Generac Power Systems Portable Generator 68L User Manual

Serial Number

6.8L

100kW

Models

STANDBY GENERATOR

OWNER'S MANUAL

A new standard of reliability

This manual should remain with the unit.

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Standby Generator Sets

Important Safety Instructions

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe

operation be copied and posted in potential hazard areas. Safety should be stressed to all

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



GENERAL HAZARDS

WARNING:



• For safety reasons, the manufacturer recommends

that this equipment be installed, serviced and

repaired by an Authorized Service Dealer or other

competent, qualified electrician or installation tech-

nician who is familiar with applicable codes, stan-

dards and regulations. The operator also must

comply with all such codes, standards and regula-

tions.

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

WARNING:



This product contains or emits chemicals

known to the state of California to cause

• Installation, operation, servicing and repair of this

(and related) equipment must always comply with

applicable codes, standards, laws and regulations.

Adhere strictly to local, state and national electri-

cal and building codes. Comply with regulations

the Occupational Safety and Health Administration

(OSHA) has established. Also, ensure that the

generator is installed, operated and serviced in

accordance with the manufacturer’s instructions

and recommendations. Following installation, do

nothing that might render the unit unsafe or in

noncompliance with the aforementioned codes,

standards, laws and regulations.

• The engine exhaust fumes contain carbon monox-

ide gas, which can be DEADLY. This dangerous gas,

if breathed in sufficient concentrations, can cause

unconsciousness or even death. For that reason,

adequate ventilation must be provided. Exhaust

gases must be piped safely away from any building

or enclosure that houses the generator to an area

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

This exhaust system must be installed properly, in

strict compliance with applicable codes and stan-

dards.

cancer, birth defects or other reproductive harm.

Study these SAFETY RULES carefully before install-

ing, operating or servicing this equipment. Become

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

The generator can operate safely, efficiently and reli-

ably only if it is properly installed, operated and

maintained. Many accidents are caused by failing to

follow simple and fundamental rules or precautions.

The manufacturer cannot anticipate every possible

circumstance that might involve a hazard. The warn-

ings in this manual, and on tags and decals affixed

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

cedure, work method or operating technique is used

that the manufacturer does not specifically recom-

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

sure the procedure, work method or operating tech-

nique utilized does not render the generator unsafe.

DANGER

Despite the safe design of this generator,

operating this equipment imprudently, neglect-

ing its maintenance or being careless can cause

possible injury or death. Permit only responsible

and capable persons to install, operate or main-

tain this equipment.



• Keep hands, feet, clothing, etc., away from drive

belts, fans, and other moving or hot parts. Never

remove any drive belt or fan guard while the unit

is operating.

• Adequate, unobstructed flow of cooling and venti-

lating air is critical in any room or building hous-

ing the generator to prevent buildup of explosive

gases and to ensure correct generator operation.

Do not alter the installation or permit even partial

blockage of ventilation provisions, as this can seri-

ously affect safe operation of the generator.

• Keep the area around the generator clean and

uncluttered. Remove any materials that could

become hazardous.

Potentially lethal voltages are generated by



these machines. Ensure all steps are taken to

render the machine safe before attempting to

work on the generator.

Parts of the generator are rotating and/or hot

during operation. Exercise care near running



generators.

• When working on this equipment, remain alert

at all times. Never work on the equipment when

physically or mentally fatigued.

• Inspect the generator regularly, and promptly

repair or replace all worn, damaged or defective

parts using only factory-approved parts.

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Standby Generator Sets

Important Safety Instructions

• Before performing any maintenance on the gen-

• 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 person-

nel, disable the generator’s automatic start circuit

(battery cables, etc.) before working on or around

the unit. Then, place a “Do Not Operate” tag on

the generator control panel and on the transfer

switch.

erator, disconnect its battery cables to prevent

accidental start-up. Disconnect the cable from the

battery post indicated by a NEGATIVE, NEG or (–)

first. Reconnect that cable last.

• Never use the generator or any of its parts as a

step. Stepping on the unit can stress and break

parts, and may result in dangerous operating con-

ditions from leaking exhaust gases, fuel leakage,

oil leakage, etc.

• In case of accident caused by electric shock, imme-

diately shut down the source of electrical power.

If this is not possible, attempt to free the victim

from the live conductor. AVOID DIRECT CONTACT

WITH THE VICTIM. Use a nonconducting imple-

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

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

scious, apply first aid and get immediate medical

help.

• Never wear jewelry when working on this equip-

ment. Jewelry can conduct electricity resulting in

electric shock, or may get caught in moving com-

ponents causing injury.

ELECTRICAL HAZARDS



• All generators covered by this manual produce

dangerous electrical voltages and can cause fatal

electrical shock. Utility power delivers extremely

high and dangerous voltages to the transfer switch

as well as the standby generator. Avoid contact

with bare wires, terminals, connections, etc., on

the generator as well as the transfer switch, if

applicable. Ensure all appropriate covers, guards

and barriers are in place before operating the gen-

erator. If work must be done around an operating

unit, stand on an insulated, dry surface to reduce

shock hazard.

FIRE HAZARDS



• Do not handle any kind of electrical device while

standing in water, while barefoot, or while hands or

feet are wet. DANGEROUS ELECTRICAL SHOCK

MAY RESULT.

• If personnel must stand on metal or concrete while

installing, operating, servicing, adjusting or repair-

ing this equipment, place insulative mats over a

dry wooden platform. Work on the equipment only

while standing on such insulative mats.

• Keep a fire extinguisher near the generator at all

times. Do NOT use any carbon tetra-chloride type

extinguisher. Its fumes are toxic, and the liquid

can deteriorate wiring insulation. Keep the extin-

guisher properly charged and be familiar with its

use. If there are any questions pertaining to fire

extinguishers, consult the local fire department.

• The National Electrical Code (NEC) requires the

frame and external electrically conductive parts

of the generator to be connected to an approved

earth ground. This grounding will help prevent

dangerous electrical shock that might be caused

by a ground fault condition in the generator set or

by static electricity. Never disconnect the ground

wire.

• Wire gauge sizes of electrical wiring, cables and

cord sets must be adequate to handle the maxi-

mum electrical current (ampacity) to which they

will be subjected.

• Before installing or servicing this (and related)

equipment, make sure that all power voltage

supplies are positively turned off at their source.

Failure to do so will result in hazardous and pos-

sibly fatal electrical shock.

• Connecting this unit to an electrical system nor-

mally supplied by an electric utility shall be by

means of a transfer switch so as to isolate the

generator electric system from the electric utility

distribution system when the generator is operat-

ing. Failure to isolate the two electric system power

sources from each other by such means will result

in damage to the generator and may also result

in injury or death to utility power workers due to

backfeed of electrical energy.

EXPLOSION HAZARDS



• Properly ventilate any room or building housing

the generator to prevent build-up of explosive gas.

• Do not smoke around the generator. Wipe up any

fuel or oil spills immediately. Ensure that no com-

bustible materials are left in the generator com-

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

EXPLOSION may result. Keep the area surround-

ing the generator clean and free from debris.

• These generator sets may operate using one of

several types of fuels. All fuel types are potentially

FLAMMABLE and/or EXPLOSIVE and should be

handled with care. Comply with all laws regulat-

ing the storage and handling of fuels. Inspect the

unit’s fuel system frequently and correct any leaks

immediately. Fuel supply lines must be prop-

erly installed, purged and leak tested according to

applicable fuel-gas codes before placing this equip-

ment into service.

• Diesel fuels are highly FLAMMABLE. Gaseous

fluids such as natural gas and liquid propane

(LP) gas are extremely EXPLOSIVE. Natural gas

is lighter than air, and LP gas is heavier than air;

install leak detectors accordingly.

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Standby Generator Sets

Important Safety Instructions

INTRODUCTION

 ^{This symbol points out potential fire hazard.}

Thank you for purchasing this model of the standby

generator set 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 equipment. The manufacturer strongly recom-

mends that the operator read this Owner's Manual

and thoroughly understand all instructions before

using this equipment. The manufacturer also strong-

ly recommends instructing other users to properly

start and operate the unit. This prepares them if they

need to operate the equipment in an emergency.

‹

READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, con-

tact the nearest Authorized Service Dealer for start-

ing, operating and servicing procedures.

‹

OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety

checks, to make sure that all maintenance for safe

operation is performed promptly, and to have the

equipment checked periodically by an Authorized

Service Dealer. Normal maintenance service and

replacement of parts are the responsibility of the

owner/operator and, as such, are not considered

defects in materials or workmanship within the terms

of the warranty. Individual operating habits and usage

contribute to the need for maintenance service.

Throughout this publication, and on tags and

decals affixed to the generator, DANGER, WARNING,

CAUTION and NOTE blocks are used to alert person-

nel to special instructions about a particular service

or operation that may be hazardous if performed

incorrectly or carelessly. Observe them carefully.

Their definitions are as follows:

DANGER

After this heading, read instructions that, if not

strictly complied with, will result in personal injury

or property damage.

Proper maintenance and care of the generator ensure

a minimum number of problems and keep operating

expenses at a minimum. See an Authorized Service

Dealer for service aids and accessories.

Operating instructions presented in this manual

assume that the standby electric system has been

installed by an Authorized Service Dealer or other

competent, qualified contractor. Installation of this

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

After this heading, read instructions that, if not

strictly complied with, may result in personal

injury or property damage.

‹

HOW TO OBTAIN SERVICE

After this heading, read instructions that, if not

strictly complied with, could result in damage to

equipment and/or property.

When the generator requires servicing or repairs,

simply contact an Authorized Service Dealer for

assistance. Service technicians are factory-trained

and are capable of handling all service needs.

NOTE:

After this heading, read explanatory statements

that require special emphasis.

When contacting an Authorized Service Dealer or the

factory about parts and service, always supply the

complete model number of the unit as given on the

front cover of this manual or on the DATA LABEL

affixed to the unit.

These safety warnings cannot eliminate the hazards

that they indicate. Common sense and strict compli-

ance with the special instructions while performing

the service are essential to preventing accidents.

Four commonly used safety symbols accompany the

DANGER, WARNING and CAUTION blocks. The type

of information each indicates is as follows:

AUTHORIZED SERVICE DEALER LOCATION

To locate the nearest AUTHORIZED

This symbol points out important safety infor-



SERVICE DEALER, please call this number:

mation that, if not followed, could endanger

1-800-333-1322

or locate us on the web at:

personal safety and/or property of others.

This symbol points out potential explosion

hazard.



www.generac.com

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Standby Generator Sets

General Information

Identification Code

IDENTIFICATION RECORD

Use this code to obtain important information about

the generator. For example, if the code is:

‹

DATA LABEL

Every generator set has a DATA LABEL that contains

important information pertinent to the generator. The

data label, which can be found attached to the gen-

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

number and its rated voltage, amps, wattage capacity,

phase, frequency, rpm, power factor, etc.

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

M — Designates generators capable of paralleling.

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

are currently available for this configura-

tion.

QT — Quiet Test Generator Series

100 — kw Rating

GENERATOR SET DATA

MADE IN USA

5.4 — Engine Size in Liters

SERIAL

RATED KVA

RATED AMPS

ALT RPM

MODEL

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

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

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

L = 346/600, Three-phase

PHASE

RATED KW

RATED VOLTAGE

POWER FACTOR

ENGINE RPM

HERTZ

PRODUCTION DATE

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

S — Enclosure Material: A = Aluminum; S

= Steel (Corrosion Resistant Aluminum

Enclosure Material, Steel is Standard)

N — Emission Equipment: N = No Equipment;

Y = Catalytic Converter and Air/Fuel Ratio

Controller

ALTERNATOR SUBTRANSIENT REACTANCE

ALTERNATOR TRANSIENT REACTANCE

CLASS

ROTOR

STATOR WINDING INSULATION AT 25°C AMBIENT

GENERAC POWER SYSTEMS, INC.

WAUKESHA, WI

A — Industrial Dealer Product

NOTE:

Voltage Codes

The identification code letter following the unit’s

engine size is the generator’s “voltage code.”

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.

Groups and Assembly Numbers

Generator Model and Serial Number

The manual drawing listing lists the groups and cor-

responding assembly numbers for each unit. The

assembly numbers refer to exploded view drawing

numbers that are applicable to the specific generator

model. These drawings are located in the back half

of this manual.

This number is the key to numerous engineering and

manufacturing details pertaining to your unit. Always

supply this number when requesting service, order-

ing parts or seeking information.

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Standby Generator Sets

Equipment Description

EQUIPMENT DESCRIPTION

COOLANT RECOMMENDATIONS

This equipment is a revolving field, alternating cur-

rent generator set. It is powered by a gaseous fueled

engine operating at 1800 rpm for 4-pole direct drive

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

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

Specifications section for exact numbers. The unit

comes complete with a sound attenuated enclosure,

internally mounted muffler, control console, main-

line circuit breaker, battery charger, and protective

alarms as explained in the following paragraph.

Use a mixture of half low silicate ethylene glycol

base anti-freeze and deionized water. Cooling system

capacity is listed in the specifications. Use only deion-

ized water and only low silicate anti-freeze. If desired,

add a high quality rust inhibitor to the recommended

coolant mixture. When adding coolant, always add

the recommended 50-50 mixture.

Do not use any chromate base rust inhibitor



All AC connections, including the power leads from

the alternator, 120 volt battery charger input and

control connections to the transfer switch are avail-

able in the main connection box.

with ethylene glycol base anti-freeze or chro-

mium hydroxide (“green slime”) forms and will

cause overheating. Engines that have been oper-

ated with a chromate base rust inhibitor must

be chemically cleaned before adding ethylene

glycol base anti-freeze. Using any high silicate

anti-freeze boosters or additives will also cause

overheating. The manufacturer also recommends

that any soluble oil inhibitor is NOT used for this

equipment.

The generator incorporates the following generator

features:

• Rotor and Stator insulation is Class H rated as

defined by NEMA MG1-32.6, NEMA MG1-1.66.

The generator is self ventilated and drip-proof con-

structed.

• The voltage waveform deviation, total harmonic

content of the AC waveform and telephone influ-

ence factor have been evaluated and are acceptable

according to NEMA MG1-32.

DANGER

Do not remove the radiator pressure cap while

the engine is hot or serious burns from boiling

liquid or steam could result.



Ethylene glycol base antifreeze is poisonous.

Do not use mouth to siphon coolant from the

radiator, recovery bottle or any container. Wash

hands thoroughly after handling. Never store

used antifreeze in an open container because

animals are attracted to the smell and taste of

antifreeze even though it is poisonous to them.

ENGINE OIL RECOMMENDATIONS

The unit has been filled with 15W-40 engine oil at

the factory. Use a high-quality detergent oil classified

“For Service CC, SD, SE, SF.” Detergent oils keep the

engine cleaner and reduce carbon deposits. Use oil

having the following SAE viscosity rating, based on

the ambient temperature range anticipated before the

next oil change:



Temperature

Above 80° F (27° C)

32° to 80° F (0° to 27° C)

Below 32° F (0° C)

Oil Grade (Recommended)

SAE 30W or 15W-40

SAE 20W-20 or 15W-40

See Note

Any attempt to crank or start the engine before

it has been properly serviced with the recom-

mended oil may result in an engine failure.



NOTE:

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

mended to use the optional Cold Weather Start Kit

(part number listed in the Specification Section).

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

30 synthetic oil.

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Standby Generator Sets

Engine Protective Devices

‹

OIL PRESSURE SENSING

ENGINE PROTECTIVE DEVICES

The standby generator may be required to operate for

long periods of time without an operator on hand to

monitor such engine conditions as coolant tempera-

ture, oil pressure or rpm. For that reason, the engine

has several devices designed to protect it against

potentially damaging conditions by automatically

shutting down the unit when the oil pressure is too

low, the coolant temperature is too high, the coolant

level is too low, or the engine is running too fast.

An analog Oil Pressure Sender (OPS) is used for

monitoring the engine oil pressure. This sender

allows the control panel to measure and display the

Engine oil pressure.

The OPS is a resistive device, whose resistance

changes based on engine oil pressure. The resistance

of the sender results in a voltage being developed

across the sender. As the oil pressure increases,

the resistance will decrease, causing the voltage to

decrease. This changing voltage is converted to 4-

20mA signal by a signal conditioner module. The

corresponding 4-20mA signal is read by the control

panel and displayed as the oil pressure.

NOTE:

Engine protective switches and sensors are men-

tioned here for the reader's convenience. Also refer

to the applicable control panel manual for addi-

tional automatic engine shutdown information.

The control panel will monitor and display oil pres-

sure anytime the DC input to the control panel is

present.

‹

COOLANT TEMPERATURE SENSING

An analog Water Temperature Sender (WTS) is locat-

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

nected to the panel and allows the panel to monitor

and display the temperature of the coolant system.

Should the oil pressure drop below the 8 psi range,

the engine shutdown is initiated. The unit should not

be restarted until oil is added. Turn the AUTO/OFF/

MANUAL switch to the OFF position, then back to

AUTO to restart.

The WTS is a resistive device whose resistance chang-

es based on coolant temperature. The resistance of

the sender results in a voltage being developed across

the sender. As the Coolant temperature increases,

the resistance will decrease, causing the voltage to

decrease. This changing voltage is converted to 4-

20mA signal by a signal conditioner module. The

corresponding 4-20mA signal is read by the control

panel and displayed as the coolant temperature.

‹

OVERCRANK SHUTDOWN

When the control panel receives a start signal, it ini-

tiates the programmed starting sequence. The start

sequence consists of the number of crank attempts,

the length of each crank attempt, and the rest time

between each crank attempt. If the engine has not

started by the end of the final crank attempt, an

Overcrank alarm is generated, the control panel will

sound the alarm and display the message "Failed to

start".

The control panel will monitor and display the cool-

ant temperature anytime the DC input to the control

panel is present.

If the temperature exceeds approximately 140° C

(284° F), the engine shutdown will be initiated. The

generator will automatically restart and the display

will reset once the temperature has returned to an

operating level.

‹

OVERSPEED SHUTDOWN

A speed circuit controls engine cranking, start-up,

operation and shutdown. Engine speed signals are

delivered to the circuit board whenever the unit is

running. Should the engine over speed above a safe,

preset value, the circuit board initiates an automatic

engine shutdown. Contact the nearest Authorized

Dealer if this failure occurs.

‹

LOW COOLANT LEVEL

A Low Coolant Level (LCL) sensor is placed in the

generators coolant system. This sensor allows the

panel to detect a Low Coolant Level condition.

‹

RPM SENSOR LOSS SHUTDOWN

If the speed signal to the control panel is lost, engine

shutdown will occur.

The LCL is a resistive device whose resistance changes

rapidly based on the presence or absence of coolant.

The resistance of the LCL results in a voltage being

developed across the LCL. This voltage changes as

the resistance changes. This changing voltage is con-

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

ule. The corresponding 4-20mA signal is read by the

control panel and displayed as the low coolant level.

‹

DC FUSE

This fuse is located inside of the control panel. It

protects the panel wiring and components from

damaging overload. Always remove this fuse before

commencing work on the generator. The unit will

not start or crank if the fuse is blown. Replace the

fuse with one of the same size, type, and rating. (See

the exploded views and parts lists at the end of this

If the level of the engine coolant drops below the level

of the low coolant level sensor, the engine shutdown

will be initiated.

manual for replacement part number.)

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Standby Generator Sets

Fuel Systems

‹

PROPANE VAPOR WITHDRAWAL FUEL SYSTEM

FUEL SYSTEM

This type of system utilizes the vapors formed above

the liquid fuel in the supply tank. Approximately 10

to 20 percent of the tank capacity is needed for fuel

expansion from the liquid to the vapor state. The

vapor withdrawal system is generally best suited for

smaller engines that require less fuel. The installer

should be aware of the following:

‹

FUEL REQUIREMENTS

The standby generator may be equipped with one of

the following fuel systems:

• Natural gas fuel system

• Propane vapor (PV) fuel system

• Liquid propane (LP) fuel system

The Manual Drawing Listing that is affixed to the

unit includes the “Identification Code,” which may be

used to identify the type of fuel system installed on

the unit.

• The natural gas and LP gas systems are similar.

However, the natural gas system delivers gas at a

pressure of approximately five inches water col-

umn to the carburetor.

• When ambient temperatures are low and engine

fuel consumption is high, the vapor withdrawal

system may not function efficiently.

• Ambient temperatures around the supply tank

must be high enough to sustain adequate vaporiza-

tion, or the system will not deliver the needed fuel

volume.

• In addition to the cooling effects of ambient air, the

vaporization process itself provides an additional

cooling effect.

Recommended fuels should have a Btu content of at

least 1,000 Btu's per cubic foot for natural gas; or at

least 2,520 Btu's per cubic foot for LP gas. Ask the

fuel supplier for the Btu content of the fuel.

Required fuel pressure for natural gas is 11 inches

to 14 inches water column (0.4 to 0.5 psi); and for

liquid propane, 11 inches to 14 inches of water

column (0.4 to 0.5 psi).

NOTE:

Any piping used to connect the generator to the

fuel supply should be of adequate size to ensure

the fuel pressure NEVER drops below 11 inches

water column for natural gas or 11 inches water

column for liquid propane for all load ranges.

‹

LP FUEL SYSTEM

LP is supplied as a liquid in pressure tanks. It is

usually made up of propane, butane, or a mixture of

the two gases. Propane tends to vaporize readily even

at temperatures as low as -20° F (-29° C). However,

butane reverts to its liquid state when temperatures

drop below 32° F (0° C).

NOTE:

It is the responsibility of the installer to make sure

that only the correct recommended fuel is sup-

plied to the generator fuel system. Thereafter, the

owner/operator must make certain that only the

proper fuel is supplied.

LP in a liquid withdrawal system must be converted

to its gaseous state before it is introduced into the

engine carburetor. A vaporizer-converter is generally

used to accomplish this. In such a converter, heated

engine coolant is ported through the converter to

provide the necessary heat for conversion of the fuel

from a liquid to a gaseous state.

‹

NATURAL GAS FUEL SYSTEM

Natural gas is supplied in its vapor state. In most

cases, the gas distribution company provides piping

from the main gas distribution line to the standby

generator site. The following information applies to

natural gas fuel systems.

• Gas pressure in a building is usually regulated by

national, state and local codes.

• To reduce gas pressure to a safe level before

the gas enters a building, a primary regulator is

needed. The natural gas supplier may or may not

supply such a regulator.

• It is the responsibility of the gas supplier to make

sure sufficient gas pressure is available to operate

the primary regulator.

• Gas pressure at the inlet to the fuel shutoff sole-

noid should not exceed approximately 14 inches

water column (0.5 psi). Optimum pressure at the

fuel shutoff solenoid is 11 inches water column

(0.4 psi).

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Standby Generator Sets

Specifications

Engine Lubrication System

SPECIFICATIONS

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

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

Crankcase Oil Capacity....................................................6 U.S. qts.

‹

GENERATOR

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

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

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

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

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

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

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

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

Load Capacity (Standby Rating) ..........................................100kW*

‹

COOLING SYSTEM

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

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

Fan Speed................................................................................ 1670

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

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

Air Flow (inlet air including alternator and

combustion air).......................................................... 5500 ft3/min.

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

Heat Rejection to Coolant ..........................................342,000 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

Generator Output Voltage/kW - 60 Hz

120/240V, 1-phase, 1.0 pf

120/208V, 3-phase, 0.8 pf

100

Amp CB Size

417

347

150

450

400

175

‹

FUEL SYSTEM

277/480V, 3-phase, 0.8 pf

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

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

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

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

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

Generator Locked Rotor KVA Available @ Voltage Dip of 35%

Single-phase or 208 3-phase........................................... 200 KVA

480V, 3-phase .................................................................. 240 KVA

‹

ENGINE

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

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

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

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

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

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

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

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

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

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

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

Exercise

Cycle

130/52

25%

Load

50%

Load

75%

Load

991/400 1260/507

100%

Load

371/149

713/287

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

factory set for the specific fuel.

‹

ELECTRICAL SYSTEM

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

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

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

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

Engine Parameters

Rated Synchronous RPM..............................................60 Hz, 2300

HP at rated kW................................................................60 Hz, 168

Voltage Regulator

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

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

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

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

V/F Adjustable, Adjustable

Exhaust System

Exhaust Flow at Rated Output 60 Hz.................................. 888 cfm

Exhaust Temperature at Rated Output.................................. 960° F

Combustion Air Requirements (Natural Gas)

Flow at rated power, 60 Hz ................................................. 262 cfm

Voltage and Gain

Power Adjustment for Ambient Conditions

Temperature Deration

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

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

Altitude Deration

Governor

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

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

Steady State Regulation...................................................... 0.25%

Adjustments:

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

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

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

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

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Standby Generator Sets

Specifications

Figure 1 — Interconnections

‹

COLD WEATHER KIT

For cold climates, optional cold weather kit (part num-

ber 0F6148A) is recommended. The kit includes:

• Battery Warmer

• 4” Junction Box with hardware

• 700 Cold Cranking Amp Battery

• 6 qt. pack 5W-30 synthetic oil (engine)

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

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Standby Generator Sets

Specifications

NOTE:

5.4L & 6.8L IGNITION DESCRIPTION

This single-fire Ignition is intended to operate with

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

engine.

The ignition cover does not need to be removed to

see the LED.

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

pickup CAM sensor and individual coil-on-plug coils

for each spark-plug.

‹

IGNITION SHUTDOWN ON LOSS OF CRANK

OR CAM SIGNALS

The ignition will stop firing the coils immediately fol-

lowing the loss of the crank signal. The ignition will

stop firing the coils after approx. 3 seconds following

the loss of the cam signal.

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

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

for each spark-plug.

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

put is connected to one spark plug resulting in that

spark plug being fired only during the compression

cycle.

‹

DIAGNOSTIC BLINK PATTERNS (RED LED

LOCATED ON THE IGNITION CONTROL

BOARD)

Engine Timing versus Engine Speed for the 6.8L

engine is:

During normal ignition operation the RED LED

flashes at a 0.5 sec ON and a 0.5 sec OFF rate. This

is considered one (1) blink.

RPM

1800 rpm

3600 rpm

NG/LP Engine Timing (BTDC)

22 degrees

LED Fault Code with Priority as shown:

24 degrees

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

3.0 seconds and then repeats

Engine Timing versus Engine Speed for the 5.4L

engine is:

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

RPM

1800 rpm

3600 rpm

NG/LP Engine Timing (BTDC)

26 degrees

3.0 seconds and then repeats

Only one fault is displayed at a time. If multiple faults

exist then the highest priority fault must be resolved

prior to a lower priority fault being displayed. In the

event that an ignition fault has occurred the ignition

will wait 60 seconds before powering down.

26 degrees

‹

IGNITION POWER-UP INPUT ("56 LINE

INPUT")

When battery voltage is applied to this input the igni-

tion will power-up. For the ignition to power itself

down, battery voltage must be removed from this

input.

NOTE:

The ignition cover does not need to be removed to

see the LED.

‹

IGNITION ENABLE ("14 LINE INPUT")

This input must be connected to the +12V battery for

the ignition to turn-on the coils. If this input is con-

nected to battery ground the ignition will stop firing

the coils and will power down within approximately

2 seconds. In the event that an ignition fault has

occurred, however, the ignition will wait 60 seconds

before powering down. This allows time to view the

diagnostic LED located on the ignition board.

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Standby Generator Sets

General Information

GENERATOR AC LEAD CONNECTIONS

ALTERNATOR POWER WINDING

CONNECTIONS

See “Voltage Codes”. This generator may be rated

at any one of three voltages, either single-phase or

three-phase. The electrical wires in the unit’s AC con-

nection (lower) panel should be installed according to

the number of leads and the voltage/phase required

for the application. If there are any questions regard-

ing lead connection, refer to the wiring diagrams at

the back of this manual.

‹

3-PHASE ALTERNATORS

The generator is designed to supply 3-phase electri-

cal 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 and 7.3.

Voltage codes apply to the type of stator assembly

installed on a particular generator.

The rated voltage between circuit breaker terminals

E1-E2, E1-E3 and E2-E3 is either 480V or 208V

depending on the model.

‹

FOUR-LEAD, SINGLE-PHASE STATOR

The rated voltage between each circuit breaker termi-

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

depending on the model.

Four-lead generators are built to supply electrical

loads with voltage code "A" (240V, 1-phase, 60Hz).

Electrical power is produced in the stator power

windings. These windings were connected at the fac-

tory to the main circuit breaker as shown in Figure

7.1.

Figure 7.2 — Stator Power Winding

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

The rated voltage between each circuit breaker ter-

minal is 240V. The rated voltage between each circuit

breaker terminal and the neutral point 00 is 120V.

Figure 7.1 — Four-lead, Single-phase Stator

L - L

S10

S11

S12

L - N

Figure 7.3 — Stator Power Winding

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

L - L

S10

S12

S11

L - N

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Standby Generator Sets

Installation

‹

PRIOR TO INITIAL START-UP

INSTALLATION

Refer to the separate “Installation Guide QT Product

Line” supplied with the unit.

Prior to initially starting the generator, it must

be properly prepared for use. Any attempt to

crank or start the engine before it has been

properly serviced with the recommended types

and quantities of engine fluids (oil, coolant, fuel,

etc.) may result in an engine failure.



PREPARATION BEFORE START-UP

The instructions in this section assume that the

standby generator has been properly installed, ser-

viced, tested, adjusted and otherwise prepared for

use by a competent, qualified installation contractor.

Be sure to read the “Safety Rules”, as well as all other

safety information in this manual, before attempting

to operate this (and related) equipment.

‹

ENGINE COOLANT

Have the engine cooling system properly filled with

the recommended coolant mixture. Check the system

for leaks and other problems. See “Specifications”

and “Coolant” sections.

Before starting the generator for the first time, the

installer must complete the following procedures. For

follow-up maintenance information and/or service

intervals, please refer to the “Maintenance” section

and the “Service Schedule”.

‹

BELT TENSION

Check-the engine-fan belt tension and condition prior

to placing the unit into service and at recommended

intervals. Belt tension is correct when a force of

approximately 22 pounds (10 kg), applied midway

between pulleys, deflects the belt about 3/8- to 5/8-

inch (10 to 16 mm).

‹

TRANSFER SWITCH

If this generator is used to supply power to any elec-

trical system normally powered by an electric utility,

the National Electrical Code requires that a transfer

switch be installed. The transfer switch prevents elec-

trical backfeed between two different electrical sys-

tems. (For additional information, see the applicable

transfer switch manual for this unit.) The transfer

switch, as well as the generator and other standby

components, must be properly located and mounted

in strict compliance with applicable codes, standards

and regulations.

‹

ELECTRICAL SYSTEM

Make sure the generator is properly connected to an

approved earth ground.

Make sure the generator battery is fully charged,

properly installed and interconnected, and ready for

use.

‹

FUEL SYSTEM

Check to ensure that there are no loose electrical con-

nections. Restrain any loose wires to keep them clear

of any moving generator set components.

Make sure the fuel supply system to the genera-

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

sure and (b) is properly purged and leak tested

according to code. No fuel leakage is permitted. See

“Specifications” for more information.

INITIAL INSPECTION FOR QT GENSET

STARTUP

‹

GENERATOR SET LUBRICATION

Inspect for the following.

Check the engine crankcase oil level before operating

and add oil to the proper level – the dipstick “FULL”

mark. Never operate the engine with the oil level

below the dipstick “ADD” mark. See “Specifications”

and “Engine Oil Recommendations”.

• Freight Damage.

• Manuals present.

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

• Correct fuel piping.

• Correct muffler installation for external applica-

NOTE:

tion.

This engine is shipped from the manufacturer

with “break-in” oil. This oil should be changed

after 30 hours of operation.

• Adequate air flow, clearances and ventilation per

installation drawings and applicable codes.

• Correct AC and DC wire size, connections and

grounding. Control and communication wiring to/

from the transfer switch must be run in a separate

conduit from the AC power leads.

• Battery charger connection to 120 VAC.

• Communication wires connected between transfer

switch and generator (HTS only).

Check the oil level in the generator gearbox (if so

equipped) prior to initial use and at the intervals

indicated by the “Service Schedule.” The recom-

mended oil is SAE 90 gear lubricant.

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

ernor, make sure the governor is properly lubricated

with clean engine oil.

• Unit secured to pad.

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Standby Generator Sets

Installation

• Check voltage at the generator terminals.

START-UP CHECKLIST

• For 3-phase units, check phase rotation at the

transfer switch terminals. The generator phase

rotation must match the utility phase rotation.

• Check for coolant, fuel, oil, and exhaust leaks.

• Close the generators main line circuit breaker.

• Turn the generator set off.

Before working on the generator, ensure the fol-

lowing:



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

position.

• Connect the UTILITY supply to the transfer

• The 120VAC supply to the battery charger is

switch.

switched OFF.

• Set the AUTO/OFF/MANUAL switch to AUTO.

• Disconnect utility power before the transfer

switch.

‹

PREPARATION FOR START-UP

Engine should start, transfer to load.

Run at least 15 minutes on generator power.

Make certain all 3-phase loads are functioning

correctly (correct phase rotation).

• Ensure that the 120VAC circuit breaker to the bat-

tery charger is open.

• Remove the fuse from the the control panel. For

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

control box and remove the 15 Amp ATO fuse in

the lower left-hand corner of the control box.

• Connect the battery cables to the battery. Attach

negative battery cable last.

• Reconnect Utility power

Transfer switch will transfer back to Utility and

engine will shut down within the given time

parameters set up for the specific transfer switch

and controller.

• Close the 120VAC circuit breaker to the battery

• Install all covers, access plates and door panels.

• Put the Owners Manual in a safe and accessible

place.

charger.

• Measure the voltage at the battery before and after

the charger is turned on.

• Make certain the AUTO/OFF/MANUAL switch is in

• Verify all AC electrical connections are tight at the

circuit breaker and transfer switch.

• Visually inspect entire area looking for loose paper,

plastic wrappings, leaves, etc.

the AUTO position.

‹

START-UP INSPECTION

• Check all hoses clamps fittings for leaks or dam-

When a start-up is performed by an Authorized

Service Dealer, a standard three-part form titled

“Start-up Inspection for Standby Power Systems”

(part no. 067377), should be completed by the instal-

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

mation on locating the nearest Authorized Service

Dealer. The installer should complete the form and

disseminate copies as follows:

age.

• Check all electrical plugs throughout the genera-

tor. Ensure each plug is seated correctly and fully

inserted into its receptacle.

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

position.

• Open the valve to the engine fuel line.

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

lines).

• Open the generator main line circuit breaker.

• Connect a manometer to the gas line and record

the static pressure. It must be as listed in the

Specifications.

• White copy: Mail to Generac Warranty Department,

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

2062.

• Pink Copy: For service file of installing dealer.

• Yellow Copy: For the customer’s records.

• Insert the fuse into the control panel.

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

UAL position. The engine should now crank and

start.

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Standby Generator Sets

Operation

GENERATOR CONTROL AND

OPERATION

Do not crank the engine continuously for longer

than 30 seconds, or the heat may

damage the starter motor.



Refer to the appropriate control panel operator’s

manual for this unit.

• Let engine stabilize and warm up.

OPERATING UNIT WITH MANUAL

• Check all applicable instrument and gauge read-

ings. When certain that all readings are correct,

move the transfer switch manual handle to its

STANDBY (GENERATOR) position, i.e., load cir-

cuits supplied by the generator.

TRANSFER SWITCH

If the generator was installed in conjunction with a

transfer switch capable of manual operation only, the

following procedure applies. A manually operated

transfer switch is one that will not provide automatic

start-up and does not include an intelligence circuit.

• Set the standby generator’s main line circuit break-

er to its ON (or CLOSED) position.

• Load circuits are now powered by the standby

generator.

‹

ENGINE START-UP AND TRANSFER

For additional information, refer to the applicable

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

erature pertaining to the specific transfer switch.

‹

RETRANSFER AND SHUTDOWN

For additional information, refer to the applicable

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

erature pertaining to the specific transfer switch.

DANGER

To transfer the load back to the utility power source

and shut down the generator, follow these direc-

tions:

The Maintenance Disconnect Switch and the

AUTO/OFF/MANUAL switches (if so equipped)



must be set properly, or the generator will crank

and start as soon as the utility power to the

transfer switch is turned off. Refer to applicable

control panel and transfer switch manuals for

more information.

• Set the standby generator’s main line circuit break-

er to its OFF (or OPEN) position.

• Manually move the transfer switch handle to its

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

connected to the utility.

• Turn ON the utility power supply to the transfer

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

ity power source main line circuit breaker).

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

to stabilize internal temperatures.

Do not proceed until certain that utility source

voltage is available to the transfer switch and

the transfer switch main contacts are set to

UTILITY.



Do not attempt manual operation until all power



supplies to the transfer switch have been posi-

• Shut down the generator.

tively turned off, or extremely dangerous - pos-

sibly lethal - electrical shock will result.

OPERATING UNIT WITH AUTOMATIC

Transfer switch enclosure doors should be kept



TRANSFER SWITCH

closed and locked. Only authorized personnel

If the generator has been installed with an automatic

transfer switch, such as an RTS, HTS, or GTS-type

transfer switch, the engine may be started and

stopped automatically or manually.

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:

NOTE:

Refer to the applicable manual for your trans-

fer switch and to “Transfer Switch Start Signal

Connections”. In addition, please note the dangers

under “Engine Start-up and Transfer.”

• Turn OFF or disconnect the utility power circuit

to the transfer switch, using the means provided

(such as the utility source main line circuit break-

er).

• Set the transfer handle to its UTILITY (NORMAL)

position with load circuits connected to the utility

power supply.

• Set the standby generator’s main line circuit break-

er to its OFF (or OPEN) position.

• Start the generator.

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Standby Generator Sets

Maintenance

MAINTENANCE PERFORMED BY

AUTHORIZED SERVICE FACILITIES

The exhaust system parts from this product get



extremely hot and remain hot after shutdown.

High grass, weeds, brush, leaves, etc. must

remain clear of the exhaust. Such materials may

ignite and burn from the heat of the exhaust

system.

Before working on the generator, ensure the fol-

lowing:



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

position.

• The 15A fuse has been removed from the con-

CHECKING FLUID LEVELS

trol box.

• The 120VAC supply to the battery charger is

switched OFF.

‹

CHECK ENGINE OIL

Check engine crankcase oil level (Figure 10.1) at least

every 20 hours of operation, or prior to use.

‹

EVERY THREE MONTHS

• Remove oil dipstick and wipe dry with a clean, lint-

free cloth.

1. Check battery state of charge and condition.

2. Inspect and test fuel system.

3. Check transfer switch.

4. Inspect exhaust system.

5. Check engine ignition system.

6. Check fan belts.

• 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.

‹

ONCE EVERY SIX MONTHS

1. Test Engine Safety Devices (low oil pressure, low

coolant level, high coolant temperature).

Figure 10.1 - Oil Dipstick and Oil Fill Cap

Oil Fill

‹

ONCE ANNUALLY

Oil

Dipstick

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

2. Clean, inspect generator.

3. Flush cooling system.

‹

FIRST 100 OPERATING HOURS

1. Change engine oil and oil filter. (After initial

change, service engine oil and filter at 150 operat-

ing hours or 6 months, whichever comes first.)

‹

EVERY 500 OPERATING HOURS

1. Service air cleaner.

2. Check starter.

3. Check engine DC alternator.

Oil Filter

COOLING SYSTEM

Air intake and outlet openings in the generator com-

partment must be open and unobstructed for contin-

ued proper operation. This includes such obstruc-

tions as high grass, weeds, brush, leaves and snow.

‹

BATTERY FLUID

Check battery electrolyte fluid at least once weekly.

Fluid should cover separators in all battery cells. If

fluid level is low, add distilled water to cover tops of

separators. DO NOT USE TAP WATER IN BATTERY.

Without sufficient cooling and ventilating air flow, the

engine/generator quickly overheats, which causes it

to shut down.

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Standby Generator Sets

Maintenance

‹

ENGINE COOLANT

‹

CHECK FAN BELT

Check coolant level in coolant recovery bottle. See the

“Specifications” section.

• Inspect fan belts every three months. Replace any

damaged, deteriorated, worn or otherwise defec-

tive belt.

• Check fan belt tension. Thumb pressure, exerted

midway between pulleys, should deflect about 3/8

to 5/8 inch. Adjust belt tension as required.

• Add recommended coolant mixture as necessary.

• Periodically remove radiator pressure cap to make

sure the coolant recovery system is functioning

properly. Coolant should be at bottom of radiator

filler neck. If coolant level is low, inspect gasket in

radiator pressure cap. Replace cap, if necessary.

To have pressure cap tested, contact an Authorized

Service Dealer. Inspect cooling system and coolant

recovery system for leaks.

‹

INSPECT ENGINE GOVERNOR

Visually inspect electronic governor.

DANGER

Do not attempt to adjust the governor. Only

qualified service facilities should adjust the gov-



MAINTENANCE OWNER/

OPERATOR CAN PERFORM

ernor. Excessively high operating speeds are dan-

gerous 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 fre-

quency and voltage are supplied only at the

proper governed speed. Some connected electri-

cal load devices may be damaged by incorrect

frequency and/or voltage. Only qualified service

technicians should adjust the governed speed.

‹

CHECK ENGINE OIL LEVEL

Refer to the “Checking Fluid Levels” section.

‹

CHECK BATTERY

• Check battery fluid level each week as outlined

under “Check Fluid Levels”.

• Check battery cables for condition, tightness, cor-

rosion or damage. Clean, tighten or replace as

necessary.

‹

CHANGING ENGINE OIL

Refer to maintenance performed by authorized ser-

vice facilities for engine oil and filter change frequen-

cies.

‹

EXERCISE SYSTEM

Start the generator engine at least once every seven

days and let it run at least 20 minutes. See the

“Weekly Exercise Cycle” section.

Drain the oil while the engine is still warm from run-

ning. This means warm up the engine, shut it down

and drain immediately as follows:

‹

INSPECT COOLING SYSTEM

1. Remove OIL DRAIN HOSE from its retaining

clip.

2. Loosen and remove OIL DRAIN HOSE CAP. Drain

oil completely into suitable container.

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

DRAIN HOSE CAP, and re-install into its retaining

clip.

• Inspect engine cooling system at least once each

month.

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

Correct any discrepancies found.

• Check hose clamps for tightness.

‹

CHECK ENGINE COOLANT LEVEL

4. Turn OIL FILTER (Figure 10.2) counterclockwise

and remove. Dispose of old filter.

See the “Checking Fluid Levels” section.

5. Apply light coating of new engine oil to seal of new

oil filter.-Install FILTER and tighten by hand only.

DO NOT OVERTIGHTEN.

‹

PERFORM VISUAL INSPECTION

Complete a thorough visual inspection of the entire

engine-generator monthly. Look for obvious damage,

loose, missing or corroded nuts, bolts and other fas-

teners. Look for fuel, oil or coolant leaks.

6. Remove OIL FILL CAP. Add recommended oil (see

SPECIFICATIONS). DO NOT FILL ABOVE THE

DIPSTICK “FULL” MARK. Crankcase oil capacity

is 4.0 U.S. quarts (3.8 liters).

‹

INSPECT EXHAUST SYSTEM

After refilling the crankcase with oil, always



Inspect the exhaust system at least once every three

months. Check all exhaust system pipes, mufflers,

clamps, etc. for condition, tightness, leaks, security,

damage.

check oil level on dipstick. NEVER OPERATE

ENGINE WITH OIL BELOW THE DIPSTICK “ADD”

MARK.

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Standby Generator Sets

Maintenance

7. Start engine and check for oil leaks.

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.

Figure 10.2 - Oil Filter

Oil Fill

3. Check the spark plug gap using a wire feeler

gauge. Adjust the gap to 1.14 mm (0.045 inch)

by carefully bending the ground electrode (Figure

10.4).

Oil

Dipstick

Figure 10.4 – Setting the Spark Plug Gap

SET PLUG GAP AT 1.14 mm

(0.045 inch)

Oil Filter

CHANGING THE ENGINE AIR CLEANER

‹

To replace the engine air cleaner, (part number

0A4637), remove the air cleaner cover and replace

the air filter making sure it is positioned properly

before reattaching the cover.

‹

COOLANT CHANGE

Every year, have an Authorized Service Facility

drain, flush and refill the cooling system. See the

“Specifications” section for cooling system recom-

mendations.

Figure 10.3 — Engine Air Filter

Air Filter

MISCELLANEOUS MAINTENANCE

‹

CLEANING THE GENERATOR

Keep the generator as clean and as dry as possible.

Dirt and moisture that accumulates on internal gen-

erator windings have an adverse effect on insulation

resistance.

Periodically clean generator exterior surfaces. A soft

brush may be used to loosen caked on dirt. Use a

vacuum system or dry, low pressure air to remove

any accumulations of dirt. The generator is housed

inside an all-weather enclosure, clean the enclosure

with a soft, damp cloth or sponge and water.

Once each year, have the generator cleaned and

inspected by an Authorized Service Dealer. That

dealer will use dry, low pressure air to clean internal

windings. Parts inside the control console should be

cleaned and inspected at this time as well.

See the “Service Schedule” section for air cleaner

maintenance.

‹

SPARK PLUGS

Finally, have the insulation resistance of stator and

rotor windings checked. If insulation resistances are

excessively low, the generator may require drying.

Reset the spark plug gap or replace the spark plugs

as necessary.

1. Clean the area around the base of the spark plugs

to keep dirt and debris out of the engine. Clean

by scraping or washing using a wire brush and

commercial solvent. Do not blast the spark plugs

to clean.

. 0 v 0 8 / 0 5

M a i n t 0 0 4 R e

10-3

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Standby Generator Sets

Maintenance

‹

BATTERY

Battery electrolyte fluid is an extremely caus-



All lead-acid storage batteries discharge when not in

use. Refer to specific instructions and warnings that

accompany the battery. If such information is not

available, observe the following precautions when

handling a battery:

tic sulfuric acid solution that can cause severe

burns. Do not permit fluid to contact eyes, skin,

clothing, painted surfaces, etc. Wear protective

goggles, protective clothing and gloves when

handling a battery. If the fluid is spilled, flush

the affected area immediately with clear water.

• DO NOT use jumper cables and a booster battery

to crank or start the generator engine.

Do not use any jumper cables or booster battery

to crank and start the generator engine. If the

battery has completely discharged, remove it

from the generator for recharging.



• DO NOT recharge a weak battery while it is

installed in the generator. Remove battery from

generator and recharge in a well-ventilated area,

away from fuel vapors, sparks, heat or flames.

• Battery electrolyte fluid is an extremely caustic

sulfuric solution that can cause severe burns. DO

NOT permit fluid to contact eyes, skin, clothing,

painted surfaces, wiring insulation, etc. If any bat-

tery fluid is spilled, flush the affected area with

clear water immediately.

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.

• Always wear safety glasses, rubber apron and

Be sure the 120VAC power supply to the battery

is turned OFF, or sparking may occur at the bat-

tery posts as the cables are attached and cause

an explosion.

gloves when handling a battery.



• Batteries give off explosive hydrogen gas while

charging. The gas can form an explosive mixture

around the battery for several hours after charging.

Any spark, heat or flames can ignite the gas and

cause an explosion which can shatter the battery,

causing blindness or other serious injury.

‹

BATTERY REPLACEMENT

When replacing batteries, use the same number and

the type of battery that follows:

‹

BATTERY MAINTENANCE

BCI Group No.

CCA

The battery should be inspected per the “Service

Schedule” section. The following procedure should

be followed for inspection:

24F-6

525 @ 0 deg. F

NOTE:

The BCI number should be located directly on the

battery.

1. Inspect the battery posts and cables for tightness

and corrosion. Tighten and clean as necessary.

2. Check the battery fluid level of unsealed batteries

and, if necessary, fill with DISTILLED WATER

ONLY. DO NOT USE TAP WATER IN BATTER-

IES.

3. Have the state of charge and condition checked.

This should be done with an automotive-type bat-

tery hydrometer.

REPAIR PARTS

The latter portion of this manual consists of exploded

views, parts lists and electrical data pertaining to this

generator set. The parts lists consist of (a) an item

number, (b) a part number, (c) the quantity required,

and (d) a description of the part. The item number

corresponds to an identical number on the exploded

view drawing.

DANGER

Storage batteries give off explosive hydrogen

gas. This gas can form an explosive mixture



around the battery for several hours after charg-

ing. The slightest spark can ignite the gas and

cause an explosion. Such an explosion can shat-

ter the battery and cause blindness or other

injury. Any area that houses a storage battery

must be properly ventilated. Do not allow smok-

ing, open flame, sparks or any spark producing

tools or equipment near the battery.

. 0 v 0 8 / 0 5

M a i n t 0 0 4 R e

10-4

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Standby Generator Sets

Service Schedule

SERVICE SCHEDULE

30 KW - 150 KW STANDBY GAS ENGINE DRIVEN GENERATOR SETS

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

150 kW in size. The established intervals in the schedule are the maximum recommended when the unit is used

in an average service application. They will need to be decreased (performed more frequently) if the unit is used

in a severe application. Use calendar time, from the previous maintenance interval to determine the next required

maintenance interval.

Service Maintenance Interval Information:

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

1 An early inspection of the generator set to insure it is ready to operate when required and to identify any poten-

tial problem areas.

This inspection may be performed by the end user providing the following safety steps are taken to prevent

the engine from starting automatically without warning:

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

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

Manual switch to the “OFF” position.

• Remove the 15 amp control panel fuse.

• Turn off the battery charger.

• Remove the negative battery cable.

The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition

from burning out sensitive control panel components and circuits.

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

operation when required.

2 A wear-in service inspection of the generator set to insure it is ready to operate and carry the load when

required, and to identify any potential problem areas.

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

the unit.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge

to accomplish and should be performed only by an Authorized Service Dealer.

3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required,

and to identify any potential problem areas.

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

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge

to accomplish and should be performed only by an Authorized Service Dealer.

4 A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required,

and to identify any potential problem areas.

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

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge

to accomplish and should be performed only by an Authorized Service Dealer.

5 A comprehensive inspection of the generator set to insure it is properly serviced and ready to operate and carry

the load when required, and to identify any potential problem areas.

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

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge

to accomplish and should be performed only by an Authorized Service Dealer.

. A v 0 9 / 0 5

v S S c h r d 0 0 1 R e

11-1

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Standby Generator Sets

Service Schedule

Maintenance Level 1

Level 2

Level 3

Level 4

Level5

Tasks

Recom-

mended

Task

Required

Task

Required

Task

Required

Task

Comp. to be done Comp. to be done Comp.

Required

Comp. to be done Comp.

Bi- (Date-

Annually/ Initials) annually/ Initials)

100 hrs. 250 hrs.

to be done (Date- 3 months/ (Date-

monthly/

10 hrs.

Semi-

(Date- to be done (Date-

Initials)

Initials) Break-in Initials) annually/

30 hrs. 50 hrs.

1. Disable the unit

from operating

per the first page

warning.

2. Check the engine

oil level. Adjust

as necessary.

3. Check the engine

coolant level.

Adjust as

necessary.

4. Check the engine

coolant thermal

protection level.

Correct as

necessary.

5. Check the natural

gas delivery

system for leaks

and correct

pressure on gas

engine driven

units. Tighten

connections as

necessary.

6. Check the air

inlets and outlets

for debris. Clean

as necessary.

7. Check the battery

electrolyte level

and specific

gravity if

accessible. Adjust

as necessary.

8. Check the battery

posts, cables,

and charger for

loose

connections,

corrosion, and

proper operation.

Correct as

necessary.

9. Check the unit

wiring for loose

connections,

corrosion, and

damage. Correct

as necessary.

. A v 0 9 / 0 5

v S S c h r d 0 0 1 R e

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Standby Generator Sets

Service Schedule

Maintenance Level 1

Level 2

Level 3

Level 4

Level5

Tasks

Recom-

mended

Task

Required

Task

Required

Task

Required

Task

Comp. to be done Comp. to be done Comp.

Required

Comp. to be done Comp.

Bi- (Date-

Annually/ Initials) annually/ Initials)

100 hrs. 250 hrs.

to be done (Date- 3 months/ (Date-

monthly/

10 hrs.

Semi-

(Date- to be done (Date-

Initials)

Initials) Break-in Initials) annually/

30 hrs. 50 hrs.

10. Check the engine

accessory drive

belts and fan

coupling device

if equipped for

correct tension,

wear, weather

cracking, and

damage. Replace

as necessary.

11. Check the engine

valve clearance.

Adjust as

necessary.

12. Visually inspect

the unit looking

for leaks, wear or

damage, loose

connections or

components, and

corrosion. Correct

as necessary.

13. Test the engine

and transfer

switch safety

devices. Correct

and/or adjust as

necessary.

14. Initiate an

automatic start

and transfer of

the unit to site

load and exercise

it for at least 1

hour looking for

leaks, loose

connections or

components, and

abnormal

operating

conditions.

Correct as

necessary.

15. Replace the

engine

accessory

drive belts.

16. Check gearbox

oil level (if

equipped).

17. Change gearbox

oil (if equipped).

. A v 0 9 / 0 5

v S S c h r d 0 0 1 R e

11-3

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Standby Generator Sets

Service Schedule

Maintenance Level 1

Level 2

Level 3

Level 4

Level5

Tasks

Recom-

mended

Task

Required

Task

Required

Task

Required

Task

Comp. to be done Comp. to be done Comp.

Required

Comp. to be done Comp.

Bi- (Date-

Annually/ Initials) annually/ Initials)

100 hrs. 250 hrs.

to be done (Date- 3 months/ (Date-

monthly/

10 hrs.

Semi-

(Date- to be done (Date-

Initials)

Initials) Break-in Initials) annually/

30 hrs. 50 hrs.

18. Start and

exercise the unit

at full rated load

(use a load bank

if the site load is

not enough) for

at least 2 hours

looking for leaks,

loose

connections or

components, and

abnormal

operating

conditions.

Correct as

necessary.

19. Perform an

engine oil

analysis (send a

sample to a lab

for results).

Change the

engine oil and

filters if the

analysis results

indicate this is

required.

20. Change the

engine oil.

21. Replace the

engine oil filter(s).

22. Replace engine

spark plugs.

Clean and re-gap

or replace as

necessary.

23. Replace the

engine air

filter(s).

24. Perform a 5

minute no-load

operational run

of the unit

looking for any

post service

problems.

25. Return the unit

to standby setup

for operation

when required.

. A v 0 9 / 0 5

v S S c h r d 0 0 1 R e

11-4

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Standby Generator Sets

Troubleshooting

TROUBLESHOOTING GUIDE

PROBLEM

Engine won’t crank.

CAUSE

1. 15 amp fuse blown.

CORRECTION

1. Replace fuse.

2. Loose or corroded or defective

battery cables.

2. Tighten, clean or replace

battery cables as necessary.

3. Replace contactor.*

3. Defective starter contactor.

4. Defective starter motor.

5. Dead or Defective Battery.

6. 5 amp fuse blown.

4. Replace starter motor.*

5. Remove, change or replace battery.

6. Replace fuse.*

Engine cranks but won't start

Engine starts hard, runs rough.

Engine starts then shuts down.

1. Out of fuel.

1. Replenish fuel.

2. Replace solenoid.*

3. Reconnect wire.

2. Fuel solenoid (FS) is defective

3. Open Wire #14A from Engine Control

circuit board.

4. Spark plugs defective.

5. Door on tank not closed.

4. Clean, regap or replace plugs.

5. Close door on tank.

1. Flame arrestor (air cleaner) plugged or

damaged.

2. Plugged fuel line.

1. Clean or replace as needed.

2. Unclog fuel line.

3. Defective spark plugs.

4. Fuel pressure incorrect.

3. Clean, regap or replace plugs.

4. Confirm fuel pressure to regulator is as

recommended in SPECIFICATIONS.

1. Engine oil level is low.

2. Engine is overheated.

1. Check oil and add oil as needed.

2. Check cooling system for leaks.

3. Replace switch.*

3. Defective Low Oil Pressure Switch

4. Defective Coolant Temperature Switch

5. Defective Control Module circuit board.

6. Coolant Level is Low.

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 switch.*

2. Reconnect/close wire.

engine continues to run

2. Open/disconnected wire #15A between

AUTO/OFF/MANUAL switch and Control

Module circuit board.

3. Defective Control Module circuit board

3. Replace board.*

No AC output from generator.

1. Check main line circuit breaker.

2. Check circuit breaker & fuses.

3. Transfer switch set to NORMAL position

4. Generator internal failure.

1. Reset to ON or CLOSED.

2. Reset and replace, if necessary.

3. Set to GENERATOR position.

4. *

5. Thermal circuit breaker open.

5. Auto-reset - Wait 5 min. and

attempt restart.

*Contact the nearest Authorized Dealer for assistance.

. 0 v 0 8 / 0 5 l s b h r t T 0 0 1 R e

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Standby Generator Sets

Notes

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Standby Generator Sets

Notes

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Standby Generator Sets

Notes

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Standby Generator Sets

Notes

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0F2885

0F2883

0F9637 (4)

PANEL CB CONN BOX

STAND RH CONTROL

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

4.6L 80KW 1PHASE)

STAND LH CONTROL C5 GRBX

BUSHING SNAP SB-2.5-31

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

80KW 1PHASE)

1.)

UL CIRCUIT BREAKER (FD)

0F2887

065469

0D5572

0D5573

0D5575

0D5576

0F0199

065960

022473

022097

022127

0C2454

029289

0F1733

COVER FD FRM CB

DECAL DANGER HIGH VOLTAGE

CB 0150A 3P 600V S FD6 LL

CB 0175A 3P 600V S FD6 LL

CB 0225A 3P 600V S FD6 LL

CB 0250A 3P 600V S FD6 LL

INSULATOR CB FD FRAME 30MIL

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

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

0F3685

023484N

086961

067617030A

067617030B

043180

022264

0C3990

057701

022155

0C2428

0F3618

0A9457

057073

0D5466

0A7822

022237

022241

049226

0C2266

0C2454

042568

022473

022097

049813

0D4698

0F4464

025433

024469

067210A

0D6029

051713

081008

077043J

INTERFACE 1PH 240V

INTERFACE 3PHS 416/480V

INTERFACE 3PHS 208/240V

WASHER FLAT M4

NUT HEX 1/4-20 STEEL

WASHER LOCK #8-M4

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

TAPE ELEC 1/2 FOAM (AS REQ’D)

DECAL CUSTOMER CONNECT INSIDE

SCREW PHTT M4-0.7 X 10 ZYC

BLOCK TERM 20A 8 X 6 X 1100V

WASHER LOCK #6

SCREW PHTT #6-32 X 1/2 ZYC

DECAL CPL CUST CONN H CTRL

DECAL NEUTRAL

(1) 9

REF.

2.)

UL CIRCUIT BREAKER (JD+LD)

0F2721

065469

0D5577

0D5578

0D5579

0D5581

0D5585

0F2353

022770

022473

022097

022127

0C2454

029289

0F1733

COVER CIR BRKR JD/LD

DECAL DANGER HIGH VOLTAGE

CB 0300A 3P 600V S JD6 LL

CB 0350A 3P 600V S JD6 LL

CB 0400A 3P 600V S JD6 LL

CB 0600A 3P 600V S LD6

JUNCTION BLOCK 3/8-16

(2) 15

(2) 16

(1) 26

BUS BAR NEUTRAL BLOCK 390

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

WASHER LOCK 3/8

NUT HEX 3/8-16 STEEL

WASHER LOCK M5

SCREW PHTT M5-0.8 X 16 ZYC

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

SCREW HHC M6-1.0 X 20 G8.8

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

NUT HEX M6 X 1.0 G8 YEL CHR

BLOCK TERM 20A 6 X 3 X 1100V

DECAL CUST CONN 120V UTILITY

LUG SLDLSS #6-14 X 13/64 CU

SCREW HHTT #10-32 X 3/8 CZ

DECAL GROUND LUG

CB 0450A 3P 600V S LD6 LL

INSULATOR CIRCUIT BR. JD/LD

SCREW RHM 1/4-20 X 3

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

NUT HEX 1/4-20 STEEL

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

TAPE ELEC 1/2 FOAM (AS REQ’D)

DECAL CUSTOMER CONNECT INSIDE

(1) ITEM INCLUDED WITH HARNESS.

(2) ITEM INCLUDED WITH 0D5464B.

(3) ITEM IS PART OF 9R.

SCREW HHTT M6-1.0 X 16 ZYC

WASHER FLAT M5

GROMMET 1.25 X .25 X .75

CONDUIT FLEX 2.0" ID

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

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

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

HOLE.

1 PHASE)

(3) 37

0F6156

029289

0F8656

0F3113

REF

PLATE WIRE SNGL GALV

TAPE ELEC 1/2 FOAM (AS REQ’D)

ASSY PCB 4.6L IGNITION MODULE

ASSY PCB HSB CTRL IGN MODULE (ALL OTHER

APPLICATIONS EXCEPT 4.6L G3)

SCREW HHC M6-1.0 X 16 G8.8

SCREW PPHM #10/32 X 2

WASHER FLAT #10 ZINC

WASHER LOCK #10

NUT HEX #10-32 STEEL

047411

036943

023897

022152

022158

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3.)

UL CIRCUIT BREAKER (225AF)

COVER CB C5 225AF

DECAL DANGER HIGH VOLTAGE

CIRCUIT BREAKERS 200A FRAME

COVER CB DISH 225AF

RIVET POP .125 X .275 SS

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

WASHER FLAT #8 ZINC

WASHER LOCK #8-M4

NUT HEX #8-32 STEEL

TAPE ELEC 1/2 FOAM

DECAL CUSTOMER CONNECT INSIDE

5.)

UL CIRCUIT BREAKER (800AF)

COVER CB C5 800AF

DECAL DANGER HIGH VOLTAGE

CIRCUIT BREAKERS 800A FRAME

INSULATOR CB 800AF

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

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

0F4173

065469

0F4165$

0F4186

036261

053640

038150

022264

022471

029289

0F1733

022129

0F8432

0C2454

0F8451

049897

022145

045771

0F8843

W/CB

REF

0F4176

065469

0F4167$

0F8433

024196

022473

022097

022127

0C2454

029289

060619

022131

022237

045772

0F8452

097950

0F1733

W/CB

REF

NUT HEX 1/4-20 STEEL

SCREW THF M6-1X16 N WA Z/JS

TAPE ELEC 1/2 FOAM

SCREW SHC M10-1.50 X 40 G12.9

WASHER FLAT 3/8-M10 ZINC

WASHER LOCK 3/8

NUT HEX M10-1.5 G8 YEL CHR

LUG SLDLSS 500-750 X 2 MCM AL/CU

SCREW SHC M10-1.25 X 70 G8.8

DECAL CUSTOMER CONNECT INSIDE

TERM COVER VITZROTECH 400AF CB

WASHER LOCK M8-5/16

INSULATOR CB 225AF

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

LUG SLDLSS 300 MCM-6 AL/CU

SCREW SHC M8-1.25 X 20 G8

WASHER FLAT 5/16-M8 ZINC

NUT HEX M8-1.25 G8 CLEAR ZINC

BUS BAR 200A LUG ADAPTOR

TERMINAL COVER CB

(1) W

(1) U

6.)

NEUTRAL BLOCK 390 / 200-400A

BUS BAR NEUTRAL BLOCK 390

SCREW HHC M8-1.25 X 45 G8.8 FT

WASHER FLAT 5/16-M8 ZINC

WASHER LOCK M8-5/16

NUT HEX M8-1.25 G8 YEL CHR

SCREW HHC 1/4-28 X 3/4 G5

WASHER LOCK M6-1/4

0D5466

039287

022145

022129

045771

045335

022097

0A7822

4.)

(2) L

(2) M

(1) S

UL CIRCUIT BREAKER (400AF)

COVER CB C5 400AF

DECAL DANGER HIGH VOLTAGE

CIRCUIT BREAKERS 400A FRAME

DECAL CUSTOMER CONNECT INSIDE

SCREW RHM 10-32 X 4

WASHER FLAT #10 ZINC

WASHER LOCK #10

NUT HEX #10-32 STEEL

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

TAPE ELEC 1/2 FOAM

SCREW SHC M10-1.5 X 25 G12.9

WASHER LOCK M10

BUS BAR CB ADAPTER 225-400 A

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

WASHER FLAT 3/8-M10 ZINC

TERM COVER CB

0F4175

065469

0F4166$

0F1733

042419

023897

022152

022158

0C2454

029289

052647

046526

W/CB

REF

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

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

WITH CIRCUIT BREAKERS.

2/3

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

0A7822

022131

W/CB

(2) W

023334

022097

022473

W/CB

2/3

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

WASHER LOCK M6-1/4

WASHER FLAT 1/4-M6 ZINC

SCREW SHC M10-1.5 X 25 G12.9

WASHER LOCK M10

(2) X

W/CB

2/3

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055173

022129

0E2747A

0A3870

0A3009

0F5564D

0F5563D

0A3881D

0A3881B

0A3882B

0A3883B

052624

0A5580

0A1633

0F7351

0F7349

0F7348

0F7350

068113

022392

043123

051779

052259

051769

068406

072878

087272

068405C

092950

090063

090152

023365

033143

090064

083485

031980

083401

042561

033212

083549

0A4089

SCREW HHC M8-1.25 X 20 G10.9

WASHER LOCK M8-5/16

FAN SAE ALTERNATOR (G/B)

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

HUB DRIVE 390 SAE GB

RTR 390 100KB3 GB SAE TECHUM

RTR 390 130KB4 GB SAE TECHUM

RTR 390 80GB BR BRLSS

RTR 390 80GB 1P BRLSS

RTR 390 100GB 1P BRLSS

RTR 390 125GB 1P BRLSS

BEARING BALL 6212 SEALED

SCREW HHC M14-2.0 X 140 G8.8

WASHER 390 SAE ALT.

STR 390 130 GB4 CPL

STR 390 80 AB3 CPL

STR 390 100 AB3 CPL

STR 390 130 AB4 CPL

CARRIER REAR BRG 15"

PIN DOWEL 1/2 X 1-1/4

WASHER LOCK M14

NUT HEX M14-2.0 G8 YEL CHR

8 *

WASHER FLAT M12

WASHER LOCK M12

SCREW HHC M12-1.75 X 60 G10.9

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

ASSY EXCITER 2.00" STK

EXITER FIELD 2" LG SPD CONN

COLLAR SLIP FIT 390 MM

BRIDGE SUPPORT DIODE 15"

ASSY BRIDGE RECTIFIER

WASHER SHAKEPROOF INT #8

SCREW HHM #8-32 X 7/8

CAP END ROTOR 390MM

PLATE NUT

TIE WRAP UL 14.6 X .14 NATL

BRACKET-STATOR WIRE

CLAMP HOSE #36 1.88-2.7

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

SLEEVE RUBBER

ASSY SCROLL 390 SAE

KIT PARTS

0A2491

0A2497

0A2496

056326

022307

022473

045757

047411

0A2110

I/N’S: 41 THRU 49

SHROUD ALT SHEET METAL

SCREEN SHROUD SAE

BRKT TENSIONER SAE SCROLL

TRIM VINYL BLACK 1/8 GP

WASHER LOCK M6-1/4

WASHER FLAT 1/4-M6 ZINC

SCREW HHC M6-1.0 X 25 G8.8

SCREW HHC M6-1.0 X 16 G8.8

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

8.4 FT.

* ROTOR REPLACEMENT PART

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0F2885

0G0171

0G0171A

0G0172

023484N

0F4677

067617030A

067617030B

043180

022264

0C3990

057701

022155

0C2428

0F3618

0A9457

057073

0D5466

0A7822

022237

022241

049226

0C2266

0C2454

042568

022473

022097

049813

0D4698

0F4464

025433

024469

067210A

0D6029

051713

081008

077043J

0F6156

PANEL CB CONN BOX

STAND, RH CONTROL CPL C5

STAND RH CONTROL CPL C5 2 HOLE

STAND, LH CONTROL CPL C5

BUSHING SNAP SB-2.5-31

ASSY PCB INTERFACE 1PH 240V

INTERFACE 3PHS 416/480V

INTERFACE 3PHS 208/240V

WASHER FLAT M4

37***

029289

0F3113

047411

036943

023897

022152

022158

REF

TAPE ELEC 1/2 FOAM (AS REQ’D)

ASSY PCB HSB CTRL IGN MODULE

SCREW HHC M6-1.0 X 16 G8.8

SCREW PPHM #10/32 X 2

WASHER FLAT #10 ZINC

WASHER LOCK #10

NUT HEX #10-32 STEEL

WASHER LOCK #8-M4

1.)

T****

UL CIRCUIT BREAKER (800AF)

REF

SCREW PHTT M4-0.7 X 10 ZYC

BLOCK TERM 20A 8 X 6 X 1100V

WASHER LOCK #6

SCREW PHTT #6-32 X 1/2 ZYC

DECAL CPL CUST CONN H CTRL

DECAL NEUTRAL

JUNCTION BLOCK 3/8-16

BUS BAR NEUTRAL BLOCK 390

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

WASHER LOCK 3/8

0G0173

065469

0F4167$

0F8433

022477

022473

022097

022127

0F1733

029289

060619

022131

022237

045772

0F8452

0D2576

W/CB

COVER, CB 803 C5

9 *

15 **

16 **

26 *

REF.

DECAL DANGER HIGH VOLTAGE

CIRCUIT BREAKERS 800A FRAME

INSUL CB 800AF

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

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

NUT HEX 1/4-20 STEEL

DECAL CUSTOMER CONNECT INSIDE

TAPE ELEC 1/2 FOAM

SCREW SHC M10-1.50 X 40 G12.9

WASHER FLAT 3/8-M10 ZINC

WASHER LOCK 3/8

NUT HEX M10-1.5 G8 YEL CHR

LUG SLDLSS 500-750X2 MCM AL/CU

SCREW SHC M10-1.5 X 70 G10.9

TERM. COVER VITZROTECH 400AF CB

NUT HEX 3/8-16 STEEL

WASHER LOCK M5

SCREW PHTT M5-0.8 X 16 ZYC

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

SCREW HHC M6-1.0 X 20 G8.8

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

NUT HEX M6 X 1.0 G8 YEL CHR

BLOCK TERM 20A 6 X 3 X 1100V

DECAL CUST CONN 120V UTILITY

LUG SLDLSS #6-14 X 13/64 CU

SCREW HHTT #10-32 X 3/8 CZ

DECAL GROUND LUG

2.)

NEUTRAL BLOCK 390 / 200-400A

0D5466

039287

022145

022129

045771

045335

083896

0A7822

BUS BAR NEUTRAL BLOCK 390

SCREW HHC M8-1.25 X 45 G8.8 FT

WASHER FLAT 5/16-M8 ZINC

WASHER LOCK M8-5/16

NUT HEX M8-1.25 G8 YEL CHR

SCREW HHC 1/4-28 X 3/4 G5

WASHER LOCK 1/4-M6 SS

SCREW HHTT M6-1.0 X 16 ZYC

WASHER FLAT M5

GROMMET 1.25 X .25 X .75

CONDUIT FLEX 2.0" ID

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

PLATE WIRE SNGL GALV

* ITEM INCLUDED WITH HARNESS

** ITEM INCLUDED WITH 0D5464B

*** ITEM IS PART OF 9R.

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

SUPPLIED WITH CIRCUIT BREAKERS.

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0F2687

0F2611

0F5254

0F5253

0F7077

046526

051756

0C2454

052250

076749

0F2573

0F2610

0F2572

0F5689

0F2862

0F2560

022131

039414

052625

0F2561

0C8165

0D6795

0C7043

0E8909

048031C

0C8146

082774

0F2686

0F5463

0F8695

0F4028

0F4030

0F4032

0F4496

042911

0F2872

022304

022195

022196

049813

049820

022145

022129

035685

045764

065852

0C7649

055596

069860E

069811

080713

022473

022097

042568

0F5050

039253

051769

0C8145

0E2507

090283

0C8566

0F2776A

052644

REF

WELDMENT RADIATOR SUPPORT150

RADIATOR 680 X 680 X 70 CPL

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

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

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

WASHER LOCK M10

SCREW HHC M10-1.5 X 20 G8.8

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

TAPE FOAM 1 X 1 (26.75” LG)

TANK COOLANT RECOVERY

PULLEY FAN V-GROOVE 9"

FAN 26" LH ROTATION

ARM TENSIONER

SCREW SHC SHLDR LKG M8 X 16 LG

SPRING TENSION CPL

PULLEY V-BELT 4" FLANGED

WASHER FLAT 3/8-M10 ZINC

SCREW HHC M8-1.25 X 35 G8.8

SCREW SHC M10-1.5 X 35 G12.9

HUB FLEX PLATE

NUT HEX LOCK 5/16-24 NY INS

SCREW HHC M12-1.5 X 60 G8.8

DISK FLEX

COUPLING HUB FLEX (MACH)

CLAMP HOSE BAND 1/4

SCREW HHC 5/16-24 X 1.124

KEY WOODRUFF 4 X 19D

HOSE RADIATOR UPPER CPL

HOSE LOWER RAD CPL C5 6.8L

ASSY BRG/SHAFT CPL FANDRIVE

PULLEY 6.5" DIA MACHINED (6.8L 100KW)

PULLEY 6" DIA MACHINED (6.8L 130KW)

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

PULLEY 4.5" DIA MACHINED (5.4L 100KW)

SCREW HHC M10-1.5 X 30 G8.8

SCREW HHC 1/2-13 X 2" G8

WASHER FLAT 1/2 ZINC

48 *

WASHER LOCK 1/2

NUT HEX 1/2-13 STEEL

NUT HEX M6 X 1.0 G8 YEL CHR

NUT HEX LOCK M8-1.25 NY INS

WASHER FLAT 5/16-M8 ZINC

WASHER LOCK M8-5/16

CLAMP HOSE #28 1.32-2.25

SCREW HHTT M4-0.7 X 8 BP

SPRING CLIP HOLDER .37-.62

CLAMP HOSE .38-.87

BARBED STR 3/8 NPT X 3/8

HOSE DRAIN ASSY 28"

CAP HEX 1/4 NPT BRASS

BRACKET COOLANT TANK

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

SCREW HHC M6-1.0 X 20 G8.8

SHIELD RADIATOR C5

SCREW HHC M8-1.25 X 20 G8.8

WASHER LOCK M12

WASHER FLEX (THIN)

PROBE, COOLANT LEVEL 3/8 NPTF

CAP RADIATOR 13 PSI

SCREW HHFC M6-1.0 X 20 G8.8

BRACKET, SIGNAL CONDITIONER

SPACER .5 X 1.5 X .25 STL/ZINC

* ITEM 48 IS INCLUDED WITH 47.

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0F3384

065852

052252

052257

052259

055597

052251A

052860

0F2895

045764

090502

061383

043107

022473

049813

057192

022131

046526

0536210360

042909

022261

022129

022145

045771

053557

0F2591

0F2910

038750

022097

022447

BASE CPL 100-130KW 6.8L GB

SPRING CLIP HOLDER .37-.62

DAMPENER VIBRATION

SPACER .49 X .62 X 1.87 PWDR/ZINC

WASHER FLAT M12

SCREW HHC M12-1.75 X 85 G8.8

DAMPENER VIBRATION 50 WHITE

NUT LOCKING M12-1.75

SUPPORT ENG 5.4L LH/RH 6.8L RH

SCREW HHTT M4-0.7 X 8 BP

SCREW SHC M10-1.5 X 60 G12.9

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

SCREW HHC M8-1.25 X 25 G8.8

WASHER FLAT 1/4-M6 ZINC

NUT HEX M6 X 1.0 G8 YEL CHR

SCREW SHC M10-1.5 X 30 G12.9

WASHER FLAT 3/8-M10 ZINC

WASHER LOCK M10

WIRE ASSEM #4GA GRD

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

SCREW HHC M12-1.75 X 40 G8.8

TOWER GB COMPROD C5

SUPPORT ENGINE 6.8L LH SIDE

SCREW HHC M6-1.0 X 30 G8.8

WASHER LOCK M6-1/4

WASHER SHAKEPROOF INT 1/4

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0F3408A

0F3411A

058665

022131

050331A

050331

038805Z

038804U

045771

022129

027482

075763

0C2454

0F3409

022097

049813

042568

0G0783

TRAY BATTERY 27F

STRAP BATTERY RETAINMENT 27F

BATTERY 12VDC 90-AH 27F

WASHER FLAT 3/8-M10 ZINC

BATTERY POST COVER RED +

BATTERY POST COVER BLK -

CABLE BATTERY BACLK #1 X 26.00

CABLE BATTERY RED #1 X 28.00

NUT HEX M8-1.25 G8 YEL CHR

WASHER LOCK M8-5/16

WASHER SHAKEPROOF EXT 5/16 STL

BOOT BATTERY CABLE

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

SUPPORT BATTERY TRAY

WASHER LOCK M6-1/4

NUT HEX M6 X 1.0 G8 YEL CHR

SCREW HHC M6-1.0 X 20 G8.8

SUPPORT 27F BATTERY

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0F2123

0F2122

095613

051756

046526

049814

051735

0F2097

072879

097557B

097785

095970

095968

0E6866

070263

057019

026847

097784

095969

095967

0E6865

095966

095976

095971

096777

057019S

096379

048189

095979

021159

097557A

057163

0F6518

0F3201

020443

094666A

099828

099828A

026925

097557C

038591

025066

031578

052625

049814

0A1786

027175

045772

052243

057642

0F6487

0F6355

0F6477

0F6557

GEAR CASE ENG. MACHINED

GEAR CASE ALT. MACHINED

SEAL OIL

SCREW HHC M10-1.5 X 20 G8.8

WASHER LOCK M10

SCREW HHC M10-1.5 X 25 G8.8

SCREW HHC M10-1.5 X 70 G8.8

GASKET 390 GEARBOX

SPACER .69 X 2.75 X .37 ST/ZNC

KEY 10 X 16 X 46

GEAR OUTPUT 1.65:1

GEAR OUT 390-50H 37T

GEAR OUT 390-60H 35T

GEAR OUTPUT 2:1 50HZ 390

SCREW HHC M16-2.0 X 35 G10.9

BALL BRG 65 X 120 X 23

BREATHER

GEAR INPUT 1.65: 1

GEAR INPT 390-50 25T

GEAR INPT 390-60 27T

GEAR INPUT 2:1 50HZ 390

SHAFT 390 INPUT GEAR

COLLAR HARDENED

SEAL OIL

SNAP RING INT 120MM

BEARING #6213 SEALED

PLATE INTRNL BRG RET

PIN DOWEL M8 X 24

PLATE BEARING THRST

SPACER STRESSPROOF

KEY 10 X 16 X 40

PLUG PIPE 3/8" MAGNETIC

SCREW HHFC M10-1.5 X 25 G10.9

COVER GEARBOX GUARD

COUPLING INNER DRAWN

COUPLING OUTER MACHN

DAMPER GB CPLR VIBRA

PLUG STD PIPE 3/8 STEEL SQ HD

KEY 10 X 16 X 50

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

COUPLING FULL 3/8-18

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

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

SCREW HHC M10-1.5 X 25 G8.8

RETAINING COMPOUND

LUBE GREASE SAE #90 80W90 (NOT SHOWN)

NUT HEX M10-1.5 G8 YEL CHR

SCREW HHC M10-1.5 X 60 G8.8

SCREW HHC M10-1.5 X 40 G10.9

WASHER FLAT M10 SEALING COPPER

GASKET SEAL PLATE 390 GB

ENHANCER GEAR OIL (NOT SHOWN)

THREADLOCK AND SEALANT

REF.

2.5cc

.200 GAL

.050 GAL

0.4cc

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COMPONENTS INCLUDED IN 0F1826E

0F1823

0F1824

0F2606

036261

0F5763

0F1732

0E9764

0F1725C

0F1958

0F2256

0E3161

029673

049226

079224

051713

0F5886

051716

0C3990

043280

055014

043184

0F2557

0F5884

0C2265

0F4333

0F5883

0F6305

0F6305A

0F6277

ENCL H CONTROL PANEL

COVER CONTROL PANEL

HINGE CONTINUOUS H-PNL

RIVET POP .125 X .275 SS

ASSY PROGRAMMED PM H-100

DECAL FUSES LOCATED INSIDE

RAIL SNAPTRACK PCB HOLDER BULK (12” LG)

ASSY PCB 2AMP 12V UL BATT CHGR

PLATE HARNESS CLAMP

ASSY PCB PWR AVR W/AMP HEADER

ASSY PCB BOSCH GOV DRIVER

DIO BRIDGE 25A 600V

WASHER LOCK M5

SCREW PPHM M5-0.8 X 30 SS

WASHER FLAT M5

SCREW HHPM M5-0.8 X 12

NUT HEX M5-0.8 G8 CLEAR ZINC

SCREW PHTT M4-0.7 X 10 ZYC

WASHER FLAT M4

SCREW PPHM M4-0.7 X 8 BLK OX

WASHER LOCK M4

DECAL WARNING BATT CHRG 12/24V

SCREW PHTT M3.5-0.6 X 10

SCREW PHTT M4-0.7 X 12 ZYC

CONN DUST CAP W/CHAIN DB9

WASHER FLAT M3.5

SEAL COVER 3.18 X 12.7 X 382

SEAL COVER 3.18 X 12.7 X 283

ASSY HARNESS H-PNL SW (NOT SHOWN)

COMPONENTS INCLUDED IN WIRE HARNESS

0F1263

0F1262

0F1264

0E9049B

055911

ADPTR RH SIDE WICKMAN 178.6191

HOLDER FUSE WICKMANN 178.6150

ADPTR LH SIDE WICKMAN 178.6192

ASSY PCB G-PANEL RELAY 12VDC

BLOCK TERM 20A 12 X 6 X 1100V

COMPONENTS NOT INCLUDED IN 0F1826E OR WIRE HARNESS

056739

RELAY SOLENOID 12VDC PNL MNT

DPE BREAKER SEE DRAWING 0F9280

BOOST RESISTOR SEE DRAWING 0F9280

COVER CONTROL PANEL SIDE

SCREW HHC 1/4-20 X 3/4 G5

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

0F2627A

022287

022473

022097

043182

051714

052777

0C2323

0F5459

0F5461

022127

0F5460

0E7403C

0E7403B

0F6145

091526

0C2699

051713

049226

WASHER LOCK M3

NUT HEX M3-0.5 G8 YEL CHR

WASHER FLAT M3

SCREW PHTT #6-32 X 5/8 ZYC

DECAL CPL CONTROL PANEL FUSES

DECAL 5.4/6.8L TB3

NUT HEX 1/4-20 STEEL

A/R

DECAL CPL 5.4/6.8L RELAY BOARD

FUSE ATO TYPE 15 AMP (BLUE)

FUSE ATO TYPE 10 AMP (RED)

SEAL WEATHER .45" DIA

SCREW PPHM M5-0.8 X 12 ZNC

SCREW PHTT #6-32 X 3/8 ZYC

WASHER FLAT M5

WASHER LOCK M5

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0F2807C

0F2807E

0F9207

0F2807B

0F2807D

0F9208

0F4505

0A6765

0F4710

0F7200

080762

0F2809

0F2981A

0F2962

0C2454

022097

0F2830

0F4462

0C2454

0F4367

0F4368

0F2773C

0F2773D

0D3159

088775

0F2808

0F5447

022473

0F6214

080762

0F6803

049813

049721

088510

REF

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

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

PIPE EXH MANIFOLD 4.6L RH

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

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

PIPE EXH MANIFOLD 4.6L LH

GLASS PACK 23.5" LG 2.5" IN/OUT

RING GASKET 2.5 DIA

WASHER LOCK M10 SS

SCREW HHC M10-1.5 X 50 SS FTH

BOLT U 3/8-16 X 2.62

PIPE EXHAUST CROSSOVER

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

MUFFLER STRAP

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

WASHER LOCK M6-1/4

MUFFLER BRACKET STIFFENER

RAIN CAP ALUM FOR 2-1/2" PIPE

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

HEAT SHIELD EXHAUST STACK

CAP HEAT SHIELD EXHAUST STACK

EXHAUST BLANKET 900MM LONG (6.8L C5)

EXHAUST BLANKET 850MM LONG (5.4L C5)

FLANGE EXHAUST

WASHER FLAT 3/8 SS

EXHUAST OUTLET PIPE CPL

BRKT MUFFLER

WASHER FLAT 1/4-M6 ZINC

PIPE ELBOW EXHAUST MUFFLER

REF

BOLT U 3/8-16 X 2.62

MUFFLER STRAP UPPER/LOWER

NUT HEX M6 X 1.0 G8 YEL CHR

SCREW HHC M6-1.0 X 35 G8.8 BLK

NUT HEX M10-1.5 SS

* PARTS INCLUDED IN 0F6322 KIT, GLASS PACK SHIP LOOSE.

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5 **

0F3017

039253

022129

022145

0D5419

0D7055

0D3488G

0D3488J

0D3488

0D3488K

057795A

0A6283

0F3287

0F5990

0E9868A

057796

0F3216

0F3216A

0F3216C

0F3216D

055476

0F4612

0D6658

029333A

022097

022473

042568

0D8027

0D8025

0D8026

0D8030

0F2846

0D8029

0D8028

045771

0D3454

022131

046526

064416

045772

0F3217

0F2776A

0F6151

0F4308

0F3158

057823

0E0502

0G0866

0F4301

0F4355

0G0153

057823

REF

BRACKET,D.C. ALTERNATOR LOWER

SCREW HHC M8-1.25 X 20 G8.8

WASHER LOCK M8-5/16

WASHER FLAT 5/16-M8 ZINC

OIL FILTER, FORD V-10 ENGINE

DIPSTICK TUBE, FORD 6.8L

BELT SERPENTINE (65.0" LG) (1800 RPM)

BELT SERPENTINE (65.3" LG) (2300 RPM)

BELT SERPENTINE (67.16" LG) (3000 RPM)

SERPENTINE BELT (68.3" LG) (3600 RPM)

BARBED EL 90 3/4 PLASTIC

HOSE PREFORMED BLOCK HEATER

BRACKET DC ALTERNATOR UPPER

HARN ENG 6.8L H-100 (NOT SHOWN)

ALTERNATOR DC W/OUT PULLEY

GROMMET

PULLEY 80 OD DC ALTERNATOR (1800 RPM)

PULLEY 102 OD DC ALTERNATOR (2300 RPM)

PULLEY 132 OD DC ALTERNATOR (3000 RPM)

PULLEY 160 OD DC ALTERNATOR (3600 RPM)

BUSHING REDUCER 3/8 TO 1/8 GAL

SENDER OIL PRESSURE 1/8" NPT

DIPSTICK 6.8L FORD

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

WASHER LOCK M6-1/4

WASHER FLAT 1/4 ZINC

SCREW HHC M6-1.0 X 20 G8.8

BOLT WATER PUMP PULLEY

BOLT GROOVED IDLER PULLEY

BOLT BELT TENSIONER

TENSIONER ENG. AUTOMATIC BELT

PULLEY WATER PUMP FORD (1800RPM UNITS)

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

PULLEY GROOVED ENGINE IDLER

NUT HEX M8-1.25 G8 YEL CHR

18 *

ENGINE 6.8L FORD (V-10)

WASHER FLAT 3/8-M10 ZINC

WASHER LOCK M10

SCREW HHC M10-1.5 X 45 G8.8 FT

NUT HEX M10-1.5 G8 YEL CHR

SPACER DC ALTERNATOR PULLEY

BRACKET SIGNAL CONDITIONER

CAP RUBBER

BRACKET DC ALT STABILIZER

OIL COOLER FORD (150KW 3600RPM)

CLAMP HOSE #10 .56-1.06

TEMPERATURE SENDER DELPHI

HOSE OIL COOLER PREFORMED 3/4 (150KW 3600RPM)

HOSE OIL COOLER (150KW 3600RPM)

ADAPTOR 1/2" NPT - 3/8" NPT (150KW 3600RPM)

BARBED EL 90 1/2 NPT X 3/4 HOSE (150KW 3600RPM)

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

* NOTE: I/N 18 IS FOR HOLDING SENSOR TO I/N 35.

**I/N 5 PART OF I/N 29.

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039253

0D5418

052625

047411

0D5623

0D2608

070006

070008

055934M

047290

046526

057823

057765

049340

0D5417

049821

022129

070010

0F2776A

022097

048191

022473

029333A

0D9913

055596

069860E

0D4255

057772

0D6686

0F3131

0D3805

021113

077996

022131

048031J

052647

0D2244M

0D3808

0F5114

0F5454

079121

SCREW HHC M8-1.25 X 20 G8.8

STARTER MOTOR FORD V-10 ENGINE

SCREW SHC M10-1.5 X 35 G12.9

SCREW HHC M6-1.0 X 16 G8.8

HEAT SHIELD EXHAUST

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

WASHER LOCK M8 SSTL

WASHER FLAT M8 SS

CLAMP VINYL .75 X .343 Z

23 *

HOSE 3/8 ID SINGLE BRAID (15”)

WASHER LOCK M10

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

ADAPTER M14-1.50 X 3/8 NPT

BARBED EL 90 1/4 NPT X 3/8

SCREW HHC M10-1.0 X 25 G10.9

SCREW SHC M8-1.25 X 30 G12.9

WASHER LOCK M8-5/16

SCREW HHC M8-1.25 X 35 SS F-TH

BRACKET SIGNAL CONDITIONER

WASHER LOCK M6-1/4

DOWEL PIN M10 X 24

WASHER FLAT 1/4 ZINC

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

SCREW SHC M8-1.25 X 35 SS

BARBED STR 3/8 NPT X 3/8

HOSE DRAIN ASSY 28"

GASKET EXHAUST MANIFOLD

WASHER NYLON .565

ASSEMBLY 6.8L G-BOX FLYWHEEL

HOUSING FLYWHEEL 6.8L FORD MCH

COVER FLYWHEEL MACH 6.8L V-10

PLATE DAMPNER RETNR

CAP HOSE (2300 & 3000RPM UNITS ONLY)

WASHER FLAT 3/8-M10 ZINC

HOSE CLAMP BAND 5/8"

SCREW SHC M10-1.5 X 25 G12.9

ASSY MAGPICKUP(3/8-24 MALE)

EXH MANIFOLD MACH 6.8L V-10

DECAL REFER TO OWNERS MANUAL

PLATE MAG PICK-UP ADAPTOR

SCREW SHC M10-1.50 X 100 G10.9

REF.

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

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0D2513D

0F5419

0F4268

0F4270A

0F6977

037561

047411

022097

049811

0F4269

022473

AIR CLNR BTM PLT W/CPLR 8.1L

ELEMENT AIR FILTER

TOP PLATE VENTURI

HOLD DOWN AIR CLEANER PLATED

PLATE AIR CLEAN TOP 5.4L/6.8L

NUT WING 1/4-20 NYLK

SCREW HHC M6-1.0 X 16 G8.8

WASHER LOCK M6-1/4

WASHER FLAT M6

GASKET MIXER BODY

WASHER FLAT 1/4-M6 ZINC

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049721

065908

0F6261G

0F6261C

0F6261D

052617

022304

022129

045773

022195

040173

0C7649

030131

031015

039130

057822

059057

0A8064

0D1509

050279

0F2756A

0D2696B

0E4390

0E4392

0F0960

0F3885

0F3694

0F3691C

0F3691D

0F3691E

026915

059057

035461

081017

046580

039294

022097

047290

052223

0D2698

059057

064346

0F4408

0F6279

SCREW HHC M6-1.0 X 35 G8.8 BLK

SUPPORT NAT GAS SOLENOID

REGULATOR ASSM 5.4L 80KW NG

REGULATOR ASSM 5.4L 100KW NG

REGULATOR ASSM 6.8L 100KW NG

SCREW HHC M12-1.75 X 20 G8.8

WASHER FLAT 1/2 ZINC

WASHER LOCK M8-5/16

NUT HEX M12-1.75 G8 YEL CHR

WASHER LOCK 1/2

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

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

ELBOW 90D 1-1/4 NPT

NIPPLE PIPE 1-1/4 NPT X 3

NIPPLE CLOSE 1.25 NPT X 1.625

CLAMP HOSE #8 .53-1.00

HOSE 3/4 ID SAE-30R2 (42” LG)

BSHG RDCR HEX 1-1/4-3/4

DECAL INLET PRESSURE

DECAL FUEL INLET NG

MACHINING, INTAKE ADAPTOR 60MM (5.4L FORD)

ADAPTOR THROTTLE BODY (BOSCH) (6.8L FORD GEARBOX)

GASKET GOVERNOR ACTUATOR

ACTUATOR BOSCH 60 GOVERNOR

REDUCER 3.0" TO 2.75" TURBO

MIXER 40/60MM ACTUATOR ASSY

O-RING 2-7/8 X 3-1/16 X 3/32

VENTURI THROTTLE 38MM (5.4L 80KW)

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

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

NIPPLE CLOSE 3/4 X 1.375

HOSE 3/4 ID SAE-30R2 (42” LG)

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

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

SCREW SHC M6-1.0 X 45 G12.9

CLAMP HOSE #44 2.31-3.25

WASHER LOCK M6-1/4

HOSE 3/8 ID SINGLE BRAID (42” LG)

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

GASKET ADAPTER THROT BODY (6.8L FORD ONLY)

HOSE 3/4 ID SAE-30R2 (42” LG)

PIPE TEE 1-1/4 NPT

Y CONNECTOR 500 SERIES BARBS

HARNESS FUEL JUMPER DUAL REG

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033212

065908

0F6261H

0F6261J

0F6261K

0F6261L

0F6261M

052617

022304

022129

045773

064346

0A8064

030131

031015

088963

026915

057823

059057

0D2698

0D1509

050280

0D2696B

0F2756A

0E4390

0E4392

0F0960

0F3885

0F3694

0F3691B

0F3691D

0F3691E

0F3691F

0F3691J

022195

0F6279

081017

046580

039294

022097

047290

040173

039130

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

SUPPORT NAT GAS SOLENOID

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

REGULATOR ASSM 5.4L 100KW LPV (5.4L 100KW)

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

REGULATOR ASSM 6.8L 130KW LPV (6.8L 130KW)

REGULATOR ASSM 6.8L 150KW LPV (6.8L 150KW)

SCREW HHC M12-1.75 X 20 G8.8

WASHER FLAT 1/2 ZINC

WASHER LOCK M8-5/16

NUT HEX M12-1.75 G8 YEL CHR

PIPE TEE 1-1/4 NPT

BSHG RDCR HEX 1-1/4-3/4

ELBOW 90D 1-1/4 NPT

NIPPLE PIPE 1-1/4 NPT X 3

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

NIPPLE CLOSE 3/4 X 1.375

CLAMP HOSE #10 .56-1.06

HOSE 3/4 ID SAE-30R2 (45” LG)

GASKET ADAPTER THROT BODY

DECAL INLET PRESSURE

DECAL FUEL INLET LPG (LP VAPOR APPLICATION)

ADAPTOR THROTTLE BODY (BOSCH) (6.8L)

MACHINING INTAKE ADAPTOR 60MM (5.4L)

GASKET GOVERNOR ACTUATOR

ACTUATOR BOSCH 60 GOVERNOR

REDUCER 3.0" TO 2.75" TURBO

MIXER 40/60MM ACTUATOR ASSY

O-RING 2-7/8 X 3-1/16 X 3/32

VENTURI THROTTLE 36MM (5.4L 80KW)

VENTURI THROTTLE 40MM (5.4L 100KW)

VENTURI THROTTLE 42MM (6.8L 100KW)

VENTURI THROTTLE 44MM (6.8L 130KW)

VENTURI THROTTLE 50MM (6.8L 150KW)

WASHER LOCK 1/2

HARNESS FUEL JUMPER DUAL REG

BARBED STR 1/4 NPT X 1/2

SCREW SHC M6-1.0 X 45 G12.9

CLAMP HOSE #44 2.31-3.25

WASHER LOCK M6-1/4

HOSE 3/8 ID SINGLE BRAID (42” LG)

CLAMP HOSE #5.5 .62-.62

NIPPLE CLOSE 1.25 NPT X 1.625

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(2) 1

(2) 2

(2) 3

(2) 4

(2) 5

(2) 6

(2) 7

0F5873

0F5868

0F5872

0F5871

0F5869

0F5870

0F5867

REAR WRAP C5

DOOR C5

CENTER SUPPORT C5

DISCHARGE DUCT LH & RH SIDE C5

FRONT CORNERS C5

DISCHARGE CENTER DUCT C5

ROOF C5 ALUM

0C2454

0F2766

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

SPLITTER

(1)44

0F3181

0F3185

0F3416

0F3949

0C2634A

022473

022097

022127

0F3072

078115

0F3949B

0F3949A

0F5048D

0E5968

SPLITTER SHORT

STRINGER SPLITTER C3

SUPPORT SPLITTER C5 130KW

INSULATION CORNER POST

ASSEMBLY COVER ACCESS

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

NUT HEX 1/4-20 STEEL

INSULATION RETAINMENT HANGER

WASHER SELF LOCKING DOME

INSULATION SPLITTER

INSULATION SHORT LOUVER

VISE-ACTION LATCH SLOTTED CIR

GASKET EXTRUDED TRIM (566” LG)

TAB PULL

INSULATION SPLITTER SML

INSULATION ROOF TOP REAR

RETAINER INSULATION (740)

RIVET POP .1875 X .450 SS

INSULATION ROOF TOP

0F5049

0F3949L

0F3949E

0F3890A

087233

0F3949C

0F3949D

0F3949G

0F3949J

0F3949K

0F3949F

0F3890B

0F3890

INSULATION DOOR

INSULATION DISCHARGE DUCT

INSULATION CENTER SUPPORT

INSULATION DISCHARGE DUCT TOP

INSULATION INNER DUCT SIDE

RETAINER INSULATION (820)

RETAINER INSULATION (450)

SCREW HHC M6-1.0 X 20 G8.8

ASSY WIRE 14 AWG 20.9" GRN/YEL

WASHER SHAKEPROOF INT 1/4

NUT HEX M6 X 1.0 G8 YEL CHR

NUT HEX LOCK M6-1.0 SS NY INS

ASSY WIRE 14 AWG 34.8" GRN/YEL

SPLITTER C5

042568

0912970088

022447

049813

077992

0912970094

0F2766A

0F3949M

0F8869D

0E3257

INSULATION SPLITTER SHRT MPS

KEY VISE-ACTION LATCH SLOT CIR

SCREW TH-FRM M6 W/CAP SHKPRF W

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

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

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

FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS.

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

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

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Standby Generator Sets

Warranty

GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR

COMMERCIAL PRODUCT 50kW AND ABOVE

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

Power Systems, Inc. will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or

an Authorized/Certified Generac Power Systems Dealer, or branch thereof, is found to be defective under normal use and service, in accordance with

the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Authorized/

Certified Generac Power Systems Dealer, or branch thereof. This warranty applies only to Generac Power Systems Generators used in "Standby"

applications, as Generac Power Systems, Inc. has defined Standby, provided said generator has been properly installed and inspected on-site by

appropriate personnel. Scheduled maintenance, as outlined by the generator owner's manual, is highly recommended. This should be performed by

an Authorized/ Certified Generac Power Systems Dealer, or branch thereof. This will verify service has been performed on the unit throughout the war-

ranty period.

WARRANTY SCHEDULE

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

• - ALL COMPONENTS

YEAR TWO — Limited comprehensive coverage on parts listed.

• - ALL COMPONENTS

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

Guidelines:

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

branch thereof.

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

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

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

Manual.

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

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

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

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

applicable).

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

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

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

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

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

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

warranty.

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

normally exist.

6. Failures caused by any external cause or act of God such as, but not limited to, collision, fire, theft, freezing, vandalism, riot or wars, lightning,

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

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

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

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

defective part(s).

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

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

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

13. Overtime, holiday, or emergency labor.

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

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

cause of the problem.

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

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

MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow

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

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

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

DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.

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

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

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

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

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

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

Printed in U.S.A.

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