1 TIE WRAP UL 7.4" X .19" BLK (NOT SHOWN)

24 0D9913 18 SCREW SHC M8-1.25 X 35 SS

25 055596 1 BARBED STR 3/8 NPT X 3/8

26 069860E 1 HOSE DRAIN ASSY 28"

27 0D4255 2 GASKET EXHAUST MANIFOLD

28 057772 1 WASHER NYLON .565

29 0D6686 1 ASSEMBLY 6.8L G-BOX FLYWHEEL

30 0D3803 1 FLYWHEEL HOUSING MACH 6.8L V10

31 0D3805 1 COVER FLYWHEEL MACH 6.8L V-10

32 021113 1 PLATE DAMPNER RETNR

33 077996 1 CAP HOSE (2300 & 3000RPM UNITS ONLY)

34 022131 7 WASHER FLAT 3/8-M10 ZINC

35 048031J 1 HOSE CLAMP BAND 5/8"

36 052647 9 SCREW SHC M10-1.5 X 25 G12.9

37 0D2244M 1 ASSY MAGPICKUP(3/8-24 MALE)

38 0D3808 2 EXH MANIFOLD MACH 6.8L V-10

39 0F5114 1 DECAL REFER TO OWNERS MANUAL

41 079121 2 SCREW SHC M10-1.50 X 100 G10.9

43 057823 2 CLAMP HOSE #10 .56-1.06

44 053660 1 BARBED STR 1/4 NPT X 5/8

45 087599 1 PLUG PLASTIC 3/8 NPT

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

1 0D2513D 1 AIR CLNR BTM PLT W/CPLR 8.1L

2 0F5419 1 ELEMENT AIR FILTER

3 0F4268 1 TOP PLATE VENTURI

4 0F4270A 1 HOLD DOWN AIR CLEANER PLATED

5 0F6977 1 PLATE AIR CLEAN TOP 5.4L/6.8L

6 037561 1 NUT WING 1/4-20 NYLK

7 047411 4 SCREW HHC M6-1.0 X 16 G8.8

8 022097 4 WASHER LOCK M6-1/4

9 049811 4 WASHER FLAT M6

10 0F4269 1 GASKET MIXER BODY

11 022473 1 WASHER FLAT 1/4-M6 ZINC

1 0F2807C 1 PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5)

0F2807E 1 PIPE EXH MAN R/H 5.4L G/B & 2P (5.4L C5)

2 0F2807B 1 PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5)

0F2807D 1 PIPE EXH MAN L/H 5.4L G/B & 2P (5.4L C5)

3 088510 6 NUT HEX M10-1.5 SS

4 0A6765 2 RING GASKET 2.5 DIA

5 0F4710 6 WASHER LOCK M10 SS

6 0F7200 6 SCREW HHC M10-1.5 X 50 SS FTH

7 080762 6 BOLT U 3/8-16 X 2.62

8 0F2809 1 PIPE EXHAUST CROSSOVER

9 0F2981A 2 MUFFLER 7" X 9" X 25" (2) 2.5" IN/2.5" OUT

10 0F2962 2 MUFFLER STRAP

11 047411 4 SCREW HHC M6-1.0 X 16 G8.8

12 022097 8 WASHER LOCK M6-1/4

13 0F2830 2 MUFFLER BRACKET STIFFENER

14 049721 4 SCREW HHC M6-1.0 X 35 G8.8 BLK

15 049813 4 NUT HEX M6 X 1.0 G8 YEL CHR

16 0F6803 4 MUFFLER STRAP UPPER/LOWER

17 0F6214 2 PIPE ELBOW EXHAUST MUFFLER

18 0F2773C 2 EXHAUST BLANKET 900MM LONG (6.8L C5)

0F2773D 2 EXHAUST BLANKET 850MM LONG (5.4L C5)

19 0D3159 2 FLANGE EXHAUST

20 088775 6 WASHER FLAT 3/8 SS

21 022473 12 WASHER FLAT 1/4-M6 ZINC

22 0F5447 1 BRACKET MUFFLER

1 0G17730GS0R 1 GUARD BELT RIGHT HAND C5

2 0G17710GS0R 1 GUARD BELT TOP C5

3 0G17720GS0R 1 GUARD BELT BOTTOM C5

4 0G17740GS0R 1 GUARD BELT LEFT HAND C5

5 056326 1 TRIM VINYL BLACK 1/8GP

6 0C2454 10 SCREW THF M6-1 X 16 N WA Z/JS

7 022131 4 WASHER FLAT 3/8-M10 ZINC

8 046526 4 WASHER LOCK M10

9 051756 4 SCREW HHC M10-1.5 X 20 G8.8

10 081008B 1 GROMMET 1.25 X .25 X 1.00

COMPONENTS INCLUDED IN 0G4140E

1 0F1823CST06 1 ENCL H/G CONTROL PANEL

2 0F1824AST06 1 COVER CONTROL PANEL

3 0F2606 1 HINGE CONTINUOUS H PANEL

4 036261 7 RIVET POP .125 X .275 SS

5 0F5763 1 ASSY PROGRAMMED H-100

6 0F1732 1 DECAL FUSES LOCATED INSIDE

7 0E9764 1 RAIL SNAPTRACK PCB HOLDER BULK (12”LG)

8 0F1740C 1 ASSY PCB 10A UL BATT CHRGR 12V

9 0F1958 1 PLATE HARNESS CLAMP

10 0F2256 1 ASSY PCB PWR AVR W/AMP HEADER

11 0E3161 1 ASSY PCB BOSCH GOV DRIVER

12 029673 1 DIO BRIDGE 25A 600V

13 049226 11 WASHER LOCK M5

14 079224 4 SCREW PPHM M5-0.8 X 30 SS

15 051713 11 WASHER FLAT M5

16 0F5886 6 SCREW HHPM M5-0.8 X 12

17 051716 5 NUT HEX M5-0.8 G8 YEL CHR

18 043180 3 WASHER FLAT M4

19 0C3990 3 SCREW PHTT M4-0.7 X 10 ZYC

20 0F4333 1 CONN DUST CAP W/CHAIN DB9

21 0F5883 1 WASHER FLAT M3.5

22 0F5884 1 SCREW PHTT M3.5-0.6 X 10

23 055014 10 SCREW PPHM M4-0.7 X 8 BLX OX

24 022264 10 WASHER LOCK #8-M4

25 0G3546 1 DECAL WRN BATT CHRG 12/24V BI

26 0G3648 1 M5-0.8 CAPTIVE PANEL KNLD HD

27 0F6305 2 SEAL COVER 3.18 X 12.7 X 382

28 0F6305A 1 SEAL COVER 3.18 X 12.7 X 283

29 0G4329 1 HARNESS H-PNL INTEGRATED SW (NOT SHOWN)

COMPONENTS INCLUDED IN WIRE HARNESS

A 0F1263 1 ADPTR RH SIDE WICKMANN 178.6191

B 0F1262 4 HOLDER FUSE WICKMANN 178.6150

C 0F1264 1 ADPTR LH SIDE WICKMANN 178.6192

D 0E9049B 1 ASSY PCB G-PANEL RELAY 12VDC

E 055911 1 BLOCK TERM 20A 12 X 6 X 1100V

COMPONENTS NOT INCLUDED IN 0G4140E OR WIRE HARNESS

50 056739 1 RELAY CONTACTOR 12VDC

51 - 1 DPE BREAKER SEE DRAWING 0F9280

52 - 1 BOOST RESISTOR SEE DRAWING 0F9280

53 0F2627B 1 COVER CONTROL PANEL SIDE

54 022287 2 SCREW HHC 1/4-20 X 3/4 G5

55 022473 4 WASHER FLAT M6-1/4

56 022097 2 WASHER LOCK M6-1/4

57 043182 3 WASHER LOCK M3

58 051714 3 NUT HEX M3-0.5 G8 YEL CHR

59 052777 3 WASHER FLAT M3

60 0C2323 2 SCREW PHTT #6-32 X 5/8 ZYC

61 0F5459 1 DECAL CPL CONTROL PANEL FUSES

62 0F5461 1 DECAL CPL 5.4/6.8L TB3

63 022127 2 NUT HEX 1/4-20 STEEL

64 0F5460 1 DECAL CPL 5.4/6.8L RELAY BOARD

65 0E7403C 1 FUSE ATO TYPE 15 AMP (BLUE)

66 0E7403B 2 FUSE ATO TYPE 10 AMP (RED)

67 0F6145 A/R SEAL WEATHER .45"DIA

68 0C2699 2 SCREW PHTT #6-32 X 3/8 ZYC

69 0C2266 4 SCREW PHTT M5-0.8 X 16 ZYC

1

0H20530ST03

1

WELDMENT RADIATOR SUPPORT C5

2 0F2611 1 RADIATOR 680 X 680 X 70 CPL

3 0F5254 1 V-BELT 31/64" X 62-3/8"

0F7077 1 V-BELT 1/2" X 63-3/8" (6.8L, 100KW & 130KW)

4 046526 12 WASHER LOCK M10

(2) 5 059981 4 SCREW HHC M10-1.5 X 30 C10.9

6 0C2454 2 SCREW THF M6-1 X 16 N WA Z/JS

7 052250 2 TAPE FOAM 1 X 1 (26.75” LG)

8 076749 1 TANK COOLANT RECOVERY

9 0F2573 1 PULLEY FAN V-GROOVE 9"

10 0F2610 1 FAN 26" LH ROTATION

11

0H20620ST03

1

ARM

BELT TENSIONER

(2) 12 0H2051 1 SHOULDER BOLT 1/2 X 2-1/4"

13 0F2862 1 SPRING TENSION CPL

14 0F2560 1 PULLEY V-BELT 4" FLANGED

15 022131 15 WASHER FLAT 3/8-M10 ZINC

(2) 16 039287 1 SCREW HHC M8-1.25 X 45 C8.8

17 0C8566 8 SCREW HHFC M6-1.0 X 20 G8.8

18 0F2561 1 HUB FLEX PLATE

19 0C8165 4 NUT HEX LOCK 5/16-24 NY INS

(2) 20 0D6795 1 SCREW HHC M12-1.5 X 60 G8.8

21 0C7043 12 DISK FLEX

22 0E8909 1 COUPLING HUB FLEX (MACH)

0E8909A 1 COUPLING HUB FLEX (MACHINING)

23 048031C 1 CLAMP HOSE BAND 1/4

(2) 24 0C8146 4 SCREW HHC 5/16-24 X 1.124

25 082774 2 KEY WOODRUFF 4 X 19D

26 0F2686 1 HOSE RADIATOR UPPER CPL

27 0F5463 1 HOSE LOWER RAD CPL C5 6.8L

28 0F8695 1 ASSY BRG/SHAFT CPL FANDRIVE

29 0F4028 1 PULLEY 6.5" DIA MACHINED (6.8L 100KW)

0F4030 1 PULLEY 6" DIA MACHINED (6.8L 130KW)

0F4032 1 PULLEY 5.5" DIA MACHINED (5.4L 80KW & 6.8L 150KW)

(2) 30 042911 1 SCREW HHC M10-1.5 X 30 G8.8

31 0F2872 1 SCREW HHC 1/2-13 X 2" G8

32 022304 1 WASHER FLAT 1/2 ZINC

33 022195 1 WASHER LOCK 1/2

34 022196 1 NUT HEX 1/2-13 STEEL

35 049813 8 NUT HEX M6 X 1.0 G8 YEL CHR

36 052677 1 WASHER NYLON .50 X .87 X .06

37 090283 1 CAP RADIATOR 13 PSI

38 0F2776A 1 BRACKET, SIGNAL CONDITIONER

39 022145 4 WASHER FLAT 5/16-M8 ZINC

40 022129 2 WASHER LOCK M8-5/16

41 052644 1 SPACER .5 X 1.5 X .25 STL/ZINC

42 035685 4 CLAMP HOSE #28 1.32-2.25

43 045764 1 SCREW HHTT M4-0.7 X 8 BP

44 065852 1 SPRING CLIP HOLDER .37-.62

45 0C7649 1 CLAMP HOSE .38-.87

46 055596 1 BARBED STR 3/8 NPT X 3/8

47 069860E 1 HOSE DRAIN ASSY 28"

(1) 48 069811 REF CAP HEX 1/4 NPT BRASS

49 080713 1 BRACKET COOLANT TANK

50 022473 24 WASHER FLAT 1/4-M6 ZINC

51 022097 16 WASHER LOCK M6-1/4

52 042568 8 SCREW HHC M6-1.0 X 20 G8.8

53 0F5050B 1 SHIELD RADIATOR

54 039253 3 SCREW HHC M8-1.25 X 20 G8.8

55 051769 1 WASHER LOCK M12

56 0C8145 8 WASHER FLEX (THIN)

57 0H1827 1 PROBE COOLANT LEVEL 3/8-18NPTF

58 0H23980ST03 1 BRACKET TENSIONER SPRING

59 029032 1 HOSE 9/32 ID (43”LG)

60 049820 2 NUT HEX LOCK M8-1.25 NY INS

(3) 61 0H2844 2 (REF)

BEARING SLEEVE 1/2/ X 3/4 X 1

62 0G53150AL0R 1 SPACER CPL COOLING FAN 1/8"

63 051756 4 SCREW HHC M10-1.5 X 20 C8.8

64 052625 3 SCREW SHC M10-1.5 X 35 G12.9

(1) ITEM 48 IS INCLUDED WITH 47.

(2) APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THREADS.

(3) ITEM 61 IS INCLUDED WITH ITEM 1.

1 0G15310GS0R 2 PANEL C5 FRONT SIDES

2 0G15320GS0R 2 PANEL C5 REAR SIDES

3 0G15300GS0R 1 PANEL LOWER FRONT

4 0G15290GS0R 1 PANEL C5 TOP

0H30010GS0R 1 PANEL C5 TOP

5 0G15330GS0R 1 PANEL C5 TOP MOUNT

6 0C2454 20 SCREW THF M6-1 X 16 N WA Z/JS

(1) 7 0D3215B 2 ACCESS COVER 160 X 170 GALV

(1) 8 0C2454 8 SCREW THF M6-1 X 16 N WA Z/JS

(1) NOT REQUIRED FOR UNITS WITH CATALYST.

1 033212 4 SCREW HHC 5/16-18 X 1-1/4 G5

2 065908 1 SUPPORT NAT GAS SOLENOID

3 0G9191L 1 REG ASSY 6.8L 130KW DUAL LP QT

0G9191M 1 REG ASSY 6.8L 150KW DUAL LP QT

0G9190A 1 REG ASSY 6.8L 100KW LPV CPL

0G9239A 1 REG ASSY 5.4L 80KW LPV CPL

4 052617 2 SCREW HHC M12-1.75 X 20 G8.8

5 022304 2 WASHER FLAT 1/2 ZINC

6 022129 4 WASHER LOCK M8-5/16

7 045773 2 NUT HEX M12-1.75 G8 YEL CHR

8 064346 1 PIPE TEE 1-1/4 NPT

9 0A8064 2 BSHG RDCR HEX 1-1/4-3/4

10 030131 1 ELBOW 90D 1-1/4 NPT

11 031015 1 NIPPLE PIPE 1-1/4 NPT X 3 (100KW & 130KW)

088963 1 NIPPLE PIPE 1.25 NPT X 5.5 BL IRN (150KW)

12 026915 2 NIPPLE CLOSE 3/4 X 1.375

13 057823 4 CLAMP HOSE #10 .56-1.06

14 059057 2 HOSE 3/4 ID SAE-30R2 (45” LG)

15 0D2698 1 GASKET ADAPTER THROT BODY

16 0D1509 1 DECAL INLET PRESSURE

17 050280 1 DECAL FUEL INLET LPG

18 0H2353 1 ASSY,ADAPTER,THROTTLE BODY

0F2756A 1 MACHINING, INTAKE ADAPTOR 60MM

19 0E4390 1 GASKET GOVERNOR ACTUATOR

20 0E4392 1 ACTUATOR BOSCH 60 GOVERNOR

21 0F0960 1 REDUCER 3.0" TO 2.75" TURBO

22 0F3885 1 MIXER 40/60MM ACTUATOR ASSY

23 0G3167 2 O-RING 2-3/4 X 3/32 X 2-15/16

24 0F3691E 1 VENTURI THROTTLE 42MM (6.8L 100KW)

0F3691F 1 VENTURI THROTTLE 44MM (6.8L 130KW)

0F3691J 1 VENTURI THROTTLE 50MM (6.8L 150KW)

0F3691B 1 VENTURI, THROTTLE 36MM (5.4L 80KW)

25 022195 2 WASHER LOCK 1/2

26 0G5989 1 HARNESS, FUEL JUMPER DUAL REG

27 026073A 1 PLUG STD PIPE 1/4 STEEL SQ HD

28 0D2157 4 SCREW SHC M6-1.0 X 50 C8.8

29 039294 1 CLAMP HOSE #44 2.31-3.25

30 022097 4 WASHER LOCK M6-1/4

(1)31 042568 2 SCREW HHC M6-1.0 X 20 G8.8

(1)32 049811 2 WASHER FLAT M6

33 039130 1 NIPPLE CLOSE 1.25 NPT X 1.625

34 066212 1 CLAMP HOSE #52 2.81-3.75

(1)35 0G46350ST03 1 BRACKET, HOSE RISER

(1)36 022097 2 WASHER LOCK M6-1/4

(1) G6.8L UNITS ONLY

1 033212 4 SCREW HHC 5/16-18 X 1-1/4 G5

2 065908 1 SUPPORT NAT GAS SOLENOID

3 0G9191A 1 REG ASSY 6.8L 130KW DUAL NG QT

0G9191B 1 REG ASSY 6.8L 150KW DUAL NG QT

4 052617 2 SCREW HHC M12-1.75 X 20 G8.8

5 022304 2 WASHER FLAT 1/2 ZINC

6 022129 4 WASHER LOCK M8-5/16

7 045773 2 NUT HEX M12-1.75 G8 YEL CHR

8 022195 2 WASHER LOCK 1/2

9 039130 1 NIPPLE CLOSE 1.25 NPT X 1.625

10 030131 1 ELBOW 90D 1-1/4 NPT

11 031015 1 NIPPLE PIPE 1-1/4 NPT X 3 (130KW)

088963 1 NIPPLE PIPE 1.25 NPT X 5.5 BL IRN (150KW)

12 0G5989 1 HARNESS, FUEL JUMPER DUAL REG

13 057822 12 CLAMP HOSE #8 .53-1.00

14 059057 2 HOSE 3/4 ID SAE-30R2 (42” LG)

15 0F4408 2 Y CONNECTOR 500 SERIES BARBS

16 0D1509 1 DECAL INLET PRESSURE

17 050279 1 DECAL FUEL INLET NG

18 0H2353 1 ASSY,ADAPTER,THROTTLE BODY

19 0E4390 1 GASKET GOVERNOR ACTUATOR

20 0E4392 1 ACTUATOR BOSCH 60 GOVERNOR

21 0F0960 1 REDUCER 3.0" TO 2.75" TURBO

22 0F3885 1 MIXER 40/60MM ACTUATOR ASSY

23 0G3167 2 O-RING 2-3/4 X 3/32 X 2-15/16

24 0F3691F 1 VENTURI THROTTLE 44MM (130KW)

0F3691J 1 VENTURI THROTTLE 50MM (150KW)

25 026915 2 NIPPLE CLOSE 3/4 X 1.375

26 0A8064 2 BSHG RDCR HEX 1-1/4-3/4

27 026073A 1 PLUG STD PIPE 1/4 STEEL SQ HD

28 0D2157 4 SCREW SHC M6-1.0 X 50 C8.8

29 039294 1 CLAMP HOSE #44 2.31-3.25

30 022097 6 WASHER LOCK M6-1/4

31 049811 2 WASHER FLAT M6

32 0D2698 1 GASKET ADAPTER THROT BODY

33 042568 2 SCREW HHC M6-1.0 X 20 G8.8

34 064346 1 PIPE TEE 1-1/4 NPT

35 059057 2 HOSE 3/4 ID SAE-30R2 (12” LG)

36 066212 1 CLAMP HOSE #52 2.81-3.75

37 0G46350ST03 1 BRACKET, HOSE RISER

38 059057 2 HOSE 3/4 ID SAE-30R2 (9.5” LG)

(2) 1 0F58730ST01 1 REAR WRAP C5

(2) 2 0F58680ST01 4 DOOR C5

(2) 3 0F58720ST01 2 CENTER SUPPORT C5

(3) 4 0F58710AL01 2 DISCHARGE DUCT LH & RH SIDE C5

(2) 5 0F58690ST01 2 FRONT CORNERS C5

(2) 6 0F58700ST01 1 DISCHARGE CENTER DUCT C5

(3) 7 0F58670AL01 1 ROOF C5 ALUM

11 0C2454 86 SCREW THF M6-1 X 16 N WA Z/JS

12 0F2766 2 SPLITTER

13 0F3181 4 SPLITTER SHORT

14 0F3185 2 STRINGER SPLITTER C3

15 0F3416 2 SUPPORT SPLITTER C5 130KW

16 0F3949 2 INSULATION CORNER POST

17 0C2634A 1 ASSEMBLY COVER ACCESS

18 022473 5 WASHER FLAT 1/4-M6 ZINC

19 022097 1 WASHER LOCK M6-1/4

20 022127 1 NUT HEX 1/4-20 STEEL

21 0F3072 20 INSULATION RETAINMENT HANGER

22 078115 58 WASHER SELF LOCKING DOME #4-40

23 0F3949B 3 INSULATION SPLITTER

24 0F3949A 4 INSULATION SHORT LOUVER

25 0F5048D 4 VISE-ACTION LATCH SLOTTED CIR

26 0E5968 1 GASKET EXTRUDED TRIM (566” LG)

27 0F5049 4 TAB PULL

28 0F3949L 2 INSULATION SPLITTER SML

29 0F3949E 1 INSULATION ROOF TOP REAR

30 0F3890A 9 RETAINER INSULATION (740)

31 087233 2 RIVET POP .1875 X .450 SS

32 0F3949C 1 INSULATION ROOF TOP

33 0F3949D 4 INSULATION DOOR

34 0F3949G 1 INSULATION DISCHARGE DUCT

35 0F3949J 2 INSULATION CENTER SUPPORT

36 0F3949K 1 INSULATION DISCHARGE DUCT TOP

37 0F3949F 2 INSULATION INNER DUCT SIDE

38 0F3890B 4 RETAINER INSULATION (820)

39 0F3890 14 RETAINER INSULATION (450)

40 042568 4 SCREW HHC M6-1.0 X 20 G8.8

42 022447 4 WASHER SHAKEPROOF INT 1/4

43 049813 4 NUT HEX M6 X 1.0 G8 YEL CHR

(1) 44 077992 28 NUT HEX LOCK M6-1.0 SS NY INS

45 0912970094 4 ASSY WIRE 14 AWG 34.8" GRN/YEL

46 0F2766A 1 SPLITTER C5

47 0F3949M 1 INSULATION SPLITTER SHRT MPS

48 0F8869D 1 KEY VISE-ACTION LATCH SLOT CIR

49 0E3257 6 SCREW TH-FRM M6 W/CAP SHKPRF W

50 078115A 12 WASHER SELF LOCKING DOME #8-32

51 066760 1 STRIP SEALANT 1/8 X 1 (44.52”LG)

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

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

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

FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS. ALL ROOF PANELS

ARE TO BE SECURED IN THE SAME MANNER.

(2) NOTE: PART NUMBER SHOWN IS FOR TAN / STEEL. REFER TO THE SAMPLE

GUIDE BELOW FOR AVAILABLE COLOR AND/OR ALUMINUM PART NUMBER FORMAT.

0FXXXX0ST01 = TAN / STEEL 0FXXXX0ST13 = BISQUE / STEEL

0FXXXX0AL01 = TAN / ALUMINUM 0FXXXXALT13 = BISQUE / ALUMINUM

0FXXXX0ST08 = T- GRAY / STEEL 0FXXXX0ST14 = GRAY / STEEL

0FXXXX0AL08 = T- GRAY / ALUMINUM 0FXXXXALT14 = GRAY / ALUMINUM

0FXXXX0ST05 = WHITE / STEEL

0FXXXX0AL05 = WHITE / ALUMINUM

(3) PART NUMBER SHOWN IS FOR TAN. SEE GUIDE BELOW FOR AVAILABLE COLOR AND PART NUMBER

FORMAT.

0FXXXX0AL08 = T- GRAY / ALUMINUM 0FXXXXALT13 = BISQUE / ALUMINUM

0FXXXX0AL05 = WHITE / ALUMINUM 0FXXXXALT14 = GRAY / ALUMINUM

Stationary Emergency Generator

Warranty

Printed in U.S.A.

GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR

COMMERCIAL STATIONARY EMERGENCY PRODUCT 50kW AND ABOVE

For a period of two (2) years from the date of sale, Generac Power Systems, Inc. will, at its option, repair or replace any part(s) which, upon examina-

tion, inspection, and testing by Generac Power Systems or an Authorized/Certified Generac Power Systems Dealer, or branch thereof, is found to be

defective under normal use and service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims

to be defective must be examined by the nearest Authorized/ Certified Generac Power Systems Dealer, or branch thereof. This warranty applies

only to Generac Power Systems Generators used in "Stationary Emergency" applications, as Generac Power Systems, Inc. has defined Stationary

Emergency, provided said generator has been properly installed and inspected on-site by appropriate personnel. Scheduled maintenance, as outlined

by the generator owner's manual, is highly recommended. This should be performed by an Authorized/Certified Generac Power Systems Dealer, or

branch thereof. This will verify service has been performed on the unit throughout the warranty period.

WARRANTY SCHEDULE

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

• - ALL COMPONENTS

YEAR TWO — Limited comprehensive coverage on parts listed.

• - ALL COMPONENTS

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

Guidelines:

• Any and all warranty repairs and/or concerns, must be performed and/or addressed by an Authorized/Certified Generac Power Systems Dealer, or

branch thereof.

• A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a Non - Generac Power

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

• All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty, Policies, and Procedures Flat Rate

Manual.

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

ownership of original structure.

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

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

• Engine coolant heaters (block-heaters), heater controls and circulating pumps are only covered during the first year of the warranty provision (If

applicable).

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

1. 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.

4. Units sold, rated or used for "Prime Power", "Trailer Mounted" or "Rental Unit" applications as Generac Power Systems have defined Prime Power,

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

5. Units used for prime power in place of existing utility power where utility is present or in place of utility power where utility power service does not

normally exist.

6. Failures caused by any act of God and other force majeure events beyond the manufactures control.

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.

9. Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the

defective part(s).

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. Any implied warranties which

are allowed by law, shall be limited in duration to the terms of the express warranty provided herein. Some states do not allow limitations on how long

an implied warranty lasts, so the above limitation may not apply to purchaser/owner.

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

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

DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.

Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/

owner. Purchaser/owner agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gives purchaser/owner

specific legal rights. Purchaser/owner also may have other rights that vary from state to state

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

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

1-888-GENERAC (1-888-436-3722)

Bulletin 0171370SVE / Rev. C 12.08 / Printed in U.S.A.

EXPLODED VIEW: EV AIR CLEANER

DRAWING #: 0F3569

GROUP D

ITEM PART# QTY. DESCRIPTION

REVISION: CN-0008186-G Page 2 of 2

DATE: 7/11/17

1 0D2513D 1 AIR CLNR BTM PLT W/CPLR 8.1L

0D2513E 1 PLATE AIR CLEANER W/COUPLER

2 0F5419 1 ELEMENT AIR FILTER

3 0F4268 1 TOP PLATE VENTURI

4 0F4270A 1 HOLD DOWN AIR CLEANER PLATED

5 0F6977 1 PLATE AIR CLEAN TOP 5.4L/6.8L

6 037561 1 NUT WING 1/4-20 NYLK

7 047411 4 SCREW HHC M6-1.0 X 16 G8.8

8 022097 4 WASHER LOCK M6-1/4

9 057795B REF BARBED EL 90 5/8 PLASTIC

10 0F4269 1 GASKET MIXER BODY

11 022473 3 WASHER FLAT 1/4-M6 ZINC

12 0A4256 1 INDICATOR FILTER MINDER (USE WITH ITEM #1 P/N 0D2513E)

13 0G5954 1 GROMMET .625 X 1.25 X .433

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

2 022129 6 WASHER LOCK M8-5/16

4 0E2747A 1 FAN SAE ALTERNATOR (G/B)

5 0A3870 1 KEY SQ 3/8 X 1-9/16 STEEL

6 0A3009 1 HUB DRIVE 390 SAE GB

7 0F5564D 1 RTR 390 100KB3 GB SAE TECHUM

0F5563D 1 RTR 390 130KB4 GB SAE TECHUM

0A3881D 1 RTR 390 80GB BR BRLSS

0A3881B 1 RTR 390 80GB 1P BRLSS

0A3882B 1 RTR 390 100GB 1P BRLSS

0A3883B 1 RTR 390 125GB 1P BRLSS

8 * 052624 1 BEARING BALL 6212 SEALED

9 0A5580 4 SCREW HHC M14-2.0 X 140 G8.8

10 0A1633 4 WASHER 390 SAE ALT.

11 0F7024J 1 STR-390-80LB3 SAE

0F7351 1 STR 390 130 GB4 CPL

0F7349 1 STR 390 80 AB3 CPL

0F7348 1 STR 390 100 AB3 CPL

0F7350 1 STR 390 130 AB4 CPL

0F7024D 1 ASSY STR 390 80KB3 SAE

12 068113 1 CARRIER REAR BRG 15"

13 022392 2 PIN DOWEL 1/2 X 1-1/4

14 043123 4 WASHER LOCK M14

15 051779 4 NUT HEX M14-2.0 G8 YEL CHR

16 052259 2 WASHER FLAT M12

17 051769 3 WASHER LOCK M12

18 068406 3 SCREW HHC M12-1.75 X 60 G10.9

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

20 087272 1 ASSY EXCITER 2.00" STK

21 068405C 1 EXITER FIELD 2" LG SPD CONN

22 092950 1 COLLAR SLIP FIT 390 MM

25 090063 1 BRIDGE SUPPORT DIODE 15"

26 090152 1 ASSY BRIDGE RECTIFIER

27 023365 3 WASHER SHAKEPROOF INT #8

28 033143 2 SCREW HHM #8-32 X 7/8

29 090064 1 CAP END ROTOR 390MM

30 083485 2 PLATE NUT

31 031980 2 TIE WRAP UL 14.6 X .14 NATL

32 083401 1 BRACKET-STATOR WIRE

33 042561 1 CLAMP HOSE #36 1.88-2.7

34 033212 2 SCREW HHC 5/16-18 X 1-1/4 G5

35 083549 1 SLEEVE RUBBER

40 0A4089 1 ASSY SCROLL 390 SAE

KIT PARTS I/N’S: 41 THRU 49 (INCLUDED IN I/N 40)

41 0A2491 2 SHROUD ALT SHEET METAL

42 0A2497 2 SCREEN SHROUD SAE

43 0A2496 2 BRKT TENSIONER SAE SCROLL

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

45 022307 6 WASHER LOCK M6-1/4

46 022473 6 WASHER FLAT 1/4-M6 ZINC

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

48 047411 4 SCREW HHC M6-1.0 X 16 G8.8

49 0A2110 14 SCREW SWAGE 1/4-20 X 1/2 ZYC

* ROTOR REPLACEMENT PART

EXPLODED VIEW: EV MOUNTING BASE

DRAWING #: 0F3587

GROUP C

ITEM PART# QTY. DESCRIPTION

REVISION: CN-0027708-F Page 2 of 2

DATE: 7/25/2019

(1)1 0L0574AST0R 1 MTG BASE C5 100-130KW 6.8L G8

2 G065852 1 SPRING CLIP HOLDER .37-.62

3 G052252 4 DAMPENER VIBRATION

4 G052257 4 SPACER .49 X .62 X 1.87 PWDR/ZINC

5 G052259 8 WASHER FLAT M12

6 G055597 4 SCREW HHC M12-1.75 X 85 G8.8

7 052251A 4 DAMPENER VIBRATION 50 WHITE

8 G052860 4 NUT LOCKING M12-1.75

(1)9 0L06890ST0R 1 ENGINE SUPPORT 6.8L RH

10 G045764 1 SCREW HHTT M4-0.7 X 8 BP

11 G052243 6 SCREW HHC M10-1.5 X 60 C8.8

12 G061383 1 LUG SOLDERLESS 3/0-#4 X 13/32 CU

13 G043107 2 SCREW HHC M8-1.25 X 25 G8.8

14 0A4456 1 WASHER LOCK SPECIAL 3/8

15 --- -- --------

16 (1)0L01390ST0R 1 5.4L RH ENGINE MOUNT SPACER

17 G022131 7 WASHER FLAT 3/8-M10 ZINC

18 G046526 7 WASHER LOCK M10

19 0536210410 1 ASSY WIRE 14.00”

20 --- -- --------

21 0C3168 1 WASHER LOCK SPECIAL 5/16-M8

22 G022129 1 WASHER LOCK M8-5/16

23 G022145 2 WASHER FLAT 5/16-M8 ZINC

24 G045771 2 NUT HEX M8-1.25 G8 YEL CHR

25 G053557 4 SCREW HHC M12-1.75 X 40 G8.8

26 0F2591 2 TOWER GB COMPROD C5

(1)27 0L01480ST0R 1 ENGINE MOUNT 6.8L LH SIDE

28 --- -- --------

29 --- -- --------

30 --- -- --------

31 G051735 1 SCREW HHC M10-1.5 X 70 C8.8

32 0L0123 1 SPACER .41 X .75 X 1.68 ST/ZNC

NOTES (UNLESS OTHERWISE SPECIFIED):

(1) SHEET METAL PARTS LISTED IN THE BOM TABLE, PRIOR TO 1/1/16, ARE REPRESENTING GENERIC

PARTS (NO COLOR) :

• MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO SAP BOM.

• CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY)

IN THE SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).

EXPLODED VIEW: EV BATTERY 27F GEAR BOX

DRAWING #: 0G0775

GROUP C

ITEM PART# QTY. DESCRIPTION

REVISION: J-5800-B Page 2 of 2

DATE: 7/23/13

(1)1 0F3408AST0R 1 TRAY BATTERY 27F

2 0F3411A 1 STRAP BATTERY RETAINMENT 27F

3 058665 1 BATTERY 12VDC 90-AH 27F

4 022131 1 WASHER FLAT 3/8-M10 ZINC

5 050331A 1 BATTERY POST COVER RED +

6 050331 1 BATTERY POST COVER BLK -

7 038805Z 1 CABLE BATTERY BACLK #1 X 26.00

8 038804U 1 CABLE BATTERY RED #1 X 28.00

9 045771 1 NUT HEX M8-1.25 G8 YEL CHR

10 022129 1 WASHER LOCK M8-5/16

11 027482 1 WASHER SHAKEPROOF EXT 5/16 STL

12 075763 1 BOOT BATTERY CABLE

13 0C2454 8 SCREW THF M6-1 X 16 N WA Z/JS

14 0F3409 1 SUPPORT BATTERY TRAY

15 022097 2 WASHER LOCK M6-1/4

16 049813 2 NUT HEX M6 X 1.0 G8 YEL CHR

17 042568 2 SCREW HHC M6-1.0 X 20 G8.8

18 0G0783 1 SUPPORT 27F BATTERY

NOTES (UNLESS OTHERWISE SPECIFIED):

(1) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)

•

MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.

•

CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR

CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).

1 033212 4 SCREW HHC 5/16-18 X 1-1/4 G5

2 065908 1 SUPPORT NAT GAS SOLENOID

3 0G9191A 1 REG ASSY 6.8L 130KW DUAL NG QT

0G9191B 1 REG ASSY 6.8L 150KW DUAL NG QT

4 052617 2 SCREW HHC M12-1.75 X 20 G8.8

5 022304 2 WASHER FLAT 1/2 ZINC

6 022129 4 WASHER LOCK M8-5/16

7 045773 2 NUT HEX M12-1.75 G8 YEL CHR

8 022195 2 WASHER LOCK 1/2

9 039130 1 NIPPLE CLOSE 1.25 NPT X 1.625

10 030131 1 ELBOW 90D 1-1/4 NPT

11 031015 1 NIPPLE PIPE 1-1/4 NPT X 3 (130KW)

088963 1 NIPPLE PIPE 1.25 NPT X 5.5 BL IRN (150KW)

12 0G5989 1 HARNESS, FUEL JUMPER DUAL REG

13 057822 12 CLAMP HOSE #8 .53-1.00

14 059057 2 HOSE 3/4 ID SAE-30R2 (42” LG)

15 0F4408 2 Y CONNECTOR 500 SERIES BARBS

16 0D1509 1 DECAL INLET PRESSURE

17 050279 1 DECAL FUEL INLET NG

18 0H2353 1 ASSY,ADAPTER,THROTTLE BODY

19 0E4390 1 GASKET GOVERNOR ACTUATOR

20 0E4392 1 ACTUATOR BOSCH 60 GOVERNOR

21 0F0960 1 REDUCER 3.0" TO 2.75" TURBO

22 0F3885 1 MIXER 40/60MM ACTUATOR ASSY

23 0G3167 2 O-RING 2-3/4 X 3/32 X 2-15/16

24 0F3691F 1 VENTURI THROTTLE 44MM (130KW)

0F3691J 1 VENTURI THROTTLE 50MM (150KW)

25 026915 2 NIPPLE CLOSE 3/4 X 1.375

26 0A8064 2 BSHG RDCR HEX 1-1/4-3/4

27 026073A 1 PLUG STD PIPE 1/4 STEEL SQ HD

28 0D2157 4 SCREW SHC M6-1.0 X 50 C8.8

29 039294 1 CLAMP HOSE #44 2.31-3.25

30 022097 6 WASHER LOCK M6-1/4

31 049811 2 WASHER FLAT M6

32 0D2698 1 GASKET ADAPTER THROT BODY

33 042568 2 SCREW HHC M6-1.0 X 20 G8.8

34 064346 1 PIPE TEE 1-1/4 NPT

35 059057 2 HOSE 3/4 ID SAE-30R2 (12” LG)

36 066212 1 CLAMP HOSE #52 2.81-3.75

37 0G46350ST03 1 BRACKET, HOSE RISER

38 059057 2 HOSE 3/4 ID SAE-30R2 (9.5” LG)

COM PONE NTS INCL UDE D IN 0G4140E

1 0F1823CST03 1 ENCL H/G CONTROL PANE L

2 0F1824AST03 1 CO VER CONTRO L PANE L

3 0F2606 1 HING E CONT INUOUS H PANE L

4 036261 7 RIVET POP .12 5 X .275 S S

5 0F5763 1 ASS Y PROGRAMME D H- 100

6 0F1732 1 DECAL FUSES LOCATED INS IDE

7 0E9764 1 RAIL SNAP TRACK PCB HO LDER BULK ( 12”LG)

8 0F1740C 1 AS SY PCB 10A UL BATT CHRGR 12V

9 0F1958 1 PLATE HARNESS CLAMP

10 0F2256 1 ASSY P CB PWR AVR W/AMP HEADER

11 0E3161 1 ASS Y P CB BOS CH GOV DRIVE R

12 0296 73 1 DIO BRIDG E 25A 600V

13 0492 26 11 WASHER LO CK M5

14 0792 24 4 S CREW PPHM M5-0.8 X 30 S S

15 0517 13 11 WASHER FLAT M5

16 0F5886 6 SCREW HHPM M5-0.8 X 12

17 0517 16 5 NUT HEX M5-0.8 G8 Y EL CHR

18 0431 80 3 W ASHE R FLAT M4

19 0C3990 3 SCREW PHTT M4- 0.7 X 10 Z YC

20 0F4333 1 CO NN DUST CAP W/CHAIN DB9

21 0F5883 1 WASHER FLAT M3 .5

22 0F5884 1 SCREW PHTT M3.5- 0.6 X 10

23 0550 14 10 SCREW PPHM M4- 0.7 X 8 BLX O X

24 0222 64 10 WASHER LO CK #8-M4

25 0G 3546 1 DECAL W RN B AT T CHRG 12/24V BI

26 0G 3648 1 M5-0.8 CAPTIVE PANE L KNLD HD

27 0F6305 2 SEAL COVER 3.18 X 12.7 X 382

28 0F6305A 1 S EAL COVER 3.18 X 12.7 X 283

29 0G 4329 1 HARNE SS H-PNL INTEGRATED SW (NO T SHO WN)

COM PONE NTS INCL UDED IN WIRE HARNESS

A 0F1263 1 ADP TR RH SIDE WICKMANN 178.6191

B 0F1262 4 HO LDE R F USE WICKMANN 178.61 50

C 0F1264 1 ADP TR LH SIDE W ICKMANN 1 78.6192

D 0E 9049B 1 ASSY PCB G-PANEL RELAY 12VDC

E 0559 11 1 BL OCK TERM 20A 12 X 6 X 1100V

COM PONE NTS NOT INCLUDE D IN 0G 4140E O R WIRE HARNESS

50 0567 39 1 RELAY CONTACTOR 12VDC

51 - 1 DP E B REAKER SEE DRAW ING 0F9280

52 - 1 BO OST RESIST OR SEE DRAWING 0F 9280

53 0F2627B 1 CO VER CONTRO L PANEL S IDE

54 0222 87 2 S CREW HHC 1 /4-2 0 X 3/4 G5

55 0224 73 4 W ASHE R FLAT M6-1/4

56 0220 97 2 W ASHE R LO CK M6-1/4

57 0431 82 3 W ASHE R LO CK M3

58 0517 14 3 NUT HEX M3-0.5 G8 Y EL CHR

59 0527 77 3 W ASHE R FLAT M3

60 0C2323 2 SCREW PHTT #6-32 X 5/8 Z YC

61 0F5459 1 DECAL CP L CONTROL PANEL FUS ES

62 0F5461 1 DECAL CP L 5.4/6.8L TB3

63 0221 27 2 NUT HEX 1/4-20 S TEEL

64 0F5460 1 DECAL CP L 5.4/6.8L RELAY BO ARD

65 0E7403C 1 F USE ATO TYP E 15 AMP (BL UE )

66 0E7403B 2 F USE ATO TYP E 10 AMP (RED)

67 0F6145 A/R SEAL WEATHER .45"DIA

68 0C2699 2 SCREW PHTT #6-32 X 3/8 Z YC

69 0C2266 4 SCREW PHTT M5- 0.8 X 16 Z YC

1 0F3017 1 BRACKET,D.C. ALTERNATOR LOWER

2 039253 3 SCREW HHC M8-1.25 X 20 G8.8

3 022129 4 WASHER LOCK M8-5/16

4 022145 4 WASHER FLAT 5/16-M8 ZINC

(2) 5 0D5419 REF OIL FILTER, FORD V-10 ENGINE

6 0D7055 1 DIPSTICK TUBE, FORD 6.8L

7 0D3488G 1 BELT SERPENTINE (65.0" LG) (1800 RPM)

0D3488J 1 BELT SERPENTINE (65.3" LG) (2300 RPM)

0D3488 1 BELT SERPENTINE (67.16" LG) (3000 RPM)

0D3488K 1 SERPENTINE BELT (68.3" LG) (3600 RPM)

8 057795A 1 BARBED EL 90 3/4 PLASTIC

9 059057 1 HOSE 3/4 ID SAE-30R2 (16.75”LG)

10 0F3287 1 BRACKET DC ALTERNATOR UPPER

(3) 11 0F5990 1 HARN ENG 6.8L H-100 (USE WITH PROBE P/N 0E2507)

0H2595 1 HARN ENG G6.8L G3 H-100 (USE WITH PROBE P/N 0H1827)

0F4419 1 HARN ENG 6.8L G-100 (USE WITH PROBE P/N 0E2507)

0H3081 1 HARN ENG G6.8L G3 MQT 480V (USE WITH PROBE P/N 0H1827)

0F9786 1 HARN ENG 6.8L G-100 MQT 208V (USE WITH PROBE P/N 0E2507)

0H3080 1 HARN ENG G6.8L G3 MQT 208V (USE WITH PROBE P/N 0H1827)

12 0E9868A 1 ALTERNATOR DC W/OUT PULLEY

13 057796 1 GROMMET

14 0F3216 1 PULLEY 80 OD DC ALTERNATOR (1800 RPM)

0F3216A 1 PULLEY 102 OD DC ALTERNATOR (2300 RPM)

0F3216C 1 PULLEY 132 OD DC ALTERNATOR (3000 RPM)

0F3216D 1 PULLEY 160 OD DC ALTERNATOR (3600 RPM)

15 035579 1 BSHG RDCR HEX 1/4 TO 1/8

16 0F4612 1 SENDER OIL PRESSURE 1/8" NPT

17 0D6658 1 DIPSTICK 6.8L FORD

(3) (1) 18 029333A 2 TIE WRAP UL 7.4" X .19" BLK

19 022097 3 WASHER LOCK M6-1/4

20 022473 3 WASHER FLAT 1/4 ZINC

21 042568 3 SCREW HHC M6-1.0 X 20 G8.8

22 0D8027 4 BOLT WATER PUMP PULLEY

23 0D8025 1 BOLT GROOVED IDLER PULLEY

24 0D8026 3 BOLT BELT TENSIONER

25 0D8030 1 TENSIONER ENG. AUTOMATIC BELT

26 0F2846 1 PULLEY WATER PUMP FORD (1800RPM UNITS)

0D8029 1 PULLEY ENGINE WATER PUMP (2-POLE & GEAR BOX)

27 0D8028 1 PULLEY GROOVED ENGINE IDLER

28 045771 1 NUT HEX M8-1.25 G8 YEL CHR

29 0D3454A 1 ENGINE G6.8L G3 V-10

0H0923 1 ENGINE G6.8L G3 V-10 (2009)

30 022131 2 WASHER FLAT 3/8-M10 ZINC

31 046526 1 WASHER LOCK M10

32 064416 1 SCREW HHC M10-1.5 X 45 G8.8 FT

33 045772 1 NUT HEX M10-1.5 G8 YEL CHR

34 0F3217 1 SPACER DC ALTERNATOR PULLEY

35 0F2776A 1 BRACKET SIGNAL CONDITIONER

36 0F6151 1 CAP RUBBER

37 0F4308 1 BRACKET DC ALT STABILIZER

38 0F3158 1 OIL COOLER FORD (150KW 3600RPM)

39 057823 2 CLAMP HOSE #10 .56-1.06

40 0E0502 1 TEMPERATURE SENDER DELPHI

41 0G0866 1 HOSE OIL COOLER PREFORMED 3/4 (150KW 3600RPM)

42 0F4301 1 HOSE OIL COOLER (150KW 3600RPM)

44 047527 1 BARBED STR 1/2NPT X 3/4

45 057823 4 CLAMP HOSE #10 .56-1.06 (150KW 3600RPM)

46 0E0992A 10 PLUG EXPANSION 14 OD

47 078637 A/R ADHESIVE LOCTITE 620

48 0G7519 1 DECAL EMISSION CTRL INFO 6.8L

49 0E8286 1 ELBOW 45D STREET 1/2NPT BRASS

(1) NOTE: I/N 18 IS FOR HOLDING SENSOR TO I/N 35.

(2) I/N 5 PART OF I/N 29.

(3) NOTE: NOT SHOWN)

EXPLODEDVIEW: EV GEARBOX ASSY 390 ALT

DRAWING#: 0F1792

GROUP D

APPLICABLETO:

ITEM PART# QTY. DESCRIPTION

REVISION: CN-0021689-G Page 2 of 2

DATE: 11/14/2018

1 0F2123 1 GEAR CASE ENG. MACHINED

2 0F2122 1 GEAR CASE ALT. MACHINED

3 095613 1 SEAL OIL

4 051756 2 SCREW HHC M10-1.5 X 20 G8.8

5 046526 42 WASHER LOCK M10

6 049814 4 SCREW HHC M10-1.5 X 25 G8.8

7 051735 8 SCREW HHC M10-1.5 X 70 G8.8

8 0F2097 1 GASKET 390 GEARBOX

9 072879 1 SPACER .69 X 2.75 X .37 ST/ZNC

10 097557B 1 KEY 10 X 16 X 46

11 0H3114 1 GEAR OUTPUT 1.65:1

095970 1 GEAR OUT 390-50H 37T

095968 1 GEAR OUT 390-60H 35T

0E6866 1 GEAR OUTPUT 2:1 50HZ 390

12 070263 2 SCREW HHC M16-2.0 X 35 G10.9

13 057019 2 BALL BRG 65 X 120 X 23

14 026847 1 BREATHER

15 0H3113 1 GEAR INPUT 1.65: 1

095969 1 GEAR INPT 390-50 25T

095967 1 GEAR INPT 390-60 27T

0E6865 1 GEAR INPUT 2:1 50HZ 390

16 095966 1 SHAFT 390 INPUT GEAR

17 095976 1 COLLAR HARDENED

18 095971 1 SEAL OIL

19 096777 1 SNAP RING INT 120MM

20 057019S 1 BEARING #6213 SEALED

22 096379 1 PLATE INTRNL BRG RET

23 048189 2 PIN DOWEL M8 X 24

24 095979 1 PLATE BEARING THRST

25 021159 1 SPACER STRESSPROOF

26 097557A 1 KEY 10 X 16 X 40

27 057163 1 PLUG PIPE 3/8" MAGNETIC

28 0F6518 4 SCREW HHFC M10-1.5 X 25 G10.9

29 0F3201 1 COVER GEARBOX GUARD

30 020443 1 COUPLING INNER DRAWN

31 094666A 1 COUPLING OUTER MACHN

32 099828 8 DAMPER GB CPLR VIBRA

33 099828A 8 DAMPER GB CPLR VIBRA

34 026925 2 PLUG STD PIPE 3/8 STEEL SQ HD

35 097557C 1 KEY 10 X 16 X 50

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

37 025066 1 COUPLING FULL 3/8-18

38 031578 6 SCREW HHC 3/8-16 X 1-1/2 G8

052625 REF. SCREW SHC M10-1.5 X 35 G12.9 (FORD ENGINES)

39 049814 10 SCREW HHC M10-1.5 X 25 G8.8

40 0A1786 2.5cc RETAINING COMPOUND

41 027175 .200 GAL LUBE GREASE SAE #90 80W90 (NOT SHOWN)

44 045772 10 NUT HEX M10-1.5 G8 YEL CHR

45 052243 10 SCREW HHC M10-1.5 X 60 G8.8

46 057642 2 SCREW HHC M10-1.5 X 40 G10.9

47 0F6487 4 WASHER FLAT M10 SEALING COPPER

48 0F6355 1 GASKET SEAL PLATE 390 GB

49 0F6477 .050 GAL ENHANCER GEAR OIL (NOT SHOWN)

50 0F6557 0.4cc THREADLOCK AND SEALANT

51 026924 1 ELBOW 90D STREET 3/8

1

0F2687

1

WELDMENT RADIATOR SUPPORT150

2 0F2611 1 RADIATOR 680 X 680 X 70 CPL

3 0F5254 1 V-BELT 31/64" X 62-3/8"

0F5253 1 V-BELT 31/64" X 61-3/8" (5.4L 100KW ONLY)

0F7077 1 V-BELT 1/2" X 63-3/8" (6.8L 100 130KW)

4 046526 12 WASHER LOCK M10

5 051756 8 SCREW HHC M10-1.5 X 20 G8.8

6 0C2454 2 SCREW THF M6-1 X 16 N WA Z/JS

7 052250 2 TAPE FOAM 1 X 1 (26.75” LG)

8 076749 1 TANK COOLANT RECOVERY

9 0F2573 1 PULLEY FAN V-GROOVE 9"

10 0F2610 1 FAN 26" LH ROTATION

11 0G56820ST03 1 FLAT TENSIONER ARM

12

0G2990

1

SHOULDER BOLT 3/8 X 1/2"

13 0F2862 1 SPRING TENSION CPL

14 0F2560 1 PULLEY V-BELT 4" FLANGED

15 022131 15 WASHER FLAT 3/8-M10 ZINC

(2) 16 039287 1 SCREW HHC M8-1.25 X 45 C8.8

17 052625 3 SCREW SHC M10-1.5 X 35 G12.9

18 0F2561 1 HUB FLEX PLATE

19 0C8165 5 NUT HEX LOCK 5/16-24 NY INS

20 0D6795 1 SCREW HHC M12-1.5 X 60 G8.8

21 0C7043 12 DISK FLEX

22 0E8909 1 COUPLING HUB FLEX (MACH)

0E8909A 1 COUPLING HUB FLEX (MACHINING)

23 048031C 1 CLAMP HOSE BAND 1/4

24 0C8146 4 SCREW HHC 5/16-24 X 1.124

25 082774 2 KEY WOODRUFF 4 X 19D

26 0F2686 1 HOSE RADIATOR UPPER CPL

27 0F5463 1 HOSE LOWER RAD CPL C5 6.8L

28 0F8695 1 ASSY BRG/SHAFT CPL FANDRIVE

29 0F4028 1 PULLEY 6.5" DIA MACHINED (6.8L 100KW)

0F4030 1 PULLEY 6" DIA MACHINED (6.8L 130KW)

0F4032 1 PULLEY 5.5" DIA MACHINED (5.4L 80KW & 6.8L

150KW)

0F4496 1 PULLEY 4.5" DIA MACHINED (5.4L 100KW)

30 042911 1 SCREW HHC M10-1.5 X 30 G8.8

31 0F2872 1 SCREW HHC 1/2-13 X 2" G8

32 022304 2 WASHER FLAT 1/2 ZINC

33 022195 1 WASHER LOCK 1/2

34 022196 1 NUT HEX 1/2-13 STEEL

35 049813 8 NUT HEX M6 X 1.0 G8 YEL CHR

36 070015 1 NUT HEX LOCK 5/16-18 NY INS SS

39 022145 1 WASHER FLAT 5/16-M8 ZINC

40 022129 1 WASHER LOCK M8-5/16

42 035685 4 CLAMP HOSE #28 1.32-2.25

43 045764 1 SCREW HHTT M4-0.7 X 8 BP

44 065852 1 SPRING CLIP HOLDER .37-.62

45 0C7649 1 CLAMP HOSE .38-.87

46 055596 1 BARBED STR 3/8 NPT X 3/8

47 069860E 1 HOSE DRAIN ASSY 28"

(1) 48 069811 REF CAP HEX 1/4 NPT BRASS

49 080713 1 BRACKET COOLANT TANK

50 022473 16 WASHER FLAT 1/4-M6 ZINC

51 022097 16 WASHER LOCK M6-1/4

52 042568 8 SCREW HHC M6-1.0 X 20 G8.8

53 0F5050 1 SHIELD RADIATOR C5

54 039253 1 SCREW HHC M8-1.25 X 20 G8.8

55 051769 1 WASHER LOCK M12

56 0C8145 8 WASHER FLEX (THIN)

57 0E2507 1 PROBE, COOLANT LEVEL 3/8 NPTF

58 090283 1 CAP RADIATOR 13 PSI

59 0C8566 8 SCREW HHFC M6-1.0 X 20 G8.8

60 0F2776A 1 BRACKET, SIGNAL CONDITIONER

61 052644 1 SPACER .5 X 1.5 X .25 STL/ZINC

62 0G4376 1 WASHER BELLEVILLE .75X.38X.028

63 0G56830ST03 1 BENT 90 TENSIONER ARM SUPPORT

64 051698 1 SCREW HHC M8-1.25 X 75 C8.8

65 049820 1 NUT HEX LOCK M8-1.25 NY INS

66 022145 2 WASHER FLAT 5/16-M8 ZINC

67 0G6151 1 EYEBOLT 3/8-16 X 3.5" TURNED

(1) ITEM 48 IS INCLUDED WITH 47.

(2) APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THREADS.

EXPLODED VIEW: EV MUFFLER 4.6/5.4/6.8L CPL C5

DRAWING #: 0F2969

GROUP D

ITEM PART# QTY. DESCRIPTION

REVISION: K-1591-J Page 2 of 2

DATE: 1/29/15

1 0F2807C 1 PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5)

0F2807E 1 PIPE EXH MAN R/H 5.4L G/B & 2P (5.4L C5)

0F9207 1 PIPE EXH MANIFOLD 4.6L RH

2 0F2807B 1 PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5)

0F2807D 1 PIPE EXH MAN L/H 5.4L G/B & 2P (5.4L C5)

0F9208 1 PIPE EXH MANIFOLD 4.6L LH

4 0A6765 2 RING GASKET 2.5 DIA

5 0F4710 6 WASHER LOCK M10 SS

6 0F7200 6 SCREW HHC M10-1.5 X 50 SS FTH

7 080762 8 BOLT U 3/8-16 X 2.62

8 0F2809 1 PIPE EXHAUST CROSSOVER

9 0F2981A 2 MFLR 7" X 9" X 25" (2) 2.5" IN/2.5" OUT

10 0F2962 2 MUFFLER STRAP

11 0C2454 4 SCREW THF M6-1 X 16 N WA Z/JS

12 022097 12 WASHER LOCK M6-1/4

13 0F2830 2 MUFFLER BRACKET STIFFENER

18 0F2773C 2 EXHAUST BLANKET 900MM LONG (6.8L C5)

0F2773D 2 EXHAUST BLANKET 850MM LONG (5.4L C5)

19 0D3159 1 FLANGE EXHAUST

20 088775 6 WASHER FLAT 3/8 SS

21 0F2808 2 EXHUAST OUTLET PIPE CPL

22 0F5447 1 BRKT MUFFLER

23 022473 20 WASHER FLAT 1/4-M6 ZINC

24 0F6214 2 PIPE ELBOW EXHAUST MUFFLER

26 0L1789 8 MUFFLER STRAP UPPER/LOWER

27 049813 8 NUT HEX M6 X 1.0 G8 YEL CHR

28 049721 12 SCREW HHC M6-1.0 X 35 G8.8 BLK

29 088510 6 NUT HEX M10-1.5 SS

30 0C9748 1 PLUG M18-1.50

1 0F2807C 1 PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5)

0F2807E 1 PIPE EXH MAN R/H 5.4L G/B & 2P (5.4L C5)

0F9207 1 PIPE EXH MANIFOLD 4.6L RH

2 0F2807B 1 PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5)

0F2807D 1 PIPE EXH MAN L/H 5.4L G/B & 2P (5.4L C5)

0F9208 1 PIPE EXH MANIFOLD 4.6L LH

4 0A6765 2 RING GASKET 2.5 DIA

5 0F4710 6 WASHER LOCK M10 SS

6 0F7200 6 SCREW HHC M10-1.5 X 50 SS FTH

7 080762 8 BOLT U 3/8-16 X 2.62

8 0F2809 1 PIPE EXHAUST CROSSOVER

9 0F2981A 2 MFLR 7" X 9" X 25" (2) 2.5" IN/2.5" OUT

10 0F2962 2 MUFFLER STRAP

11 0C2454 4 SCREW THF M6-1 X 16 N WA Z/JS

12 022097 8 WASHER LOCK M6-1/4

13 0F2830 2 MUFFLER BRACKET STIFFENER

18 0F2773C 2 EXHAUST BLANKET 900MM LONG (6.8L C5)

0F2773D 2 EXHAUST BLANKET 850MM LONG (5.4L C5)

19 0D3159 1 FLANGE EXHAUST

20 088775 6 WASHER FLAT 3/8 SS

21 0F2808 2 EXHUAST OUTLET PIPE CPL

22 0F5447 1 BRKT MUFFLER

23 022473 12 WASHER FLAT 1/4-M6 ZINC

24 0F6214 2 PIPE ELBOW EXHAUST MUFFLER

26 0F6803 4 MUFFLER STRAP UPPER/LOWER

27 049813 4 NUT HEX M6 X 1.0 G8 YEL CHR

28 049721 8 SCREW HHC M6-1.0 X 35 G8.8 BLK

29 088510 6 NUT HEX M10-1.5 SS

30 0C9748 1 PLUG M18-1.50

EXPLODED VIEW: EV BLOCK HEATER 6.8L

DRAWING #: 0G0878D

GROUP A

ITEM PART# QTY. DESCRIPTION

REVISION: K-2046-C Page 2 of 2

DATE: 12/21/15

1 047411 2 SCREW HHC M6-1.0 X 16 G8.8

2 022097 4 WASHER LOCK M6-1/4

3 022473 4 WASHER FLAT 1/4 ZINC

4 084918G 1 HEATER ENG 1500W 120V

5 0G0015 4 CLAMP HOSE 7/8” OD DOUBLE WIRE

6 042568 2 SCREW HHC M6-1.0 X 20 G8.8

7 055934D 1 CLAMP VINYL 1.06 X .406 Z

8 084427 1 BRACKET HEATER

9 035467 1 NIPPLE CLOSE 3/8NPT X 1 VIBRA

10 049813 2 NUT HEX M6-1.0 G8 YEL CHR

11 050967 1 HOSE COOL 5/8 ID 20R3 (33”LG)

12 022129 1 WASHER LOCK M8-5/16

13 042907 1 SCREW HHC M8-1.25 X 16 G8.8

14 0C4905 2 BARBED EL 45 3/8NPT X 5/8OD

0C4905 1 BARBED EL 45 3/8NPT X 5/8OD (150KW ONLY)

15 0A6283 1 HOSE PREFORMED BLOCK HEATER

16 025066 1 COUPLING FULL 3/8-18

17 059057 1 HOSE 3/4 ID SAE-30R2 (8”LG) (150KW ONLY)

18 057823 2 CLAMP HOSE #10 .56-1.06 (150KW ONLY)

19 0L4800 1 BARB Y 5/8 HOSE (150KW ONLY)

20 050967 1 HOSE COOL 5/8 ID 20R3 (24”LG) (150KW ONLY)

21 0F4355 REF. ADAPTER 1/2”NPT X 3/8”NPT (150KW ONLY)

22 0G0153 REF. BARBED EL 90 1/2NPT X 3/4 HOSE (150KW ONLY)

23 057823 REF. CLAMP HOSE #10 .56-1.06 (150KW ONLY)

24 0G0866 REF. HOSE OIL COOLER PREFORMED 3/4 (150KW ONLY) (SEE SPECIAL NOTE)

1 047411 2 SCREW HHC M6-1.0 X 16 G8.8

2 022097 4 WASHER LOCK M6-1/4

3 022473 4 WASHER FLAT 1/4 ZINC

4 084918G 1 HEATER ENG 1500W 120V

5 0G0015 4 CLAMP HOSE 7/8” OD DOUBLE WIRE

6 042568 2 SCREW HHC M6-1.0 X 20 G8.8

7 055934D 1 CLAMP VINYL 1.06 X .406 Z

8 084427 1 BRACKET HEATER

9 035467 1 NIPPLE CLOSE 3/8NPT X 1 VIBRA

10 049813 2 NUT HEX M6-1.0 G8 YEL CHR

11 050967 1 HOSE COOL 5/8 ID 20R3 (33”LG)

12 022129 1 WASHER LOCK M8-5/16

13 042907 1 SCREW HHC M8-1.25 X 16 G8.8

14 0C4905 2 BARBED EL 45 3/8NPT X 5/8OD

0C4905 1 BARBED EL 45 3/8NPT X 5/8OD (150KW ONLY)

15 0A6283 1 HOSE PREFORMED BLOCK HEATER

16 025066 1 COUPLING FULL 3/8-18

17 059057 1 HOSE 3/4 ID SAE-30R2 (8”LG) (150KW ONLY)

18 057823 2 CLAMP HOSE #10 .56-1.06 (150KW ONLY)

19 0G8847 1 BARB Y UNIVERSAL 5/8-3/4 HOSE (150KW ONLY)

20 050967 1 HOSE COOL 5/8 ID 20R3 (24”LG) (150KW ONLY)

21 0F4355 REF. ADAPTER 1/2”NPT X 3/8”NPT (150KW ONLY)

22 0G0153 REF. BARBED EL 90 1/2NPT X 3/4 HOSE (150KW ONLY)

23 057823 REF. CLAMP HOSE #10 .56-1.06 (150KW ONLY)

24 0G0866 REF. HOSE OIL COOLER PREFORMED 3/4 (150KW ONLY) (SEE SPECIAL NOTE)

1 0F6207 1 OUTLET 20A GFCI

0E3573 1 COVER,BLANK 4X2 1/8 HNDY BX

2 0C9275 1 BOX HANDY 2-1/8 X 4

3 025393 2 SCREW HHTT #10-24 X 3/8 CZ

4 0G0896 REF HARN ALT CON BOX 1PH QT

0G0897 REF HARN ALT CON BOX 3PH QT

5 070208 1 GROMMET .87 X .25 X .62

1

0F2885

1

PANEL CB CONN BOX

2 0G0171 1 STAND RH CONTROL CPL C5

0G0171A 1 STAND RH CONTROL CPL C5 2 HOLE

3 0G0172 1 STAND LH CONTROL CPL C5

4 023484N 1 BUSHING SNAP SB-2.5-31

5 086961 1 INTERFACE 1PH 240V

067617030A - INTERFACE 3PHS 416/480V

067617030B - INTERFACE 3PHS 208/240V

6 043180 4 WASHER FLAT M4

7 022264 6 WASHER LOCK #8-M4

8 0C3990 6 SCREW PHTT M4-0.7 X 10 ZYC

9 * 057701 REF. BLOCK TERM 20A 8 X 6 X 1100V

10 022158 2 NUT HEX #10-32 STEEL

11 0F8565 1 DECAL H-100 RB3 CUST CONN

12 0F3618 1 DECAL CPL CUST CONN H CTRL

13 0A9457 1 DECAL NEUTRAL

14 057073 2 JUNCTION BLOCK 3/8-16

15 ** 0D5466 REF. BUS BAR NEUTRAL BLOCK 390

16 ** 0A7822 REF. LUG SLDLSS 600/250-1/0 X 1/4-28

17 022237 4 WASHER LOCK 3/8

18 022241 4 NUT HEX 3/8-16 STEEL

19 049226 6 WASHER LOCK M5

20 0C2266 6 SCREW PHTT M5-0.8 X 16 ZYC

21 0C2454 10 SCREW THF M6-1 X 16 N WA Z/JS

22 042568 4 SCREW HHC M6-1.0 X 20 G8.8

23 022473 12 WASHER FLAT 1/4-M6 ZINC

24 022097 8 WASHER LOCK M6-1/4

25 049813 4 NUT HEX M6 X 1.0 G8 YEL CHR

26 0E9764 6” RAIL SNAPTRACK PCB HOLDER BULK

27 0G6962B 1 ASSY RELAY PCB 12VDC

28 025433 1 LUG SLDLSS #6-14 X 13/64 CU

29 024469 1 SCREW HHTT #10-32 X 3/8 CZ

30 067210A 1 DECAL GROUND LUG

31 0D6029 4 SCREW HHTT M6-1.0 X 16 ZYC

32 051713 2 WASHER FLAT M5

33 081008 1 GROMMET 1.25 X .25 X .75

34 077043J 3 CONDUIT FLEX 2.0" ID

35 0F6156 1 PLATE WIRE SNGL GALV

36

029289

1

TAPE ELEC 1/2 FOAM (AS REQ’D)

37 *** 0F3113 REF ASSY PCB HSB CTRL IGN MODULE

38 047411 4 SCREW HHC M6-1.0 X 16 G8.8

39 036943 2 SCREW PPHM #10/32 X 2

40 023897 3 WASHER FLAT #10 ZINC

41 022152 2 WASHER LOCK #10

42 045764 1 SCREW HHTT M4-0.7 X 8 ZP

43 023762 1 WASHER SHAKEPROOF EXT #10 STL

1.) UL CIRCUIT BREAKER (800AF)

A 0G0173 1 COVER, CB 803 C5

C 0F4167$ REF CIRCUIT BREAKERS 800A FRAME

D 0F8433 2 INSUL CB 800AF

E 022477 4 SCREW RHM 1/4-20 X 1-1/2

F 022473 8 WASHER FLAT 1/4-M6 ZINC

G 022097 4 WASHER LOCK M6-1/4

H 022127 4 NUT HEX 1/4-20 STEEL

J 0F1733 1 DECAL CUSTOMER CONNECT INSIDE

K 029289 2 TAPE ELEC 1/2 FOAM

L 060619 2/3 SCREW SHC M10-1.50 X 40 G12.9

M 022131 2/3 WASHER FLAT 3/8-M10 ZINC

N 022237 2/3 WASHER LOCK 3/8

P 045772 2/3 NUT HEX M10-1.5 G8 YEL CHR

R 0F9721 2/3 LUG SLDLSS 3/0-400X3 MCM AL/CU

S 0D2157 4/6 SCREW SHC M6-1.0 X 50 G8.8

T **** W/CB 2 TERM. COVER VITZROTECH 400AF CB

U 0G3259 1 DECAL TERMINAL SHOCK HZD BI

V 022097 4/6 WASHER LOCK M6-1/4

2.) NEUTRAL BLOCK 390 / 200-400A

A 0D5466 1 BUS BAR NEUTRAL BLOCK 390

B 039287 1 SCREW HHC M8-1.25 X 45 G8.8 FT

C 022145 1 WASHER FLAT 5/16-M8 ZINC

D 022129 1 WASHER LOCK M8-5/16

E 045771 1 NUT HEX M8-1.25 G8 YEL CHR

F 045335 2 SCREW HHC 1/4-28 X 3/4 G5

G 083896 2 WASHER LOCK 1/4-M6 SS

H 0A7822 1 LUG SLDLSS 600/250-1/0 X 1/4-28

* ITEM INCLUDED WITH HARNESS

** ITEM INCLUDED WITH 0D5464B

*** ITEM IS PART OF 9R.

**** HARDWARE FOR MTG. CB TERMINAL COVERS IS SUPPLIED WITH

CIRCUIT BREAKERS.

EXPLODED VIEW: EV EXHAUST 5.4L&6.8L O/S C5

DRAWING #: 0G1344

GROUP D

ITEM PART# QTY. DESCRIPTION

REVISION: K-1591-B Page 2 of 2

DATE: 1/29/15

1 0F2807C 1 PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5)

0F2807G 1 PIPE EXH MAN R/H 5.4L D/D CPL (5.4L C5)

2 0F2807B 1 PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5)

0F2807D 1 PIPE EXH MAN L/H 5.4L G/B & 2P (5.4L C5)

3 088510 6 NUT HEX M10-1.5 SS

4 0A6765 2 RING GASKET 2.5 DIA

5 0F4710 6 WASHER LOCK M10 SS

6 0F7200 6 SCREW HHC M10-1.5 X 50 SS FTH

(1)7 080762 8/6 BOLT U 3/8-16 X 2.62

8 0F2809 1 PIPE EXHAUST CROSSOVER

9 0F2981A 2 MUFFLER 7" X 9" X 25" (2) 2.5" IN/2.5" OUT

10 0F2962 2 MUFFLER STRAP

11 0C2454 4 SCREW HWHT M6-1 X 16 N WA Z/JS

12 022097 12 WASHER LOCK M6-1/4

13 0F2830 2 MUFFLER BRACKET STIFFENER

14 049721 12 SCREW HHC M6-1.0 X 35 G8.8 BLK

15 049813 8 NUT HEX M6 X 1.0 G8 YEL CHR

16 0L1789 8 MUFFLER STRAP UPPER/LOWER

17 0F6214 2 PIPE ELBOW EXHAUST MUFFLER

18 0F2773C 2 EXHAUST BLANKET 900MM LONG (6.8L C5)

0F2773D 2 EXHAUST BLANKET 850MM LONG (5.4L C5)

19 0D3159 2 FLANGE EXHAUST

20 088775 6 WASHER FLAT 3/8 SS

21 022473 20 WASHER FLAT 1/4-M6 ZINC

22 0F5447 1 BRACKET MUFFLER

(2) 23 0F2808 2 EXHAUST OUTLET PIPE CPL

(1) QTY. REQUIRED FOR ENCLOSED UNITS / QTY. REQUIRED FOR OPEN SETS.

(2) ENCLOSED SETS ONLY.

Generac QT13068ANANA Manual

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Model:	QT13068ANANA