Owner's Manual
Stationary Emergency Generator
QT
6.8L
70kW Models
EPA Certified
with Optional Catalyst
nNOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT
APPLICATIONS.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST
FUMES! OUTDOOR INSTALLATION ONLY!
This manual should remain with the unit.
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Safety Instructions
nSAVE 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.
This symbol points out potential fire hazard.
INTRODUCTION
Thank you for purchasing this model of the stationary emergency
generator product line.
This symbol points out potential electrical shock hazard.
Every effort was expended to make sure that the information and
instructions in this manual were both accurate and current at the
time the manual was written. However, the manufacturer reserves
the right to change, alter or otherwise improve this product(s) at
any time without prior notice.
The operator is responsible for proper and safe use of the equip-
ment. The manufacturer strongly recommends that the operator
read this Owner's Manual and thoroughly understand all instruc-
tions before using this equipment. The manufacturer also strongly
recommends instructing other users to properly start and operate
the unit. This prepares them if they need to operate the equipment
in an emergency.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest
Service Dealer for starting, operating and servicing procedures.
For safety reasons, the manufacturer recommends that this
equipment be installed, serviced and repaired by a Service
Dealer or other competent, qualified electrician or installation
technician who is familiar with applicable codes, standards and
regulations. The operator also must comply with all such codes,
standards and regulations.
Throughout this publication, and on tags and decals affixed to the
generator, DANGER, WARNING, CAUTION and NOTE blocks are
used to alert personnel to special instructions about a particular
service or operation that may be hazardous if performed incor-
rectly or carelessly. Observe them carefully. Their definitions are
as follows:
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety checks, to
make sure that all maintenance for safe operation is performed
promptly, and to have the equipment checked periodically by a
Service Dealer. Normal maintenance service and replacement of
parts are the responsibility of the owner/operator and, as such,
are not considered defects in materials or workmanship within the
terms of the warranty. Individual operating habits and usage con-
tribute to the need for maintenance service.
INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF
NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.
Indicates a hazardous situation or action which, if not
avoided, could result in death or serious injury.
Proper maintenance and care of the generator ensure a minimum
number of problems and keep operating expenses at a minimum.
See a Service Dealer for service aids and accessories.
Indicates a hazardous situation or action which, if not
avoided, could result in minor or moderate injury.
NOTE:
Operating instructions presented in this manual assume that the
generator electric system has been installed by a Service Dealer or
other competent, qualified contractor. Installation of this equipment
is not a “do-it-yourself” project.
Notes contain additional information important to a procedure
and will be found within the regular text body of this manual.
These safety warnings cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the special
instructions while performing the service are essential to prevent-
ing accidents.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs, simply contact
a Service Dealer for assistance. Service technicians are factory-
trained and are capable of handling all service needs.
Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTION blocks. The type of information each
indicates is as follows:
When contacting a dealer about parts and service, always supply
the complete Model Number, Serial Number and Type Code (where
applicable) from the DATA LABEL that is affixed to the unit.
This symbol points out important safety information that,
if not followed, could endanger personal safety and/or
n
property of others.
This symbol points out potential explosion hazard.
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Safety Instructions
• The engine exhaust fumes contain carbon monoxide gas, which
SAFETY RULES
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 compli-
ance with applicable codes and standards.
Study these SAFETY RULES carefully before installing, operating
or servicing this equipment. Become familiar with this Owner’s
Manual and with the unit. The generator can operate safely, effi-
ciently and reliably only if it is properly installed, operated and
maintained. Many accidents are caused by failing to follow simple
and fundamental rules or precautions.
The manufacturer cannot anticipate every possible circumstance
that might involve a hazard. The warnings in this manual, and on
tags and decals affixed to the unit are, therefore, not all inclusive.
If a procedure, work method or operating technique is used that
the manufacturer does not specifically recommend, ensure that it
is safe for others. Also make sure the procedure, work method or
operating technique utilized does not render the generator unsafe.
• Keep hands, feet, clothing, etc., away from drive belts, fans,
and other moving or hot parts. Never remove any drive belt or
fan guard while the unit is operating.
• Adequate, unobstructed flow of cooling and ventilating air is
critical in any room or building housing the generator to prevent
buildup of explosive gases and to ensure correct generator
operation. Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seriously affect
safe operation of the generator.
• Keep the area around the generator clean and uncluttered.
Remove any materials that could become hazardous.
• When working on this equipment, remain alert at all times.
Never work on the equipment when physically or mentally
fatigued.
• Inspect the generator regularly, and promptly repair or replace
all worn, damaged or defective parts using only factory-
approved parts.
• Before performing any maintenance on the generator, discon-
nect 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 dan-
gerous operating conditions from leaking exhaust gases, fuel
leakage, oil leakage, etc.
nDespite 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 respon-
sible and capable persons to install, operate or
maintain this equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
nParts 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 a Service
Dealer or other competent, qualified electrician or installation
technician who is familiar with applicable codes, standards
and regulations. The operator also must comply with all such
codes, standards and regulations.
ELECTRICAL HAZARDS
• Installation, operation, servicing and repair of this (and related)
equipment must always comply with applicable codes, stan-
dards, laws and regulations. Adhere strictly to local, state and
national electrical and building codes. Comply with regulations
the Occupational Safety and Health Administration (OSHA) has
established. Also, ensure that the generator is installed, operat-
ed and serviced in accordance with the manufacturer’s instruc-
tions and recommendations. Following installation, do nothing
that might render the unit unsafe or in noncompliance with the
aforementioned codes, standards, laws and regulations.
• All stationary emergency generators covered by this manual
produce dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely high and dan-
gerous voltages to the transfer switch as well as the generator.
Avoid contact with bare wires, terminals, connections, etc.,
on the generator as well as the transfer switch, if applicable.
Ensure all appropriate covers, guards and barriers are in place
before operating the generator. If work must be done around
an operating unit, stand on an insulated, dry surface to reduce
shock hazard.
• Do not handle any kind of electrical device while stand-
ing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
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Safety Instructions
• If personnel must stand on metal or concrete while installing,
FIRE HAZARDS
operating, servicing, adjusting or repairing this equipment,
place insulative mats over a dry wooden platform. Work on the
equipment only while standing on such insulative mats.
• The National Electrical Code (NEC) requires the frame and
external electrically conductive parts of the generator to be con-
nected to an approved earth ground. This grounding will help
prevent dangerous electrical shock that might be caused by a
ground fault condition in the generator or by static electricity.
Never disconnect the ground wire.
• Keep a fire extinguisher near the generator at all times. Do NOT
use any carbon tetra-chloride type extinguisher. Its fumes are
toxic, and the liquid can deteriorate wiring insulation. Keep the
extinguisher properly charged and be familiar with its use. If
there are any questions pertaining to fire extinguishers, consult
the local fire department.
EXPLOSION HAZARDS
• Wire gauge sizes of electrical wiring, cables and cord sets must
be adequate to handle the maximum electrical current (ampac-
ity) 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.
• Properly ventilate any room or building housing the generator to
prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any fuel or oil
spills immediately. Ensure that no combustible materials are left
in the generator compartment, or on or near the generator, as
FIRE or EXPLOSION may result. Keep the area surrounding the
generator clean and free from debris.
• Connecting this unit to an electrical system normally supplied
by an electric utility shall be by means of a transfer switch so as
to isolate the generator electric system from the electric utility
distribution system when the generator is operating. Failure to
isolate the two electric system power sources from each other
by such means will result in damage to the generator and may
also result in injury or death to utility power workers due to
backfeed of electrical energy.
• These generators may operate using one of several types
of fuels. All fuel types are potentially FLAMMABLE and/or
EXPLOSIVE and should be handled with care. Comply with all
laws regulating the storage and handling of fuels. Inspect the
unit’s fuel system frequently and correct any leaks immediately.
Fuel supply lines must be properly installed, purged and leak
tested according to applicable fuel-gas codes before placing
this equipment into service.
• Stationary emergency generators installed with an automatic
transfer switch will crank and start automatically when normal
(utility) source voltage is removed or is below an acceptable
preset level. To prevent such automatic start-up and possible
injury to personnel, disable the generator’s automatic start cir-
cuit (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.
• 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.
• In case of accident caused by electric shock, immediately
shut down the source of electrical power. If this is not pos-
sible, attempt to free the victim from the live conductor. AVOID
DIRECT CONTACT WITH THE VICTIM. Use a nonconducting
implement, such as a dry rope or board, to free the victim from
the live conductor. If the victim is unconscious, apply first aid
and get immediate medical help.
• Never wear jewelry when working on this equipment. Jewelry
can conduct electricity resulting in electric shock, or may get
caught in moving components causing injury.
CALIFORNIA PROPOSITION 65 WARNING
Engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects
and other reproductive harm.
CALIFORNIA PROPOSITION 65 WARNING
This product contains or emits chemicals known to the
State of California to cause cancer, birth defects and
other reproductive harm.
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General Information
NOTE:
IDENTIFICATION RECORD
For actual information related to this particular model, please
refer to the Manual Drawing Listing located at the end of this
manual, or to the data label affixed to the unit.
DATA LABEL
Every generator set includes DATA LABEL that contains important
information pertinent to the generator. The data label is attached to
the lower connection box on the generator and lists the unit serial
number, rated voltage, amps, wattage capacity, phase, frequency,
rpm, power factor, and production date.
Stationary Emergency Generator Model and Serial
Number
This number is the key to numerous engineering and manufactur-
ing details pertaining to your unit. Always supply this number
when requesting service, ordering parts or seeking information.
Data Label
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Equipment Description
EQUIPMENT DESCRIPTION
COOLANT RECOMMENDATIONS
Use a mixture of half low silicate ethylene glycol base anti-freeze
and deionized water. Cooling system capacity is listed in the
specifications. Use only deionized water and only low silicate
anti-freeze. If desired, add a high quality rust inhibitor to the rec-
ommended coolant mixture. When adding coolant, always add the
recommended 50-50 mixture.
This equipment is a revolving field, alternating current Stationary
Emergency Generator set. It is powered by a gaseous fueled
engine operating at 1800 rpm for 4-pole direct drive units, 3600
rpm for 2-pole direct drive units and 2300 - 3000 rpm for quiet
drive gear units. See the Specifications section for exact numbers.
The unit comes complete with a sound attenuated enclosure, inter-
nally mounted muffler, control console, mainline circuit breaker,
battery charger, and protective alarms as explained in the following
paragraph.
Do not use any chromate base rust inhibitor
with ethylene glycol base anti-freeze or chro-
All AC connections, including the power leads from the alterna-
tor, 120 volt battery charger input and control connections to the
transfer switch are available in the main connection box.
mium hydroxide (“green slime”) forms and will
cause overheating. Engines that have been
operated with a chromate base rust inhibitor
must be chemically cleaned before adding eth-
ylene glycol base anti-freeze. Using any high
silicate anti-freeze boosters or additives will
also cause overheating. The manufacturer also
recommends that any soluble oil inhibitor is
NOT used for this equipment.
The Stationary Emergency Generator incorporates the following
generator features:
• Rotor and Stator insulation is Class H rated as defined by NEMA
MG1-32.6, MG1-1.66. The generator is self ventilated and drip-
proof constructed.
• The voltage waveform deviation, total harmonic content of the
AC waveform and telephone influence factor have been evalu-
ated and are acceptable according to NEMA MG1-32.
Do not remove the radiator pressure cap while
the engine is hot or serious burns from boiling
liquid or steam could result.
ENGINE OIL RECOMMENDATIONS
The unit has been filled with 5W-20 engine oil at the factory. Use
a high-quality detergent oil classified “For Service SJ or SH.”
Detergent oils keep the engine cleaner and reduce carbon deposits.
When changing the engine oil, be sure to use 5W-30 engine oil
(synthetic oil is recommended).
Ethylene glycol base antifreeze is poisonous.
Do not use mouth to siphon coolant from the
radiator, recovery bottle or any container. Wash
hands thoroughly after handling. Never store
used antifreeze in an open container because
animals are attracted to the smell and taste of
antifreeze even though it is poisonous to them.
Any attempt to crank or start the engine before
it has been properly serviced with the recom-
mended oil may result in an engine failure.
NOTE:
For temperatures below 32° F, it is strongly recommended to
use the optional Cold Weather Start Kit. The oil grade for tem-
peratures below 32° F is 5W-30 synthetic oil.
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Engine Protective Devices
OVERCRANK SHUTDOWN
ENGINE PROTECTIVE DEVICES
The Stationary Emergency Generator may be required to operate
for long periods of time without an operator on hand to monitor
such engine conditions as coolant temperature, oil pressure or
rpm. For that reason, the engine has several devices designed to
protect it against potentially damaging conditions by automatically
shutting down the unit when the oil pressure is too low, the coolant
temperature is too high, the coolant level is too low, or the engine
is running too fast.
After a prespecified duration of cranking, this function ends the
cranking if the engine has failed to start. The overcrank message
will turn ON. Turn OFF the AUTO/OFF/MANUAL switch, then turn
switch back to AUTO to reset the generator control board.
NOTE:
If the fault is not corrected, the overcrank feature will continue
to activate.
NOTE:
Approximate Crank Cycle Times
• 15 seconds ON
• 7 seconds OFF
• 7 seconds ON
Engine protective switches and sensors are mentioned here for
the reader’s convenience. Also refer to the applicable control
panel manual for additional automatic engine shutdown infor-
mation.
• 7 seconds OFF
• Repeat for 45 seconds
• Approximately 90 seconds total.
HIGH COOLANT TEMPERATURE SENDER
An analog coolant temperture sender, located in the engine's
cooling system will cause an engine shutdown if the temperature
should exceed approximately 125° C (257° F). The generator will
automatically restart once the temperature has returned to a safe
operating level.
OVERSPEED SHUTDOWN
A speed circuit controls engine cranking, start-up, operation and
shutdown. Engine speed signals are delivered to the circuit board
whenever the unit is running. Should the engine overspeed above
a safe, preset value, the circuit board initiates an automatic engine
shutdown. Contact the nearest Authorized Dealer if this failure
occurs.
LOW COOLANT LEVEL SENSOR
To prevent overheating, the engine has a low coolant level sensor.
If the level of engine coolant drops below the level of the low cool-
ant level sensor, the engine automatically shuts down.
RPM SENSOR LOSS SHUTDOWN
If the speed signal to the control panel is lost, engine shutdown
will occur.
LOW OIL PRESSURE SWITCH
This switch has normally closed contacts that are held open by
engine oil pressure during cranking and operating. Should oil pres-
sure drop below the 8 psi range, switch contacts close, and the
engine shuts down. The unit should not be restarted until oil is
added, and the AUTO/OFF/MANUAL switch must be turned to OFF
and then back to AUTO.
DC FUSES
A fuse (7.5 amp) is located on the control panel. It protects the
panel 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.
A fuse (25 amp) is located in the engine wire harness adjacent
to the DC alternator. It is used to prevent circuit failure due to DC
alternator falure. It will also protect the system in the event of a
wiring short-dircuit. If this fuse is blown, the generator will not
operate. Replace these fuses with the same size, type, and rating.
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Fuel System
NATURAL GAS FUEL SYSTEM
FUEL SYSTEM
Natural gas is supplied in its vapor state. In most cases, the gas
distribution company provides piping from the main gas distribu-
tion line to the standby generator site. The following information
applies to natural gas fuel systems.
FUEL REQUIREMENTS
The Stationary Emergency Generator may be equipped with one of
the following fuel systems:
• Gas pressure in a building is usually regulated by national, state
and local codes.
• To reduce gas pressure to a safe level before the gas enters a
building, a primary regulator is needed. The natural gas supplier
may or may not supply such a regulator.
• It is the responsibility of the gas supplier to make sure sufficient
gas pressure is available to operate the primary regulator.
• Gas pressure at the inlet to the fuel shutoff solenoid must never
exceed approximately 14 inches water column (0.5 psi).
• Natural gas fuel system
• Propane vapor (LPV) fuel system
Recommended fuels should have a Btu content of at least 1,000
Btu's per cubic foot for natural gas; or at least 2,520 Btu's per
cubic foot for LP gas. Ask the fuel supplier for the Btu content of
the fuel.
NOTE:
The fuel consumption requirements are identified in the
Specifications section of the Owner's Manual. Refer to the
Installation Manual if assistance is required for the sizing of
the pipe diameter for the generator. Any piping used to connect
the generator to the fuel supply should be of adequate size to
achieve the 100% load fuel consumption requirements identi-
fied in the Specifications section regardless of actual load.
PROPANE VAPOR WITHDRAWAL FUEL SYSTEM
This type of system utilizes the vapors formed above the liquid
fuel in the supply tank. Approximately 10 to 20 percent of the tank
capacity is needed for fuel expansion from the liquid to the vapor
state. The vapor withdrawal system is generally best suited for
smaller engines that require less fuel. The installer should be aware
of the following:
NOTE:
TherecommendedfuelpressureisidentifiedintheSpecifications
section this manual.
• When ambient temperatures are low and engine fuel consump-
tion is high, the vapor withdrawal system may not function
efficiently.
• Ambient temperatures around the supply tank must be high
enough to sustain adequate vaporization, or the system will not
deliver the needed fuel volume.
NOTE:
It is the responsibility of the installer to make sure that only
the correct recommended fuel is supplied to the generator fuel
system. Thereafter, the owner/operator must make certain that
only the proper fuel is supplied.
• In addition to the cooling effects of ambient air, the vaporization
process itself provides an additional cooling effect.
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Specifications
Engine Lubrication System
SPECIFICATIONS
Type of Oil Pump ...............................................................Gear
Oil Filter .......................................................Full Flow, Cartridge
Crankcase Oil Capacity ............................................ 5 U.S. qts.
STATIONARY EMERGENCY GENERATOR
Type......................................................................Synchronous
Rotor Insulation.............................................................Class H
Stator Insulation............................................................Class H
Total Harmonic Distortion..............................................< 3.5%
Telephone Interference Factor (TIF) .................................. < 50
Alternator Output Leads 1-phase.....................................4-wire
Alternator Output Leads 3-phase.....................................6-wire
Bearings ..................................................................Sealed Ball
Coupling ................................................................Flexible Disc
Load Capacity (Standby Rating)....................................70 kW*
COOLING SYSTEM
Type............................................................................... Closed
Water Pump............................................................. Belt Driven
Fan Speed.........................................................................2300
Fan Diameter..............................................................22 inches
Fan Mode....................................................................... Pusher
Air Flow (inlet air including alternator and
combustion air) .................................................5200 ft3/min.
Coolant Capacity....................................................4.5 U.S. gal.
Heat Rejection to Coolant....................................287,000 Btu/h
Maximum Operating Air Temp. on Radiator......... 60 °C (150 °F)
Maximum Ambient Temperature......................... 50 °C (140 °F)
* NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE
J1349, ISO3046 and DIN 6271 Standards. kW rating is based on LPG fuel and may derate
with natural gas.
Excitation System ......................................................Brushless
Circuit Breaker Size (Amps)
FUEL SYSTEM
Voltage
LP kW CB Amps NG kW CB Amps
Type of Fuel ........................................ Propane or Natural Gas*
Carburetor............................................................... Down Draft
Secondary Fuel Regulator............................................ Standard
Fuel Shut-off Solenoid................................................. Standard
Operating Fuel Pressure ...............11 in. - 14 in. Water Column
120/240 V - 1ø
120/208 V - 3ø
120/240 V - 3ø
277/480 V - 3ø
67
70
70
70
300 292
300 243
250 211
125 105
64
67
67
67
300 267
300 232
250 201
125 101
Fuel Consumption - ft3/hr (Natural Gas/LPV)
Generator Locked Rotor kVA Available @ Voltage Dip of 35%
Single-phase..............................................................145 kVA
480 V, 3-phase..........................................................160 kVA
208 V, 3-phase..........................................................145 kVA
Exercise
25%
50%
75%
100%
Load
Cycle
Load
Load
Load
110/44.2
260/104
500/200 696/280 1020/411
* Engine is not field convertible between natural gas and propane. Jet size and ignition timing
are factory set for the specific fuel.
ENGINE
Make ........................................................................... Generac
Model ............................................................................. V-type
Cylinders and Arrangement ...................................................10
Displacement...............................................................6.8 Liter
Bore............................................................ 90.2 mm (3.55 in.)
Stroke....................................................... 105.9 mm (4.17 in.)
Compression Ratio.......................................................... 9-to-1
Air Intake System......................................... Naturally Aspirated
Valve Seats................................................................ Hardened
Lifter Type.................................................................. Hydraulic
ELECTRICAL SYSTEM
Battery Charge Alternator.....................................12 V, 30 Amp
Smart Charger .......................................................12 V, 2 Amp
Recommended Battery.......................................... 24F 525CCA
System Voltage............................................................ 12 Volts
NOTE:
Battery dimensions (L x W x H) for the Group 24 battery should
not exceed 10 3/4" x 6 13/16" x 9" (273 mm x 173 mm x 229
mm).
Engine Parameters
Rated Synchronous rpm.........................................60 Hz, 1800
Voltage Regulator
Type...........................................................................Electronic
Regulation........................................................................± 1%
Exhaust System
Exhaust Flow at Rated Output 60 Hz.............................557 cfm
Exhaust Temperature at Rated Output..............................890 °F
Power Adjustment for Ambient Conditions
Temperature Deration
3% for every 10 °C above °C ..............................................25
1.65% for every 10 °F above °F ..........................................77
Altitude Deration
1% for every 100 m above m............................................183
3% for every 1000 ft. above ft. .........................................600
Combustion Air Requirements (Natural Gas)
Flow at rated power, 60 Hz...........................................205 cfm
Governor
Type...........................................................................Electronic
Frequency Regulation.............................................Isochronous
Steady State Regulation ............................................ ± 0.25 %
Controller ................................................................. Nexus
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Specifications
WEATHER AND MAINTENANCE KITS
To keep the generator running at its peak, the following kits are
offered:
• Cold Weather Kit
~ Recommended for climates with temperatures below 32 °F.
• Scheduled Maintenance Kit
~ Kit includes the recommended parts to maintain the genera-
tor. Refer to the Service Schedule for regular maintenance
intervals.
For additional information, or to order any of these kits, please
contact an Authorized Service Dealer or Customer Service
Representative.
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General Information
ALTERNATOR AC LEAD
ALTERNATOR POWER WINDING
CONNECTIONS
CONNECTIONS
The electrical wires in the unit’s AC connection (lower) panel
should be installed according to the number of leads and the
voltage/phase required for the application. The voltage and phase
are described on the generator data label. The number of lead
wires can be identified using the Specifications section and the
power output rating on the generator data label. For example, if
the generator produces 130kW, 277/480 Volt, 3-phase power, the
generator has 12 alternator output leads. Figure 7.3 describes the
stator power winding connection for the generator.
3-PHASE ALTERNATORS ("Y" CONFIGURATION)
The Stationary Emergency Generator is designed to supply
3-phase electrical loads. Electric power is produced in the alterna-
tor power windings. These windings were connected at the factory
to the main circuit breaker with a “Y” configuration as shown in
Figures 7.2 through 7.6.
The rated voltage between circuit breaker terminals E1-E2, E1-E3
and E2-E3 is 480V, 208V or 600V depending on the model.
The rated voltage between each circuit breaker terminal and the
neutral point 00 is 277V, 120V, or 346V depending on the model.
FOUR-LEAD, SINGLE-PHASE STATOR
Four-lead alternators (see Figure 7.1) are designed to supply elec-
trical loads with voltage code “A” (240V, 1-phase, 60 Hz). Electrical
power is produced in the stator power windings. These windings
were connected at the factory to the main circuit breaker as shown
in Figure 7.1.
Figure 7.2 — Stator Power Winding
Connections - 3-phase, 277/480V (6 Lead)
E1
The rated voltage between each circuit breaker terminal is 240V.
The rated voltage between each circuit breaker terminal and the
neutral point 00 is 120V.
S1
INTERNAL
CONNECTIONS
Figure 7.1 — Four-lead, Single-phase Stator
L - L
S4
S6
00 (NEUTRAL)
S5
S2
S3
E3
E2
L - N
Figure 7.3 — Stator Power Winding
Connections - 3-phase, 277/480V (12 Lead)
E1
S1
S4
S7
L - L
S12
S10
S9
S8
S11
S6
S5
S2
S3
E3
E2
L - N
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General Information
Figure 7.4 — Stator Power Winding
Connections - 3-phase, 120/208V (6 Lead)
3-PHASE ALTERNATORS ("DELTA" CONFIGURATION)
The Stationary Emergency Generator is designed to supply
3-phase electrical loads. Electric power is produced in the alterna-
tor power windings. These windings were connected at the factory
to the main circuit breaker with a "Delta" configuration as shown
in Figures 7.7 and 7.8.
INTERNAL CONNECTIONS
E1
S1
S1
The rated voltage between circuit breaker terminals E1-E2, E1-E3
and E2-E3 is 240V.
The rated voltage between E2 and the neutral point 00 is 208V. The
rated voltage E1-00 and E3-00 is approximately 120V.
L-L
S4
S6
S4
00 (NEUTRAL)
S5
NOTE: The voltage measured from E2 to 00 can greatly vary when
single phase load is placed on alternator.
S3
S2
Figure 7.7 — Stator Power Winding
S6 S5
Connections - 3-phase, 120/240V (6 Lead)
E3
E2
S3
S2
E2
L-N
Figure 7.5 — Stator Power Winding
Connections - 3-phase, 120/208V (12 Lead)
ꢀ
0V
A
C
E1
2ꢁVAC
S7
S1
208ꢂC
L-L
240ꢂC
S10
S12
S4
S5
S9
S2
S6 S11
E3
E2
Figure 7.8 — Stator Power Winding
Connections - 3-phase, 120/240V (12 Lead)
S3
S8
L-N
Figure 7.6 — Stator Power Winding
Connections - 3-phase, 346/600V (6 Lead)
E2
S2
S12
E1
S1
INTERNAL
S9
S5
CONNECTIONS
240 VAC
S8
240 VAC
S6
208 VAC
L - L
S3
S11
E1
NB
S4
S6
E3
S10
S1
00 (NEUTRAL)
240 VAC
S5
120 VAC
S2
E2
120 VAC
S3
E3
L - N
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Control Panel
Upon power up, this controller will go through a system self test
CONTROL PANEL INTERFACE
which will check for the presence of utility voltage on the DC
circuits. This is done to prevent damage if the installer mistakenly
connects AC utility power sense wires into the DC terminal block.
If utility voltage is detected, the controller will display a warning
message and lock out the generator, preventing damage to the
controller. Power to the controller must be removed to clear this
warning.
USING THE AUTO/OFF/MANUAL SWITCH
With the switch set to AUTO, the engine may
crank and start at any time without warning.
Such automatic starting occurs when utility
power source voltage drops below a preset
level or during the normal exercise cycle. To
prevent possible injury that might be caused
by such sudden starts, always set the switch
to OFF and remove the fuse before work-
ing on or around the generator or transfer
switch. Then, place a “DO NOT OPERATE”
tag on the generator panel and on the trans-
fer switch.
Utility voltage must be turned on and present at the N1 and N2
terminals inside the generator control panel for this test to be
performed and pass.
NOTE:
DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT
WIRES IS NOT WARRANTABLE!
This test will be performed each time the controller is powered
up.
Next, the user must enter the minimum settings to operate. These
settings are current date and time and exercise day and time. The
maintenance intervals will be initialized (i.e. started) the first time
the clock is set. If the clock is never set at power up, the mainte-
nance intervals will be reset every time power is applied.
1. “AUTO” Position – Selecting this switch activates fully auto-
matic system operation. It also allows the unit to automati-
cally start and exercise the engine every seven days with the
setting of the exercise timer (see the Setting the Exercise
Timer section).
2. “OFF” Position – This switch position shuts down the engine.
If a subsequent power loss (loss of battery power) occurs the
Installation assistant will operate upon power restoration. The self
test routine will be run and then the customer will be required to
re-enter the time and date, as this is not retained during a power
loss. The unit will not require re-activation.
This position also prevents automatic operation.
3. “MANUAL” Position – Set the switch to MANUAL to crank
and start the engine. Transfer to standby power will not occur
unless there is a utility failure.
ACTIVATE THE GENERATOR
When battery power is applied to the generator during the instal-
lation process, the controller will turn ON and the LCD screen will
illuminate. However, the generator still needs to be activated before
it will automatically run in the event of a power outage.
DISPLAY INTERFACE MENUS
The LCD display is organized as detailed below:
• The “Home” page, this page is the default page which will be
displayed if no keys are pressed for 30 seconds. This page
normally shows the current Status message and the current
date and time. The highest priority active Alarm and/or Warning
will be automatically posted on this page as well as flashing
the backlight when such an event is detected. In the case of
multiple Alarms or Warnings, only the first message will be
displayed. To clear an Alarm or Warning, see the Protection
Systems section - Clear Alarm.
• The display backlight is normally off. If the user presses any
key, the backlight will come on automatically and remain on for
30 seconds after the last key was pressed.
• The “Main Menu” page will allow the user to navigate to all other
pages or sub-menus by using the Left/Right and Enter keys.
This page can be accessed at any time with several presses of
the dedicated Escape key. Each press of the Escape key takes
you back to the previous menu until the main menu is reached.
This page displays the following options: HISTORY; STATUS;
EDIT; AND DEBUG. (See the Appendix - "Menu System".)
Activating the generator is a simple one time process that is guided
by the controller screen prompts. Once the product is activated,
the controller screen will not prompt you again, even if you discon-
nect the generator battery.
To obtain the activation code, record the generator serial number
and log onto www.activategen.com or call 1-888-9ACTIVATE and
follow the steps to retrieve the activation code.
After obtaining your activation code, please complete the following
steps at the generator’s control panel in the Activation Chart on the
following page.
NOTE:
The generator will only run in manual until the passcode has
been entered.
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Control Panel
ACTIVATION CHART
CHOOSE LANGUAGE
TROUBLESHOOTING
Display Reads:
Use ARROW keys to scroll to desired lan-
guage. Press ENTER to select.
If the wrong language is chosen, it can be
changed later using the “edit” menu.
Language
-
English
+
Escape
Enter
Display Reads:
Press ENTER to begin the activation pro-
cess.
If ESCAPE is pressed instead of ENTER,
your generator will only run in manual mode
(for test purposes) and NOT ACTIVATED will
be displayed. You will need to remove the
generator control panel fuse AND disconnect
the T1, N1 and N2 connector in the external
connection box (if equipped); or disconnect
utility input (main breaker) to the transfer
switch for 3-5 seconds and reconnect, then
begin with Step 1.
Activate me (ENT) or
ESC to run in manual
Escape
Enter
Display Reads:
If you do not have your activation code,
go to www.activategen.com or call
1-888-9ACTIVATE (922-8482).
To Activate go to
www.activategen.com
If you already have your activation code,
wait 3-5 seconds for the next display.
Escape
Enter
ENTER ACTIVATION CODE (Passcode)
TROUBLESHOOTING
Display Reads:
Use ARROW keys to scroll and find the first
number of your Activation Code.
Serial 123456789
Passcode XXXXX +/-
Press ENTER to select.
Repeat this step until all digits have been
entered.
Escape
Enter
Use ESCAPE to correct previous digits.
Display Reads:
Activation is complete when all digits are
entered above and your screen shows this
display.
What happens if “Wrong Passcode Try
Again” appears?
“SELECT HOUR (0-23)”
“-
Re-enter the activation code. If a second
attempt is unsuccessful, check the number
against the code given on activategen.com.
If it is correct and the generator will not
accept it, contact 1-888-9ACTIVATE (922-
8482).
6
+”
Follow the controller prompts to continue
setting the time function. Refer to your
Owner’s Manual with questions.
Escape
Enter
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Control Panel
• If utility is still lost after the “line interrupt period”, run the engine
INSTALLATION ASSISTANT
Interconnect System Self Test Feature (follow the on-screen
prompts).
up to normal RPM and transfer the load. At this time the con-
troller will exit the exercise routine and assume full automatic
operation.
Upon power up, this controller will go through a system self test
which will check for the presence of utility voltage on the DC
circuits. This is done to prevent damage if the installer mistakenly
connects AC utility power sense wires into the DC terminal block.
If utility voltage is detected, the controller will display a warning
message and lock out the generator, preventing damage to the
controller. Power to the controller must be removed to clear this
warning.
USER ADJUSTABLE SETTINGS
Factory
Default
Minimum
Setting
Maximum
Setting
Setting
Increment
1 min
Exercise
time
23:59
(11:59 pm)
2 pm
Wed
00:00 (12 am)
Sun
Exercise
day
Utility voltage must be turned on and present at the N1 and N2
terminals inside the generator control panel for this test to be
performed and pass.
Sat
1 day
Current
Time
23:59
(11:59 pm)
12 am 00:00 (12 am)
1 min
NOTE:
Current
Day
Sun
Jan
Sun
Jan
Sat
Dec
1 day
DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT
WIRES IS NOT WARRANTABLE!
Current
Month
1 month
1 year
This test will be performed each time the controller is powered
up.
Current
Year
2008
2008
2100
Upon first power up of the generator, the display interface will
begin an installation assistant. The assistant will prompt the user
to set the minimum settings to operate. These settings are simply:
Current Date/Time and Exercise Day/Time. The maintenance inter-
vals will be initialized when the exercise time is entered.
Language
Contrast
English
80%
French
0%
Spanish
100%
N/A
1%
The exercise settings can be changed at any time via the "EDIT"
menu (see Appendix, "Menu System").
FUEL CONVERSION
For fuel conversion steps, refer to the GenSpec section,
RECONFIGURING THE FUEL SYSTEM.
If the 12 volt battery is disconnected or the fuse removed, the
Installation Assistant will operate upon power restoration. The
only difference is the display will only prompt the customer for the
current Time and Date.
OPERATION
IF THE INSTALLER TESTS THE GENERATOR PRIOR TO
INSTALLATION, PRESS THE “ENTER” KEY TO AVOID SETTING
UP THE EXERCISE TIME. THIS WILL ENSURE THAT WHEN
THE CUSTOMER POWERS UP THE UNIT, HE WILL STILL BE
PROMPTED TO ENTER AN EXERCISE TIME.
This system is intended to supply standby power in the event of a
utility failure. The control system will monitor the utility voltage to
determine if stand-by power is required. Should the utility voltage
fail, the generator will start and run normally, detaching from the
utility and supplying the customer load from the generator. When
utility power returns, the controller will re-transfer the customer
load back to utility and shut down the generator.
SETTING THE EXERCISE TIMER
This generator is equipped with an exercise timer. Once it is set,
the generator will start and exercise every seven days, on the day
of the week and at the time of day specified. During this exercise
period, the unit runs for approximately 12 minutes and then shuts
down. Transfer of loads to the generator output does not occur
during the exercise cycle unless utility power is lost.
AUTOMATIC TRANSFER OPERATION
To select automatic operation, do the following:
1. Make sure the transfer switch main contacts are set to their
UTILITY position, i.e., loads connected to the utility power
source.
2. Be sure that normal UTILITY power source voltage is avail-
able to transfer switch terminal lugs N1 and N2 (Refer to the
Electrical Data section).
3. Set the generator’s AUTO/OFF/MANUAL switch to AUTO.
4. Set the generator’s main circuit breaker to its ON (or CLOSED)
position.
With the preceding steps complete, the generator will start auto-
matically when utility source voltage drops below a preset level.
After the unit starts, loads are transferred to the standby power
source. Refer to the Sequence of Automatic Operation section.
LOW SPEED EXERCISE
The standard start sequence will be initiated.
• All 1800 rpm units will exercise at 1400 RPM
• All 3600 rpm units will exercise at 1800 RPM
If utility is lost during exercise the controller will do the following:
• Wait for the “line interrupt period” for utility to return. If utility
returns within the “line interrupt period”, continue to exercise
at low RPM.
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Control Panel
SEQUENCE OF AUTOMATIC OPERATION
Initial Conditions: Generator in Auto ready to run, load being sup-
plied by the Utility Source through the transfer switch.
MANUAL START
Allows the user to start and run the generator manually.
Transfer of the load to the generator will occur if utility is lost while
the unit is running in the manual mode (only if activated).
1. When the utility voltage fails (falls below 60% of nominal), a
10-30 second (programmable) “line interrupt” delay timer is
started. The factory set time delay is 10 seconds. If at the
end of the line interrupt time the utility voltage is above 60%
the engine will not crank. If the utility voltage is still below
the 60% of nominal at the end of the line interrupt time, the
unit will crank and start. If the unit cranks for more than 10
seconds and the utility voltage rises above 80% of nominal
(programmed pickup voltage) and the unit has not started, the
crank cycle will abort.
2. As soon as the unit starts a 5 second “warm-up” timer is initi-
ated. When the warm-up timer expires the control will transfer
the load to the generator (through the RTS switch) if the utility
voltage is less than 80% of nominal. If the utility voltage is
greater than the 80% of nominal at the end of the warm-up
time the load will not be transferred to the generator and a one
minute low-speed cool down period will start. At the end of
the one minute cool down period the generator will stop.
3. Once the unit is running and the switch has transferred the
load to the generator the unit will monitor utility voltage.
When utility voltage returns (above the programmable pickup
voltage, normally 80% of nominal), a 15 second “Return to
Utility” timer will start. At the end of the return to utility time,
if the utility voltage is still above the pickup voltage, the unit
will transfer the load back to the utility source and run the unit
through a one minute cool down period. When the cool down
period is over the unit will shut down and be ready for the next
outage.
ALARM AND WARNING MESSAGES
Alarms are defined as “Latching” which means they must be
cleared before the alarm message on the screen will clear. They
can be of type “Shutdown” or not and are logged in the alarm log.
Alarms are all annunciated on the display).
Warnings are “Non Latching” meaning the message automati-
cally clears when the warning condition goes away. Warnings can
not be of type “Shutdown” but they are logged in the alarm log.
Warnings are all annunciated on the display.
LOW OIL PRESSURE SHUTDOWN ALARM
There is a 10 second delay before oil pressure is monitored.
HIGH COOLANT TEMPERATURE SHUTDOWN ALARM
There is a 10 second delay before engine temperature is moni-
tored.
Once running there is a 1/4 second delay before shut down. The
limit is set at 125° C or 257° F.
OVERCRANK SHUTDOWN ALARM
Occurs if the engine has not started within the specified crank
cycle.
4. If during the cool down period utility voltage should fall below
60% of nominal the 5 second warm-up timer is initiated and
the unit will transfer the load back to the generator and con-
tinue to monitor the utility.
OVERSPEED SHUTDOWN ALARM
Warning indicator is measured and calculated by the microproces-
sor. Overspeed is defined as +20% of nominal engine speed for 3
seconds, or +25% immediate.
CRANK CYCLES AND OVERCRANK SHUTDOWN
If the unit fails to start during a cranking period it will display the
Overcrank Shutdown Alarm. The system will control the cranking
cycles as follows:
Nominal engine speed = 60.0 Hz
RPM SENSOR FAILURE SHUTDOWN ALARM
During cranking: If the board does not see a valid RPM signal
within four (4) seconds of cranking it will shut down and lock out
on RPM sensor loss.
The first crank cycle is a 16 second crank time followed by a 7
second rest. The next 5 cycles will be 7 seconds of cranking time
each followed by a 7 second rest time.
If the unit fails to start by the end of the 6 crank/rest cycles
the Overcrank Shutdown Alarm will display and the unit will not
attempt to crank until the alarm is reset.
During running: If the RPM signal is lost for one full second the
board will shut the engine down, wait 15 seconds, then re-crank
the engine if in AUTO, it will not re-crank in MANUAL.
If no RPM signal is detected within the first four (4) seconds of
cranking, the control board will shut the engine down and latch out
on RPM sensor loss.
AUTO START
This unit is designed to automatically start in the event of a util-
ity failure or brown out condition. Brown out is defined as utility
voltage less than 60% nominal, while utility is considered good
when it is restored to at least the pickup value, 80% of nominal.
These levels are fixed. The “Line Interrupt period” is an adjustable
parameter by the dealer. If 2-wire start mode is activated, the unit
will start when 2-wire start is active.
If the RPM signal is detected the engine will start and run normally.
If the RPM signal is subsequently lost the control board will try
two more re-cranks before latching out and flashing the RPM
Sensor Failure message (if it is in AUTO).
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Control Panel
Figure 1 – Generator Control Panel
CHECK ENGINE MESSAGE
MISSING CAM PULSE ALARM
The control system has detected an emissions related fault. This
fault cannot be cleared using the control panel interface. The unit
will continue to operate in automatic mode. Contact your local
servicing dealer.
This is a shutdown alarm. The alarm will activate after five (5)
seconds of continuously missing cam pulses.
MISSING CRANK PULSE ALARM
This is a shutdown alarm. The alarm will activate after 12 con-
secutive revs where crank pulses are missing.
UNDER-FREQUENCY SHUTDOWN ALARM
After starting, if the generator stays under frequency for more than
30 seconds, it will shutdown.
LOW FUEL PRESSURE WARNING
Fuel pressure is monitored by a digital sensor with a fixed setpoint
of below five (5) inches water column.
LOW BATTERY ALARM
While running, if the average battery voltage falls below 11.9 volts
for one (1) minute, the low battery alarm will be displayed.
GOVERNOR SENSOR FAULT ALARM
The governor position is monitored by an analog feedback signal. If
the throttle position is seen outside of the normal operating range,
a shutdown alarm is displayed. If the throttle is commanded to
move, and no movement is seen, a shutdown alarm is displayed.
LOW BATTERY WARNING
The microprocessor will continually monitor the battery voltage
and display the Low Battery Voltage message if the battery voltage
falls below 12.2 Volts for one (1) minute.
WIRING ERROR ALARM
No other action is taken on a low battery warning condition. The
warning will automatically clear if the battery voltage rises above
12.2 volts.
When power is first apllied to the contoller, the software will per-
form a check on the wiring of the transfer output, and ensure it
does not have high voltage on the wire. If this is the case, it will
signal a miswire alarm and will not run. The test can be skipped
by use of the escape key.
NOTE:
The battery sentinel is a separate feature that monitors battery
condition.
UNDERVOLTAGE ALARM
If the generator voltage falls below 60% for >5 seconds, an alarm
will be issued.
LOW COOLANT LEVEL ALARM
This is a shutdown alarm. The sensor will be continuously moni-
tored. If an error condition is seen for five (5) consecutive sec-
onds, the alarm will be displayed.
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Control Panel
OVERVOLTAGE ALARM
ALARM CANCEL
If the generator voltage rises above 110% for >3 seconds, an
alarm will be issued.
When the generator is shut down due to a latching alarm, the Auto
/Off/ Manual switch must be set to the off position and the ENTER
key pressed to unlatch any active fault and clear the corresponding
fault alarm message.
If the generator voltage rises above 130% for >0.2 seconds, an
alarm will be issued.
INTERNAL FAILURE SHUTDOWN ALARM
Any internal failure that can be detected such as corrupted
firmware will cause this shutdown alarm. This alarm cannot be
cleared.
COMMON ALARM RELAY
The common alarm relay will be activated if there is a shutdown
alarm. It will not activate on warnings or indicate that the Auto/Off/
Manual switch is in the OFF position. The OFF position will clear
the alarms and the relay. The relay will not be used to indicate a
generator is not activated.
CANBUS ALARM
The common alarm connections are wired to a set of potential-
free (dry) contacts on the Nexus controller board. These Normally
Open (N.O.) contacts close when an alarm condition occurs and
are used to activate a remote signaling device. The circuit is rated
for a maximum of 130mA at 24 VDC. The connections are a short
set of free hanging wires that exit the engine harness loom directly
behind the Nexus Control Panel and are labeled numbers 209 and
210.
Where applicable, if the Canbus communications link fails to com-
municate, a “Canbus Alarm” will be generated. This only applies
to systems with external ignition modules. The alarm may be
generated if:
1. The physical link is broken.
2. The Ignition Module fails or resets.
3. The Nexus Controller fails or resets.
4. Having the Battery Chargers 120 VAC connected without a
battery installed.
MAINTENANCE ALERTS
Maintenance alerts will be provided for these conditions.
5. A blown 10 amp Ignition Module fuse (approximately 12
inches away from the starter).
6. A blown 25 amp system fuse (located approximately 12
inches away from the DC alternator).
NOTE:
SERVICE SCHEDULE ‘A’
Inspect Accessory Drive Alert
Coolant Change & Flush
1yr / 100hrs*
1yr / 100hrs
1yr / 100hrs
1yr / 100hrs*
1yr / 100hrs
1yr / 100hrs
6mo / 50hrs*
The “Canbus Alarm” will not clear on its own. To clear the
alarm, press the “enter” key to acknowledge the alarm. The
alarm will clear and if the fault is still present, the alarm will
reoccur.
Inspect Spark Plugs Alert
Change Oil & Filter Alert
IGNITION ALARM
When an ignition alarm occurs, a generic message “Ignition Fault”
will be displayed as the fault code.
Inspect Battery Alert
Change / Inspect Air Filter Alert
Clean/Inspect Air Inlet & Exhaust
* Items require a 3 month / 30 hour break-in change or check.
MAINTENANCE WARNING
When a maintenance period expires, a warning message will be
posted. The warning can be reset by hitting the Enter key. Resetting
will clear the warning and reset the maintenance counters for the
condition annunciated. The history log will reflect the maintenance
warning.
SERVICE SCHEDULE ‘B’
Change / Inspect spark plugs alert
2yr/ 250hr
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Operation
STATIONARY EMERGENCY
GENERATOR CONTROL AND
OPERATION
Do not crank the engine continuously for lon-
ger than 30 seconds, or the heat may
damage the starter motor.
n
Refer to the appropriate control panel operator’s manual for this
unit.
• Let engine stabilize and warm up.
• Check all applicable instrument and gauge readings. When
certain that all readings are correct, move the transfer switch
manual handle to the STANDBY (or EMERGENCY STANDBY)
position, i.e., load circuits supplied by the generator.
• Set the generator’s main line circuit breaker to its ON (or
CLOSED) position.
OPERATING UNIT WITH MANUAL
TRANSFER SWITCH
If the Stationary Emergency Generator was installed in conjunction
with a transfer switch capable of manual operation only, the fol-
lowing procedure applies. A manually operated transfer switch is
one that will not provide automatic start-up and does not include
an intelligence circuit.
• 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 literature pertaining to the
specific transfer switch.
ENGINE START-UP AND TRANSFER
For additional information, refer to the applicable control panel
manual for this unit, as well as any literature pertaining to the
specific transfer switch.
To transfer the load back to the utility power source and shut down
the generator, follow these directions:
• Set the generator’s main line circuit breaker to its OFF (or OPEN)
position.
• Manually move the transfer switch handle to its UTILITY
(NORMAL) position, i.e., load circuits connected to the utility.
• Turn ON the utility power supply to the transfer switch, using
the means provided (such as the utility power source main line
circuit breaker).
• Let the generator run at no-load for a few minutes to stabilize
internal temperatures.
• Shut down the generator.
nThe 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 appli-
cable control panel and transfer switch manuals
for more information.
nDo not proceed until certain that utility source
voltage is available to the transfer switch and
OPERATING UNIT WITH AUTOMATIC
the transfer switch main contacts are set to
UTILITY.
TRANSFER SWITCH
Do not attempt manual operation until all
power supplies to the transfer switch have been
If the Stationary Emergency Generator has been installed with an
automatic transfer switch, the engine may be started and stopped
automatically or manually.
positively turned off, or extremely dangerous -
possibly lethal - electrical shock will result.
NOTE:
Transfer switch enclosure doors should be kept
closed and locked. Only authorized personnel
Refer to the applicable manual for your transfer switch and to
“Transfer Switch Start Signal Connections”. In addition, please
note the dangers under “Engine Start-up and Transfer.”
should be allowed access to the transfer switch
interior. Extremely high and dangerous voltages
are present in the transfer switch.
In order to transfer load from the utility source to the generator,
follow these directions:
• Turn OFF or disconnect the utility power circuit to the transfer
switch, using the means provided (such as the utility source
main line circuit breaker).
• Set the transfer handle to its UTILITY (NORMAL) position with
load circuits connected to the utility power supply.
• Set the generator’s main line circuit breaker to its OFF (or OPEN)
position.
• Start the generator.
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Maintenance
Refer to the Service Schedule for engine oil and filter change fre-
quencies.
GENERAL MAINTENANCE
Drain the oil while the engine is still warm from running. This
means warm up the engine, shut it down and drain immediately
as follows:
Before working on the Stationary Emergency
Generator, ensure the following:
• The AUTO/OFF/MANUAL switch is in the OFF position.
• The control panel fuse has been removed from the control
box.
1. Remove the drain hose from its retaining clip or cut the zip-tie
securing the oil drain hose.
2. Loosen and remove OIL DRAIN HOSE CAP. Drain oil com-
• The 120VAC supply to the battery charger is switched OFF.
• The negative battery cable has been removed.
pletely into suitable container.
3. When all oil has drained, install and tighten OIL DRAIN HOSE
CAP and secure drain hose with a new zip-tie, or place the
hose in its retaining clip.
CHECK ENGINE OIL
Check engine crankcase oil level (Figure 10.1) according to the
Service Schedule and SIB10-10-L24G.
4. Turn OIL FILTER (Figure 10.1) counterclockwise and remove.
Properly dispose of old filter.
5. Apply light coating of new engine oil to seal of new oil fil-
ter. Install FILTER and tighten by hand only. DO NOT OVER
TIGHTEN.
• Remove oil dipstick and wipe dry with a clean, lint-free cloth.
• Install oil dipstick, then remove again.
• Oil should be between FULL and ADD marks.
• If oil level is below the dipstick ADD mark, remove oil fill cap.
Add the recommended oil to bring oil level up to the FULL
mark. DO NOT FILL ABOVE THE “FULL” MARK. See “Engine Oil
Recommendations” for recommended oils.
6. Remove OIL FILL CAP and add recommended oil. Crankcase
oil capacity is listed in the "Specifications" section.
After refilling the crankcase with oil, always
check oil level on dipstick. NEVER OPERATE
ENGINE WITH OIL BELOW THE DIPSTICK
“ADD” MARK.
n
Figure 10.1 - Oil Dipstick and Oil Fill Cap
Oil Fill
7. Start engine and check for oil leaks.
Oil
Dipstick
8. Shut OFF engine and wait 10 minutes for the oil to settle down
into the oil pan. Recheck oil level on dipstick. DO NOT fill
above the dipstick "FULL" mark.
9. Dispose of used oil at a proper collection center.
COOLING INTAKE/OUTLET
Air intake and outlet openings in the generator compartment must
be open and unobstructed for continued proper operation. This
includes such obstructions as high grass, weeds, brush, leaves
and snow.
Without sufficient cooling and ventilating air flow, the engine/gen-
erator quickly overheats, which causes it to shut down. (See the
installation diagram.)
Oil Filter
The exhaust system parts from this product
get extremely hot and remains hot after shut-
down. High grass, weeds, brush, leaves, etc.
must remain clear of the exhaust. Such mate-
rials may ignite and burn from the heat of the
exhaust system.
CHANGING ENGINE OIL
Hot oil may cause burns. Allow engine to
INSPECT COOLING SYSTEM
• Inspect engine cooling system. See the Service Schedule.
• Check hoses for damage, deterioration, leaks, etc. Correct any
discrepancies found.
cool before draining oil. Avoid prolonged
n
or repeated skin exposure with used oil.
Thoroughly wash exposed areas with soap.
• Check hose clamps for tightness.
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Maintenance
ENGINE COOLANT
CHECK FAN BELT
Checkcoolantlevelincoolantrecoverybottle.See theSpecifications
and Service Schedule sections.
• Inspect fan belts every year. Replace any damaged, deterio-
rated, worn or otherwise defective belt.
• Check fan belt tension. Thumb pressure, exerted midway
between pulleys, should deflect about 3/8 to 5/8 of an inch.
Adjust belt tension as required.
• Add recommended coolant mixture as necessary.
• Periodically remove radiator pressure cap (only when engine
has cooled down) to make sure the coolant recovery system
is functioning properly. Coolant should be at bottom of radia-
tor filler neck. If coolant level is low, inspect gasket in radiator
pressure cap. Replace cap, if necessary. To have pressure cap
tested, contact a Service Facility. Inspect cooling system and
coolant recovery system for leaks.
• Check fan belt alignment (see Figure 10.2).
Figure 10.2 – Fan Belt
COOLANT CHANGE
Every year, have a service facility drain, flush and refill the cooling
system. See the Specifications and Service Schedule for cooling
system recommendations.
OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL
SYSTEM
Engine cranking, start up and running are controlled by a solid
state Engine Controller circuit board. Battery voltage is delivered
to that circuit board via the control panel fuse. This overcurrent
protection device will open if the circuit is overloaded.
If a circuit breaker opens or a fuse element
melts, find the cause of the overload before
resetting the circuit breaker or replacing the
fuse.
n
INSPECT ENGINE GOVERNOR
Visually inspect electronic governor.
EXERCISE SYSTEM
Starts the Stationary Emergency Generator engine once every
seven days and lets it run for 12 minutes.
Do not attempt to adjust the governor. Only
qualified service facilities should adjust
n
the governor. Excessively high operating
speeds are dangerous and increase the
risk of personal injury. Low speeds impose
a heavy load on the engine when adequate
engine power is not available and may
shorten engine life. Correct rated frequency
and voltage are supplied only at the proper
governed speed. Some connected electrical
load devices may be damaged by incorrect
frequency and/or voltage. Only qualified ser-
vice technicians should adjust the governed
speed.
PERFORM VISUAL INSPECTION
Complete a thorough visual inspection of the entire engine-genera-
tor monthly. Look for obvious damage, loose, missing or corroded
nuts, bolts and other fasteners. Look for fuel, oil or coolant leaks.
INSPECT EXHAUST SYSTEM
Inspect the exhaust system at least once every year. Check all
exhaust system pipes, mufflers, clamps, etc. for condition, tight-
ness, leaks, security, damage.
CHANGING THE ENGINE AIR FILTER
To replace the engine air filter, remove the air filter cover and
replace the air filter making sure it is positioned properly before
reattaching the cover (Figure 10.3).
See the Service Schedule for air filter maintenance.
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Maintenance
nBattery electrolyte fluid is an extremely cor-
rosive sulfuric acid solution that can cause
Figure 10.3 – Engine Air Filter
severe burns. Do not permit fluid to contact
eyes, skin, clothing, painted surfaces, etc.
Wear protective goggles, protective clothing
and gloves when handling a battery. If fluid
is spilled, flush the affected area immediate-
ly with clear water.
Air Filter
Do not use any jumper cables or booster
battery to crank and start the generator
engine. If the battery has completely dis-
charged, remove it from the generator for
recharging.
n
Be sure the AUTO/OFF/MANUAL switch is
set to the OFF position, before connecting
the battery cables. If the switch is set to
AUTO or MANUAL, the generator can crank
and start as soon as the battery cables are
connected.
n
Be sure the 120VAC power supply to the bat-
tery is turned OFF, or sparking may occur at
the battery posts as the cables are attached
and cause an explosion.
SPARK PLUGS
Reset the spark plug gap or replace the spark plugs as neces-
sary.
1. Clean the area around the base of the spark plugs to keep dirt
and debris out of the engine. Clean by scraping or washing
using a wire brush and commercial solvent. Do not blast the
spark plugs to clean.
2. Remove the spark plugs and check the condition. Replace
the spark plugs if worn or if reuse is questionable. See the
“Service Schedule” section for recommended inspection.
3. Check the spark plug gap using a wire feeler gauge. See the
Specifications section for the required spark plug gap.
BATTERY REPLACEMENT
NOTE:
Unit DOES NOT include battery.
When supplying or replacing the battery, the recommended num-
ber and type of battery is listed in the Specifications Section.
NOTE:
The BCI number should be located directly on the battery.
BATTERY MAINTENANCE
The battery should be inspected per the Service Schedule section.
The following procedure should be followed for inspection:
BATTERY FLUID
Check battery electrolyte fluid based on the Service Schedule.
Fluid should cover separators in all battery cells. If fluid level is
low, add distilled water to cover tops of separators. DO NOT USE
TAP WATER IN BATTERY.
1. Inspect the battery posts and cables for tightness and corro-
sion. Tighten and clean as necessary.
2. Check the battery fluid level of unsealed batteries and, if
necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP
WATER IN BATTERIES.
CLEANING THE STATIONARY EMERGENCY GENERATOR
Keep the generator as clean and as dry as possible. Dirt and
moisture that accumulates on internal generator windings have an
adverse effect on insulation resistance.
3. Have the state of charge and condition checked. This should
be done with an automotive-type battery hydrometer.
Periodically clean generator exterior surfaces. A soft brush may be
used to loosen caked on dirt. Use a vacuum system or dry, low
pressure air to remove any accumulations of dirt. The generator is
housed inside an all-weather enclosure, clean the enclosure with a
soft, damp cloth or sponge and water.
Storage batteries give off explosive hydrogen
gas. This gas can form an explosive mixture
around the battery for several hours after
charging. The slightest spark can ignite the
gas and cause an explosion. Such an explo-
sion can shatter the battery and cause blind-
ness or other injury. Any area that houses a
storage battery must be properly ventilated.
Do not allow smoking, open flame, sparks or
any spark producing tools or equipment near
the battery.
Once each year have the generator cleaned and inspected by a
Service Dealer. That dealer will use dry, low pressure air to clean
internal windings.
Finally, have the insulation resistance of stator and rotor windings
checked. If insulation resistances are excessively low, the genera-
tor may require drying.
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Service Schedule
SERVICE SCHEDULE
System / Component
Frequency
Procedure
Weekly - W
Monthly - M
Yearly - Y
Inspect
Change
Clean
Fuel
Fuel Lines & Connections
Lubrication
M
X
Oil Level
M
Y
X*
Oil
X**
X**
Oil Filter
Y
Cooling
Engine Coolant Lines & Connections
Engine Coolant Level
Engine Coolant
M
M
Y
X
X
X
Enclosure Louvers
Engine
W
X
X
Air Cleaner
Y
Y
X
X
X***
X***
Spark Plugs
Battery
Remove Corrosion, Ensure Dryness
Clean & Tighten Battery Terminals
Check Charge State
Check Electrolyte Level
General Condition
Vibration, Noise, Leakage, Temperature
Generator System
Complete Tune-up and System Inspection
Footnotes
M
M
M
M
X
X
X
X
X
X
X***
X***
M
Y
X
To be completed by an Authorized Service Dealer.
* Inspect the oil level monthly or every 12 hours during continuous operation.
** Change oil and oil filter after the first 30 hours of operation and then every 100 hours or annually thereafter, whichever occurs first.
Change sooner when operating under heavy load or in a dusty or dirty environment or in high ambient temperatures.
*** Replace as necessary.
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Troubleshooting
TROUBLESHOOTING GUIDE
PROBLEM
Engine won’t crank.
CAUSE
CORRECTION
1. Control panel 7.5 amp fuse blown.
2. Loose or corroded or defective
battery cables.
1. Replace fuse.*
2. Tighten, clean or replace
battery cables as necessary.*
3. Replace contactor.*
4. Replace starter motor.*
5. Remove, change or replace battery.*
3. Defective starter contactor.
4. Defective starter motor.
5. Dead or Defective Battery.
Engine cranks but won't start.
Engine starts hard, runs rough.
1. Out of fuel.
2. Fuel solenoid (FS) is defective
3. Spark plugs defective.
1. Replenish fuel/turn on fuel valve.
2. Replace solenoid.*
3. Clean, regap or replace plugs.
1. Air cleaner plugged or damaged.
2. Defective spark plugs.
3. Fuel pressure incorrect.
1. Clean or replace as needed.
2. Clean, regap or replace plugs.
3. Confirm fuel pressure to regulator is as
recommended in SPECIFICATIONS.*
4. Confirm fuel pressure to regualtor is as
recommended in SPECIFICATIONS.*
5. Reconfigure the fuel system. (See
RECONFIGURING THE FUEL SYSTEM in
manual.*
4. Insufficient fuel supply.
5. Fuel system set to wrong fuel type.
Engine starts then shuts down.
1. Engine oil level is low.
2. Engine is overheated.
3. Defective Low Oil Pressure Switch
4. Defective Coolant Temperature Switch
5. Defective Control Module circuit board.
6. Coolant Level is Low.
1. Check oil and add oil as needed.
2. Check cooling system for leaks.
3. Replace switch.*
4. Replace switch.*
5. Replace board.*
6. Repair leak - Add coolant.
7. Replace Switch.*
7. Defective Low Coolant Level Switch
AUTO/OFF/MANUAL Switch at OFF, 1. Defective AUTO/OFF/MANUAL switch
1. Replace board.*
2. Replace board.*
engine continues to run.
2. Defective Control Module circuit board
No AC output from generator.
1. Main line circuit breaker is tripped/open.
2. Generator internal failure.
1. Reset to ON/CLOSED.
2. *
3. Thermal circuit breaker open.
3. Auto-reset - Wait 5 min. and attempt restart.
*Contact the nearest Dealer for assistance.
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United States Environmental Protection Agency Warranty Statement
(Stationary Emergency Spark-Ignited Generators)
Warranty Rights, Obligations and Coverage
The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission
Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system or compo-
nent on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diagnosis, replace-
ment parts and labor provided it be done by a Generac Authorized Warranty Service Facility. Your emission control system may include parts
such as the fuel metering, ignition, and exhaust systems and other related emission related components listed below. Generac will warrant
the emissions control systems on your 2009 and later model year engines provided there has been no abuse, neglect, unapproved modifica-
tion, or improper maintenance of your engine. For engines less than 130 HP the warranty period is two years from the date of sale to the ulti-
mate purchaser. For engines greater than or equal to 130 HP the warranty period is three years or 2500 hours of operation, whichever
comes first, from the date of the engine being placed into service. For high-cost warranted components, the Emission Control System war-
ranty is valid for 5 years or 3500 hours of operation, whichever comes first.
Purchaser's/Owner's Warranty Responsibilities
As the engine purchaser/owner you are responsible for the following: 1) The engine must be installed and configured in accordance to Gen-
erac's installation specifications. 2) The completion of all maintenance requirements listed in your Owner's Manual. 3) Any engine setting
adjustment must be done in accordance and consistent with the instructions in the Owner's Manual. 4) Any emission control system or com-
ponent must be maintained and operated appropriately in order to ensure proper operation of the engine and control system to minimize
emissions at all times.
Generac may deny any/or all Emission Control System Warranty coverage or responsibility of the engine, or an emission control system or
component on your engine thereof, if it has failed due to abuse, neglect, unapproved modification or improper maintenance, or the use of
counterfeit and/or “gray market” parts not made, supplied or approved by Generac. Warranty service can be arranged by contacting either
your selling dealer or a Generac Authorized Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. The purchaser/owner shall
be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the inspection or
repair facilities. The purchaser/owner shall be responsible for any and/or all damages or losses incurred while the engine is being trans-
ported/shipped for inspection or warranty repairs. Contact Generac Power Systems Inc. for additional Emission Control System Warranty
related information, Generac Power Systems, Inc., PO. Box 8, Waukesha, WI 53187, or call 1-800-333-1322 or www.generac.com.
Important Note
This warranty statement explains your rights and obligations under the Emission Control System Warranty, which is provided to you by Gen-
erac pursuant to federal law. Note that this warranty shall not apply to any incidental, consequential, or indirect damages caused by defects
in materials or workmanship or any delay in repair or replacement of the defective part(s). This warranty is in place of all other warranties,
expressed or implied. Specifically, Generac makes no other warranties as to the merchantability or fitness for a particular purpose. Any
implied warranties which are allowed by law, shall be limited in duration to the terms of the express warranty provided herein. Some states
do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
Emission Related Parts Include the Following (if so equipped)
1) Fuel Metering System
3) Ignition System Including A) Spark Plug, B) Ignition Module,
C) Ignition Coil, D) Spark Plug Wires
1.1) Gasoline Carburetor Assembly and Internal Components
A) Fuel Filter, B) Carburetor, C) Fuel Pump
4) Exhaust System
A) Catalyst Assembly*, B) Exhaust Manifold, C) Muffler,
D) Exhaust Pipe, E) Muffler Gasket
1.2) Carburetion Assembly and Its Components
A) Fuel Controller, B) Carburetor and Its Gaskets,
C) Mixer and Its Gaskets, D) Primary Gas Regulator,
E) Liquid Vaporizer
5) Crankcase Breather Assembly Including
A) Breather Connection Tube, B) PCV Valve
1.3) Fuel Regulator
6) Oxygen Sensor
2) Air Induction System Including A) Intake Pipe/Manifold,
B) Air Cleaner
7) Diagnostic Emission-Control System
*High-Cost Warranted Component
EmsnWrnty001
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United States Environmental Protection Agency Compliance Requirements
(Stationary Emergency Spark-Ignited Generators)
Purchaser's/Owner's Record Keeping Responsibilities
The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain your record
keeping requirements for compliance with Subpart JJJJ- Standards of Performance for Stationary Spark Ignition Internal Combustion
Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60. As the engine purchaser/owner who operates and maintains
their certified emergency stationary engine and emission control system according to applicable emission related guidelines as specified in
this Owner's Manual, you are required to meet the following notification and record keeping requirements to demonstrate compliance: 1)
Maintain documentation that the engine is certified to meet emission standards. 2) Record keeping of maintenance conducted. 3) Record
keeping of the provision allowing natural gas engines to operate using propane for a maximum of 100 hours per year as an alternate fuel
solely during emergency operations provided the engine is not certified to operate on propane. 4) Meet all compliance notifications submitted
to the purchaser/owner and maintain all supporting documentation. 5) Record keeping of hours of operation, including what classified the
operation as emergency and how many hours are spent for non-emergency operation. For emergency engines greater than or equal to 130
HP, record keeping of hours of operation begins January 1, 2011. For emergency engines less than 130 HP, record keeping of hours of oper-
ation begins January 1, 2009; engines are equipped with non-resettable hour meters to facilitate record keeping.
Specific Air Quality Management or Air Pollution Control Districts may have different and additional record keeping/reporting requirements.
Your permit to construct and/or operate the engine may be contingent upon compliance with those requirements. Check with your local Air
Quality Management or Air Pollution Control District for specific requirements.
Emergency stationary internal combustion engines (ICE) may be operated for the purpose of maintenance checks and readiness testing,
provided that the tests are recommended by Federal, State or local government, Generac, or the insurance company associated with the
engine. Maintenance checks and readiness testing of such units is limited to 100 hours per year. There is no time limit on the use of emer-
gency stationary ICE in emergency situations. The purchaser/owner may petition the Administrator for approval of additional hours to be
used for maintenance checks and readiness testing, but a petition is not required if the owner maintains records indicating that Federal,
State, or local standards require maintenance and testing of emergency ICE beyond 100 hours per year. Emergency stationary ICE may
operate up to 50 hours per year in non emergency situations, but those 50 hours are counted towards the 100 hours per year provided for
maintenance and testing.
The 50 hours per year for non-emergency situations cannot be used for peak shaving or to generate income for a facility to supply power to
an electric grid or otherwise supply power as part of a financial arrangement with another entity. For purchaser/owner of emergency engines,
any operation other than emergency operation, maintenance and testing, and operation in non-emergency situations for 50 hours per year,
as permitted in this section is prohibited.
If you operate and maintain your certified emergency stationary SI internal combustion engine and emissions control systems in accordance
to the specifications and guidelines in this Owner’s Manual, EPA will not require engine performance testing. If not, your engine will be con-
sidered non-certified and you must demonstrate compliance according to Subpart JJJJ - Standards of Performance for Stationary Spark Igni-
tion Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60.
Emission-Related Installation Instructions
Your certified emergency stationary engine has pre-set emission control systems or components that require no adjustment. Inspection and
replacement of an emissions related component is required to be done so in accordance with the requirements cited in the United States
Environmental Protection Agency Warranty Statement or can be arranged by contacting either your selling dealer or a Generac Authorized
Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. Failing to follow these instructions when installing a certified engine in a
piece of non-road equipment violates federal law 40 CFR 1068.105 (b), subject to fines or penalties as described in the Clean Air Act.
EmsnWrnty001
Revision F (04/15)
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Notes
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EXPLODED VIEW: EV CPL ALTERNATOR BRUSHLESS
DRAWING #: 0F5924
GROUP A
ITEM
PART#
QTY.
DESCRIPTION
1
0F3182
0F6194
0F3183
0F6195
0F6203
068405C
087272
072878
0C9708
0F3726B
0C2454
023454
0F8408
046526
0A2601
072879
092950
04576100CJ
052646
043123
051779
022392
052259
051769
0E7230
0C2428
022155
077043F
020151
023365
033133
033143
086032
090063
090064
090152
022661L
028739A
085662D
068113
068406
023484K
023484N
052624
0F3518
0F3517
0F3519
0F3520
1
1
1
1
1
1
1
1
REF
1
10
1
4
4
1
1
1
4
4
4
4
2
2
3
3
2
2
1
1
3
1
2
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
ROTOR 390 70AB3 CPL
RTR 390 70KB3 CPL
STATOR 390 70AB3 CPL
STR 390 70KB3 CPL
2
STR 390 70GB3 CPL
3
4
5
6
7
EXITER FIELD 2" LG SPD CONN
ASSY EXCITER 2.00" STK
KEY SQ 3/8 X 3-1/4 STEEL
INSTR HYPOT TEST (NOT SHOWN)
ASSY FLYWHEEL CPL
SCREW THF M6-1 X 16 N WA Z/JS
KEY WOODRUFF #E
SCREW HHC M10-1.50 X 16 G10.9
WASHER LOCK M10
SCREW HHC M16-2.0 X 45 G8.8
SPACER .69 X 2.75 X .37 ST/ZNC
COLLAR SLIP FIT 390 MM
STUD M14-2.0 X 650 G5 ZINC
WASHER FLAT M14
WASHER LOCK M14
NUT HEX M14-2.0 G8 YEL CHR
PIN DOWEL 1/2 X 1-1/4
WASHER FLAT M12
WASHER LOCK M12
8
9
10
11
12
13
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
50 *
51
52
53
54
SCREW HHC M12-1.75 X 80 G10.9
SCREW PHTT #6-32 X 1/2 ZYC
WASHER LOCK #6
CONDUIT FLEX 1.25” ID
CLAMP VINYL .312 X .203 Z
WASHER SHAKEPROOF INT #8
SCREW HHM #8-32 X 3/8
SCREW HHM #8-32 X 7/8
LUG RT-ANG #10/10-12
BRIDGE SUPPORT DIODE 15"
CAP END ROTOR 390MM
ASSY BRIDGE RECTIFIER
SLEEVING UL #0 .330 ID (3” LG)
TIE WRAP UL 3.9" X .10" BLK
TIE WRAP UL 17.7 X .35 BLK HT
REAR BEARING CARRIER
SCREW HHC M12-1.75 X 60 G10.9
BUSHING SNAP SB-1750-22
BUSHING SNAP SB-2.5-31
BEARING BALL 6212 SEALED
SIDE LH EXCITER SHIELD
SIDE RH EXCITER SHIELD
BOTTOM EXCITER SHIELD
REAR COVER EXCITER SHLD
* ROTOR REPLACEMENT PARTS.
** PARTS INCLUDED WITH CURRENT TRANSFORMER.
(CURRENT TRANSFORMER AND HARDWARE NOT USED WITH NEXUS CONTROL PANEL)
REVISION: K-1254-L
DATE: 2/9/15
Page 2 of 2
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EXPLODED VIEW: EV CONBOX C3 NEXUS
DRAWING #: 0H9747
APPLICABLE TO:
GROUP A
ITEM
PART#
QTY.
DESCRIPTION
1
2
(2)3
(2)4
5
0H9742
0H6265
0F5376S0AR
0F5396S0AR
0H6169D
0H6267
057073
1
1
1
1
1
BACK PANEL CONBOX SUPPORT C3
TOP PANEL CONNBOX SUPPORT C2
MX150L SLRRMNT 22-18 8P W/O GA
MX150L SLRRMNT 22-18 12P W/OGA
ASSY PROG 2010 IGN MOD 10CYL
COVER VOLTAGE SHIELD
6
7
1
2
JUNCTION BLOCK 3/8-16
(3)8
9
(2)10
(2)11
(1)12
13
14
15
16
0A7822
0H6160
0D7393T
0D7393U
0H67330ST0R
0D3700
0A2115
022473
REF
1
2
2
1
6
2
12
2
LUG SLDLSS 600/250-1/0X1/4-28
COVER WIRE ENTRY CONNBOX
TERM BLOCK 3P UL 12-20AWG
TERM BLOCK 4P UL 12-20AWG
BRACKET GIMBAL CONTROL PNL
NUT FLANGE M6-1.0 NYLOK
WASHER NYLON .257
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
022097
17
18
(1)19
20
21
0H7115
REF
0H81040AS0R
045764
2
1
1
2
12
4
KNOB M6-1.0 CONTROL PANEL
ASSY CTRL PROGRAMMED
COVER DPE BREAKER NEXUS RAW
SCREW HHTT M4-0.7 X 8 ZP
SCREW HWHT M6-1 X 16 N WA Z/JS
WASHER FLAT #10 ZINC
0C2454
023897
22
23
036943
2
SCREW PPHM #10-32 X 2
24
25
0D7177V
051713
2
6
DIODE BRIDGE 1P 35A 1000V
WASHER FLAT M5
26
049226
6
WASHER LOCK M5
27
28
29
051716
056326
022237
6
1
2
NUT HEX M5-0.8 G8 CLEAR ZINC
TRIM VINYL BLACK 1/8GP ( “LG)
WASHER LOCK 3/8
30
022241
2
NUT HEX 3/8-16 STEEL
31
32
33
34
35
36
37
0H8006
0D3580
025507
061383
022131
1
4
2
1
2
1
1
DECAL CAUTION ELEC SHOCK SM
SCREW SHC M5-0.8 X 20 C12.9
WASHER LOCK EXT 7/16 STL
LUG SLDLSS 3/0-#4 X 13/32 CU
WASHER FLAT 3/8-M10 ZINC
SCREW HHC M10-1.5 X 25 C8.8
TAPE ELEC 1/2 FOAM
049814
029289
38
046526
1
WASHER LOCK M10
39
40
41
42
43
44
045772
056739
042568
0F5458
0D6029
052857
1
1
2
12
4
NUT HEX M10-1.5 G8 YEL CHR
RELAY SOLENOID 12VDC PNL MNT
SCREW HHC M6-1.0 X 20 C8.8
SCREW HHSP #10 X 3/8 HI-LOW
SCREW HHTT M6-1.0 X 16 ZYC
NUT TOP LOCK FL M6-1.0
4
45
022152
2
WASHER LOCK #10
46
022158
2
NUT HEX #10-32 STEEL
47
48
(1)49
50
51
0H7292
0H7293
0H97300ST0R
0J0489
1
1
1
1
1
3
DECAL CUSTOMER CONTROL CONNECT
DECAL CONBOX TB1 CONNECTIONS
SHIELD HIGH/LOW C5
DECAL CU STOMER POWER CONNECT
CB 4.5A 1P AUTO 30KW CNT45K
WASHER FLAT M3
048476
052777
52
53
043182
3
WASHER LOCK M3
54
051714
045335
083896
0D5466
039287
067989
0D7178T
0J1618
3
NUT HEX M3-0.5 G8 CLEAR ZINC
SCREW HHC 1/4-28 X 3/4 G5
WASHER LOCK 1/4-M6 SS
BUSBAR NEUTRAL BLOCK 390
SCREW HHC M8-1.25 X 45 C8.8
NUT HEX FL WHIZ M8-1.25
FUSE ATO TYPE 7.5AMP (BROWN)
HARN EXCITATION NEXUS C3/C5(NOT SHOWN)
RES WW 25R 5% 25W QK CONN
(3)55
(3)56
(3)57
(3)58
(3)59
60
REF
REF
REF
REF
REF
REF
1
61
62
0F5752B
1
REVISION: K-3487-H
DATE: 8/4/15
Page 3 of 6
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EXPLODED VIEW: EV CONBOX C3 NEXUS
DRAWING #: 0H9747
APPLICABLE TO:
GROUP A
ITEM
PART#
QTY.
DESCRIPTION
63
64
65
0J3060
0A9457
067210A
1
1
1
GASKET WIRE ENTRY COVER
DECAL NEUTRAL
DECAL GROUND LUG
UL CIRCUIT BREAKER (225AF)
A
B
C
D
E
F
G
H
J
0H9750
1
1
REF
1
1
3
6
3
3
9
3
6
4
12
4
4
4
4
1
COVER CB G 225AF C3
0F4186
0F4148
0F8432
0H7311
058306
022145
0F8451
0F8843
022129
045771
049897
053640
0C2454
036261
038150
022264
022471
0G3259
COVER CB DISH 3P G 225AF
CB 0125A 3P 480V G 225AF
INSUL CB 225AF
STANDOFF CB BOX CONBOX
SCREW SHC M8-1.25 X 25 C12.9
WASHER FLAT 5/16-M8 ZINC
LUG SLDLSS 300 MCM-6 AL/CU
BUS BAR 200A LUG ADAPTOR
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 CLEAR ZINC
SCREW SHC M8-1.25 X 20 G8
SCREW RHM #8-32 X 3-1/4
SCREW HWHT M6-1 X 16 N WA Z/JS
RIVET POP .125 X .275 SS
WASHER FLAT #8 ZINC
K
L
M
N
P
R
S
T
WASHER LOCK #8-M4
NUT HEX #8-32 STEEL
DECAL TERMINAL SHOCK HZD BI
U
V
UL CIRCUIT BREAKER (400AF)
A
B
C
0H9751
1
8
REF
REF
1
3
6
6
6
4
4
4
4
3
3
4
1
COVER CB G 400AF C3
0C2454
0F4153
0F4154
0H9270
0A7822
022473
022097
023334
042419
023897
022152
022158
052647
046526
036261
0G3259
SCREW HWHT M6-1 X 16 N WA Z/JS
CB 0250A 3P 480V G 400AF
CB 0300A 3P 480V G 400AF
COVER CB DISH G 400AF C5
LUG SLDLSS 600/250-1/0X1/4-28
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
SCREW HHC 1/4-28 X 1/2 G5
SCREW RHM 10-32 X 4
WASHER FLAT #10 ZINC
WASHER LOCK #10
NUT HEX #10-32 STEEL
SCREW SHC M10-1.5 X 25 C12.9
WASHER LOCK M10
RIVET POP .125 X .275 SS
DECAL TERMINAL SHOCK HZD BI
D
E
F
G
H
J
K
L
M
N
P
R
S
UL CIRCUIT BREAKER (KG-JG EATON)
A
B
C
0H9757
REF
REF
REF
REF
REF
REF
1
4
4
12
3
COVER CB E KG C3
COVER CB E JG C3
CB 0250 3P 600V E JG LL
CB 0300 3P 600V E KG LL
INSULATOR CB E 3P KG
0H9755
0H5580
0H5582
0H5581A
0H5576A
0H6734
0D2157
0D3700
0C2454
049897
022129
022145
INSULATOR CB E 3P JG
D
E
F
G
H
J
STANDOFF CB MOUNT CONBOX
SCREW SHC M6-1.0 X 50 C8.8
NUT FLANGE M6-1.0 NYLOK
SCREW HWHT M6-1 X 16 N WA Z/JS
SCREW SHC M8-1.25 X 20 G8
WASHER LOCK M8-5/16
3
3
K
WASHER FLAT 5/16-M8 ZINC
REVISION: K-3487-H
DATE: 8/4/15
Page 4 of 6
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EXPLODED VIEW: EV CONBOX C3 NEXUS
DRAWING #: 0H9747
APPLICABLE TO:
GROUP A
ITEM
PART#
QTY.
DESCRIPTION
UL CIRCUIT BRAEAKER (FG)
A
B
C
D
E
F
G
H
J
K
L
M
N
P
0H9758
0F4186
0H5491
1
1
REF
1
1
3
3
3
4
4
4
4
4
COVER CB E FG C3
COVER CB DISH 3P G 225AF
CB 0125 3P 600V E FG LL
INSULATOR CB 3P E TYPE CC/FG
STANDOFF CB BOX CONBOX
SCREW HHC M5-0.8 X 20 G8.8
WASHER LOCK M5
WASHER FLAT #10 ZINC
RIVET POP .125 X .275 SS
SCREW PPHM #8-32 X 1-3/4 ZINC
WASHER FLAT #8 ZINC
0H4698A
0H7311
052619
049226
023897
036261
0H5721
038150
022264
022471
0C2454
WASHER LOCK #8-M4
NUT HEX #8-32 STEEL
SCREW HWHT M6-1 X 16 N WA Z/JS
12
UL CIRCUIT BREAKER (ED)
A
B
C
D
E
F
G
H
J
0H9752
0D9693
0F0492
0H6734
048927
023897
022152
022158
0C2454
0A8278
022097
0D5621
1
REF
1
1
4
4
4
4
12
3
COVER CB S ED C3
CB 0125A 3P 480V S ED4 LL
INSULATOR CB S(ED-3P)
STANDOFF CB MOUNT CONBOX
SCREW RHM #10-32 X 4-1/2
WASHER FLAT #10 ZINC
WASHER LOCK #10
NUT HEX #10-32 STEEL
SCREW HWHT M6-1 X 16 N WA Z/JS
SCREW SHC 1/4-28 X 3/4 G8.8 NZ
WASHER LOCK M6-1/4
K
L
M
3
3
WASHER-STEP 1/2ODX9/32ID BRASS
UL CIRCUIT BREAKER (VL-JG)
A
B
C
D
E
F
G
H
J
0H9754
1
REF
1
4
3
3
3
4
4
COVER CB S VL C3
0H7519
0H6734
042419
040976
022129
022145
023897
022152
022158
0C2454
CB 0300A 3P 600V S JG-VL LL
STANDOFF CB MOUNT CONBOX
SCREW RHM 10-32 X 4
SCREW SHC M8-1.25 X 20 C12.9
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
WASHER FLAT #10 ZINC
WASHER LOCK #10
K
L
4
12
NUT HEX #10-32 STEEL
SCREW HWHT M6-1 X 16 N WA Z/JS
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).
(2) INCLUDED WITH HARNESS P/N 0H6692.
(3) INCLUDED WITH NEUTRAL BLOCK P/N 0D5464B.
REVISION: K-3487-H
DATE: 8/4/15
Page 5 of 6
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EXPLODED VIEW: EV CONBOX C3 NEXUS
DRAWING #: 0H9747
APPLICABLE TO:
GROUP A
THIS PAGE LEFT INTENTIONALLY BLANK
REVISION: K-3487-H
DATE: 8/4/15
Page 6 of 6
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
0F3408
0F3411
058208
022131
050331A
050331
038805T
038804Y
045771
022129
027482
075763
0C2454
0F3409
1
1
1
1
1
1
1
1
1
1
1
1
8
1
TRAY BATTERY
STRAP BATTERY RETAINMENT
BATT 12VDC 24F 625
WASHER FLAT 3/8-M10 ZINC
BATT POST COVER RED +
BATT POST COVER BLK -
CABLE BATT BLK #1 X 40.00
CABLE BATT RED #1 X 35.00
NUT HEX M8-1.25 G8 YEL CHR
WASHER LOCK M8-5/16
WASHER SHAKEPROOF EXT 5/16 STL
BOOT BATTERY CABLE
SCREW THF M6-1X16 N WA Z/JS
SUPPORT BATTERY TRAY
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EXPLODED VIEW: EV MTG BASE C3 5.4L 55KW
DRAWING #: 0H5677
GROUP C
ITEM
PART#
QTY.
DESCRIPTION
(2)1
2
3
0L0574BST0R
065852
1
1
4
MTG BASE C5 5.4/55KW 6.8/70KW
SPRING CLIP HOLDER .37-.62
DAMPENER VIBRATION
052252
4
5
052257
052259
4
4
SPACER .49 X .62 X 1.87 PWDR/ZINC
WASHER FLAT M12
6
7
8
055597
052251A
052860
4
4
4
SCREW HHC M12-1.75 X 85 G8.8
DAMPENER VIBRATION 50 WHITE
NUT LOCKING M12-1.75
(1)9
10
11
12
13
16
(1)17
(1)18
19
20
21
22
23
24
(2)25
26
27
0L06890ST0R
045764
1
1
7
1
1
1
7 / 8
7 / 8
1
1
2
1
2
2
1
1
1
ENGINE SUPPORT 6.8L RH
SCREW HHTT M4-0.7 X 8 BP
SCREW HHC M10-1.5 X 60 C8.8
LUG SOLDERLESS 3/0-#4 X 13/32 CU
SCREW HHC M8-1.25 X 25 G8.8
5.4L RH ENGINE MOUNT SPACER
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
052243
061383
043107
0L01390ST0R
022131
046526
0536210410
ASSY WIRE 14.00”
042909
022261
022129
022145
SCREW HHC M8-1.25 X 30 G8.8
WASHER SHAKEPROOF INT 3/8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
NUT HEX M8-1.25 G8 YEL CHR
ENGINE MOUNT 6.8L LH SIDE (5.4L ONLY)
SCREW HHC M10-1.5 X 70 C8.8
SPACER .41 X .75 X 1.68 ST/ZNC
045771
0L01480ST0R
051735
0L0123
NOTES (UNLESS OTHERWISE SPECIFIED):
(1) QTY. REQ. FOR 5.4L / QTY. REQ. FOR 6.8L
(2) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
•
•
MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO XA BOM.
CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR
CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
REVISION: K-2274-C
DATE: 3/17/15
Page 2 of 2
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EXPLODED VIEW: EV ENGCOMPRT R/H 6.8 (CPL)
DRAWING #: 0F3058
GROUP D
ITEM
PART#
QTY.
DESCRIPTION
1
2
3
0D5623
0D5418
022131
0F3514
022473
0F2776A
029333A
057772
0F2929
0F9965C
0F9965C
0D5417
057823
057765
049340
069860E
042909
022129
0D9913
047290
022097
055596
077996
0C7649
047411
0G0321
0D3808
0D4255
070010
0D2244M
0F3844
052647
046526
039253
070008
070006
0D2608
0F5114
0F5454
0F6104
048031P
048031J
0G1462
2
1
1
HEAT SHIELD EXHAUST
STARTER MOTOR FORD V-10 ENGINE
WASHER FLAT 3/8-M10 ZINC
SPACER FLEXPLATE 5.4L/6.8L (1800 RPM UNITS ONLY)
WASHER FLAT 1/4-M6 ZINC
BRACKET SIGNAL CONDITIONER
TIE WRAP UL 7.4" X .19" BLK (NOT SHOWN)
WASHER NYLON .565
4
1
(3) 5
(3) 6
(1) 7
8
9
10
1 / 2
A/R
1
1
1
1
2
REF.
1
1
1
1
3
4
18
1
1
1
1
1
1
1
2
2
2
1
8
6
6
1
10
30
10
1
ENGINE ADAPTER 5.4L/6.8L
FLEX PLATE 2 POLE (1800 RPM UNITS ONLY)
FLEX PLATE 2 POLE (3600 RPM UNITS ONLY)
SCREW HHC M10-1.0 X 25 G10.9
CLAMP HOSE #10 .56 - 1.06 (1800 RPM UNITS ONLY)
ADAPTER M14-1.50 X 3/8 NPT
BARBED EL 90 1/4NPT X 3/8
HOSE DRAIN ASSY 28"
SCREW HHC M8-1.25 X 30 G8.8
WASHER LOCK M8-5/16
SCREW SHC M8-1.25 X 35 SS
HOSE 3/8 ID SINGLE BRAID
(2) 11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
40
43
44
45
WASHER LOCK M6-1/4
BARBED STR 3/8 NPT X 3/8
CAP HOSE (1800 RPM UNITS ONLY)
CLAMP HOSE .38-.87
SCREW HHC M6-1.0 X 16 G8.8
HOSE COOL 5/8" ID 250#WP (14”)
EXH MANIFOLD MACH 6.8L V-10
GASKET EXHAUST MANIFOLD
SCREW HHC M8-1.25 X 35 SS G8.8
ASSY MAGPICKUP (3/8-24 MALE)
WASHER FLAT .43 X 1.00
SCREW SHC M10-1.5 X 25 G12.9
WASHER LOCK M10
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT M8 SS
WASHER LOCK M8 SSTL
SCREW HHC 5/16-18 X 1/2 SSTL
DECAL REFER TO OWNERS MANUAL
PLATE MAG PICK-UP ADAPTOR
COVER STARTER 5.4 & 6.8 FORD CPL
CLAMP HOSE BAND .88"
CLAMP HOSE BAND .63
HOSE BARB REDUCER 5/8"-3/8"ID
1
1
2
1
1
(1) NOTE: I/N 7 IS FOR HOLDING SENSORS TO I/N 6.
(2) NOTE: I/N 11 IS PART OF ENGINE P/N 0D3454.
(3) QTY. REQ. FOR NON-MQT / QTY REQ. FOR MQT EPA CERT. (NOT REQUIRED
FOR NEXUS CONTROL PANELS)
REVISION: J-4243-L
DATE: 2/19/13
Page 2 of 2
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EXPLODED VIEW: EV AIR CLEANER
DRAWING #: 0F3569
GROUP D
ITEM
PART#
QTY.
DESCRIPTION
1
0D2513D
0D2513E
0F5419
0F4268
0F4270A
0F6977
037561
047411
022097
057795B
0F4269
022473
0A4256
0G5954
1
1
1
1
1
1
1
4
4
1
1
3
1
1
AIR CLNR BTM PLT W/CPLR 8.1L
PLATE AIR CLEANER W/COUPLER
ELEMENT AIR FILTER
2
3
4
5
6
7
8
9
10
11
12
13
TOP PLATE VENTURI
HOLD DOWN AIR CLEANER PLATED
PLATE AIR CLEAN TOP 5.4L/6.8L
NUT WING 1/4-20 NYLK
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
BARBED EL 90 5/8 PLASTIC
GASKET MIXER BODY
WASHER FLAT 1/4-M6 ZINC
INDICATOR FILTER MINDER (USE WITH ITEM #1 P/N 0D2513E)
GROMMET .625 X 1.25 X .433
REVISION: J-9801-E
DATE: 9/19/14
Page 2 of 2
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EXPLODED VIEW: EV ENGINE COM PRT L/H SIDE 6.8L
DRAWING #: 0J0212
APPLICABLE TO:
GROUP D
ITEM
PART#
QTY.
DESCRIPTION
1
2
(2)3
(2)4
(1)5
6
0F3017
039253
022129
022145
0D5419
0D7055
0D3488G
0D3488J
0D3488
0D3488K
057795B
059057
0F3287
0H9133
0E9868A
0G5954
0F3216
0F3216A
0F3216C
0F3216D
035579
0H7435
0D6658
0H0777
022097
022473
042568
0D8027
0D8025
0D8026
0D8030
0F2846
0D8029
0D8028
045771
0H0923
022131
046526
064416
045772
0F3217
0F6151
0F4308
0F3158
057823
0E0502
0G0866
0F4301
0E8286
047527
057823
0E0992A
078637
047411
055934D
1
3
4/5
4/5
REF
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
6
6
2
4
1
3
1
1
1
1
1/2
1
2
1
1
1
1
1
1
1
2
1
1
1
1
1
4
BRACKET,D.C. ALTERNATOR LOWER
SCREW HHC M8-1.25 X 20 C8.8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
OIL FILTER
DIPSTICK TUBE, FORD 6.8L
BELT SERPENTINE (65.0" LG) (1800 RPM)
BELT SERPENTINE (65.3" LG) (2300 RPM)
BELT SERPENTINE (67.16" LG) (3000 RPM)
SERPENTINE BELT (68.3" LG) (3600 RPM)
BARBED EL 90 5/8 PLASTIC
HOSE 3/4 ID SAE-30R2 (16.75”LG)
BRACKET DC ALTERNATOR UPPER
HARN ENG G6.8L G3 NEXUS (USE WITH PROBE P/N 0H1827) (NOT SHOWN)
ALTERNATOR DC W/OUT PULLEY
GROMMET .625 X 1.25 X .433
PULLEY 80 OD DC ALTERNATOR (1800 RPM)
PULLEY 102 OD DC ALTERNATOR (2300 RPM)
PULLEY 132 OD DC ALTERNATOR (3000 RPM)
PULLEY 160 OD DC ALTERNATOR (3600 RPM)
BSHG RDCR HEX 1/4 TO 1/8
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
HARN LOW OIL PRESS SWITCH ASSY
DIPSTICK G6.8L G3
DECAL LSI EPA CERTIFICATION
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
SCREW HHC M6-1.0 X 20 G8.8
SCREW WP PULLEY M8-1.25 X 19
BOLT HEX FL HD M8-1.25 X 28
BOLT HEX FL HD M8-1.25 X 31
TENSIONER ENG. AUTOMATIC BELT
PULLEY WATER PUMP G3 (1800RPM UNITS)
PULLEY ENGINE WATER PUMP (2-POLE & GEAR BOX)
PULLEY GROOVED ENGINE IDLER
NUT HEX M8-1.25 G8 CLEAR ZINC
ENGINE G6.8L G3 V-10 (2009 +)
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
SCREW HHC M10-1.5 X 45 C8.8 FT
NUT HEX M10-1.5 G8 YEL CHR
SPACER DC ALTERNATOR PULLEY
CAP RUBBER
BRACKET DC ALT STABILIZER
OIL COOLER G3 (150KW 3600RPM)
CLAMP HOSE #10 .56-1.06
TEMPERATURE SENDER DELPHI
HOSE OIL COOLER PREFORMED 3/4 (150KW 3600RPM)
HOSE OIL COOLER (150KW 3600RPM)
ELBOW 45D STREET 1/2NPT BRASS (150KW 3600RPM)
BARBED STR 1/2NPT X 3/4 (150KW 3600RPM)
CLAMP HOSE #10 .56-1.06 (150KW 3600RPM)
PLUG EXPANSION 14 OD
27
(2)28
29
30
31
32
33
34
36
37
38
39
40
(2)41
(2)42
(2)43
(2)44
(2)45
46
10
A/R
4
47
48
(2)49
ADHESIVE LOCTITE 620
SCREW HHC M6-1.0 X 16 C8.8
CLAMP STL/VNL 1.06 X .406 Z
4/7
(1) I/N 5 PART OF I/N 29.
(2) PART OR QUANTITY REQUIRED FOR 150KW UNITS ONLY.
REVISION: K-3804-C
DATE: 9/3/15
Page 2 of 2
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EXPLODED VIEW: EV COOL PKG 6.8L C3
DRAWING #: 0J6324
GROUP D
ITEM
PART#
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
0F3144
035685
0F2857A
0F4168
0F4169
0J6180
0F2820
051756
046526
022131
052250
0F4412
039253
022129
022097
0C8566
0D3700
089685
0F5589
0C2454
055596
0C7649
069860E
045764
065852
080712
076749
048031C
069811
072252
085662
0E2507
022145
090283
077043J
029032
1
4
1
1
1
1
1
4
4
4
2
1
8
8
8
8
8
1
2
10
1
1
1
1
1
1
1
2
REF
1
8
1
8
1
WELDMENT RAD SUPPORT C3 (22")
CLAMP HOSE #28 1.32-2.25
RADIATOR 581 X 585 X 70 CPL LH
HOSE UPPER RADIATOR C3
HOSE LOWER RADIATOR C3
ADAPTOR, 6.8L FAN
FAN 22" DIA 10 BLADE
SCREW HHC M10-1.5 X 20 G8.8
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
TAPE FOAM 1 X 1 (23” LG)
SPACER FAN 6.8L
SCREW HHC M8-1.25 X 20 G8.8
WASHER LOCK M8-5/16
10
11
12
13
14
17
18
19
20
21
22
23
24
25
26
27
28
29
30
(1)31
32
33
34
35
36
37
38
WASHER LOCK M6-1/4
SCREW HHFC M6-1.0 X 20 G8.8
NUT FLANGE M6-1.0 NYLOK
GROMMET .75 X .12 X .50
GUARD FAN C3 CPL
SCREW THF M6-1 X 16 N WA Z/JS
BARBED STR 3/8 NPT X 3/8
CLAMP HOSE .38-.87
HOSE DRAIN ASSY 28"
SCREW HHTT M4-0.7 X 8 BP
SPRING CLIP HOLDER .37-.62
BRKT COOLANT RECOVERY TANK
TANK COOLANT RECOVERY
CLAMP HOSE BAND 1/4
CAP HEX 1/4 NPT BRASS
GROMMET 1.37 X .06 X 1.00
TIE WRAP UL 14.6 X .14 BLK
PROBE COOLANT LEVEL 3/8NPTF (USE WITH HARN P/N 0F5990 & 0F5991)
WASHER FLAT 5/16-M8 ZINC
CAP RADIATOR 13 PSI
CONDUIT FLEX 2.0"ID
HOSE 9/32 ID (41”LG)
1
1
NOTES (UNLESS OTHERWISE SPECIFIED):
(1)ITEM 31 IS INCLUDED WITH ITEM 25.
(2) FASTEN HOSE TO FAN GUARD USING 3 TIE WRAPS I/N 33. DIRECT HOSE TOWARD BASE OF UNIT
AND AWAY FROM EXHAUST COMPONENTS.
REVISION: K-1082-B
DATE: 11/12/14
Page 2 of 2
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EXPLODED VIEW: EV EXHUAST CPL 7OKW C3
DRAWING #: 0J6343
APPLICABLE TO:
GROUP D
ITEM
PART#
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
0J6177
0J6179
0F2808B
0A6765
0F4710
0F7200
080762
0F2809
0F2981A
0F2962
045757
022097
0F2830
0F4505A
0D3159
022473
0F2773D
088775
0F5447
0F6166
0C2454
1
1
2
2
6
6
6
1
2
2
4
4
2
2
2
4
2
6
1
2
4
PIPE, EXH MANIFOLD 6.8L C3 RH (6.8L 70KW)
PIPE EXH MANIFOLD 6.8L C3 LH (6.8L 70KW)
PIPE EXHAUST MUFFLER OUT
RING GASKET, 2.5DIA
WASHER LOCK M10 SS
SCREW HHC M10-1.5 X 50 SS FTH
BOLT U 3/8-16 X 2.62
PIPE EXHAUST CROSSOVER
MFLR 7" X 9" X 25" (2) 2.5" IN/2.5" OUT
MUFFLER STRAP
SCREW HHC M6-1.0 X 25 C8.8
WASHER LOCK M6-1/4
MUFFLER BRACKET STIFFENER
MUFF SEC 23.5" X 2.55IN/2.5OUT
FLANGE, EXHAUST
WASHER FLAT 1/4-M6 ZINC
EXHAUST BLANKET 800MM LG (6.8L 70KW)
WASHER FLAT 3/8 SS
BRKT MUFFLER
PIPE LH MUFFLER SIDE
SCREW HWHT M6-1 X 16 N WA Z/JS
REVISION:-A-
DATE: 9/13/11
PAGE 2 OF 2
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EXPLODED VIEW: EV EXHAUST CPL 7OKW C3
DRAWING #: 0J6343A
APPLICABLE TO:
GROUP D
ITEM
PART#
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
0J6177
0J6179
0F2808B
0A6765
0F4710
0F7200
080762
0G0007
0F2981A
0F2962
045757
022097
0F2830
0H2099A
022473
0F2773D
088775
0F5447
0H0639A
0F2773
0F9071
0F6166
0L1789
0G3163A
0C2454
0D3159
049813
049721
1
1
2
2
6
6
8
1
1
1
2
6
1
1
10
2
6
1
1
1
1
1
4
1
4
2
4
4
PIPE, EXH MANIFOLD 6.8L C3 RH (6.8L 70KW)
PIPE EXH MANIFOLD 6.8L C3 LH (6.8L 70KW)
PIPE EXHAUST MUFFLER OUT
RING GASKET, 2.5DIA
WASHER LOCK M10 SS
SCREW HHC M10-1.5 X 50 SS FTH
BOLT U 3/8-16 X 2.62
DIFFUSER EXHAUST WELDMENT
MFLR 7" X 9" X 25" (2) 2.5" IN/2.5" OUT
MUFFLER STRAP
SCREW HHC M6-1.0 X 25 C8.8
WASHER LOCK M6-1/4
MUFFLER BRACKET STIFFENER
CATALYST 3-WAY
WASHER FLAT 1/4-M6 ZINC
EXHAUST BLANKET 800MM LG (6.8L 70KW)
WASHER FLAT 3/8 SS
9
10
11
12
13
14
16
17
18
19
20
21
22
23
24
25
26
27
28
29
BRKT MUFFLER
PIPE, EXHAUST RH CPL EM
EXHAUST BLANKET 1015M LONG
SENSOR OXYGEN
PIPE LH MUFFLER SIDE
MUFFLER STRAP UPPER/LOWER
BLANKET EXHAUST MUFFLER 584MM
SCREW HWHT M6-1 X 16 N WA Z/JS
FLANGE, EXHAUST
NUT HEX M6-1.0 G8 CLEAR ZINC
SCREW HHC M6-1.0 X 35 C8.8 CLR
NOTES (UNLESS OTHERWISE SPECIFIED):
(1) EXHAUST BLANKET SHOULD NOT COVER OXYGEN SENSOR (ITEM 22).
REVISION: K-1591-C
DATE: 1/28/15
PAGE 2 OF 2
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EXPLODED VIEW: EV FUEL 6.8L NG LPV CPL EMSN
DRAWING #: 0J1704
APPLICABLE TO:
GROUP E
ITEM
PART#
QTY.
DESCRIPTION
1
2
3
049721
075580
0H0651
0H0651A
039253
022145
022129
045771
042568
0H5476
026812
0F8379
0D2698
057823
059057
049811
0J7476
0E4390
0E4392
0F0960
0F3885
0G3167
0F3691B
026073A
0D2157
039294
022097
026915
0G46350ST0R
039450
077879
0F1866A
077879
0G4588
0C2454
077879
025655
4
1
1
1
2
2
2
2
2
1
2
1
1
4
2
2
1
1
1
1
1
2
1
1
4
2
10
2
1
2
1
1
1
1
2
1
1
SCREW HHC M6-1.0 X 35 G8.8 BLK
FLANGE FUEL INLET
REG 6.8L CPL 70KW LPV EMSN
REG 6.8L CPL 70KW NG EMSN
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 CLEAR ZINC
SCREW HHC M6-1.0 X 20 G8.8
HARN FUEL JUMPER SINGLE REG
ELBOW 90D 3/4NPT
NIPPLE PIPE 3/4NPT X 7
GASKET ADAPTER THROT BODY
CLAMP HOSE #10 .56-1.06
HOSE 3/4 ID SAE-30R2 (38.5” LG)
WASHER FLAT M6
ADAPTOR THROTTLE BODY
GASKET, GOVERNOR ACTUATOR
ACTUATOR BOSCH 60, GOVERNOR
REDUCER 3.0" TO 2.75" TURBO
MIXER, 40/60MM ACTUATOR ASSY
O-RING 2-3/4 X 3/32 X 2-15/16
VENTURI, THROTTLE 36MM
PLUG STD PIPE 1/4 STEEL SQ HD
SCREW SHC M6-1.0 X 50 C8.8
CLAMP HOSE #44 2.31-3.25
WASHER LOCK M6-1/4
NIPPLE CLOSE 3/4 X 1.375
BRACKET, HOSE RISER
BARBED EL 90 3/16 X 1/8
HOSE VACUUM 5/32 (5.5”LG)
BARBED EL W/VENT (.052")
HOSE VACUUM 5/32 (11”LG)
PIPE TEE W/BRACKET WELDED
SCREW TH-FRM M6-1 X 16 N WA Z/JS
HOSE VACUUM 5/32 (10.5” LG)
4
5
6
7
8
9
10
11
12
13
14
15
18
19
20
21
22
23
24
25
26
27
28
29
(1)30
31
32
33
34
35
36
37
38
PLUG STD PIPE 3/4 STEEL SQ HD
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 XA BOM.
CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR
CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
REVISION: J-8381-D
DATE: 4/22/14
PAGE 2 OF 2
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EXPLODED VIEW: EV FUEL SYSTEM 6.8L NG/LPV CPL
DRAWING #: 0J1705
APPLICABLE TO:
GROUP E
ITEM
PART#
QTY.
DESCRIPTION
1
2
3
049721
075580
0G9189A
0G9189B
039253
022145
022129
045771
042568
0H5476
026812
0F8379
0D2698
057823
059057
049811
0J7476
0E4390
0E4392
0F0960
0F3885
0G3167
0F3691B
026073A
0D2157
039294
022097
026915
0G46350ST0R
025655
4
1
1
1
2
2
2
2
2
1
2
1
1
4
2
2
1
1
1
1
1
2
1
1
4
2
10
2
1
1
SCREW HHC M6-1.0 X 35 G8.8 BLK
FLANGE FUEL INLET
REG ASSY 6.8L 70KW LPV CPL
REG ASSY 6.8L 70KW NG CPL
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 CLEAR ZINC
SCREW HHC M6-1.0 X 20 G8.8
HARN FUEL JUMPER SINGLE REG
ELBOW 90D 3/4NPT
NIPPLE PIPE 3/4NPT X 7
GASKET ADAPTER THROT BODY
CLAMP HOSE #10 .56-1.06
HOSE 3/4 ID SAE-30R2 (38.5” LG)
WASHER FLAT M6
ADAPTOR THROTTLE BODY
GASKET, GOVERNOR ACTUATOR
ACTUATOR BOSCH 60, GOVERNOR
REDUCER 3.0" TO 2.75" TURBO
MIXER, 40/60MM ACTUATOR ASSY
O-RING 2-3/4 X 3/32 X 2-15/16
VENTURI, THROTTLE 36MM
PLUG STD PIPE 1/4 STEEL SQ HD
SCREW SHC M6-1.0 X 50 C8.8
CLAMP HOSE #44 2.31-3.25
WASHER LOCK M6-1/4
4
5
6
7
8
9
10
11
12
13
14
15
18
19
20
21
22
23
24
25
26
27
28
29
(1)30
31
NIPPLE CLOSE 3/4 X 1.375
BRACKET, HOSE RISER
PLUG STD PIPE 3/4 STEEL SQ HD
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 XA BOM.
CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR
CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
REVISION: K-3796-E
DATE: 8/31/15
PAGE 2 OF 2
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EXPLODED VIEW: EV ENCLOSURE C3
DRAWING #: 0G2898
GROUP F
ITEM
PART#
QTY.
DESCRIPTION
(2) 1
(2) 2
(2) 3
(3) 4
(2) 5
(2) 6
(2) 7
(1)8
(1)9
10
0F58660AL0R
0F5861AAL0R
0F58650AL0R
0F58640AL0R
0F58620ALOR
0F58630AL0R
0F58600AL0R
0C2454
1
4
2
2
2
1
1
60
16
1
REAR WRAP AL
DOOR AL
CENTER SUPPORT AL
DUCT, DISCHRG AL
FRONT CRNR AL
DUCT, CNTR DISCHRG AL
ROOF, AL
SCREW THF M6-1 X 16 N WA Z/JS
SCREW TH-FRM M6 W/CAP SHKPRF W
GASKET EXTRUDED TRIM (547” LG)
INSUL SPLITTER SMALL
0E3257
0E5968
0J2624A
11
3
12
0F2766
3
SPLITTER
14
15
16
17
18
19
0F3185
0F3416
0J2624B
0F4487A
022473
2
2
1
1
5
1
STRINGER SPLITTER C3
SUPPORT SPLITTER C5 130KW
INSUL ROOF TOP REAR
ASSEMBLY COVER ACCESS
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
022097
20
21
22
25
26
27
022127
0F3072
078115
0F5048D
0F5049B
0J2624
1
NUT HEX 1/4-20 STEEL
12
30
4
2
3
INSULATION RETAINMENT HANGER
WASHER SELF LOCKING DOME #4-40
VISE-ACTION LATCH SLOTTED CIR
PULL TAB DOOR LOCK SS
INSULATION SPLITTER
29
30
31
32
33
34
35
36
37
38
40
41
(1) 42
43
44
0J2624D
0F4073F
087233
0G0257
066760
0J2624C
0F3890B
0F4073B
078115A
042568
022447
049813
077992
0912970090
0F8869D
1
1
2
1
1
4
3
1
10
4
4
4
29
4
1
INSULATION ROOF TOP
INSULATION DUCT TOP
RIVET POP .1875 X .450 SS
REFLECTIVE HEAT SHIELD 2.4L
STRIP SEALANT 1/8 X 1 (44.5”LG)
INSULATION DOOR
RETAINER INSULATION (820)
INSULATION DUCT FRONT
WASHER SELF LOCKING DOME #8-32
SCREW HHC M6-1.0 X 20 G8.8
WASHER SHAKEPROOF INT 1/4
NUT HEX M6 X 1.0 G8 YEL CHR
NUT HEX LOCK M6-1.0 SS NY INS
ASSY WIRE 14AWG GRN/YEL
KEY VISE-ACTION LATCH SLOT CIR
(1) ENCLOSURE NOTE: ALL PANELS THAT FASTEN TO THE BASEFRAME MUST BE SECURED USING I/N 8 & 9 (THREAD FORMING FASTENERS) AND I/N 42
(LOCK NUT). LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS. ALL
PANEL TO PANEL CONNECTIONS TO INCLUDE AT LEAST ONE CONNECTION POINT USING I/N 9 (THREAD FORMING FASTENER).
(2) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
•
•
MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR CORRECT MATERIAL
AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
REVISION: J-4499-K
DATE: 4/1/13
Page 2 of 2
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Notes
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Notes
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. A v 0 4 / 0 7 k P g B 0 0 a 1 c R e
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Owner's Manual
Stationary Emergency Generator
QT
6.8L
70kW Models
EPA Certified
with Optional Catalyst
nNOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT
APPLICATIONS.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST
FUMES! OUTDOOR INSTALLATION ONLY!
This manual should remain with the unit.
. 0 J 1 6 t N r 1 o a 7 P
. A v 1 0 / 1 0 e v r 2 0 C 0 o R e
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Table of Contents
OPERATION..........................................................................9-1
SECTION
PAGE
Stationary Emergency Generator Control and Operation.........9-1
Operating Unit with Manual Transfer Switch...........................9-1
Operating Unit with Automatic Transfer Switch ......................9-1
INTRODUCTION....................................................................1-1
SAFETY RULES ....................................................................1-2
IDENTIFICATION RECORD ....................................................2-1
MAINTENANCE...................................................................10-1
Maintenance Performed by Authorized Service Dealers .......10-1
Cooling System...................................................................10-1
Checking Fluid Levels..........................................................10-1
Maintenance Owner/Operator Can Perform..........................10-2
Miscellaneous Maintenance ................................................10-3
EQUIPMENT DESCRIPTION ..................................................3-1
Equipment Description ..........................................................3-1
Engine Oil Recommendations................................................3-1
Coolant Recommendations ...................................................3-1
SERVICE SCHEDULE..........................................................11-1
ENGINE PROTECTIVE DEVICES............................................4-1
Engine Protective Devices .....................................................4-1
TROUBLESHOOTING ..........................................................12-1
Troubleshooting Guide.........................................................12-1
FUEL SYSTEMS ...................................................................5-1
SPECIFICATIONS..................................................................6-1
EMISSIONS WARRANTY ....................................................13-1
NOTES
GENERAL INFORMATION .....................................................7-1
Alternator AC Lead Connections............................................7-1
Alternator Power Winding Connections..................................7-1
EXPLODED VIEWS & PARTS LISTS
WIRING DIAGRAMS & SCHEMATICS
CONTROL PANEL .................................................................8-1
Control Panel Interface..........................................................8-1
Activate the Generator...........................................................8-1
Display Interface Menus........................................................8-1
Setting the Exercise Timer.....................................................8-3
User Adjustable Settings .......................................................8-3
Fuel Conversion ....................................................................8-3
Operation..............................................................................8-3
Auto Start.............................................................................8-4
Manual Start.........................................................................8-4
Alarm and Warning Messages...............................................8-4
Common Alarm Relay...........................................................8-6
Maintenance Alerts ...............................................................8-6
Menu System........................................................................8-7
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Safety Instructions
nSAVE 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.
This symbol points out potential fire hazard.
INTRODUCTION
Thank you for purchasing this model of the stationary emergency
generator product line.
This symbol points out potential electrical shock hazard.
Every effort was expended to make sure that the information and
instructions in this manual were both accurate and current at the
time the manual was written. However, the manufacturer reserves
the right to change, alter or otherwise improve this product(s) at
any time without prior notice.
The operator is responsible for proper and safe use of the equip-
ment. The manufacturer strongly recommends that the operator
read this Owner's Manual and thoroughly understand all instruc-
tions before using this equipment. The manufacturer also strongly
recommends instructing other users to properly start and operate
the unit. This prepares them if they need to operate the equipment
in an emergency.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest
Service Dealer for starting, operating and servicing procedures.
For safety reasons, the manufacturer recommends that this
equipment be installed, serviced and repaired by a Service
Dealer or other competent, qualified electrician or installation
technician who is familiar with applicable codes, standards and
regulations. The operator also must comply with all such codes,
standards and regulations.
Throughout this publication, and on tags and decals affixed to the
generator, DANGER, WARNING, CAUTION and NOTE blocks are
used to alert personnel to special instructions about a particular
service or operation that may be hazardous if performed incor-
rectly or carelessly. Observe them carefully. Their definitions are
as follows:
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety checks, to
make sure that all maintenance for safe operation is performed
promptly, and to have the equipment checked periodically by a
Service Dealer. Normal maintenance service and replacement of
parts are the responsibility of the owner/operator and, as such,
are not considered defects in materials or workmanship within the
terms of the warranty. Individual operating habits and usage con-
tribute to the need for maintenance service.
INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF
NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.
Indicates a hazardous situation or action which, if not
avoided, could result in death or serious injury.
Proper maintenance and care of the generator ensure a minimum
number of problems and keep operating expenses at a minimum.
See a Service Dealer for service aids and accessories.
Indicates a hazardous situation or action which, if not
avoided, could result in minor or moderate injury.
NOTE:
Operating instructions presented in this manual assume that the
generator electric system has been installed by a Service Dealer or
other competent, qualified contractor. Installation of this equipment
is not a “do-it-yourself” project.
Notes contain additional information important to a procedure
and will be found within the regular text body of this manual.
These safety warnings cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the special
instructions while performing the service are essential to prevent-
ing accidents.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs, simply contact
a Service Dealer for assistance. Service technicians are factory-
trained and are capable of handling all service needs.
Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTION blocks. The type of information each
indicates is as follows:
When contacting a dealer about parts and service, always supply
the complete Model Number, Serial Number and Type Code (where
applicable) from the DATA LABEL that is affixed to the unit.
This symbol points out important safety information that,
if not followed, could endanger personal safety and/or
n
property of others.
This symbol points out potential explosion hazard.
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Safety Instructions
• The engine exhaust fumes contain carbon monoxide gas, which
SAFETY RULES
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 compli-
ance with applicable codes and standards.
Study these SAFETY RULES carefully before installing, operating
or servicing this equipment. Become familiar with this Owner’s
Manual and with the unit. The generator can operate safely, effi-
ciently and reliably only if it is properly installed, operated and
maintained. Many accidents are caused by failing to follow simple
and fundamental rules or precautions.
The manufacturer cannot anticipate every possible circumstance
that might involve a hazard. The warnings in this manual, and on
tags and decals affixed to the unit are, therefore, not all inclusive.
If a procedure, work method or operating technique is used that
the manufacturer does not specifically recommend, ensure that it
is safe for others. Also make sure the procedure, work method or
operating technique utilized does not render the generator unsafe.
• Keep hands, feet, clothing, etc., away from drive belts, fans,
and other moving or hot parts. Never remove any drive belt or
fan guard while the unit is operating.
• Adequate, unobstructed flow of cooling and ventilating air is
critical in any room or building housing the generator to prevent
buildup of explosive gases and to ensure correct generator
operation. Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seriously affect
safe operation of the generator.
• Keep the area around the generator clean and uncluttered.
Remove any materials that could become hazardous.
• When working on this equipment, remain alert at all times.
Never work on the equipment when physically or mentally
fatigued.
• Inspect the generator regularly, and promptly repair or replace
all worn, damaged or defective parts using only factory-
approved parts.
• Before performing any maintenance on the generator, discon-
nect 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 dan-
gerous operating conditions from leaking exhaust gases, fuel
leakage, oil leakage, etc.
nDespite 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 respon-
sible and capable persons to install, operate or
maintain this equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
nParts 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 a Service
Dealer or other competent, qualified electrician or installation
technician who is familiar with applicable codes, standards
and regulations. The operator also must comply with all such
codes, standards and regulations.
ELECTRICAL HAZARDS
• Installation, operation, servicing and repair of this (and related)
equipment must always comply with applicable codes, stan-
dards, laws and regulations. Adhere strictly to local, state and
national electrical and building codes. Comply with regulations
the Occupational Safety and Health Administration (OSHA) has
established. Also, ensure that the generator is installed, operat-
ed and serviced in accordance with the manufacturer’s instruc-
tions and recommendations. Following installation, do nothing
that might render the unit unsafe or in noncompliance with the
aforementioned codes, standards, laws and regulations.
• All stationary emergency generators covered by this manual
produce dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely high and dan-
gerous voltages to the transfer switch as well as the generator.
Avoid contact with bare wires, terminals, connections, etc.,
on the generator as well as the transfer switch, if applicable.
Ensure all appropriate covers, guards and barriers are in place
before operating the generator. If work must be done around
an operating unit, stand on an insulated, dry surface to reduce
shock hazard.
• Do not handle any kind of electrical device while stand-
ing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
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Safety Instructions
• If personnel must stand on metal or concrete while installing,
FIRE HAZARDS
operating, servicing, adjusting or repairing this equipment,
place insulative mats over a dry wooden platform. Work on the
equipment only while standing on such insulative mats.
• The National Electrical Code (NEC) requires the frame and
external electrically conductive parts of the generator to be con-
nected to an approved earth ground. This grounding will help
prevent dangerous electrical shock that might be caused by a
ground fault condition in the generator or by static electricity.
Never disconnect the ground wire.
• Keep a fire extinguisher near the generator at all times. Do NOT
use any carbon tetra-chloride type extinguisher. Its fumes are
toxic, and the liquid can deteriorate wiring insulation. Keep the
extinguisher properly charged and be familiar with its use. If
there are any questions pertaining to fire extinguishers, consult
the local fire department.
EXPLOSION HAZARDS
• Wire gauge sizes of electrical wiring, cables and cord sets must
be adequate to handle the maximum electrical current (ampac-
ity) 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.
• Properly ventilate any room or building housing the generator to
prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any fuel or oil
spills immediately. Ensure that no combustible materials are left
in the generator compartment, or on or near the generator, as
FIRE or EXPLOSION may result. Keep the area surrounding the
generator clean and free from debris.
• Connecting this unit to an electrical system normally supplied
by an electric utility shall be by means of a transfer switch so as
to isolate the generator electric system from the electric utility
distribution system when the generator is operating. Failure to
isolate the two electric system power sources from each other
by such means will result in damage to the generator and may
also result in injury or death to utility power workers due to
backfeed of electrical energy.
• These generators may operate using one of several types
of fuels. All fuel types are potentially FLAMMABLE and/or
EXPLOSIVE and should be handled with care. Comply with all
laws regulating the storage and handling of fuels. Inspect the
unit’s fuel system frequently and correct any leaks immediately.
Fuel supply lines must be properly installed, purged and leak
tested according to applicable fuel-gas codes before placing
this equipment into service.
• Stationary emergency generators installed with an automatic
transfer switch will crank and start automatically when normal
(utility) source voltage is removed or is below an acceptable
preset level. To prevent such automatic start-up and possible
injury to personnel, disable the generator’s automatic start cir-
cuit (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.
• 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.
• In case of accident caused by electric shock, immediately
shut down the source of electrical power. If this is not pos-
sible, attempt to free the victim from the live conductor. AVOID
DIRECT CONTACT WITH THE VICTIM. Use a nonconducting
implement, such as a dry rope or board, to free the victim from
the live conductor. If the victim is unconscious, apply first aid
and get immediate medical help.
• Never wear jewelry when working on this equipment. Jewelry
can conduct electricity resulting in electric shock, or may get
caught in moving components causing injury.
CALIFORNIA PROPOSITION 65 WARNING
Engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects
and other reproductive harm.
CALIFORNIA PROPOSITION 65 WARNING
This product contains or emits chemicals known to the
State of California to cause cancer, birth defects and
other reproductive harm.
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General Information
NOTE:
IDENTIFICATION RECORD
For actual information related to this particular model, please
refer to the Manual Drawing Listing located at the end of this
manual, or to the data label affixed to the unit.
DATA LABEL
Every generator set includes DATA LABEL that contains important
information pertinent to the generator. The data label is attached to
the lower connection box on the generator and lists the unit serial
number, rated voltage, amps, wattage capacity, phase, frequency,
rpm, power factor, and production date.
Stationary Emergency Generator Model and Serial
Number
This number is the key to numerous engineering and manufactur-
ing details pertaining to your unit. Always supply this number
when requesting service, ordering parts or seeking information.
Data Label
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Equipment Description
EQUIPMENT DESCRIPTION
COOLANT RECOMMENDATIONS
Use a mixture of half low silicate ethylene glycol base anti-freeze
and deionized water. Cooling system capacity is listed in the
specifications. Use only deionized water and only low silicate
anti-freeze. If desired, add a high quality rust inhibitor to the rec-
ommended coolant mixture. When adding coolant, always add the
recommended 50-50 mixture.
This equipment is a revolving field, alternating current Stationary
Emergency Generator set. It is powered by a gaseous fueled
engine operating at 1800 rpm for 4-pole direct drive units, 3600
rpm for 2-pole direct drive units and 2300 - 3000 rpm for quiet
drive gear units. See the Specifications section for exact numbers.
The unit comes complete with a sound attenuated enclosure, inter-
nally mounted muffler, control console, mainline circuit breaker,
battery charger, and protective alarms as explained in the following
paragraph.
Do not use any chromate base rust inhibitor
with ethylene glycol base anti-freeze or chro-
All AC connections, including the power leads from the alterna-
tor, 120 volt battery charger input and control connections to the
transfer switch are available in the main connection box.
mium hydroxide (“green slime”) forms and will
cause overheating. Engines that have been
operated with a chromate base rust inhibitor
must be chemically cleaned before adding eth-
ylene glycol base anti-freeze. Using any high
silicate anti-freeze boosters or additives will
also cause overheating. The manufacturer also
recommends that any soluble oil inhibitor is
NOT used for this equipment.
The Stationary Emergency Generator incorporates the following
generator features:
• Rotor and Stator insulation is Class H rated as defined by NEMA
MG1-32.6, MG1-1.66. The generator is self ventilated and drip-
proof constructed.
• The voltage waveform deviation, total harmonic content of the
AC waveform and telephone influence factor have been evalu-
ated and are acceptable according to NEMA MG1-32.
Do not remove the radiator pressure cap while
the engine is hot or serious burns from boiling
liquid or steam could result.
ENGINE OIL RECOMMENDATIONS
The unit has been filled with 5W-20 engine oil at the factory. Use
a high-quality detergent oil classified “For Service SJ or SH.”
Detergent oils keep the engine cleaner and reduce carbon deposits.
When changing the engine oil, be sure to use 5W-30 engine oil
(synthetic oil is recommended).
Ethylene glycol base antifreeze is poisonous.
Do not use mouth to siphon coolant from the
radiator, recovery bottle or any container. Wash
hands thoroughly after handling. Never store
used antifreeze in an open container because
animals are attracted to the smell and taste of
antifreeze even though it is poisonous to them.
Any attempt to crank or start the engine before
it has been properly serviced with the recom-
mended oil may result in an engine failure.
NOTE:
For temperatures below 32° F, it is strongly recommended to
use the optional Cold Weather Start Kit. The oil grade for tem-
peratures below 32° F is 5W-30 synthetic oil.
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Engine Protective Devices
OVERCRANK SHUTDOWN
ENGINE PROTECTIVE DEVICES
The Stationary Emergency Generator may be required to operate
for long periods of time without an operator on hand to monitor
such engine conditions as coolant temperature, oil pressure or
rpm. For that reason, the engine has several devices designed to
protect it against potentially damaging conditions by automatically
shutting down the unit when the oil pressure is too low, the coolant
temperature is too high, the coolant level is too low, or the engine
is running too fast.
After a prespecified duration of cranking, this function ends the
cranking if the engine has failed to start. The overcrank message
will turn ON. Turn OFF the AUTO/OFF/MANUAL switch, then turn
switch back to AUTO to reset the generator control board.
NOTE:
If the fault is not corrected, the overcrank feature will continue
to activate.
NOTE:
Approximate Crank Cycle Times
• 15 seconds ON
• 7 seconds OFF
• 7 seconds ON
Engine protective switches and sensors are mentioned here for
the reader’s convenience. Also refer to the applicable control
panel manual for additional automatic engine shutdown infor-
mation.
• 7 seconds OFF
• Repeat for 45 seconds
• Approximately 90 seconds total.
HIGH COOLANT TEMPERATURE SENDER
An analog coolant temperture sender, located in the engine's
cooling system will cause an engine shutdown if the temperature
should exceed approximately 125° C (257° F). The generator will
automatically restart once the temperature has returned to a safe
operating level.
OVERSPEED SHUTDOWN
A speed circuit controls engine cranking, start-up, operation and
shutdown. Engine speed signals are delivered to the circuit board
whenever the unit is running. Should the engine overspeed above
a safe, preset value, the circuit board initiates an automatic engine
shutdown. Contact the nearest Authorized Dealer if this failure
occurs.
LOW COOLANT LEVEL SENSOR
To prevent overheating, the engine has a low coolant level sensor.
If the level of engine coolant drops below the level of the low cool-
ant level sensor, the engine automatically shuts down.
RPM SENSOR LOSS SHUTDOWN
If the speed signal to the control panel is lost, engine shutdown
will occur.
LOW OIL PRESSURE SWITCH
This switch has normally closed contacts that are held open by
engine oil pressure during cranking and operating. Should oil pres-
sure drop below the 8 psi range, switch contacts close, and the
engine shuts down. The unit should not be restarted until oil is
added, and the AUTO/OFF/MANUAL switch must be turned to OFF
and then back to AUTO.
DC FUSES
A fuse (7.5 amp) is located on the control panel. It protects the
panel 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.
A fuse (25 amp) is located in the engine wire harness adjacent
to the DC alternator. It is used to prevent circuit failure due to DC
alternator falure. It will also protect the system in the event of a
wiring short-dircuit. If this fuse is blown, the generator will not
operate. Replace these fuses with the same size, type, and rating.
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Fuel System
NATURAL GAS FUEL SYSTEM
FUEL SYSTEM
Natural gas is supplied in its vapor state. In most cases, the gas
distribution company provides piping from the main gas distribu-
tion line to the standby generator site. The following information
applies to natural gas fuel systems.
FUEL REQUIREMENTS
The Stationary Emergency Generator may be equipped with one of
the following fuel systems:
• Gas pressure in a building is usually regulated by national, state
and local codes.
• To reduce gas pressure to a safe level before the gas enters a
building, a primary regulator is needed. The natural gas supplier
may or may not supply such a regulator.
• It is the responsibility of the gas supplier to make sure sufficient
gas pressure is available to operate the primary regulator.
• Gas pressure at the inlet to the fuel shutoff solenoid must never
exceed approximately 14 inches water column (0.5 psi).
• Natural gas fuel system
• Propane vapor (LPV) fuel system
Recommended fuels should have a Btu content of at least 1,000
Btu's per cubic foot for natural gas; or at least 2,520 Btu's per
cubic foot for LP gas. Ask the fuel supplier for the Btu content of
the fuel.
NOTE:
The fuel consumption requirements are identified in the
Specifications section of the Owner's Manual. Refer to the
Installation Manual if assistance is required for the sizing of
the pipe diameter for the generator. Any piping used to connect
the generator to the fuel supply should be of adequate size to
achieve the 100% load fuel consumption requirements identi-
fied in the Specifications section regardless of actual load.
PROPANE VAPOR WITHDRAWAL FUEL SYSTEM
This type of system utilizes the vapors formed above the liquid
fuel in the supply tank. Approximately 10 to 20 percent of the tank
capacity is needed for fuel expansion from the liquid to the vapor
state. The vapor withdrawal system is generally best suited for
smaller engines that require less fuel. The installer should be aware
of the following:
NOTE:
TherecommendedfuelpressureisidentifiedintheSpecifications
section this manual.
• When ambient temperatures are low and engine fuel consump-
tion is high, the vapor withdrawal system may not function
efficiently.
• Ambient temperatures around the supply tank must be high
enough to sustain adequate vaporization, or the system will not
deliver the needed fuel volume.
NOTE:
It is the responsibility of the installer to make sure that only
the correct recommended fuel is supplied to the generator fuel
system. Thereafter, the owner/operator must make certain that
only the proper fuel is supplied.
• In addition to the cooling effects of ambient air, the vaporization
process itself provides an additional cooling effect.
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Specifications
Engine Lubrication System
SPECIFICATIONS
Type of Oil Pump ...............................................................Gear
Oil Filter .......................................................Full Flow, Cartridge
Crankcase Oil Capacity ............................................ 5 U.S. qts.
STATIONARY EMERGENCY GENERATOR
Type......................................................................Synchronous
Rotor Insulation.............................................................Class H
Stator Insulation............................................................Class H
Total Harmonic Distortion..............................................< 3.5%
Telephone Interference Factor (TIF) .................................. < 50
Alternator Output Leads 1-phase.....................................4-wire
Alternator Output Leads 3-phase.....................................6-wire
Bearings ..................................................................Sealed Ball
Coupling ................................................................Flexible Disc
Load Capacity (Standby Rating)....................................70 kW*
COOLING SYSTEM
Type............................................................................... Closed
Water Pump............................................................. Belt Driven
Fan Speed.........................................................................2300
Fan Diameter..............................................................22 inches
Fan Mode....................................................................... Pusher
Air Flow (inlet air including alternator and
combustion air) .................................................5200 ft3/min.
Coolant Capacity....................................................4.5 U.S. gal.
Heat Rejection to Coolant....................................287,000 Btu/h
Maximum Operating Air Temp. on Radiator......... 60 °C (150 °F)
Maximum Ambient Temperature......................... 50 °C (140 °F)
* NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE
J1349, ISO3046 and DIN 6271 Standards. kW rating is based on LPG fuel and may derate
with natural gas.
Excitation System ......................................................Brushless
Circuit Breaker Size (Amps)
FUEL SYSTEM
Voltage
LP kW CB Amps NG kW CB Amps
Type of Fuel ........................................ Propane or Natural Gas*
Carburetor............................................................... Down Draft
Secondary Fuel Regulator............................................ Standard
Fuel Shut-off Solenoid................................................. Standard
Operating Fuel Pressure ...............11 in. - 14 in. Water Column
120/240 V - 1ø
120/208 V - 3ø
120/240 V - 3ø
277/480 V - 3ø
67
70
70
70
300 292
300 243
250 211
125 105
64
67
67
67
300 267
300 232
250 201
125 101
Fuel Consumption - ft3/hr (Natural Gas/LPV)
Generator Locked Rotor kVA Available @ Voltage Dip of 35%
Single-phase..............................................................145 kVA
480 V, 3-phase..........................................................160 kVA
208 V, 3-phase..........................................................145 kVA
Exercise
25%
50%
75%
100%
Load
Cycle
Load
Load
Load
110/44.2
260/104
500/200 696/280 1020/411
* Engine is not field convertible between natural gas and propane. Jet size and ignition timing
are factory set for the specific fuel.
ENGINE
Make ........................................................................... Generac
Model ............................................................................. V-type
Cylinders and Arrangement ...................................................10
Displacement...............................................................6.8 Liter
Bore............................................................ 90.2 mm (3.55 in.)
Stroke....................................................... 105.9 mm (4.17 in.)
Compression Ratio.......................................................... 9-to-1
Air Intake System......................................... Naturally Aspirated
Valve Seats................................................................ Hardened
Lifter Type.................................................................. Hydraulic
ELECTRICAL SYSTEM
Battery Charge Alternator.....................................12 V, 30 Amp
Smart Charger .......................................................12 V, 2 Amp
Recommended Battery.......................................... 24F 525CCA
System Voltage............................................................ 12 Volts
NOTE:
Battery dimensions (L x W x H) for the Group 24 battery should
not exceed 10 3/4" x 6 13/16" x 9" (273 mm x 173 mm x 229
mm).
Engine Parameters
Rated Synchronous rpm.........................................60 Hz, 1800
Voltage Regulator
Type...........................................................................Electronic
Regulation........................................................................± 1%
Exhaust System
Exhaust Flow at Rated Output 60 Hz.............................557 cfm
Exhaust Temperature at Rated Output..............................890 °F
Power Adjustment for Ambient Conditions
Temperature Deration
3% for every 10 °C above °C ..............................................25
1.65% for every 10 °F above °F ..........................................77
Altitude Deration
1% for every 100 m above m............................................183
3% for every 1000 ft. above ft. .........................................600
Combustion Air Requirements (Natural Gas)
Flow at rated power, 60 Hz...........................................205 cfm
Governor
Type...........................................................................Electronic
Frequency Regulation.............................................Isochronous
Steady State Regulation ............................................ ± 0.25 %
Controller ................................................................. Nexus
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Specifications
WEATHER AND MAINTENANCE KITS
To keep the generator running at its peak, the following kits are
offered:
• Cold Weather Kit
~ Recommended for climates with temperatures below 32 °F.
• Scheduled Maintenance Kit
~ Kit includes the recommended parts to maintain the genera-
tor. Refer to the Service Schedule for regular maintenance
intervals.
For additional information, or to order any of these kits, please
contact an Authorized Service Dealer or Customer Service
Representative.
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General Information
ALTERNATOR AC LEAD
ALTERNATOR POWER WINDING
CONNECTIONS
CONNECTIONS
The electrical wires in the unit’s AC connection (lower) panel
should be installed according to the number of leads and the
voltage/phase required for the application. The voltage and phase
are described on the generator data label. The number of lead
wires can be identified using the Specifications section and the
power output rating on the generator data label. For example, if
the generator produces 130kW, 277/480 Volt, 3-phase power, the
generator has 12 alternator output leads. Figure 7.3 describes the
stator power winding connection for the generator.
3-PHASE ALTERNATORS ("Y" CONFIGURATION)
The Stationary Emergency Generator is designed to supply
3-phase electrical loads. Electric power is produced in the alterna-
tor power windings. These windings were connected at the factory
to the main circuit breaker with a “Y” configuration as shown in
Figures 7.2 through 7.6.
The rated voltage between circuit breaker terminals E1-E2, E1-E3
and E2-E3 is 480V, 208V or 600V depending on the model.
The rated voltage between each circuit breaker terminal and the
neutral point 00 is 277V, 120V, or 346V depending on the model.
FOUR-LEAD, SINGLE-PHASE STATOR
Four-lead alternators (see Figure 7.1) are designed to supply elec-
trical loads with voltage code “A” (240V, 1-phase, 60 Hz). Electrical
power is produced in the stator power windings. These windings
were connected at the factory to the main circuit breaker as shown
in Figure 7.1.
Figure 7.2 — Stator Power Winding
Connections - 3-phase, 277/480V (6 Lead)
E1
The rated voltage between each circuit breaker terminal is 240V.
The rated voltage between each circuit breaker terminal and the
neutral point 00 is 120V.
S1
INTERNAL
CONNECTIONS
Figure 7.1 — Four-lead, Single-phase Stator
L - L
S4
S6
00 (NEUTRAL)
S5
S2
S3
E3
E2
L - N
Figure 7.3 — Stator Power Winding
Connections - 3-phase, 277/480V (12 Lead)
E1
S1
S4
S7
L - L
S12
S10
S9
S8
S11
S6
S5
S2
S3
E3
E2
L - N
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General Information
Figure 7.4 — Stator Power Winding
Connections - 3-phase, 120/208V (6 Lead)
3-PHASE ALTERNATORS ("DELTA" CONFIGURATION)
The Stationary Emergency Generator is designed to supply
3-phase electrical loads. Electric power is produced in the alterna-
tor power windings. These windings were connected at the factory
to the main circuit breaker with a "Delta" configuration as shown
in Figures 7.7 and 7.8.
INTERNAL CONNECTIONS
E1
S1
S1
The rated voltage between circuit breaker terminals E1-E2, E1-E3
and E2-E3 is 240V.
The rated voltage between E2 and the neutral point 00 is 208V. The
rated voltage E1-00 and E3-00 is approximately 120V.
L-L
S4
S6
S4
00 (NEUTRAL)
S5
NOTE: The voltage measured from E2 to 00 can greatly vary when
single phase load is placed on alternator.
S3
S2
Figure 7.7 — Stator Power Winding
S6 S5
Connections - 3-phase, 120/240V (6 Lead)
E3
E2
S3
S2
E2
L-N
Figure 7.5 — Stator Power Winding
Connections - 3-phase, 120/208V (12 Lead)
ꢀ
0V
A
C
E1
2ꢁVAC
S7
S1
208ꢂC
L-L
240ꢂC
S10
S12
S4
S5
S9
S2
S6 S11
E3
E2
Figure 7.8 — Stator Power Winding
Connections - 3-phase, 120/240V (12 Lead)
S3
S8
L-N
Figure 7.6 — Stator Power Winding
Connections - 3-phase, 346/600V (6 Lead)
E2
S2
S12
E1
S1
INTERNAL
S9
S5
CONNECTIONS
240 VAC
S8
240 VAC
S6
208 VAC
L - L
S3
S11
E1
NB
S4
S6
E3
S10
S1
00 (NEUTRAL)
240 VAC
S5
120 VAC
S2
E2
120 VAC
S3
E3
L - N
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Control Panel
Upon power up, this controller will go through a system self test
CONTROL PANEL INTERFACE
which will check for the presence of utility voltage on the DC
circuits. This is done to prevent damage if the installer mistakenly
connects AC utility power sense wires into the DC terminal block.
If utility voltage is detected, the controller will display a warning
message and lock out the generator, preventing damage to the
controller. Power to the controller must be removed to clear this
warning.
USING THE AUTO/OFF/MANUAL SWITCH
With the switch set to AUTO, the engine may
crank and start at any time without warning.
Such automatic starting occurs when utility
power source voltage drops below a preset
level or during the normal exercise cycle. To
prevent possible injury that might be caused
by such sudden starts, always set the switch
to OFF and remove the fuse before work-
ing on or around the generator or transfer
switch. Then, place a “DO NOT OPERATE”
tag on the generator panel and on the trans-
fer switch.
Utility voltage must be turned on and present at the N1 and N2
terminals inside the generator control panel for this test to be
performed and pass.
NOTE:
DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT
WIRES IS NOT WARRANTABLE!
This test will be performed each time the controller is powered
up.
Next, the user must enter the minimum settings to operate. These
settings are current date and time and exercise day and time. The
maintenance intervals will be initialized (i.e. started) the first time
the clock is set. If the clock is never set at power up, the mainte-
nance intervals will be reset every time power is applied.
1. “AUTO” Position – Selecting this switch activates fully auto-
matic system operation. It also allows the unit to automati-
cally start and exercise the engine every seven days with the
setting of the exercise timer (see the Setting the Exercise
Timer section).
2. “OFF” Position – This switch position shuts down the engine.
If a subsequent power loss (loss of battery power) occurs the
Installation assistant will operate upon power restoration. The self
test routine will be run and then the customer will be required to
re-enter the time and date, as this is not retained during a power
loss. The unit will not require re-activation.
This position also prevents automatic operation.
3. “MANUAL” Position – Set the switch to MANUAL to crank
and start the engine. Transfer to standby power will not occur
unless there is a utility failure.
ACTIVATE THE GENERATOR
When battery power is applied to the generator during the instal-
lation process, the controller will turn ON and the LCD screen will
illuminate. However, the generator still needs to be activated before
it will automatically run in the event of a power outage.
DISPLAY INTERFACE MENUS
The LCD display is organized as detailed below:
• The “Home” page, this page is the default page which will be
displayed if no keys are pressed for 30 seconds. This page
normally shows the current Status message and the current
date and time. The highest priority active Alarm and/or Warning
will be automatically posted on this page as well as flashing
the backlight when such an event is detected. In the case of
multiple Alarms or Warnings, only the first message will be
displayed. To clear an Alarm or Warning, see the Protection
Systems section - Clear Alarm.
• The display backlight is normally off. If the user presses any
key, the backlight will come on automatically and remain on for
30 seconds after the last key was pressed.
• The “Main Menu” page will allow the user to navigate to all other
pages or sub-menus by using the Left/Right and Enter keys.
This page can be accessed at any time with several presses of
the dedicated Escape key. Each press of the Escape key takes
you back to the previous menu until the main menu is reached.
This page displays the following options: HISTORY; STATUS;
EDIT; AND DEBUG. (See the Appendix - "Menu System".)
Activating the generator is a simple one time process that is guided
by the controller screen prompts. Once the product is activated,
the controller screen will not prompt you again, even if you discon-
nect the generator battery.
To obtain the activation code, record the generator serial number
and log onto www.activategen.com or call 1-888-9ACTIVATE and
follow the steps to retrieve the activation code.
After obtaining your activation code, please complete the following
steps at the generator’s control panel in the Activation Chart on the
following page.
NOTE:
The generator will only run in manual until the passcode has
been entered.
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Control Panel
ACTIVATION CHART
CHOOSE LANGUAGE
TROUBLESHOOTING
Display Reads:
Use ARROW keys to scroll to desired lan-
guage. Press ENTER to select.
If the wrong language is chosen, it can be
changed later using the “edit” menu.
Language
-
English
+
Escape
Enter
Display Reads:
Press ENTER to begin the activation pro-
cess.
If ESCAPE is pressed instead of ENTER,
your generator will only run in manual mode
(for test purposes) and NOT ACTIVATED will
be displayed. You will need to remove the
generator control panel fuse AND disconnect
the T1, N1 and N2 connector in the external
connection box (if equipped); or disconnect
utility input (main breaker) to the transfer
switch for 3-5 seconds and reconnect, then
begin with Step 1.
Activate me (ENT) or
ESC to run in manual
Escape
Enter
Display Reads:
If you do not have your activation code,
go to www.activategen.com or call
1-888-9ACTIVATE (922-8482).
To Activate go to
www.activategen.com
If you already have your activation code,
wait 3-5 seconds for the next display.
Escape
Enter
ENTER ACTIVATION CODE (Passcode)
TROUBLESHOOTING
Display Reads:
Use ARROW keys to scroll and find the first
number of your Activation Code.
Serial 123456789
Passcode XXXXX +/-
Press ENTER to select.
Repeat this step until all digits have been
entered.
Escape
Enter
Use ESCAPE to correct previous digits.
Display Reads:
Activation is complete when all digits are
entered above and your screen shows this
display.
What happens if “Wrong Passcode Try
Again” appears?
“SELECT HOUR (0-23)”
“-
Re-enter the activation code. If a second
attempt is unsuccessful, check the number
against the code given on activategen.com.
If it is correct and the generator will not
accept it, contact 1-888-9ACTIVATE (922-
8482).
6
+”
Follow the controller prompts to continue
setting the time function. Refer to your
Owner’s Manual with questions.
Escape
Enter
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Control Panel
• If utility is still lost after the “line interrupt period”, run the engine
INSTALLATION ASSISTANT
Interconnect System Self Test Feature (follow the on-screen
prompts).
up to normal RPM and transfer the load. At this time the con-
troller will exit the exercise routine and assume full automatic
operation.
Upon power up, this controller will go through a system self test
which will check for the presence of utility voltage on the DC
circuits. This is done to prevent damage if the installer mistakenly
connects AC utility power sense wires into the DC terminal block.
If utility voltage is detected, the controller will display a warning
message and lock out the generator, preventing damage to the
controller. Power to the controller must be removed to clear this
warning.
USER ADJUSTABLE SETTINGS
Factory
Default
Minimum
Setting
Maximum
Setting
Setting
Increment
1 min
Exercise
time
23:59
(11:59 pm)
2 pm
Wed
00:00 (12 am)
Sun
Exercise
day
Utility voltage must be turned on and present at the N1 and N2
terminals inside the generator control panel for this test to be
performed and pass.
Sat
1 day
Current
Time
23:59
(11:59 pm)
12 am 00:00 (12 am)
1 min
NOTE:
Current
Day
Sun
Jan
Sun
Jan
Sat
Dec
1 day
DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT
WIRES IS NOT WARRANTABLE!
Current
Month
1 month
1 year
This test will be performed each time the controller is powered
up.
Current
Year
2008
2008
2100
Upon first power up of the generator, the display interface will
begin an installation assistant. The assistant will prompt the user
to set the minimum settings to operate. These settings are simply:
Current Date/Time and Exercise Day/Time. The maintenance inter-
vals will be initialized when the exercise time is entered.
Language
Contrast
English
80%
French
0%
Spanish
100%
N/A
1%
The exercise settings can be changed at any time via the "EDIT"
menu (see Appendix, "Menu System").
FUEL CONVERSION
For fuel conversion steps, refer to the GenSpec section,
RECONFIGURING THE FUEL SYSTEM.
If the 12 volt battery is disconnected or the fuse removed, the
Installation Assistant will operate upon power restoration. The
only difference is the display will only prompt the customer for the
current Time and Date.
OPERATION
IF THE INSTALLER TESTS THE GENERATOR PRIOR TO
INSTALLATION, PRESS THE “ENTER” KEY TO AVOID SETTING
UP THE EXERCISE TIME. THIS WILL ENSURE THAT WHEN
THE CUSTOMER POWERS UP THE UNIT, HE WILL STILL BE
PROMPTED TO ENTER AN EXERCISE TIME.
This system is intended to supply standby power in the event of a
utility failure. The control system will monitor the utility voltage to
determine if stand-by power is required. Should the utility voltage
fail, the generator will start and run normally, detaching from the
utility and supplying the customer load from the generator. When
utility power returns, the controller will re-transfer the customer
load back to utility and shut down the generator.
SETTING THE EXERCISE TIMER
This generator is equipped with an exercise timer. Once it is set,
the generator will start and exercise every seven days, on the day
of the week and at the time of day specified. During this exercise
period, the unit runs for approximately 12 minutes and then shuts
down. Transfer of loads to the generator output does not occur
during the exercise cycle unless utility power is lost.
AUTOMATIC TRANSFER OPERATION
To select automatic operation, do the following:
1. Make sure the transfer switch main contacts are set to their
UTILITY position, i.e., loads connected to the utility power
source.
2. Be sure that normal UTILITY power source voltage is avail-
able to transfer switch terminal lugs N1 and N2 (Refer to the
Electrical Data section).
3. Set the generator’s AUTO/OFF/MANUAL switch to AUTO.
4. Set the generator’s main circuit breaker to its ON (or CLOSED)
position.
With the preceding steps complete, the generator will start auto-
matically when utility source voltage drops below a preset level.
After the unit starts, loads are transferred to the standby power
source. Refer to the Sequence of Automatic Operation section.
LOW SPEED EXERCISE
The standard start sequence will be initiated.
• All 1800 rpm units will exercise at 1400 RPM
• All 3600 rpm units will exercise at 1800 RPM
If utility is lost during exercise the controller will do the following:
• Wait for the “line interrupt period” for utility to return. If utility
returns within the “line interrupt period”, continue to exercise
at low RPM.
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Control Panel
SEQUENCE OF AUTOMATIC OPERATION
Initial Conditions: Generator in Auto ready to run, load being sup-
plied by the Utility Source through the transfer switch.
MANUAL START
Allows the user to start and run the generator manually.
Transfer of the load to the generator will occur if utility is lost while
the unit is running in the manual mode (only if activated).
1. When the utility voltage fails (falls below 60% of nominal), a
10-30 second (programmable) “line interrupt” delay timer is
started. The factory set time delay is 10 seconds. If at the
end of the line interrupt time the utility voltage is above 60%
the engine will not crank. If the utility voltage is still below
the 60% of nominal at the end of the line interrupt time, the
unit will crank and start. If the unit cranks for more than 10
seconds and the utility voltage rises above 80% of nominal
(programmed pickup voltage) and the unit has not started, the
crank cycle will abort.
2. As soon as the unit starts a 5 second “warm-up” timer is initi-
ated. When the warm-up timer expires the control will transfer
the load to the generator (through the RTS switch) if the utility
voltage is less than 80% of nominal. If the utility voltage is
greater than the 80% of nominal at the end of the warm-up
time the load will not be transferred to the generator and a one
minute low-speed cool down period will start. At the end of
the one minute cool down period the generator will stop.
3. Once the unit is running and the switch has transferred the
load to the generator the unit will monitor utility voltage.
When utility voltage returns (above the programmable pickup
voltage, normally 80% of nominal), a 15 second “Return to
Utility” timer will start. At the end of the return to utility time,
if the utility voltage is still above the pickup voltage, the unit
will transfer the load back to the utility source and run the unit
through a one minute cool down period. When the cool down
period is over the unit will shut down and be ready for the next
outage.
ALARM AND WARNING MESSAGES
Alarms are defined as “Latching” which means they must be
cleared before the alarm message on the screen will clear. They
can be of type “Shutdown” or not and are logged in the alarm log.
Alarms are all annunciated on the display).
Warnings are “Non Latching” meaning the message automati-
cally clears when the warning condition goes away. Warnings can
not be of type “Shutdown” but they are logged in the alarm log.
Warnings are all annunciated on the display.
LOW OIL PRESSURE SHUTDOWN ALARM
There is a 10 second delay before oil pressure is monitored.
HIGH COOLANT TEMPERATURE SHUTDOWN ALARM
There is a 10 second delay before engine temperature is moni-
tored.
Once running there is a 1/4 second delay before shut down. The
limit is set at 125° C or 257° F.
OVERCRANK SHUTDOWN ALARM
Occurs if the engine has not started within the specified crank
cycle.
4. If during the cool down period utility voltage should fall below
60% of nominal the 5 second warm-up timer is initiated and
the unit will transfer the load back to the generator and con-
tinue to monitor the utility.
OVERSPEED SHUTDOWN ALARM
Warning indicator is measured and calculated by the microproces-
sor. Overspeed is defined as +20% of nominal engine speed for 3
seconds, or +25% immediate.
CRANK CYCLES AND OVERCRANK SHUTDOWN
If the unit fails to start during a cranking period it will display the
Overcrank Shutdown Alarm. The system will control the cranking
cycles as follows:
Nominal engine speed = 60.0 Hz
RPM SENSOR FAILURE SHUTDOWN ALARM
During cranking: If the board does not see a valid RPM signal
within four (4) seconds of cranking it will shut down and lock out
on RPM sensor loss.
The first crank cycle is a 16 second crank time followed by a 7
second rest. The next 5 cycles will be 7 seconds of cranking time
each followed by a 7 second rest time.
If the unit fails to start by the end of the 6 crank/rest cycles
the Overcrank Shutdown Alarm will display and the unit will not
attempt to crank until the alarm is reset.
During running: If the RPM signal is lost for one full second the
board will shut the engine down, wait 15 seconds, then re-crank
the engine if in AUTO, it will not re-crank in MANUAL.
If no RPM signal is detected within the first four (4) seconds of
cranking, the control board will shut the engine down and latch out
on RPM sensor loss.
AUTO START
This unit is designed to automatically start in the event of a util-
ity failure or brown out condition. Brown out is defined as utility
voltage less than 60% nominal, while utility is considered good
when it is restored to at least the pickup value, 80% of nominal.
These levels are fixed. The “Line Interrupt period” is an adjustable
parameter by the dealer. If 2-wire start mode is activated, the unit
will start when 2-wire start is active.
If the RPM signal is detected the engine will start and run normally.
If the RPM signal is subsequently lost the control board will try
two more re-cranks before latching out and flashing the RPM
Sensor Failure message (if it is in AUTO).
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Control Panel
Figure 1 – Generator Control Panel
CHECK ENGINE MESSAGE
MISSING CAM PULSE ALARM
The control system has detected an emissions related fault. This
fault cannot be cleared using the control panel interface. The unit
will continue to operate in automatic mode. Contact your local
servicing dealer.
This is a shutdown alarm. The alarm will activate after five (5)
seconds of continuously missing cam pulses.
MISSING CRANK PULSE ALARM
This is a shutdown alarm. The alarm will activate after 12 con-
secutive revs where crank pulses are missing.
UNDER-FREQUENCY SHUTDOWN ALARM
After starting, if the generator stays under frequency for more than
30 seconds, it will shutdown.
LOW FUEL PRESSURE WARNING
Fuel pressure is monitored by a digital sensor with a fixed setpoint
of below five (5) inches water column.
LOW BATTERY ALARM
While running, if the average battery voltage falls below 11.9 volts
for one (1) minute, the low battery alarm will be displayed.
GOVERNOR SENSOR FAULT ALARM
The governor position is monitored by an analog feedback signal. If
the throttle position is seen outside of the normal operating range,
a shutdown alarm is displayed. If the throttle is commanded to
move, and no movement is seen, a shutdown alarm is displayed.
LOW BATTERY WARNING
The microprocessor will continually monitor the battery voltage
and display the Low Battery Voltage message if the battery voltage
falls below 12.2 Volts for one (1) minute.
WIRING ERROR ALARM
No other action is taken on a low battery warning condition. The
warning will automatically clear if the battery voltage rises above
12.2 volts.
When power is first apllied to the contoller, the software will per-
form a check on the wiring of the transfer output, and ensure it
does not have high voltage on the wire. If this is the case, it will
signal a miswire alarm and will not run. The test can be skipped
by use of the escape key.
NOTE:
The battery sentinel is a separate feature that monitors battery
condition.
UNDERVOLTAGE ALARM
If the generator voltage falls below 60% for >5 seconds, an alarm
will be issued.
LOW COOLANT LEVEL ALARM
This is a shutdown alarm. The sensor will be continuously moni-
tored. If an error condition is seen for five (5) consecutive sec-
onds, the alarm will be displayed.
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Control Panel
OVERVOLTAGE ALARM
ALARM CANCEL
If the generator voltage rises above 110% for >3 seconds, an
alarm will be issued.
When the generator is shut down due to a latching alarm, the Auto
/Off/ Manual switch must be set to the off position and the ENTER
key pressed to unlatch any active fault and clear the corresponding
fault alarm message.
If the generator voltage rises above 130% for >0.2 seconds, an
alarm will be issued.
INTERNAL FAILURE SHUTDOWN ALARM
Any internal failure that can be detected such as corrupted
firmware will cause this shutdown alarm. This alarm cannot be
cleared.
COMMON ALARM RELAY
The common alarm relay will be activated if there is a shutdown
alarm. It will not activate on warnings or indicate that the Auto/Off/
Manual switch is in the OFF position. The OFF position will clear
the alarms and the relay. The relay will not be used to indicate a
generator is not activated.
CANBUS ALARM
The common alarm connections are wired to a set of potential-
free (dry) contacts on the Nexus controller board. These Normally
Open (N.O.) contacts close when an alarm condition occurs and
are used to activate a remote signaling device. The circuit is rated
for a maximum of 130mA at 24 VDC. The connections are a short
set of free hanging wires that exit the engine harness loom directly
behind the Nexus Control Panel and are labeled numbers 209 and
210.
Where applicable, if the Canbus communications link fails to com-
municate, a “Canbus Alarm” will be generated. This only applies
to systems with external ignition modules. The alarm may be
generated if:
1. The physical link is broken.
2. The Ignition Module fails or resets.
3. The Nexus Controller fails or resets.
4. Having the Battery Chargers 120 VAC connected without a
battery installed.
MAINTENANCE ALERTS
Maintenance alerts will be provided for these conditions.
5. A blown 10 amp Ignition Module fuse (approximately 12
inches away from the starter).
6. A blown 25 amp system fuse (located approximately 12
inches away from the DC alternator).
NOTE:
SERVICE SCHEDULE ‘A’
Inspect Accessory Drive Alert
Coolant Change & Flush
1yr / 100hrs*
1yr / 100hrs
1yr / 100hrs
1yr / 100hrs*
1yr / 100hrs
1yr / 100hrs
6mo / 50hrs*
The “Canbus Alarm” will not clear on its own. To clear the
alarm, press the “enter” key to acknowledge the alarm. The
alarm will clear and if the fault is still present, the alarm will
reoccur.
Inspect Spark Plugs Alert
Change Oil & Filter Alert
IGNITION ALARM
When an ignition alarm occurs, a generic message “Ignition Fault”
will be displayed as the fault code.
Inspect Battery Alert
Change / Inspect Air Filter Alert
Clean/Inspect Air Inlet & Exhaust
* Items require a 3 month / 30 hour break-in change or check.
MAINTENANCE WARNING
When a maintenance period expires, a warning message will be
posted. The warning can be reset by hitting the Enter key. Resetting
will clear the warning and reset the maintenance counters for the
condition annunciated. The history log will reflect the maintenance
warning.
SERVICE SCHEDULE ‘B’
Change / Inspect spark plugs alert
2yr/ 250hr
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Operation
STATIONARY EMERGENCY
GENERATOR CONTROL AND
OPERATION
Do not crank the engine continuously for lon-
ger than 30 seconds, or the heat may
damage the starter motor.
n
Refer to the appropriate control panel operator’s manual for this
unit.
• Let engine stabilize and warm up.
• Check all applicable instrument and gauge readings. When
certain that all readings are correct, move the transfer switch
manual handle to the STANDBY (or EMERGENCY STANDBY)
position, i.e., load circuits supplied by the generator.
• Set the generator’s main line circuit breaker to its ON (or
CLOSED) position.
OPERATING UNIT WITH MANUAL
TRANSFER SWITCH
If the Stationary Emergency Generator was installed in conjunction
with a transfer switch capable of manual operation only, the fol-
lowing procedure applies. A manually operated transfer switch is
one that will not provide automatic start-up and does not include
an intelligence circuit.
• 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 literature pertaining to the
specific transfer switch.
ENGINE START-UP AND TRANSFER
For additional information, refer to the applicable control panel
manual for this unit, as well as any literature pertaining to the
specific transfer switch.
To transfer the load back to the utility power source and shut down
the generator, follow these directions:
• Set the generator’s main line circuit breaker to its OFF (or OPEN)
position.
• Manually move the transfer switch handle to its UTILITY
(NORMAL) position, i.e., load circuits connected to the utility.
• Turn ON the utility power supply to the transfer switch, using
the means provided (such as the utility power source main line
circuit breaker).
• Let the generator run at no-load for a few minutes to stabilize
internal temperatures.
• Shut down the generator.
nThe 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 appli-
cable control panel and transfer switch manuals
for more information.
nDo not proceed until certain that utility source
voltage is available to the transfer switch and
OPERATING UNIT WITH AUTOMATIC
the transfer switch main contacts are set to
UTILITY.
TRANSFER SWITCH
Do not attempt manual operation until all
power supplies to the transfer switch have been
If the Stationary Emergency Generator has been installed with an
automatic transfer switch, the engine may be started and stopped
automatically or manually.
positively turned off, or extremely dangerous -
possibly lethal - electrical shock will result.
NOTE:
Transfer switch enclosure doors should be kept
closed and locked. Only authorized personnel
Refer to the applicable manual for your transfer switch and to
“Transfer Switch Start Signal Connections”. In addition, please
note the dangers under “Engine Start-up and Transfer.”
should be allowed access to the transfer switch
interior. Extremely high and dangerous voltages
are present in the transfer switch.
In order to transfer load from the utility source to the generator,
follow these directions:
• Turn OFF or disconnect the utility power circuit to the transfer
switch, using the means provided (such as the utility source
main line circuit breaker).
• Set the transfer handle to its UTILITY (NORMAL) position with
load circuits connected to the utility power supply.
• Set the generator’s main line circuit breaker to its OFF (or OPEN)
position.
• Start the generator.
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Maintenance
Refer to the Service Schedule for engine oil and filter change fre-
quencies.
GENERAL MAINTENANCE
Drain the oil while the engine is still warm from running. This
means warm up the engine, shut it down and drain immediately
as follows:
Before working on the Stationary Emergency
Generator, ensure the following:
• The AUTO/OFF/MANUAL switch is in the OFF position.
• The control panel fuse has been removed from the control
box.
1. Remove the drain hose from its retaining clip or cut the zip-tie
securing the oil drain hose.
2. Loosen and remove OIL DRAIN HOSE CAP. Drain oil com-
• The 120VAC supply to the battery charger is switched OFF.
• The negative battery cable has been removed.
pletely into suitable container.
3. When all oil has drained, install and tighten OIL DRAIN HOSE
CAP and secure drain hose with a new zip-tie, or place the
hose in its retaining clip.
CHECK ENGINE OIL
Check engine crankcase oil level (Figure 10.1) according to the
Service Schedule and SIB10-10-L24G.
4. Turn OIL FILTER (Figure 10.1) counterclockwise and remove.
Properly dispose of old filter.
5. Apply light coating of new engine oil to seal of new oil fil-
ter. Install FILTER and tighten by hand only. DO NOT OVER
TIGHTEN.
• Remove oil dipstick and wipe dry with a clean, lint-free cloth.
• Install oil dipstick, then remove again.
• Oil should be between FULL and ADD marks.
• If oil level is below the dipstick ADD mark, remove oil fill cap.
Add the recommended oil to bring oil level up to the FULL
mark. DO NOT FILL ABOVE THE “FULL” MARK. See “Engine Oil
Recommendations” for recommended oils.
6. Remove OIL FILL CAP and add recommended oil. Crankcase
oil capacity is listed in the "Specifications" section.
After refilling the crankcase with oil, always
check oil level on dipstick. NEVER OPERATE
ENGINE WITH OIL BELOW THE DIPSTICK
“ADD” MARK.
n
Figure 10.1 - Oil Dipstick and Oil Fill Cap
Oil Fill
7. Start engine and check for oil leaks.
Oil
Dipstick
8. Shut OFF engine and wait 10 minutes for the oil to settle down
into the oil pan. Recheck oil level on dipstick. DO NOT fill
above the dipstick "FULL" mark.
9. Dispose of used oil at a proper collection center.
COOLING INTAKE/OUTLET
Air intake and outlet openings in the generator compartment must
be open and unobstructed for continued proper operation. This
includes such obstructions as high grass, weeds, brush, leaves
and snow.
Without sufficient cooling and ventilating air flow, the engine/gen-
erator quickly overheats, which causes it to shut down. (See the
installation diagram.)
Oil Filter
The exhaust system parts from this product
get extremely hot and remains hot after shut-
down. High grass, weeds, brush, leaves, etc.
must remain clear of the exhaust. Such mate-
rials may ignite and burn from the heat of the
exhaust system.
CHANGING ENGINE OIL
Hot oil may cause burns. Allow engine to
INSPECT COOLING SYSTEM
• Inspect engine cooling system. See the Service Schedule.
• Check hoses for damage, deterioration, leaks, etc. Correct any
discrepancies found.
cool before draining oil. Avoid prolonged
n
or repeated skin exposure with used oil.
Thoroughly wash exposed areas with soap.
• Check hose clamps for tightness.
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Maintenance
ENGINE COOLANT
CHECK FAN BELT
Checkcoolantlevelincoolantrecoverybottle.See theSpecifications
and Service Schedule sections.
• Inspect fan belts every year. Replace any damaged, deterio-
rated, worn or otherwise defective belt.
• Check fan belt tension. Thumb pressure, exerted midway
between pulleys, should deflect about 3/8 to 5/8 of an inch.
Adjust belt tension as required.
• Add recommended coolant mixture as necessary.
• Periodically remove radiator pressure cap (only when engine
has cooled down) to make sure the coolant recovery system
is functioning properly. Coolant should be at bottom of radia-
tor filler neck. If coolant level is low, inspect gasket in radiator
pressure cap. Replace cap, if necessary. To have pressure cap
tested, contact a Service Facility. Inspect cooling system and
coolant recovery system for leaks.
• Check fan belt alignment (see Figure 10.2).
Figure 10.2 – Fan Belt
COOLANT CHANGE
Every year, have a service facility drain, flush and refill the cooling
system. See the Specifications and Service Schedule for cooling
system recommendations.
OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL
SYSTEM
Engine cranking, start up and running are controlled by a solid
state Engine Controller circuit board. Battery voltage is delivered
to that circuit board via the control panel fuse. This overcurrent
protection device will open if the circuit is overloaded.
If a circuit breaker opens or a fuse element
melts, find the cause of the overload before
resetting the circuit breaker or replacing the
fuse.
n
INSPECT ENGINE GOVERNOR
Visually inspect electronic governor.
EXERCISE SYSTEM
Starts the Stationary Emergency Generator engine once every
seven days and lets it run for 12 minutes.
Do not attempt to adjust the governor. Only
qualified service facilities should adjust
n
the governor. Excessively high operating
speeds are dangerous and increase the
risk of personal injury. Low speeds impose
a heavy load on the engine when adequate
engine power is not available and may
shorten engine life. Correct rated frequency
and voltage are supplied only at the proper
governed speed. Some connected electrical
load devices may be damaged by incorrect
frequency and/or voltage. Only qualified ser-
vice technicians should adjust the governed
speed.
PERFORM VISUAL INSPECTION
Complete a thorough visual inspection of the entire engine-genera-
tor monthly. Look for obvious damage, loose, missing or corroded
nuts, bolts and other fasteners. Look for fuel, oil or coolant leaks.
INSPECT EXHAUST SYSTEM
Inspect the exhaust system at least once every year. Check all
exhaust system pipes, mufflers, clamps, etc. for condition, tight-
ness, leaks, security, damage.
CHANGING THE ENGINE AIR FILTER
To replace the engine air filter, remove the air filter cover and
replace the air filter making sure it is positioned properly before
reattaching the cover (Figure 10.3).
See the Service Schedule for air filter maintenance.
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Maintenance
nBattery electrolyte fluid is an extremely cor-
rosive sulfuric acid solution that can cause
Figure 10.3 – Engine Air Filter
severe burns. Do not permit fluid to contact
eyes, skin, clothing, painted surfaces, etc.
Wear protective goggles, protective clothing
and gloves when handling a battery. If fluid
is spilled, flush the affected area immediate-
ly with clear water.
Air Filter
Do not use any jumper cables or booster
battery to crank and start the generator
engine. If the battery has completely dis-
charged, remove it from the generator for
recharging.
n
Be sure the AUTO/OFF/MANUAL switch is
set to the OFF position, before connecting
the battery cables. If the switch is set to
AUTO or MANUAL, the generator can crank
and start as soon as the battery cables are
connected.
n
Be sure the 120VAC power supply to the bat-
tery is turned OFF, or sparking may occur at
the battery posts as the cables are attached
and cause an explosion.
SPARK PLUGS
Reset the spark plug gap or replace the spark plugs as neces-
sary.
1. Clean the area around the base of the spark plugs to keep dirt
and debris out of the engine. Clean by scraping or washing
using a wire brush and commercial solvent. Do not blast the
spark plugs to clean.
2. Remove the spark plugs and check the condition. Replace
the spark plugs if worn or if reuse is questionable. See the
“Service Schedule” section for recommended inspection.
3. Check the spark plug gap using a wire feeler gauge. See the
Specifications section for the required spark plug gap.
BATTERY REPLACEMENT
NOTE:
Unit DOES NOT include battery.
When supplying or replacing the battery, the recommended num-
ber and type of battery is listed in the Specifications Section.
NOTE:
The BCI number should be located directly on the battery.
BATTERY MAINTENANCE
The battery should be inspected per the Service Schedule section.
The following procedure should be followed for inspection:
BATTERY FLUID
Check battery electrolyte fluid based on the Service Schedule.
Fluid should cover separators in all battery cells. If fluid level is
low, add distilled water to cover tops of separators. DO NOT USE
TAP WATER IN BATTERY.
1. Inspect the battery posts and cables for tightness and corro-
sion. Tighten and clean as necessary.
2. Check the battery fluid level of unsealed batteries and, if
necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP
WATER IN BATTERIES.
CLEANING THE STATIONARY EMERGENCY GENERATOR
Keep the generator as clean and as dry as possible. Dirt and
moisture that accumulates on internal generator windings have an
adverse effect on insulation resistance.
3. Have the state of charge and condition checked. This should
be done with an automotive-type battery hydrometer.
Periodically clean generator exterior surfaces. A soft brush may be
used to loosen caked on dirt. Use a vacuum system or dry, low
pressure air to remove any accumulations of dirt. The generator is
housed inside an all-weather enclosure, clean the enclosure with a
soft, damp cloth or sponge and water.
Storage batteries give off explosive hydrogen
gas. This gas can form an explosive mixture
around the battery for several hours after
charging. The slightest spark can ignite the
gas and cause an explosion. Such an explo-
sion can shatter the battery and cause blind-
ness or other injury. Any area that houses a
storage battery must be properly ventilated.
Do not allow smoking, open flame, sparks or
any spark producing tools or equipment near
the battery.
Once each year have the generator cleaned and inspected by a
Service Dealer. That dealer will use dry, low pressure air to clean
internal windings.
Finally, have the insulation resistance of stator and rotor windings
checked. If insulation resistances are excessively low, the genera-
tor may require drying.
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Service Schedule
SERVICE SCHEDULE
System / Component
Frequency
Procedure
Weekly - W
Monthly - M
Yearly - Y
Inspect
Change
Clean
Fuel
Fuel Lines & Connections
Lubrication
M
X
Oil Level
M
Y
X*
Oil
X**
X**
Oil Filter
Y
Cooling
Engine Coolant Lines & Connections
Engine Coolant Level
Engine Coolant
M
M
Y
X
X
X
Enclosure Louvers
Engine
W
X
X
Air Cleaner
Y
Y
X
X
X***
X***
Spark Plugs
Battery
Remove Corrosion, Ensure Dryness
Clean & Tighten Battery Terminals
Check Charge State
Check Electrolyte Level
General Condition
Vibration, Noise, Leakage, Temperature
Generator System
Complete Tune-up and System Inspection
Footnotes
M
M
M
M
X
X
X
X
X
X
X***
X***
M
Y
X
To be completed by an Authorized Service Dealer.
* Inspect the oil level monthly or every 12 hours during continuous operation.
** Change oil and oil filter after the first 30 hours of operation and then every 100 hours or annually thereafter, whichever occurs first.
Change sooner when operating under heavy load or in a dusty or dirty environment or in high ambient temperatures.
*** Replace as necessary.
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Troubleshooting
TROUBLESHOOTING GUIDE
PROBLEM
Engine won’t crank.
CAUSE
CORRECTION
1. Control panel 7.5 amp fuse blown.
2. Loose or corroded or defective
battery cables.
1. Replace fuse.*
2. Tighten, clean or replace
battery cables as necessary.*
3. Replace contactor.*
4. Replace starter motor.*
5. Remove, change or replace battery.*
3. Defective starter contactor.
4. Defective starter motor.
5. Dead or Defective Battery.
Engine cranks but won't start.
Engine starts hard, runs rough.
1. Out of fuel.
2. Fuel solenoid (FS) is defective
3. Spark plugs defective.
1. Replenish fuel/turn on fuel valve.
2. Replace solenoid.*
3. Clean, regap or replace plugs.
1. Air cleaner plugged or damaged.
2. Defective spark plugs.
3. Fuel pressure incorrect.
1. Clean or replace as needed.
2. Clean, regap or replace plugs.
3. Confirm fuel pressure to regulator is as
recommended in SPECIFICATIONS.*
4. Confirm fuel pressure to regualtor is as
recommended in SPECIFICATIONS.*
5. Reconfigure the fuel system. (See
RECONFIGURING THE FUEL SYSTEM in
manual.*
4. Insufficient fuel supply.
5. Fuel system set to wrong fuel type.
Engine starts then shuts down.
1. Engine oil level is low.
2. Engine is overheated.
3. Defective Low Oil Pressure Switch
4. Defective Coolant Temperature Switch
5. Defective Control Module circuit board.
6. Coolant Level is Low.
1. Check oil and add oil as needed.
2. Check cooling system for leaks.
3. Replace switch.*
4. Replace switch.*
5. Replace board.*
6. Repair leak - Add coolant.
7. Replace Switch.*
7. Defective Low Coolant Level Switch
AUTO/OFF/MANUAL Switch at OFF, 1. Defective AUTO/OFF/MANUAL switch
1. Replace board.*
2. Replace board.*
engine continues to run.
2. Defective Control Module circuit board
No AC output from generator.
1. Main line circuit breaker is tripped/open.
2. Generator internal failure.
1. Reset to ON/CLOSED.
2. *
3. Thermal circuit breaker open.
3. Auto-reset - Wait 5 min. and attempt restart.
*Contact the nearest Dealer for assistance.
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United States Environmental Protection Agency Warranty Statement
(Stationary Emergency Spark-Ignited Generators)
Warranty Rights, Obligations and Coverage
The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission
Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system or compo-
nent on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diagnosis, replace-
ment parts and labor provided it be done by a Generac Authorized Warranty Service Facility. Your emission control system may include parts
such as the fuel metering, ignition, and exhaust systems and other related emission related components listed below. Generac will warrant
the emissions control systems on your 2009 and later model year engines provided there has been no abuse, neglect, unapproved modifica-
tion, or improper maintenance of your engine. For engines less than 130 HP the warranty period is two years from the date of sale to the ulti-
mate purchaser. For engines greater than or equal to 130 HP the warranty period is three years or 2500 hours of operation, whichever
comes first, from the date of the engine being placed into service. For high-cost warranted components, the Emission Control System war-
ranty is valid for 5 years or 3500 hours of operation, whichever comes first.
Purchaser's/Owner's Warranty Responsibilities
As the engine purchaser/owner you are responsible for the following: 1) The engine must be installed and configured in accordance to Gen-
erac's installation specifications. 2) The completion of all maintenance requirements listed in your Owner's Manual. 3) Any engine setting
adjustment must be done in accordance and consistent with the instructions in the Owner's Manual. 4) Any emission control system or com-
ponent must be maintained and operated appropriately in order to ensure proper operation of the engine and control system to minimize
emissions at all times.
Generac may deny any/or all Emission Control System Warranty coverage or responsibility of the engine, or an emission control system or
component on your engine thereof, if it has failed due to abuse, neglect, unapproved modification or improper maintenance, or the use of
counterfeit and/or “gray market” parts not made, supplied or approved by Generac. Warranty service can be arranged by contacting either
your selling dealer or a Generac Authorized Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. The purchaser/owner shall
be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the inspection or
repair facilities. The purchaser/owner shall be responsible for any and/or all damages or losses incurred while the engine is being trans-
ported/shipped for inspection or warranty repairs. Contact Generac Power Systems Inc. for additional Emission Control System Warranty
related information, Generac Power Systems, Inc., PO. Box 8, Waukesha, WI 53187, or call 1-800-333-1322 or www.generac.com.
Important Note
This warranty statement explains your rights and obligations under the Emission Control System Warranty, which is provided to you by Gen-
erac pursuant to federal law. Note that this warranty shall not apply to any incidental, consequential, or indirect damages caused by defects
in materials or workmanship or any delay in repair or replacement of the defective part(s). This warranty is in place of all other warranties,
expressed or implied. Specifically, Generac makes no other warranties as to the merchantability or fitness for a particular purpose. Any
implied warranties which are allowed by law, shall be limited in duration to the terms of the express warranty provided herein. Some states
do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
Emission Related Parts Include the Following (if so equipped)
1) Fuel Metering System
3) Ignition System Including A) Spark Plug, B) Ignition Module,
C) Ignition Coil, D) Spark Plug Wires
1.1) Gasoline Carburetor Assembly and Internal Components
A) Fuel Filter, B) Carburetor, C) Fuel Pump
4) Exhaust System
A) Catalyst Assembly*, B) Exhaust Manifold, C) Muffler,
D) Exhaust Pipe, E) Muffler Gasket
1.2) Carburetion Assembly and Its Components
A) Fuel Controller, B) Carburetor and Its Gaskets,
C) Mixer and Its Gaskets, D) Primary Gas Regulator,
E) Liquid Vaporizer
5) Crankcase Breather Assembly Including
A) Breather Connection Tube, B) PCV Valve
1.3) Fuel Regulator
6) Oxygen Sensor
2) Air Induction System Including A) Intake Pipe/Manifold,
B) Air Cleaner
7) Diagnostic Emission-Control System
*High-Cost Warranted Component
EmsnWrnty001
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United States Environmental Protection Agency Compliance Requirements
(Stationary Emergency Spark-Ignited Generators)
Purchaser's/Owner's Record Keeping Responsibilities
The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain your record
keeping requirements for compliance with Subpart JJJJ- Standards of Performance for Stationary Spark Ignition Internal Combustion
Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60. As the engine purchaser/owner who operates and maintains
their certified emergency stationary engine and emission control system according to applicable emission related guidelines as specified in
this Owner's Manual, you are required to meet the following notification and record keeping requirements to demonstrate compliance: 1)
Maintain documentation that the engine is certified to meet emission standards. 2) Record keeping of maintenance conducted. 3) Record
keeping of the provision allowing natural gas engines to operate using propane for a maximum of 100 hours per year as an alternate fuel
solely during emergency operations provided the engine is not certified to operate on propane. 4) Meet all compliance notifications submitted
to the purchaser/owner and maintain all supporting documentation. 5) Record keeping of hours of operation, including what classified the
operation as emergency and how many hours are spent for non-emergency operation. For emergency engines greater than or equal to 130
HP, record keeping of hours of operation begins January 1, 2011. For emergency engines less than 130 HP, record keeping of hours of oper-
ation begins January 1, 2009; engines are equipped with non-resettable hour meters to facilitate record keeping.
Specific Air Quality Management or Air Pollution Control Districts may have different and additional record keeping/reporting requirements.
Your permit to construct and/or operate the engine may be contingent upon compliance with those requirements. Check with your local Air
Quality Management or Air Pollution Control District for specific requirements.
Emergency stationary internal combustion engines (ICE) may be operated for the purpose of maintenance checks and readiness testing,
provided that the tests are recommended by Federal, State or local government, Generac, or the insurance company associated with the
engine. Maintenance checks and readiness testing of such units is limited to 100 hours per year. There is no time limit on the use of emer-
gency stationary ICE in emergency situations. The purchaser/owner may petition the Administrator for approval of additional hours to be
used for maintenance checks and readiness testing, but a petition is not required if the owner maintains records indicating that Federal,
State, or local standards require maintenance and testing of emergency ICE beyond 100 hours per year. Emergency stationary ICE may
operate up to 50 hours per year in non emergency situations, but those 50 hours are counted towards the 100 hours per year provided for
maintenance and testing.
The 50 hours per year for non-emergency situations cannot be used for peak shaving or to generate income for a facility to supply power to
an electric grid or otherwise supply power as part of a financial arrangement with another entity. For purchaser/owner of emergency engines,
any operation other than emergency operation, maintenance and testing, and operation in non-emergency situations for 50 hours per year,
as permitted in this section is prohibited.
If you operate and maintain your certified emergency stationary SI internal combustion engine and emissions control systems in accordance
to the specifications and guidelines in this Owner’s Manual, EPA will not require engine performance testing. If not, your engine will be con-
sidered non-certified and you must demonstrate compliance according to Subpart JJJJ - Standards of Performance for Stationary Spark Igni-
tion Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60.
Emission-Related Installation Instructions
Your certified emergency stationary engine has pre-set emission control systems or components that require no adjustment. Inspection and
replacement of an emissions related component is required to be done so in accordance with the requirements cited in the United States
Environmental Protection Agency Warranty Statement or can be arranged by contacting either your selling dealer or a Generac Authorized
Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. Failing to follow these instructions when installing a certified engine in a
piece of non-road equipment violates federal law 40 CFR 1068.105 (b), subject to fines or penalties as described in the Clean Air Act.
EmsnWrnty001
Revision F (04/15)
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Notes
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EXPLODED VIEW: EV CPL ALTERNATOR BRUSHLESS
DRAWING #: 0F5924
GROUP A
ITEM
PART#
QTY.
DESCRIPTION
1
0F3182
0F6194
0F3183
0F6195
0F6203
068405C
087272
072878
0C9708
0F3726B
0C2454
023454
0F8408
046526
0A2601
072879
092950
04576100CJ
052646
043123
051779
022392
052259
051769
0E7230
0C2428
022155
077043F
020151
023365
033133
033143
086032
090063
090064
090152
022661L
028739A
085662D
068113
068406
023484K
023484N
052624
0F3518
0F3517
0F3519
0F3520
1
1
1
1
1
1
1
1
REF
1
10
1
4
4
1
1
1
4
4
4
4
2
2
3
3
2
2
1
1
3
1
2
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
ROTOR 390 70AB3 CPL
RTR 390 70KB3 CPL
STATOR 390 70AB3 CPL
STR 390 70KB3 CPL
2
STR 390 70GB3 CPL
3
4
5
6
7
EXITER FIELD 2" LG SPD CONN
ASSY EXCITER 2.00" STK
KEY SQ 3/8 X 3-1/4 STEEL
INSTR HYPOT TEST (NOT SHOWN)
ASSY FLYWHEEL CPL
SCREW THF M6-1 X 16 N WA Z/JS
KEY WOODRUFF #E
SCREW HHC M10-1.50 X 16 G10.9
WASHER LOCK M10
SCREW HHC M16-2.0 X 45 G8.8
SPACER .69 X 2.75 X .37 ST/ZNC
COLLAR SLIP FIT 390 MM
STUD M14-2.0 X 650 G5 ZINC
WASHER FLAT M14
WASHER LOCK M14
NUT HEX M14-2.0 G8 YEL CHR
PIN DOWEL 1/2 X 1-1/4
WASHER FLAT M12
WASHER LOCK M12
8
9
10
11
12
13
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
50 *
51
52
53
54
SCREW HHC M12-1.75 X 80 G10.9
SCREW PHTT #6-32 X 1/2 ZYC
WASHER LOCK #6
CONDUIT FLEX 1.25” ID
CLAMP VINYL .312 X .203 Z
WASHER SHAKEPROOF INT #8
SCREW HHM #8-32 X 3/8
SCREW HHM #8-32 X 7/8
LUG RT-ANG #10/10-12
BRIDGE SUPPORT DIODE 15"
CAP END ROTOR 390MM
ASSY BRIDGE RECTIFIER
SLEEVING UL #0 .330 ID (3” LG)
TIE WRAP UL 3.9" X .10" BLK
TIE WRAP UL 17.7 X .35 BLK HT
REAR BEARING CARRIER
SCREW HHC M12-1.75 X 60 G10.9
BUSHING SNAP SB-1750-22
BUSHING SNAP SB-2.5-31
BEARING BALL 6212 SEALED
SIDE LH EXCITER SHIELD
SIDE RH EXCITER SHIELD
BOTTOM EXCITER SHIELD
REAR COVER EXCITER SHLD
* ROTOR REPLACEMENT PARTS.
** PARTS INCLUDED WITH CURRENT TRANSFORMER.
(CURRENT TRANSFORMER AND HARDWARE NOT USED WITH NEXUS CONTROL PANEL)
REVISION: K-1254-L
DATE: 2/9/15
Page 2 of 2
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EXPLODED VIEW: EV CONBOX C3 NEXUS
DRAWING #: 0H9747
APPLICABLE TO:
GROUP A
ITEM
PART#
QTY.
DESCRIPTION
1
2
(2)3
(2)4
5
0H9742
0H6265
0F5376S0AR
0F5396S0AR
0H6169D
0H6267
057073
1
1
1
1
1
BACK PANEL CONBOX SUPPORT C3
TOP PANEL CONNBOX SUPPORT C2
MX150L SLRRMNT 22-18 8P W/O GA
MX150L SLRRMNT 22-18 12P W/OGA
ASSY PROG 2010 IGN MOD 10CYL
COVER VOLTAGE SHIELD
6
7
1
2
JUNCTION BLOCK 3/8-16
(3)8
9
(2)10
(2)11
(1)12
13
14
15
16
0A7822
0H6160
0D7393T
0D7393U
0H67330ST0R
0D3700
0A2115
022473
REF
1
2
2
1
6
2
12
2
LUG SLDLSS 600/250-1/0X1/4-28
COVER WIRE ENTRY CONNBOX
TERM BLOCK 3P UL 12-20AWG
TERM BLOCK 4P UL 12-20AWG
BRACKET GIMBAL CONTROL PNL
NUT FLANGE M6-1.0 NYLOK
WASHER NYLON .257
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
022097
17
18
(1)19
20
21
0H7115
REF
0H81040AS0R
045764
2
1
1
2
12
4
KNOB M6-1.0 CONTROL PANEL
ASSY CTRL PROGRAMMED
COVER DPE BREAKER NEXUS RAW
SCREW HHTT M4-0.7 X 8 ZP
SCREW HWHT M6-1 X 16 N WA Z/JS
WASHER FLAT #10 ZINC
0C2454
023897
22
23
036943
2
SCREW PPHM #10-32 X 2
24
25
0D7177V
051713
2
6
DIODE BRIDGE 1P 35A 1000V
WASHER FLAT M5
26
049226
6
WASHER LOCK M5
27
28
29
051716
056326
022237
6
1
2
NUT HEX M5-0.8 G8 CLEAR ZINC
TRIM VINYL BLACK 1/8GP ( “LG)
WASHER LOCK 3/8
30
022241
2
NUT HEX 3/8-16 STEEL
31
32
33
34
35
36
37
0H8006
0D3580
025507
061383
022131
1
4
2
1
2
1
1
DECAL CAUTION ELEC SHOCK SM
SCREW SHC M5-0.8 X 20 C12.9
WASHER LOCK EXT 7/16 STL
LUG SLDLSS 3/0-#4 X 13/32 CU
WASHER FLAT 3/8-M10 ZINC
SCREW HHC M10-1.5 X 25 C8.8
TAPE ELEC 1/2 FOAM
049814
029289
38
046526
1
WASHER LOCK M10
39
40
41
42
43
44
045772
056739
042568
0F5458
0D6029
052857
1
1
2
12
4
NUT HEX M10-1.5 G8 YEL CHR
RELAY SOLENOID 12VDC PNL MNT
SCREW HHC M6-1.0 X 20 C8.8
SCREW HHSP #10 X 3/8 HI-LOW
SCREW HHTT M6-1.0 X 16 ZYC
NUT TOP LOCK FL M6-1.0
4
45
022152
2
WASHER LOCK #10
46
022158
2
NUT HEX #10-32 STEEL
47
48
(1)49
50
51
0H7292
0H7293
0H97300ST0R
0J0489
1
1
1
1
1
3
DECAL CUSTOMER CONTROL CONNECT
DECAL CONBOX TB1 CONNECTIONS
SHIELD HIGH/LOW C5
DECAL CU STOMER POWER CONNECT
CB 4.5A 1P AUTO 30KW CNT45K
WASHER FLAT M3
048476
052777
52
53
043182
3
WASHER LOCK M3
54
051714
045335
083896
0D5466
039287
067989
0D7178T
0J1618
3
NUT HEX M3-0.5 G8 CLEAR ZINC
SCREW HHC 1/4-28 X 3/4 G5
WASHER LOCK 1/4-M6 SS
BUSBAR NEUTRAL BLOCK 390
SCREW HHC M8-1.25 X 45 C8.8
NUT HEX FL WHIZ M8-1.25
FUSE ATO TYPE 7.5AMP (BROWN)
HARN EXCITATION NEXUS C3/C5(NOT SHOWN)
RES WW 25R 5% 25W QK CONN
(3)55
(3)56
(3)57
(3)58
(3)59
60
REF
REF
REF
REF
REF
REF
1
61
62
0F5752B
1
REVISION: K-3487-H
DATE: 8/4/15
Page 3 of 6
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EXPLODED VIEW: EV CONBOX C3 NEXUS
DRAWING #: 0H9747
APPLICABLE TO:
GROUP A
ITEM
PART#
QTY.
DESCRIPTION
63
64
65
0J3060
0A9457
067210A
1
1
1
GASKET WIRE ENTRY COVER
DECAL NEUTRAL
DECAL GROUND LUG
UL CIRCUIT BREAKER (225AF)
A
B
C
D
E
F
G
H
J
0H9750
1
1
REF
1
1
3
6
3
3
9
3
6
4
12
4
4
4
4
1
COVER CB G 225AF C3
0F4186
0F4148
0F8432
0H7311
058306
022145
0F8451
0F8843
022129
045771
049897
053640
0C2454
036261
038150
022264
022471
0G3259
COVER CB DISH 3P G 225AF
CB 0125A 3P 480V G 225AF
INSUL CB 225AF
STANDOFF CB BOX CONBOX
SCREW SHC M8-1.25 X 25 C12.9
WASHER FLAT 5/16-M8 ZINC
LUG SLDLSS 300 MCM-6 AL/CU
BUS BAR 200A LUG ADAPTOR
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 CLEAR ZINC
SCREW SHC M8-1.25 X 20 G8
SCREW RHM #8-32 X 3-1/4
SCREW HWHT M6-1 X 16 N WA Z/JS
RIVET POP .125 X .275 SS
WASHER FLAT #8 ZINC
K
L
M
N
P
R
S
T
WASHER LOCK #8-M4
NUT HEX #8-32 STEEL
DECAL TERMINAL SHOCK HZD BI
U
V
UL CIRCUIT BREAKER (400AF)
A
B
C
0H9751
1
8
REF
REF
1
3
6
6
6
4
4
4
4
3
3
4
1
COVER CB G 400AF C3
0C2454
0F4153
0F4154
0H9270
0A7822
022473
022097
023334
042419
023897
022152
022158
052647
046526
036261
0G3259
SCREW HWHT M6-1 X 16 N WA Z/JS
CB 0250A 3P 480V G 400AF
CB 0300A 3P 480V G 400AF
COVER CB DISH G 400AF C5
LUG SLDLSS 600/250-1/0X1/4-28
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
SCREW HHC 1/4-28 X 1/2 G5
SCREW RHM 10-32 X 4
WASHER FLAT #10 ZINC
WASHER LOCK #10
NUT HEX #10-32 STEEL
SCREW SHC M10-1.5 X 25 C12.9
WASHER LOCK M10
RIVET POP .125 X .275 SS
DECAL TERMINAL SHOCK HZD BI
D
E
F
G
H
J
K
L
M
N
P
R
S
UL CIRCUIT BREAKER (KG-JG EATON)
A
B
C
0H9757
REF
REF
REF
REF
REF
REF
1
4
4
12
3
COVER CB E KG C3
COVER CB E JG C3
CB 0250 3P 600V E JG LL
CB 0300 3P 600V E KG LL
INSULATOR CB E 3P KG
0H9755
0H5580
0H5582
0H5581A
0H5576A
0H6734
0D2157
0D3700
0C2454
049897
022129
022145
INSULATOR CB E 3P JG
D
E
F
G
H
J
STANDOFF CB MOUNT CONBOX
SCREW SHC M6-1.0 X 50 C8.8
NUT FLANGE M6-1.0 NYLOK
SCREW HWHT M6-1 X 16 N WA Z/JS
SCREW SHC M8-1.25 X 20 G8
WASHER LOCK M8-5/16
3
3
K
WASHER FLAT 5/16-M8 ZINC
REVISION: K-3487-H
DATE: 8/4/15
Page 4 of 6
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EXPLODED VIEW: EV CONBOX C3 NEXUS
DRAWING #: 0H9747
APPLICABLE TO:
GROUP A
ITEM
PART#
QTY.
DESCRIPTION
UL CIRCUIT BRAEAKER (FG)
A
B
C
D
E
F
G
H
J
K
L
M
N
P
0H9758
0F4186
0H5491
1
1
REF
1
1
3
3
3
4
4
4
4
4
COVER CB E FG C3
COVER CB DISH 3P G 225AF
CB 0125 3P 600V E FG LL
INSULATOR CB 3P E TYPE CC/FG
STANDOFF CB BOX CONBOX
SCREW HHC M5-0.8 X 20 G8.8
WASHER LOCK M5
WASHER FLAT #10 ZINC
RIVET POP .125 X .275 SS
SCREW PPHM #8-32 X 1-3/4 ZINC
WASHER FLAT #8 ZINC
0H4698A
0H7311
052619
049226
023897
036261
0H5721
038150
022264
022471
0C2454
WASHER LOCK #8-M4
NUT HEX #8-32 STEEL
SCREW HWHT M6-1 X 16 N WA Z/JS
12
UL CIRCUIT BREAKER (ED)
A
B
C
D
E
F
G
H
J
0H9752
0D9693
0F0492
0H6734
048927
023897
022152
022158
0C2454
0A8278
022097
0D5621
1
REF
1
1
4
4
4
4
12
3
COVER CB S ED C3
CB 0125A 3P 480V S ED4 LL
INSULATOR CB S(ED-3P)
STANDOFF CB MOUNT CONBOX
SCREW RHM #10-32 X 4-1/2
WASHER FLAT #10 ZINC
WASHER LOCK #10
NUT HEX #10-32 STEEL
SCREW HWHT M6-1 X 16 N WA Z/JS
SCREW SHC 1/4-28 X 3/4 G8.8 NZ
WASHER LOCK M6-1/4
K
L
M
3
3
WASHER-STEP 1/2ODX9/32ID BRASS
UL CIRCUIT BREAKER (VL-JG)
A
B
C
D
E
F
G
H
J
0H9754
1
REF
1
4
3
3
3
4
4
COVER CB S VL C3
0H7519
0H6734
042419
040976
022129
022145
023897
022152
022158
0C2454
CB 0300A 3P 600V S JG-VL LL
STANDOFF CB MOUNT CONBOX
SCREW RHM 10-32 X 4
SCREW SHC M8-1.25 X 20 C12.9
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
WASHER FLAT #10 ZINC
WASHER LOCK #10
K
L
4
12
NUT HEX #10-32 STEEL
SCREW HWHT M6-1 X 16 N WA Z/JS
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).
(2) INCLUDED WITH HARNESS P/N 0H6692.
(3) INCLUDED WITH NEUTRAL BLOCK P/N 0D5464B.
REVISION: K-3487-H
DATE: 8/4/15
Page 5 of 6
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EXPLODED VIEW: EV CONBOX C3 NEXUS
DRAWING #: 0H9747
APPLICABLE TO:
GROUP A
THIS PAGE LEFT INTENTIONALLY BLANK
REVISION: K-3487-H
DATE: 8/4/15
Page 6 of 6
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
0F3408
0F3411
058208
022131
050331A
050331
038805T
038804Y
045771
022129
027482
075763
0C2454
0F3409
1
1
1
1
1
1
1
1
1
1
1
1
8
1
TRAY BATTERY
STRAP BATTERY RETAINMENT
BATT 12VDC 24F 625
WASHER FLAT 3/8-M10 ZINC
BATT POST COVER RED +
BATT POST COVER BLK -
CABLE BATT BLK #1 X 40.00
CABLE BATT RED #1 X 35.00
NUT HEX M8-1.25 G8 YEL CHR
WASHER LOCK M8-5/16
WASHER SHAKEPROOF EXT 5/16 STL
BOOT BATTERY CABLE
SCREW THF M6-1X16 N WA Z/JS
SUPPORT BATTERY TRAY
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EXPLODED VIEW: EV MTG BASE C3 5.4L 55KW
DRAWING #: 0H5677
GROUP C
ITEM
PART#
QTY.
DESCRIPTION
(2)1
2
3
0L0574BST0R
065852
1
1
4
MTG BASE C5 5.4/55KW 6.8/70KW
SPRING CLIP HOLDER .37-.62
DAMPENER VIBRATION
052252
4
5
052257
052259
4
4
SPACER .49 X .62 X 1.87 PWDR/ZINC
WASHER FLAT M12
6
7
8
055597
052251A
052860
4
4
4
SCREW HHC M12-1.75 X 85 G8.8
DAMPENER VIBRATION 50 WHITE
NUT LOCKING M12-1.75
(1)9
10
11
12
13
16
(1)17
(1)18
19
20
21
22
23
24
(2)25
26
27
0L06890ST0R
045764
1
1
7
1
1
1
7 / 8
7 / 8
1
1
2
1
2
2
1
1
1
ENGINE SUPPORT 6.8L RH
SCREW HHTT M4-0.7 X 8 BP
SCREW HHC M10-1.5 X 60 C8.8
LUG SOLDERLESS 3/0-#4 X 13/32 CU
SCREW HHC M8-1.25 X 25 G8.8
5.4L RH ENGINE MOUNT SPACER
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
052243
061383
043107
0L01390ST0R
022131
046526
0536210410
ASSY WIRE 14.00”
042909
022261
022129
022145
SCREW HHC M8-1.25 X 30 G8.8
WASHER SHAKEPROOF INT 3/8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
NUT HEX M8-1.25 G8 YEL CHR
ENGINE MOUNT 6.8L LH SIDE (5.4L ONLY)
SCREW HHC M10-1.5 X 70 C8.8
SPACER .41 X .75 X 1.68 ST/ZNC
045771
0L01480ST0R
051735
0L0123
NOTES (UNLESS OTHERWISE SPECIFIED):
(1) QTY. REQ. FOR 5.4L / QTY. REQ. FOR 6.8L
(2) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
•
•
MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO XA BOM.
CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR
CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
REVISION: K-2274-C
DATE: 3/17/15
Page 2 of 2
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EXPLODED VIEW: EV ENGCOMPRT R/H 6.8 (CPL)
DRAWING #: 0F3058
GROUP D
ITEM
PART#
QTY.
DESCRIPTION
1
2
3
0D5623
0D5418
022131
0F3514
022473
0F2776A
029333A
057772
0F2929
0F9965C
0F9965C
0D5417
057823
057765
049340
069860E
042909
022129
0D9913
047290
022097
055596
077996
0C7649
047411
0G0321
0D3808
0D4255
070010
0D2244M
0F3844
052647
046526
039253
070008
070006
0D2608
0F5114
0F5454
0F6104
048031P
048031J
0G1462
2
1
1
HEAT SHIELD EXHAUST
STARTER MOTOR FORD V-10 ENGINE
WASHER FLAT 3/8-M10 ZINC
SPACER FLEXPLATE 5.4L/6.8L (1800 RPM UNITS ONLY)
WASHER FLAT 1/4-M6 ZINC
BRACKET SIGNAL CONDITIONER
TIE WRAP UL 7.4" X .19" BLK (NOT SHOWN)
WASHER NYLON .565
4
1
(3) 5
(3) 6
(1) 7
8
9
10
1 / 2
A/R
1
1
1
1
2
REF.
1
1
1
1
3
4
18
1
1
1
1
1
1
1
2
2
2
1
8
6
6
1
10
30
10
1
ENGINE ADAPTER 5.4L/6.8L
FLEX PLATE 2 POLE (1800 RPM UNITS ONLY)
FLEX PLATE 2 POLE (3600 RPM UNITS ONLY)
SCREW HHC M10-1.0 X 25 G10.9
CLAMP HOSE #10 .56 - 1.06 (1800 RPM UNITS ONLY)
ADAPTER M14-1.50 X 3/8 NPT
BARBED EL 90 1/4NPT X 3/8
HOSE DRAIN ASSY 28"
SCREW HHC M8-1.25 X 30 G8.8
WASHER LOCK M8-5/16
SCREW SHC M8-1.25 X 35 SS
HOSE 3/8 ID SINGLE BRAID
(2) 11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
40
43
44
45
WASHER LOCK M6-1/4
BARBED STR 3/8 NPT X 3/8
CAP HOSE (1800 RPM UNITS ONLY)
CLAMP HOSE .38-.87
SCREW HHC M6-1.0 X 16 G8.8
HOSE COOL 5/8" ID 250#WP (14”)
EXH MANIFOLD MACH 6.8L V-10
GASKET EXHAUST MANIFOLD
SCREW HHC M8-1.25 X 35 SS G8.8
ASSY MAGPICKUP (3/8-24 MALE)
WASHER FLAT .43 X 1.00
SCREW SHC M10-1.5 X 25 G12.9
WASHER LOCK M10
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT M8 SS
WASHER LOCK M8 SSTL
SCREW HHC 5/16-18 X 1/2 SSTL
DECAL REFER TO OWNERS MANUAL
PLATE MAG PICK-UP ADAPTOR
COVER STARTER 5.4 & 6.8 FORD CPL
CLAMP HOSE BAND .88"
CLAMP HOSE BAND .63
HOSE BARB REDUCER 5/8"-3/8"ID
1
1
2
1
1
(1) NOTE: I/N 7 IS FOR HOLDING SENSORS TO I/N 6.
(2) NOTE: I/N 11 IS PART OF ENGINE P/N 0D3454.
(3) QTY. REQ. FOR NON-MQT / QTY REQ. FOR MQT EPA CERT. (NOT REQUIRED
FOR NEXUS CONTROL PANELS)
REVISION: J-4243-L
DATE: 2/19/13
Page 2 of 2
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EXPLODED VIEW: EV AIR CLEANER
DRAWING #: 0F3569
GROUP D
ITEM
PART#
QTY.
DESCRIPTION
1
0D2513D
0D2513E
0F5419
0F4268
0F4270A
0F6977
037561
047411
022097
057795B
0F4269
022473
0A4256
0G5954
1
1
1
1
1
1
1
4
4
1
1
3
1
1
AIR CLNR BTM PLT W/CPLR 8.1L
PLATE AIR CLEANER W/COUPLER
ELEMENT AIR FILTER
2
3
4
5
6
7
8
9
10
11
12
13
TOP PLATE VENTURI
HOLD DOWN AIR CLEANER PLATED
PLATE AIR CLEAN TOP 5.4L/6.8L
NUT WING 1/4-20 NYLK
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
BARBED EL 90 5/8 PLASTIC
GASKET MIXER BODY
WASHER FLAT 1/4-M6 ZINC
INDICATOR FILTER MINDER (USE WITH ITEM #1 P/N 0D2513E)
GROMMET .625 X 1.25 X .433
REVISION: J-9801-E
DATE: 9/19/14
Page 2 of 2
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EXPLODED VIEW: EV ENGINE COM PRT L/H SIDE 6.8L
DRAWING #: 0J0212
APPLICABLE TO:
GROUP D
ITEM
PART#
QTY.
DESCRIPTION
1
2
(2)3
(2)4
(1)5
6
0F3017
039253
022129
022145
0D5419
0D7055
0D3488G
0D3488J
0D3488
0D3488K
057795B
059057
0F3287
0H9133
0E9868A
0G5954
0F3216
0F3216A
0F3216C
0F3216D
035579
0H7435
0D6658
0H0777
022097
022473
042568
0D8027
0D8025
0D8026
0D8030
0F2846
0D8029
0D8028
045771
0H0923
022131
046526
064416
045772
0F3217
0F6151
0F4308
0F3158
057823
0E0502
0G0866
0F4301
0E8286
047527
057823
0E0992A
078637
047411
055934D
1
3
4/5
4/5
REF
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
6
6
2
4
1
3
1
1
1
1
1/2
1
2
1
1
1
1
1
1
1
2
1
1
1
1
1
4
BRACKET,D.C. ALTERNATOR LOWER
SCREW HHC M8-1.25 X 20 C8.8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
OIL FILTER
DIPSTICK TUBE, FORD 6.8L
BELT SERPENTINE (65.0" LG) (1800 RPM)
BELT SERPENTINE (65.3" LG) (2300 RPM)
BELT SERPENTINE (67.16" LG) (3000 RPM)
SERPENTINE BELT (68.3" LG) (3600 RPM)
BARBED EL 90 5/8 PLASTIC
HOSE 3/4 ID SAE-30R2 (16.75”LG)
BRACKET DC ALTERNATOR UPPER
HARN ENG G6.8L G3 NEXUS (USE WITH PROBE P/N 0H1827) (NOT SHOWN)
ALTERNATOR DC W/OUT PULLEY
GROMMET .625 X 1.25 X .433
PULLEY 80 OD DC ALTERNATOR (1800 RPM)
PULLEY 102 OD DC ALTERNATOR (2300 RPM)
PULLEY 132 OD DC ALTERNATOR (3000 RPM)
PULLEY 160 OD DC ALTERNATOR (3600 RPM)
BSHG RDCR HEX 1/4 TO 1/8
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
HARN LOW OIL PRESS SWITCH ASSY
DIPSTICK G6.8L G3
DECAL LSI EPA CERTIFICATION
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
SCREW HHC M6-1.0 X 20 G8.8
SCREW WP PULLEY M8-1.25 X 19
BOLT HEX FL HD M8-1.25 X 28
BOLT HEX FL HD M8-1.25 X 31
TENSIONER ENG. AUTOMATIC BELT
PULLEY WATER PUMP G3 (1800RPM UNITS)
PULLEY ENGINE WATER PUMP (2-POLE & GEAR BOX)
PULLEY GROOVED ENGINE IDLER
NUT HEX M8-1.25 G8 CLEAR ZINC
ENGINE G6.8L G3 V-10 (2009 +)
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
SCREW HHC M10-1.5 X 45 C8.8 FT
NUT HEX M10-1.5 G8 YEL CHR
SPACER DC ALTERNATOR PULLEY
CAP RUBBER
BRACKET DC ALT STABILIZER
OIL COOLER G3 (150KW 3600RPM)
CLAMP HOSE #10 .56-1.06
TEMPERATURE SENDER DELPHI
HOSE OIL COOLER PREFORMED 3/4 (150KW 3600RPM)
HOSE OIL COOLER (150KW 3600RPM)
ELBOW 45D STREET 1/2NPT BRASS (150KW 3600RPM)
BARBED STR 1/2NPT X 3/4 (150KW 3600RPM)
CLAMP HOSE #10 .56-1.06 (150KW 3600RPM)
PLUG EXPANSION 14 OD
27
(2)28
29
30
31
32
33
34
36
37
38
39
40
(2)41
(2)42
(2)43
(2)44
(2)45
46
10
A/R
4
47
48
(2)49
ADHESIVE LOCTITE 620
SCREW HHC M6-1.0 X 16 C8.8
CLAMP STL/VNL 1.06 X .406 Z
4/7
(1) I/N 5 PART OF I/N 29.
(2) PART OR QUANTITY REQUIRED FOR 150KW UNITS ONLY.
REVISION: K-3804-C
DATE: 9/3/15
Page 2 of 2
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EXPLODED VIEW: EV COOL PKG 6.8L C3
DRAWING #: 0J6324
GROUP D
ITEM
PART#
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
0F3144
035685
0F2857A
0F4168
0F4169
0J6180
0F2820
051756
046526
022131
052250
0F4412
039253
022129
022097
0C8566
0D3700
089685
0F5589
0C2454
055596
0C7649
069860E
045764
065852
080712
076749
048031C
069811
072252
085662
0E2507
022145
090283
077043J
029032
1
4
1
1
1
1
1
4
4
4
2
1
8
8
8
8
8
1
2
10
1
1
1
1
1
1
1
2
REF
1
8
1
8
1
WELDMENT RAD SUPPORT C3 (22")
CLAMP HOSE #28 1.32-2.25
RADIATOR 581 X 585 X 70 CPL LH
HOSE UPPER RADIATOR C3
HOSE LOWER RADIATOR C3
ADAPTOR, 6.8L FAN
FAN 22" DIA 10 BLADE
SCREW HHC M10-1.5 X 20 G8.8
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
TAPE FOAM 1 X 1 (23” LG)
SPACER FAN 6.8L
SCREW HHC M8-1.25 X 20 G8.8
WASHER LOCK M8-5/16
10
11
12
13
14
17
18
19
20
21
22
23
24
25
26
27
28
29
30
(1)31
32
33
34
35
36
37
38
WASHER LOCK M6-1/4
SCREW HHFC M6-1.0 X 20 G8.8
NUT FLANGE M6-1.0 NYLOK
GROMMET .75 X .12 X .50
GUARD FAN C3 CPL
SCREW THF M6-1 X 16 N WA Z/JS
BARBED STR 3/8 NPT X 3/8
CLAMP HOSE .38-.87
HOSE DRAIN ASSY 28"
SCREW HHTT M4-0.7 X 8 BP
SPRING CLIP HOLDER .37-.62
BRKT COOLANT RECOVERY TANK
TANK COOLANT RECOVERY
CLAMP HOSE BAND 1/4
CAP HEX 1/4 NPT BRASS
GROMMET 1.37 X .06 X 1.00
TIE WRAP UL 14.6 X .14 BLK
PROBE COOLANT LEVEL 3/8NPTF (USE WITH HARN P/N 0F5990 & 0F5991)
WASHER FLAT 5/16-M8 ZINC
CAP RADIATOR 13 PSI
CONDUIT FLEX 2.0"ID
HOSE 9/32 ID (41”LG)
1
1
NOTES (UNLESS OTHERWISE SPECIFIED):
(1)ITEM 31 IS INCLUDED WITH ITEM 25.
(2) FASTEN HOSE TO FAN GUARD USING 3 TIE WRAPS I/N 33. DIRECT HOSE TOWARD BASE OF UNIT
AND AWAY FROM EXHAUST COMPONENTS.
REVISION: K-1082-B
DATE: 11/12/14
Page 2 of 2
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EXPLODED VIEW: EV EXHUAST CPL 7OKW C3
DRAWING #: 0J6343
APPLICABLE TO:
GROUP D
ITEM
PART#
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
0J6177
0J6179
0F2808B
0A6765
0F4710
0F7200
080762
0F2809
0F2981A
0F2962
045757
022097
0F2830
0F4505A
0D3159
022473
0F2773D
088775
0F5447
0F6166
0C2454
1
1
2
2
6
6
6
1
2
2
4
4
2
2
2
4
2
6
1
2
4
PIPE, EXH MANIFOLD 6.8L C3 RH (6.8L 70KW)
PIPE EXH MANIFOLD 6.8L C3 LH (6.8L 70KW)
PIPE EXHAUST MUFFLER OUT
RING GASKET, 2.5DIA
WASHER LOCK M10 SS
SCREW HHC M10-1.5 X 50 SS FTH
BOLT U 3/8-16 X 2.62
PIPE EXHAUST CROSSOVER
MFLR 7" X 9" X 25" (2) 2.5" IN/2.5" OUT
MUFFLER STRAP
SCREW HHC M6-1.0 X 25 C8.8
WASHER LOCK M6-1/4
MUFFLER BRACKET STIFFENER
MUFF SEC 23.5" X 2.55IN/2.5OUT
FLANGE, EXHAUST
WASHER FLAT 1/4-M6 ZINC
EXHAUST BLANKET 800MM LG (6.8L 70KW)
WASHER FLAT 3/8 SS
BRKT MUFFLER
PIPE LH MUFFLER SIDE
SCREW HWHT M6-1 X 16 N WA Z/JS
REVISION:-A-
DATE: 9/13/11
PAGE 2 OF 2
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EXPLODED VIEW: EV EXHAUST CPL 7OKW C3
DRAWING #: 0J6343A
APPLICABLE TO:
GROUP D
ITEM
PART#
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
0J6177
0J6179
0F2808B
0A6765
0F4710
0F7200
080762
0G0007
0F2981A
0F2962
045757
022097
0F2830
0H2099A
022473
0F2773D
088775
0F5447
0H0639A
0F2773
0F9071
0F6166
0L1789
0G3163A
0C2454
0D3159
049813
049721
1
1
2
2
6
6
8
1
1
1
2
6
1
1
10
2
6
1
1
1
1
1
4
1
4
2
4
4
PIPE, EXH MANIFOLD 6.8L C3 RH (6.8L 70KW)
PIPE EXH MANIFOLD 6.8L C3 LH (6.8L 70KW)
PIPE EXHAUST MUFFLER OUT
RING GASKET, 2.5DIA
WASHER LOCK M10 SS
SCREW HHC M10-1.5 X 50 SS FTH
BOLT U 3/8-16 X 2.62
DIFFUSER EXHAUST WELDMENT
MFLR 7" X 9" X 25" (2) 2.5" IN/2.5" OUT
MUFFLER STRAP
SCREW HHC M6-1.0 X 25 C8.8
WASHER LOCK M6-1/4
MUFFLER BRACKET STIFFENER
CATALYST 3-WAY
WASHER FLAT 1/4-M6 ZINC
EXHAUST BLANKET 800MM LG (6.8L 70KW)
WASHER FLAT 3/8 SS
9
10
11
12
13
14
16
17
18
19
20
21
22
23
24
25
26
27
28
29
BRKT MUFFLER
PIPE, EXHAUST RH CPL EM
EXHAUST BLANKET 1015M LONG
SENSOR OXYGEN
PIPE LH MUFFLER SIDE
MUFFLER STRAP UPPER/LOWER
BLANKET EXHAUST MUFFLER 584MM
SCREW HWHT M6-1 X 16 N WA Z/JS
FLANGE, EXHAUST
NUT HEX M6-1.0 G8 CLEAR ZINC
SCREW HHC M6-1.0 X 35 C8.8 CLR
NOTES (UNLESS OTHERWISE SPECIFIED):
(1) EXHAUST BLANKET SHOULD NOT COVER OXYGEN SENSOR (ITEM 22).
REVISION: K-1591-C
DATE: 1/28/15
PAGE 2 OF 2
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EXPLODED VIEW: EV FUEL 6.8L NG LPV CPL EMSN
DRAWING #: 0J1704
APPLICABLE TO:
GROUP E
ITEM
PART#
QTY.
DESCRIPTION
1
2
3
049721
075580
0H0651
0H0651A
039253
022145
022129
045771
042568
0H5476
026812
0F8379
0D2698
057823
059057
049811
0J7476
0E4390
0E4392
0F0960
0F3885
0G3167
0F3691B
026073A
0D2157
039294
022097
026915
0G46350ST0R
039450
077879
0F1866A
077879
0G4588
0C2454
077879
025655
4
1
1
1
2
2
2
2
2
1
2
1
1
4
2
2
1
1
1
1
1
2
1
1
4
2
10
2
1
2
1
1
1
1
2
1
1
SCREW HHC M6-1.0 X 35 G8.8 BLK
FLANGE FUEL INLET
REG 6.8L CPL 70KW LPV EMSN
REG 6.8L CPL 70KW NG EMSN
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 CLEAR ZINC
SCREW HHC M6-1.0 X 20 G8.8
HARN FUEL JUMPER SINGLE REG
ELBOW 90D 3/4NPT
NIPPLE PIPE 3/4NPT X 7
GASKET ADAPTER THROT BODY
CLAMP HOSE #10 .56-1.06
HOSE 3/4 ID SAE-30R2 (38.5” LG)
WASHER FLAT M6
ADAPTOR THROTTLE BODY
GASKET, GOVERNOR ACTUATOR
ACTUATOR BOSCH 60, GOVERNOR
REDUCER 3.0" TO 2.75" TURBO
MIXER, 40/60MM ACTUATOR ASSY
O-RING 2-3/4 X 3/32 X 2-15/16
VENTURI, THROTTLE 36MM
PLUG STD PIPE 1/4 STEEL SQ HD
SCREW SHC M6-1.0 X 50 C8.8
CLAMP HOSE #44 2.31-3.25
WASHER LOCK M6-1/4
NIPPLE CLOSE 3/4 X 1.375
BRACKET, HOSE RISER
BARBED EL 90 3/16 X 1/8
HOSE VACUUM 5/32 (5.5”LG)
BARBED EL W/VENT (.052")
HOSE VACUUM 5/32 (11”LG)
PIPE TEE W/BRACKET WELDED
SCREW TH-FRM M6-1 X 16 N WA Z/JS
HOSE VACUUM 5/32 (10.5” LG)
4
5
6
7
8
9
10
11
12
13
14
15
18
19
20
21
22
23
24
25
26
27
28
29
(1)30
31
32
33
34
35
36
37
38
PLUG STD PIPE 3/4 STEEL SQ HD
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 XA BOM.
CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR
CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
REVISION: J-8381-D
DATE: 4/22/14
PAGE 2 OF 2
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EXPLODED VIEW: EV FUEL SYSTEM 6.8L NG/LPV CPL
DRAWING #: 0J1705
APPLICABLE TO:
GROUP E
ITEM
PART#
QTY.
DESCRIPTION
1
2
3
049721
075580
0G9189A
0G9189B
039253
022145
022129
045771
042568
0H5476
026812
0F8379
0D2698
057823
059057
049811
0J7476
0E4390
0E4392
0F0960
0F3885
0G3167
0F3691B
026073A
0D2157
039294
022097
026915
0G46350ST0R
025655
4
1
1
1
2
2
2
2
2
1
2
1
1
4
2
2
1
1
1
1
1
2
1
1
4
2
10
2
1
1
SCREW HHC M6-1.0 X 35 G8.8 BLK
FLANGE FUEL INLET
REG ASSY 6.8L 70KW LPV CPL
REG ASSY 6.8L 70KW NG CPL
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 CLEAR ZINC
SCREW HHC M6-1.0 X 20 G8.8
HARN FUEL JUMPER SINGLE REG
ELBOW 90D 3/4NPT
NIPPLE PIPE 3/4NPT X 7
GASKET ADAPTER THROT BODY
CLAMP HOSE #10 .56-1.06
HOSE 3/4 ID SAE-30R2 (38.5” LG)
WASHER FLAT M6
ADAPTOR THROTTLE BODY
GASKET, GOVERNOR ACTUATOR
ACTUATOR BOSCH 60, GOVERNOR
REDUCER 3.0" TO 2.75" TURBO
MIXER, 40/60MM ACTUATOR ASSY
O-RING 2-3/4 X 3/32 X 2-15/16
VENTURI, THROTTLE 36MM
PLUG STD PIPE 1/4 STEEL SQ HD
SCREW SHC M6-1.0 X 50 C8.8
CLAMP HOSE #44 2.31-3.25
WASHER LOCK M6-1/4
4
5
6
7
8
9
10
11
12
13
14
15
18
19
20
21
22
23
24
25
26
27
28
29
(1)30
31
NIPPLE CLOSE 3/4 X 1.375
BRACKET, HOSE RISER
PLUG STD PIPE 3/4 STEEL SQ HD
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 XA BOM.
CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR
CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
REVISION: K-3796-E
DATE: 8/31/15
PAGE 2 OF 2
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EXPLODED VIEW: EV ENCLOSURE C3
DRAWING #: 0G2898
GROUP F
ITEM
PART#
QTY.
DESCRIPTION
(2) 1
(2) 2
(2) 3
(3) 4
(2) 5
(2) 6
(2) 7
(1)8
(1)9
10
0F58660AL0R
0F5861AAL0R
0F58650AL0R
0F58640AL0R
0F58620ALOR
0F58630AL0R
0F58600AL0R
0C2454
1
4
2
2
2
1
1
60
16
1
REAR WRAP AL
DOOR AL
CENTER SUPPORT AL
DUCT, DISCHRG AL
FRONT CRNR AL
DUCT, CNTR DISCHRG AL
ROOF, AL
SCREW THF M6-1 X 16 N WA Z/JS
SCREW TH-FRM M6 W/CAP SHKPRF W
GASKET EXTRUDED TRIM (547” LG)
INSUL SPLITTER SMALL
0E3257
0E5968
0J2624A
11
3
12
0F2766
3
SPLITTER
14
15
16
17
18
19
0F3185
0F3416
0J2624B
0F4487A
022473
2
2
1
1
5
1
STRINGER SPLITTER C3
SUPPORT SPLITTER C5 130KW
INSUL ROOF TOP REAR
ASSEMBLY COVER ACCESS
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
022097
20
21
22
25
26
27
022127
0F3072
078115
0F5048D
0F5049B
0J2624
1
NUT HEX 1/4-20 STEEL
12
30
4
2
3
INSULATION RETAINMENT HANGER
WASHER SELF LOCKING DOME #4-40
VISE-ACTION LATCH SLOTTED CIR
PULL TAB DOOR LOCK SS
INSULATION SPLITTER
29
30
31
32
33
34
35
36
37
38
40
41
(1) 42
43
44
0J2624D
0F4073F
087233
0G0257
066760
0J2624C
0F3890B
0F4073B
078115A
042568
022447
049813
077992
0912970090
0F8869D
1
1
2
1
1
4
3
1
10
4
4
4
29
4
1
INSULATION ROOF TOP
INSULATION DUCT TOP
RIVET POP .1875 X .450 SS
REFLECTIVE HEAT SHIELD 2.4L
STRIP SEALANT 1/8 X 1 (44.5”LG)
INSULATION DOOR
RETAINER INSULATION (820)
INSULATION DUCT FRONT
WASHER SELF LOCKING DOME #8-32
SCREW HHC M6-1.0 X 20 G8.8
WASHER SHAKEPROOF INT 1/4
NUT HEX M6 X 1.0 G8 YEL CHR
NUT HEX LOCK M6-1.0 SS NY INS
ASSY WIRE 14AWG GRN/YEL
KEY VISE-ACTION LATCH SLOT CIR
(1) ENCLOSURE NOTE: ALL PANELS THAT FASTEN TO THE BASEFRAME MUST BE SECURED USING I/N 8 & 9 (THREAD FORMING FASTENERS) AND I/N 42
(LOCK NUT). LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS. ALL
PANEL TO PANEL CONNECTIONS TO INCLUDE AT LEAST ONE CONNECTION POINT USING I/N 9 (THREAD FORMING FASTENER).
(2) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
•
•
MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR CORRECT MATERIAL
AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
REVISION: J-4499-K
DATE: 4/1/13
Page 2 of 2
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REPLACEMENT SHEET METAL PARTS ORDERING GUIDE
Parts listed in the manual Bill of Material on the EV drawings/Manuals are listed in the unfinished form with the default
material – usually steel or plain six or seven digit number.
0XXXXXXST0R or 0XXXXXX
Base number Suffix1 Raw
After entering serial number or model number of the unit to search/order replacement sheet metal parts follow steps below
to identify/verify correct part number:
1. Obtain Unfinished Part number from the EV drawing in the manual or Generac Website
2. Enter base number in the system – first 6 digit. Press enter.
3. The full part number of the finished/painted part will show. (example 0H5522AST19 or 0H0103AST16)
Verify that the material and color matches the unit/ replaced part per reference information below:
REFERENCE INFORMATION:
Starting in 2009 Generac Power Systems uses following part number structuring for parts with secondary finish – painted or
plated.
0XXXXXXYYZZ
Base number Suffix1 Suffix2
Suffix 1 - represent material part is made of – aluminum, steel or stainless steel
Suffix 2 - represents color or plating
Suffix 1 - Material
AL – Aluminum
ST – Steel
Suffix 2 – Color/plating
0R – Raw (unfinished)
01 – Tan
Color Used on
DO NOT ORDER
(default parts on drawings)
Genset enclosures parts until 2009
Frames, Tanks and misc. internal parts
Industrial products parts
03 – Black
SS – Stainless
05 – White
VR – Variable Material
11 – Yellow Zinc Plating
13 – Bisque
Miscellaneous internal parts
Genset enclosures parts since 2008
Gen and TSW enclosures parts since 2009
Portable Generator parts since 2009
Portable Generator parts since 2009
Portable Generator parts since 2009
Colors per customer request (Special)
Industrial products parts since 2010
14 – Grey
15 – Orange Textured
16 – XP Gray
17 – Orange Gloss
18 – Special/Customer
19 – Dark Grey
Page 1 of 1
NUMBER
GENERAC POWER SYSTEMS OWNS THE COPYRIGHT OF THIS SPECIFICATION WHICH IS SUPPLIED IN CONFIDENCE AND MUST NOT BE
COPIED OR TRANSMITTED TO OTHERS WITHOUT THE EXPRESS WRITTEN CONSENT OF GENERAC POWER SYSTEMS
REV
DATE
REPLACEMENT SHEET METAL PARTS ORDERING GUIDE
B
12/20/10
0H7169
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