Cover084 RevA 05 07 QT 5.4L 100 K W Generator Owners Manual 0G2814

User Manual: QT 5.4L

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Serial Number

5.4L
100kW
Models

STANDBY GENERATOR

OWNER'S MANUAL

A new standard of reliability

s
Not intended for use in critical life support applications. 
—CAUTION—
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
This manual should remain with the unit.
Cover084 Rev. A 05/07

Part No. 0G2814

Standby Generator Sets
Table of Contents

SECTION
PAGE
SAFETY RULES ................................................ 1-1

Fuel System ..............................................................8-1
Generator Set Lubrication ........................................8-1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Maintenance Performed by Authorized
Service Facilities .....................................................10-1

Coolant Temperature Sensing ...................................4-1
Low Coolant Level.....................................................4-1
Oil Pressure Sensing .................................................4-1
Overcrank Shutdown ................................................4-1
Overspeed Shutdown ................................................4-1
RPM Sensor Loss Shutdown.....................................4-1
DC Fuse ....................................................................4-1
FUEL SYSTEMS .....................................................5-1
Fuel Requirements ....................................................5-1
Natural Gas Fuel System ..........................................5-1
Propane Vapor Withdrawal Fuel System....................5-1
LP Fuel System .........................................................5-1
SPECIFICATIONS ...................................................6-1
Generator .................................................................6-1
Engine.......................................................................6-1
Cooling System .........................................................6-1
Fuel System ..............................................................6-1
Electrical System ......................................................6-1
Cold Weather Kit .......................................................6-2
5.4L & 6.8L Ignition Description .................................6-3
Ignition Power-up Input (“56 Line Input”) .................6-3
Ignition Enable (“14 Line Input”) ..............................6-3
Ignition Shutdown on Loss of Crank
or CAM Signals .........................................................6-3
Diagnostic Blink Patterns (Red LED Located
on the Ignition Control Board ...................................6-3
GENERAL INFORMATION.......................................7-1

Cooling System ..........................................................10-1
Checking Fluid Levels ................................................10-1
Check Engine Oil ....................................................10-1
Battery Fluid ...........................................................10-1
Engine Coolant .......................................................10-2
Maintenance Owner/Operator Can Perform ................10-2
Check Engine Oil Level ...........................................10-2
Check Battery .........................................................10-2
Exercise System ......................................................10-2
Inspect Cooling System ...........................................10-2
Check Engine Coolant Level....................................10-2
Perform Visual Inspection .......................................10-2
Inspect Exhaust System ..........................................10-2
Check Fan Belt........................................................10-2
Inspect Engine Governor ........................................10-2
Changing Engine Oil ...............................................10-2
Changing the Engine Air Cleaner ............................10-3
Spark Plugs ............................................................10-3
Coolant Change .......................................................10-3
Miscellaneous Maintenance ........................................10-3
Cleaning the Generator ...........................................10-3
Battery ....................................................................10-4
Battery Maintenance ...............................................10-4
Battery Replacement ...............................................10-4
SERVICE SCHEDULE ...........................................11-1

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

30 kW - 150 kW Standby Gas Engine
Driven Generator Sets ............................................11-1

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

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

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

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

3-phase Alternators ..................................................7-1

NOTES

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

EXPLODED VIEWS & PARTS LISTS

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

WIRING DIAGRAMS & SCHEMATICS

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

WARRANTY

Transfer Switch ........................................................8-1
Content003 Rev. 0 08/05

Standby Generator Sets
Important Safety Instructions



WARNING:

 GENERAL HAZARDS 

• For safety reasons, the manufacturer recommends
that this equipment be installed, serviced and
repaired by an Authorized Service Dealer or other
competent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations. The operator also must
comply with all such codes, standards and regulations.
• Installation, operation, servicing and repair of this
(and related) equipment must always comply with
applicable codes, standards, laws and regulations.
Adhere strictly to local, state and national electrical and building codes. Comply with regulations
the Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the
generator is installed, operated and serviced in
accordance with the manufacturer’s instructions
and recommendations. Following installation, do
nothing that might render the unit unsafe or in
noncompliance with the aforementioned codes,
standards, laws and regulations.
• The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous gas,
if breathed in sufficient concentrations, can cause
unconsciousness or even death. For that reason,
adequate ventilation must be provided. Exhaust
gases must be piped safely away from any building
or enclosure that houses the generator to an area
where people, animals, etc., will not be harmed.
This exhaust system must be installed properly, in
strict compliance with applicable codes and standards.
• Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit
is operating.
• Adequate, unobstructed flow of cooling and ventilating air is critical in any room or building housing the generator to prevent buildup of explosive
gases and to ensure correct generator operation.
Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seriously affect safe operation of the generator.
• Keep the area around the generator clean and
uncluttered. Remove any materials that could
become hazardous.
• When working on this equipment, remain alert
at all times. Never work on the equipment when
physically or mentally fatigued.
• Inspect the generator regularly, and promptly
repair or replace all worn, damaged or defective
parts using only factory-approved parts.

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



WARNING:



This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become
familiar with this Owner’s Manual and with the unit.
The generator can operate safely, efficiently and reliably only if it is properly installed, operated and
maintained. Many accidents are caused by failing to
follow simple and fundamental rules or precautions.
The manufacturer cannot anticipate every possible
circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed
to the unit are, therefore, not all inclusive. If a procedure, work method or operating technique is used
that the manufacturer does not specifically recommend, ensure that it is safe for others. Also make
sure the procedure, work method or operating technique utilized does not render the generator unsafe.

DANGER
the safe design of this generator,
 Despite
operating this equipment imprudently, neglecting its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to install, operate or maintain this equipment.
lethal voltages are generated by
 Potentially
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
of the generator are rotating and/or hot
 Parts
during operation. Exercise care near running
generators.

1-1

Safety 001 Rev. 0 08/05



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.

Standby Generator Sets
Important Safety Instructions

• Generators installed with an automatic transfer
switch will crank and start automatically when
normal (utility) source voltage is removed or is
below an acceptable preset level. To prevent such
automatic start-up and possible injury to personnel, disable the generator’s automatic start circuit
(battery cables, etc.) before working on or around
the unit. Then, place a “Do Not Operate” tag on
the generator control panel and on the transfer
switch.
• In case of accident caused by electric shock, immediately shut down the source of electrical power.
If this is not possible, attempt to free the victim
from the live conductor. AVOID DIRECT CONTACT
WITH THE VICTIM. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical
help.
• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving components causing injury.

• Before performing any maintenance on the generator, disconnect its battery cables to prevent
accidental start-up. Disconnect the cable from the
battery post indicated by a NEGATIVE, NEG or (–)
first. Reconnect that cable last.
• Never use the generator or any of its parts as a
step. Stepping on the unit can stress and break
parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.

 ELECTRICAL HAZARDS 

• All generators covered by this manual produce
dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely
high and dangerous voltages to the transfer switch
as well as the standby generator. Avoid contact
with bare wires, terminals, connections, etc., on
the generator as well as the transfer switch, if
applicable. Ensure all appropriate covers, guards
and barriers are in place before operating the generator. If work must be done around an operating
unit, stand on an insulated, dry surface to reduce
shock hazard.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
• If personnel must stand on metal or concrete while
installing, operating, servicing, adjusting or repairing this equipment, place insulative mats over a
dry wooden platform. Work on the equipment only
while standing on such insulative mats.
• The National Electrical Code (NEC) requires the
frame and external electrically conductive parts
of the generator to be connected to an approved
earth ground. This grounding will help prevent
dangerous electrical shock that might be caused
by a ground fault condition in the generator set or
by static electricity. Never disconnect the ground
wire.
• Wire gauge sizes of electrical wiring, cables and
cord sets must be adequate to handle the maximum electrical current (ampacity) to which they
will be subjected.
• Before installing or servicing this (and related)
equipment, make sure that all power voltage
supplies are positively turned off at their source.
Failure to do so will result in hazardous and possibly fatal electrical shock.
• Connecting this unit to an electrical system normally supplied by an electric utility shall be by
means of a transfer switch so as to isolate the
generator electric system from the electric utility
distribution system when the generator is operating. Failure to isolate the two electric system power
sources from each other by such means will result
in damage to the generator and may also result
in injury or death to utility power workers due to
backfeed of electrical energy.

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

 EXPLOSION HAZARDS 

• Properly ventilate any room or building housing
the generator to prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any
fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.
• These generator sets may operate using one of
several types of fuels. All fuel types are potentially
FLAMMABLE and/or EXPLOSIVE and should be
handled with care. Comply with all laws regulating the storage and handling of fuels. Inspect the
unit’s fuel system frequently and correct any leaks
immediately. Fuel supply lines must be properly installed, purged and leak tested according to
applicable fuel-gas codes before placing this equipment into service.
• Diesel fuels are highly FLAMMABLE. Gaseous
fluids such as natural gas and liquid propane
(LP) gas are extremely EXPLOSIVE. Natural gas
is lighter than air, and LP gas is heavier than air;
install leak detectors accordingly.

1-2

Safety 001 Rev. 0 08/05

Standby Generator Sets
Important Safety Instructions

INTRODUCTION

 This symbol points out potential fire hazard.
symbol points out potential electrical shock
 This
hazard.

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

The operator is responsible for proper and safe use
of the equipment. The manufacturer strongly recommends that the operator read this Owner's Manual
and thoroughly understand all instructions before
using this equipment. The manufacturer also strongly recommends instructing other users to properly
start and operate the unit. This prepares them if they
need to operate the equipment in an emergency.

READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest Authorized Service Dealer for starting, 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 personnel to special instructions about a particular service
or operation that may be hazardous if performed
incorrectly or carelessly. Observe them carefully.
Their definitions are as follows:

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

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.
NOTE:

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.

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 compliance with the special instructions while performing
the service are essential to preventing accidents.
Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type
of information each indicates is as follows:

To locate the nearest AUTHORIZED
SERVICE DEALER, please call this number:

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

1-800-333-1322

symbol points out potential explosion
 This
hazard.

or locate us on the web at:

www.generac.com
1-3

Safety 001 Rev. 0 08/05



AUTHORIZED SERVICE DEALER LOCATION

Standby Generator Sets
General Information

IDENTIFICATION RECORD

NOTE:
For actual information related to this particular
model, please refer to the Manual Drawing Listing
located at the end of this manual, or to the data
label affixed to the unit.

DATA LABEL
Every generator set has a DATA LABEL that contains
important information pertinent to the generator. The
data label, which can be found attached to the generator’s lower connection box, lists the unit’s serial
number and its rated voltage, amps, wattage capacity,
phase, frequency, rpm, power factor, etc.

Generator Model and Serial Number
This number is the key to numerous engineering and
manufacturing details pertaining to your unit. Always
supply this number when requesting service, ordering parts or seeking information.

Data Label

GENERATOR SET DATA

MADE IN USA

SERIAL

MODEL

RATED KVA

RATED KW

RATED AMPS

RATED VOLTAGE
POWER FACTOR

PHASE

HERTZ

ALT RPM

PRODUCTION DATE

ENGINE RPM

ALTERNATOR SUBTRANSIENT REACTANCE
ALTERNATOR TRANSIENT REACTANCE
ROTOR

STATOR WINDING INSULATION AT 25°C AMBIENT

GENERAC POWER SYSTEMS, INC.
WAUKESHA, WI

2-1

Identy 002 Rev. B 05/06

CLASS

Standby Generator Sets
Equipment Description

EQUIPMENT DESCRIPTION

COOLANT RECOMMENDATIONS

This equipment is a revolving field, alternating current generator set. It is powered by a gaseous fueled
engine operating at 1800 rpm for 4-pole direct drive
units, 3600 rpm for 2-pole direct drive units and
2300 - 3000 rpm for quiet drive gear units. See the
Specifications section for exact numbers. The unit
comes complete with a sound attenuated enclosure,
internally mounted muffler, control console, mainline circuit breaker, battery charger, and protective
alarms as explained in the following paragraph.

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

not use any chromate base rust inhibitor
 Do
with ethylene glycol base anti-freeze or chro-

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

mium hydroxide (“green slime”) forms and will
cause overheating. Engines that have been operated with a chromate base rust inhibitor must
be chemically cleaned before adding 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 constructed.
• The voltage waveform deviation, total harmonic
content of the AC waveform and telephone influence factor have been evaluated and are acceptable
according to NEMA MG1-32.

DANGER
not remove the radiator pressure cap while
 Do
the engine is hot or serious burns from boiling
liquid or steam could result.
glycol base antifreeze is poisonous.
 Ethylene
Do not use mouth to siphon coolant from the

ENGINE OIL RECOMMENDATIONS
The unit has been filled with 15W-40 engine oil at
the factory. Use a high-quality detergent oil classified “For Service SJ or SH.” Detergent oils keep the
engine cleaner and reduce carbon deposits. Use oil
having the following SAE viscosity rating, based on
the ambient temperature range anticipated before the
next oil change:
Temperature
Above 80° F (27° C)
32° to 80° F (0° to 27° C)
Below 32° F (0° C)

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.

Oil Grade (Recommended)
SAE 30W or 15W-40
SAE 20W-20 or 15W-40
See Note

attempt to crank or start the engine before
 Any
it has been properly serviced with the recommended oil may result in an engine failure.
NOTE:
For temperatures below 32° F, it is strongly recommended to use the optional Cold Weather Start Kit
(part number listed in the Specification Section).
The oil grade for temperatures below 32° F is 5W30 synthetic oil.

Equip001 Rev. A 08/06

3-1

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 temperature, oil pressure or rpm. For that reason, the engine
has several devices designed to protect it against
potentially damaging conditions by automatically
shutting down the unit when the oil pressure is too
low, the coolant temperature is too high, the coolant
level is too low, or the engine is running too fast.

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 420mA 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 mentioned here for the reader's convenience. Also refer
to the applicable control panel manual for additional automatic engine shutdown information.

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

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

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 changes based on coolant temperature. The resistance of
the sender results in a voltage being developed across
the sender. As the Coolant temperature increases,
the resistance will decrease, causing the voltage to
decrease. This changing voltage is converted to 420mA 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 initiates the programmed starting sequence. The start
sequence consists of the number of crank attempts,
the length of each crank attempt, and the rest time
between each crank attempt. If the engine has not
started by the end of the final crank attempt, an
Overcrank alarm is generated, the control panel will
sound the alarm and display the message "Failed to
start".

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

OVERSPEED SHUTDOWN

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.

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

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

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

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

DC FUSE
This fuse is located inside of the control panel. It
protects the panel wiring and components from
damaging overload. Always remove this fuse before
commencing work on the generator. The unit will
not start or crank if the fuse is blown. Replace the
fuse with one of the same size, type, and rating. (See
the exploded views and parts lists at the end of this
manual for replacement part number.)
4-1

EngProt002 Rev. B 10/05

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

Standby Generator Sets
Fuel Systems

FUEL SYSTEM

PROPANE VAPOR WITHDRAWAL FUEL SYSTEM

FUEL REQUIREMENTS

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

The 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 column to the carburetor.
• When ambient temperatures are low and engine
fuel consumption is high, the vapor withdrawal
system may not function efficiently.
• Ambient temperatures around the supply tank
must be high enough to sustain adequate vaporization, or the system will not deliver the needed fuel
volume.
• In addition to the cooling effects of ambient air, the
vaporization process itself provides an additional
cooling effect.

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 supplied 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 solenoid should not exceed approximately 14 inches
water column (0.5 psi). Optimum pressure at the
fuel shutoff solenoid is 11 inches water column
(0.4 psi).

FuelSys002 Rev. A 05/06

5-1

Standby Generator Sets
Specifications

SPECIFICATIONS

Engine Lubrication System
Type of Oil Pump ...................................................................... Gear
Oil Filter .............................................................Full Flow, Cartridge
Crankcase Oil Capacity ....................................................5 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 .......................................................................Flexible Disc
Load Capacity (Standby Rating) ..........................................100kW*
* NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349,

COOLING SYSTEM
Type .......................................................................................Closed
Water Pump.................................................................... Belt Driven
Fan Speed ................................................................................ 1700
Fan Diameter .....................................................................26 inches
Fan Mode ................................................................................Puller
Air Flow (inlet air including alternator and
combustion air) ........................................................... 4800 ft3/min.
Coolant Capacity ........................................................ (4.0 U.S. gal.)
Heat Rejection to Coolant ..........................................376,000 Btu/h
Maximum Operating Air Temp. on Radiator ..............60° C (150° F)
Maximum Ambient Temperature................................50° C (140° F)

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

Excitation System ............................................................. Brushless
Generator Output Voltage/kW - 60 Hz
kW
Amp CB Size
120/240V, 1-phase, 1.0 pf
100
417
500
120/208V, 3-phase, 0.8 pf
100
347
400
277/480V, 3-phase, 0.8 pf
100
150
200
Generator Locked Rotor KVA Available @ Voltage Dip of 35%
Single-phase or 208 3-phase ........................................... 190 KVA
480V, 3-phase .................................................................. 225 KVA

FUEL SYSTEM
Type of Fuel ...................................................................Natural Gas
Carburetor ...................................................................... Down Draft
Secondary Fuel Regulator .................................................Standard
Fuel Shut-off Solenoid ........................................................Standard
Operating Fuel Pressure .................... 11 in. - 14 in. Water Column

ENGINE
Make ................................................................................... Generac
Model ...................................................................................... V-type
Cylinders and Arrangement............................................................ 8
Displacement ....................................................................... 5.4 Liter
Bore ...................................................................................... 3.55 in.
Stroke ................................................................................... 4.17 in.
Compression Ratio ..................................................................9-to-1
Air Intake System ...............................................Naturally Aspirated
Valve Seats....................................................................... Hardened
Lifter Type .......................................................................... Hydraulic

Fuel Consumption - ft3/hr (Natural Gas/LPV)
Exercise
25%
50%
75%
100%
Cycle
Load
Load
Load
Load
140/56
371/149
713/287
994/400 1374/553
* 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, 3600
HP at rated kW ................................................................60 Hz, 175

Voltage Regulator
Type ................................................................................. Full Digital
Sensing................................................................................ 3-phase
Regulation .............................................................................± 1/4%
Features ............................................Built into H-100 Control Panel
V/F Adjustable, Adjustable
Voltage and Gain

Exhaust System
Exhaust Flow at Rated Output 60 Hz.................................. 953 cfm
Exhaust Temperature at Rated Output ................................ 1000° F
Combustion Air Requirements (Natural Gas)
Flow at rated power, 60 Hz ................................................. 325 cfm

Power Adjustment for Ambient Conditions
Temperature Deration
3% for every 10° C above °C ..................................................... 25
1.65% for every 10° above °F .................................................... 77
Altitude Deration
1% for every 100 m above m ................................................... 183
3% for every 1000 ft. above ft. ................................................. 600

Governor
Type .................................................................................. Electronic
Frequency Regulation ...................................................Isochronous
Steady State Regulation........................................................± 1/2%
Adjustments:
Speed ............................................................................ Selectable

Controller .............................................. H-panel
GenSpec007 Rev. C 11/05

6-1

Standby Generator Sets
Specifications

Figure 1 — Interconnections

GROUND ONLY
AT GENERATOR BOX

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

Battery Warmer
4” Junction Box with hardware
Thermostat; 20 deg “ON”, 40 deg “OFF”
6 qt. pack 5W-30 synthetic oil (engine)

6-2

GenSpec007 Rev. C 11/05

Standby Generator Sets
Specifications

5.4L & 6.8L IGNITION DESCRIPTION

NOTE:

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

The 5.4L engine uses a 36-1 crank sensor, a magpick-up CAM sensor and individual coil-on-plug coils
for each spark-plug.
With a single-fire ignition, each high-voltage coil output is connected to one spark plug resulting in that
spark plug being fired only during the compression
cycle.

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
NG/LP Engine Timing (BTDC)
1800 rpm
22 degrees
3600 rpm
24 degrees
Engine Timing versus Engine Speed for the 5.4L
engine is:
RPM
1800 rpm
3600 rpm

LED Fault Code with Priority as shown:
1. No Crank Signal: LED blinks 2 times, is OFF for
3.0 seconds and then repeats
2. No CAM Signal: LED blinks 3 times, is OFF for
3.0 seconds and then repeats
Only one fault is displayed at a time. If multiple faults
exist then the highest priority fault must be resolved
prior to a lower priority fault being displayed. In the
event that an ignition fault has occurred the ignition
will wait 60 seconds before powering down.

NG/LP Engine Timing (BTDC)
26 degrees
26 degrees

IGNITION POWER-UP INPUT ("56 LINE
INPUT")
When battery voltage is applied to this input the ignition will power-up. For the ignition to power itself
down, battery voltage must be removed from this
input.

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 connected to battery ground the ignition will stop firing
the coils and will power down within approximately
2 seconds. In the event that an ignition fault has
occurred, however, the ignition will wait 60 seconds
before powering down. This allows time to view the
diagnostic LED located on the ignition board.

GenSpec007 Rev. C 11/05

6-3

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 connection (lower) panel should be installed according to
the number of leads and the voltage/phase required
for the application. If there are any questions regarding lead connection, refer to the wiring diagrams at
the back of this manual.

3-PHASE ALTERNATORS
The generator is designed to supply 3-phase electrical loads. Electric power is produced in the alternator power windings. These windings were connected
at the factory to the main circuit breaker with a “Y”
configuration as shown in Figures 7.2 and 7.3.

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 terminal and the neutral point 00 is either 277V or 120V
depending on the model.

Four-lead generators (see Figure 7.1) are designed to
supply electrical loads with voltage code “A” (240V,
1-phase, 60 Hz). Electrical power is produced in the
stator power windings. These windings were connected at the factory to the main circuit breaker as
shown in Figure 7.1.

Figure 7.2 — Stator Power Winding
Connections - 3-phase, 277/480V (6 Lead)

The rated voltage between each circuit breaker terminal is 240V. The rated voltage between each circuit
breaker terminal and the neutral point 00 is 120V.

S1 E1

Figure 7.1 — Four-lead, Single-phase Stator

INTERNAL
CONNECTIONS
L-L

NEUTRAL

S5
E3 S3

L-N

Figure 7.3 — Stator Power Winding
Connections - 3-phase, 120/208V (6 Lead)
E1
S1

S3
E3

L-L

00 (NEUTRAL)

S6 S5

L-N
ACConn001 Rev. 0 08/05

7-1

Standby Generator Sets
Installation

PRIOR TO INITIAL START-UP

INSTALLATION
Refer to the separate “Installation Guide” supplied
with the unit.

to initially starting the generator, it must
 Prior
be properly prepared for use. Any attempt to

PREPARATION BEFORE START-UP
The instructions in this section assume that the
standby generator has been properly installed, serviced, tested, adjusted and otherwise prepared for
use by a competent, qualified installation contractor.
Be sure to read the “Safety Rules”, as well as all other
safety information in this manual, before attempting
to operate this (and related) equipment.

crank or start the engine before it has been
properly serviced with the recommended types
and quantities of engine fluids (oil, coolant, fuel,
etc.) may result in an engine failure.

ENGINE COOLANT
Have the engine cooling system properly filled with
the recommended coolant mixture. Check the system
for leaks and other problems. See “Specifications”
and “Coolant” sections.

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

TRANSFER SWITCH

Check-the engine-fan belt tension and condition prior
to placing the unit into service and at recommended
intervals. Belt tension is correct when a force of
approximately 22 pounds (10 kg), applied midway
between pulleys, deflects the belt about 3/8- to 5/8inch (10 to 16 mm).

If this generator is used to supply power to any electrical system normally powered by an electric utility,
the National Electrical Code requires that a transfer
switch be installed. The transfer switch prevents electrical backfeed between two different electrical systems. (For additional information, see the applicable
transfer switch manual for this unit.) The transfer
switch, as well as the generator and other standby
components, must be properly located and mounted
in strict compliance with applicable codes, standards
and regulations.

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

NOTE:

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

Battery charger must be connected to 120 VAC, 15
amp circuit to operate.
Check to ensure that there are no loose electrical connections. Restrain any loose wires to keep them clear
of any moving generator set components.

GENERATOR SET LUBRICATION

INITIAL INSPECTION FOR GENSET
STARTUP

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”.

Inspect for the following.
•
•
•
•
•

Freight Damage.
Manuals present.
Fluid Levels (Oil, coolant, battery, Gear Drive).
Correct fuel piping.
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.

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

8-1

Install002 Rev. C 01/07

NOTE:

Standby Generator Sets
Installation

• Open the valve to the engine fuel line.
• Bleed the fuel system of air. (necessary for long fuel
lines).
• Open the generator main line circuit breaker.
• Connect a manometer to the gas line and record
the static pressure. It must be as listed in the
Specifications.
• Insert the fuse into the control panel.
• Move the AUTO/OFF/MANUAL switch to the manual position. The engine should now crank and
start.
• Check voltage at the generator terminals.
• For 3-phase units, check phase rotation at the
transfer switch terminals. The generator phase
rotation must match the utility phase rotation.
• Check for coolant, fuel, oil, and exhaust leaks.
• Close the generators main line circuit breaker.
• Turn the generator set off.
• Connect the UTILITY supply to the transfer
switch.
• Set the AUTO/OFF/MANUAL switch to AUTO.
• Disconnect utility power before the transfer
switch.
Engine should start, transfer to load.
Run at least 15 minutes on generator power.
Make certain all 3-phase loads are functioning
correctly (correct phase rotation).
• Reconnect Utility power
Transfer switch will transfer back to Utility and
engine will shut down within the given time
parameters set up for the specific transfer switch
and controller.
• Install all covers, access plates and door panels.
• Put the Owners Manual in a safe and accessible
place.
• Make certain the AUTO/OFF/MANUAL switch is in
the AUTO position.

• Battery charger connection to 120 VAC.
• Communication wires connected between transfer
switch and generator (HTS only).
• Unit secured to pad.

START-UP CHECKLIST
working on the generator, ensure the fol Before
lowing:
• The AUTO/OFF/MANUAL switch is in the OFF
position.
• The 120VAC supply to the battery charger is
switched OFF.

PREPARATION FOR START-UP
• Ensure that the 120VAC circuit breaker to the battery charger is open.
• Remove the fuse from the the control panel. Open
the front door of the control box and remove the
15 Amp ATO fuse in the lower left-hand corner of
the control box.
• Connect the battery cables to the battery. Attach
negative battery cable last.
• Close the 120VAC circuit breaker to the battery
charger.
• Measure the voltage at the battery before and after
the charger is turned on.
• Verify all AC electrical connections are tight at the
circuit breaker and transfer switch.
• Visually inspect entire area looking for loose paper,
plastic wrappings, leaves, etc.
• Check all hoses clamps fittings for leaks or damage.
• Check all electrical plugs throughout the generator. Ensure each plug is seated correctly and fully
inserted into its receptacle.
• Verify the AUTO/OFF/MANUAL switch is in OFF
position.

8-2

Install002 Rev. C 01/07

Standby Generator Sets
Operation

GENERATOR CONTROL AND
OPERATION

not crank the engine continuously for longer
 Do
than 30 seconds, or the heat may

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

•
•

OPERATING UNIT WITH MANUAL
TRANSFER SWITCH
If the generator was installed in conjunction with a
transfer switch capable of manual operation only, the
following procedure applies. A manually operated
transfer switch is one that will not provide automatic
start-up and does not include an intelligence circuit.

•
•

ENGINE START-UP AND TRANSFER

damage the starter motor.
Let engine stabilize and warm up.
Check all applicable instrument and gauge readings. When certain that all readings are correct,
move the transfer switch manual handle to its
STANDBY (GENERATOR) position, i.e., load circuits supplied by the generator.
Set the standby generator’s main line circuit breaker to its ON (or CLOSED) position.
Load circuits are now powered by the standby
generator.

RETRANSFER AND SHUTDOWN

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

DANGER

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

Maintenance Disconnect Switch and the
 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 breaker to its OFF (or OPEN) position.
• Manually move the transfer switch handle to its
UTILITY (NORMAL) position, i.e., load circuits
connected to the utility.
• Turn ON the utility power supply to the transfer
switch, using the means provided (such as the utility power source main line circuit breaker).
• Let the generator run at no-load for a few minutes
to stabilize internal temperatures.
• Shut down the generator.

not proceed until certain that utility source
 Do
voltage is available to the transfer switch and
the transfer switch main contacts are set to
UTILITY.
not attempt manual operation until all power
 Do
supplies to the transfer switch have been positively turned off, or extremely dangerous - possibly lethal - electrical shock will result.

OPERATING UNIT WITH AUTOMATIC
TRANSFER SWITCH



Transfer switch enclosure doors should be kept
closed and locked. Only authorized personnel
should be allowed access to the transfer switch
interior. Extremely high and dangerous voltages
are present in the transfer switch.
In order to transfer load from the utility source to the
generator, follow these directions:

If the generator has been installed with an automatic
transfer switch, such as an RTS, HTS, or GTS-type
transfer switch, the engine may be started and
stopped automatically or manually.
NOTE:
Refer to the applicable manual for your transfer switch and to “Transfer Switch Start Signal
Connections”. In addition, please note the dangers
under “Engine Start-up and Transfer.”

9-1

Oper001 Rev. 0 08/05

• Turn OFF or disconnect the utility power circuit
to the transfer switch, using the means provided
(such as the utility source main line circuit breaker).
• Set the transfer handle to its UTILITY (NORMAL)
position with load circuits connected to the utility
power supply.
• Set the standby generator’s main line circuit breaker to its OFF (or OPEN) position.
• Start the generator.

Standby Generator Sets
Maintenance

MAINTENANCE PERFORMED BY
AUTHORIZED SERVICE FACILITIES

exhaust system parts from this product get
 The
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 following:
• The AUTO/OFF/MANUAL switch is in the OFF
position.
• The 15A fuse has been removed from the control box.
• The 120VAC supply to the battery charger is
switched OFF.

CHECKING FLUID LEVELS
CHECK ENGINE OIL
Check engine crankcase oil level (Figure 10.1) at least
every 20 hours of operation, or prior to use.

EVERY THREE MONTHS
1.
2.
3.
4.
5.
6.

• Remove oil dipstick and wipe dry with a clean, lintfree cloth.
• Install oil dipstick, then remove again.
• Oil should be between FULL and ADD marks.
• If oil level is below the dipstick ADD mark,
remove oil fill cap. Add the recommended oil to
bring oil level up to the FULL mark. DO NOT
FILL ABOVE THE “FULL” MARK. See “Engine Oil
Recommendations” for recommended oils.

Check battery state of charge and condition.
Inspect and test fuel system.
Check transfer switch.
Inspect exhaust system.
Check engine ignition system.
Check fan belts.

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

ONCE ANNUALLY

Oil Fill

1. Test engine governor. Adjust or repair, if needed.
2. Clean, inspect generator.
3. Flush cooling system.

FIRST 30 OPERATING HOURS
1. Change engine "break-in" oil and oil filter.

FIRST 100 OPERATING HOURS
1. Change engine oil and oil filter. (After initial
change, service engine oil and filter at 150 operating hours or 6 months, whichever comes first.)

Oil
Dipstick

EVERY 500 OPERATING HOURS
1. Service air cleaner.
2. Check starter.
3. Check engine DC alternator.

Oil Filter

COOLING SYSTEM

BATTERY FLUID

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

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.
Maint003 Rev. A 10/06

10-1

Standby Generator Sets
Maintenance

ENGINE COOLANT

INSPECT EXHAUST SYSTEM

Check coolant level in coolant recovery bottle. See the
“Specifications” section.

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

• 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.

CHECK FAN BELT
• Inspect fan belts every three months. Replace any
damaged, deteriorated, worn or otherwise defective belt.
• Check fan belt tension. Thumb pressure, exerted
midway between pulleys, should deflect about 3/8
to 5/8 inch. Adjust belt tension as required.

MAINTENANCE OWNER/
OPERATOR CAN PERFORM

INSPECT ENGINE GOVERNOR
Visually inspect electronic governor.

CHECK ENGINE OIL LEVEL

DANGER

Refer to the “Checking Fluid Levels” section.

not attempt to adjust the governor. Only
 Do
qualified service facilities should adjust the

CHECK BATTERY

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

• Check battery fluid level each week as outlined
under “Check Fluid Levels”.
• Check battery cables for condition, tightness, corrosion or damage. Clean, tighten or replace as
necessary.

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

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

INSPECT COOLING SYSTEM

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

• 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.

1. Remove OIL DRAIN HOSE from its retaining
clip.
2. Loosen and remove OIL DRAIN HOSE CAP. Drain
oil completely into suitable container.
3. When all oil has drained, install and tighten OIL
DRAIN HOSE CAP, and re-install into its retaining
clip.
4. Turn OIL FILTER (Figure 10.2) counterclockwise
and remove. Dispose of old filter.
5. Apply light coating of new engine oil to seal of new
oil filter.-Install FILTER and tighten by hand only.
DO NOT OVERTIGHTEN.
6. Remove OIL FILL CAP. Add recommended oil (see
SPECIFICATIONS). DO NOT FILL ABOVE THE
DIPSTICK “FULL” MARK. Crankcase oil capacity
is listed in the “Specifications”.

CHECK ENGINE COOLANT LEVEL
See the “Checking Fluid Levels” section.

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

10-2

Maint003 Rev. A 10/06

Standby Generator Sets
Maintenance

See the “Service Schedule” section for air cleaner
maintenance.
refilling the crankcase with oil, always
 After
check oil level on dipstick. NEVER OPERATE

SPARK PLUGS

ENGINE WITH OIL BELOW THE DIPSTICK “ADD”
MARK.
7. Start engine and check for oil leaks.

Reset the spark plug gap or replace the spark plugs
as necessary.
1. Clean the area around the base of the spark plugs
to keep dirt and debris out of the engine. Clean
by scraping or washing using a wire brush and
commercial solvent. Do not blast the spark plugs
to clean.
2. Remove the spark plugs and check the condition.
Replace the spark plugs if worn or if reuse is
questionable. See the “Service Schedule” section
for recommended inspection.
3. Check the spark plug gap using a wire feeler
gauge. Adjust the gap to 1.14 mm (0.045 inch)
by carefully bending the ground electrode (Figure
10.4).

Figure 10.2 - Oil Filter

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.

Figure 10.3 — Engine Air Filter

COOLANT CHANGE
Every year, have an Authorized Service Facility
drain, flush and refill the cooling system. See the
“Specifications” section for cooling system recommendations.

Air Filter

MISCELLANEOUS MAINTENANCE
CLEANING THE GENERATOR
Keep the generator as clean and as dry as possible.
Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation
resistance.
Periodically clean generator exterior surfaces. A soft
brush may be used to loosen caked on dirt. Use a
vacuum system or dry, low pressure air to remove
any accumulations of dirt. The generator is housed
inside an all-weather enclosure, clean the enclosure
with a soft, damp cloth or sponge and water.

Maint003 Rev. A 10/06

10-3

Standby Generator Sets
Maintenance

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.

DANGER
batteries give off explosive hydrogen
 Storage
gas. This gas can form an explosive mixture
around the battery for several hours after charging. The slightest spark can ignite the gas and
cause an explosion. Such an explosion can shatter the battery and cause blindness or other
injury. Any area that houses a storage battery
must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing
tools or equipment near the battery.

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

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

electrolyte fluid is an extremely caus 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 recharge a weak battery while it is
installed in the generator. Remove battery from
generator and recharge in a well-ventilated area,
away from fuel vapors, sparks, heat or flames.
• Battery electrolyte fluid is an extremely caustic
sulfuric solution that can cause severe burns. DO
NOT permit fluid to contact eyes, skin, clothing,
painted surfaces, wiring insulation, etc. If any battery fluid is spilled, flush the affected area with
clear water immediately.
• Always wear safety glasses, rubber apron and
gloves when handling a battery.
• Batteries give off explosive hydrogen gas while
charging. The gas can form an explosive mixture
around the battery for several hours after charging.
Any spark, heat or flames can ignite the gas and
cause an explosion which can shatter the battery,
causing blindness or other serious injury.

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

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

BATTERY REPLACEMENT

BATTERY MAINTENANCE

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

The battery should be inspected per the “Service
Schedule” section. The following procedure should
be followed for inspection:

NOTE:

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 BATTERIES.
3. Have the state of charge and condition checked.
This should be done with an automotive-type battery hydrometer.

The BCI number should be located directly on the
battery.

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

10-4

Maint003 Rev. A 10/06

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 potential problem areas.
This inspection may be performed by the end user providing the following safety steps are taken to prevent
the engine from starting automatically without warning:
To prevent injury, perform the following steps in the order indicated before starting any maintenance:
• Disable the generator set from starting and/or connecting to the load by setting the control panel Auto/Off/
Manual switch to the “OFF” position.
• Remove the 15 amp control panel fuse.
• Turn off the battery charger.
• Remove the negative battery cable.
The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition
from burning out sensitive control panel components and circuits.
Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal
operation when required.
2 A wear-in service inspection of the generator set to insure it is ready to operate and carry the load when
required, and to identify any potential problem areas.
Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of
the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by an Authorized Service Dealer.
3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required,
and to identify any potential problem areas.
Performed semi-annually or following each 50 hours of operation of the unit.
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.
SrvSchd001 Rev. B 03/07

11-1

Standby Generator Sets
Service Schedule

Maintenance
Tasks

Level 1
Recommended
to be done
monthly/
10 hrs.

Level 2

Level 3

Task
Required
Task
Required
Comp. to be done Comp. to be done
(Date- 3 months/ (DateSemiInitials) 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.

11-2

Level 4
Task
Comp.
(DateInitials)

Required
to be done
Annually/
100 hrs.

Level5
Task
Comp.
(DateInitials)

Required
to be done
Biannually/
250 hrs.

Task
Comp.
(DateInitials)

SrvSchd001 Rev. B 03/07

Standby Generator Sets
Service Schedule

Maintenance
Tasks

Level 1
Recommended
to be done
monthly/
10 hrs.

Level 2

Level 3

Task
Required
Task
Required
Comp. to be done Comp. to be done
(Date- 3 months/ (DateSemiInitials) Break-in Initials) annually/
30 hrs.
50 hrs.

Level 4
Task
Comp.
(DateInitials)

Required
to be done
Annually/
100 hrs.

Level5
Task
Comp.
(DateInitials)

Required
to be done
Biannually/
250 hrs.

Task
Comp.
(DateInitials)

10. Check the engine
accessory drive
belts and fan
coupling device
if equipped for
correct tension,
wear, weather
cracking, and
damage. Replace
as necessary.
11. Check the engine
valve clearance/
lash. Adjust as
necessary.
12. Visually inspect
the unit looking
for leaks, wear or
damage, loose
connections or
components, and
corrosion. Correct
as necessary.
13. Test the engine
and transfer
switch safety
devices. Correct
and/or adjust as
necessary.
14. Initiate an
automatic start
and transfer of
the unit to site
load and exercise
it for at least 1
hour looking for
leaks, loose
connections or
components, and
abnormal
operating
conditions.
Correct as
necessary.
15. Replace the
engine
accessory
drive belts.
16. Check gearbox
oil level (if
equipped).
17. Change gearbox
oil (if equipped).
SrvSchd001 Rev. B 03/07

11-3

Standby Generator Sets
Service Schedule

Maintenance
Tasks

Level 1
Recommended
to be done
monthly/
10 hrs.

Level 2

Level 3

Task
Required
Task
Required
Comp. to be done Comp. to be done
(Date- 3 months/ (DateSemiInitials) 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.

11-4

Level 4
Task
Comp.
(DateInitials)

Required
to be done
Annually/
100 hrs.

Level5
Task
Comp.
(DateInitials)

Required
to be done
Biannually/
250 hrs.

Task
Comp.
(DateInitials)

SrvSchd001 Rev. B 03/07

Standby Generator Sets
Troubleshooting

TROUBLESHOOTING GUIDE
PROBLEM

CAUSE

CORRECTION

Engine won’t crank.

1. 15 amp fuse blown.
2. Loose or corroded or defective
battery cables.
3. Defective starter contactor.
4. Defective starter motor.
5. Dead or Defective Battery.
6. 5 amp fuse blown.

1. Replace fuse.
2. Tighten, clean or replace
battery cables as necessary.
3. Replace contactor.*
4. Replace starter motor.*
5. Remove, change or replace battery.
6. Replace fuse.*

Engine cranks but won't start

1. Out of fuel.
2. Fuel solenoid (FS) is defective
3. Open Wire #14A from Engine Control
circuit board.
4. Spark plugs defective.
5. Door on tank not closed.

1. Replenish fuel.
2. Replace solenoid.*
3. Reconnect wire.

1. Flame arrestor (air cleaner) plugged or
damaged.
2. Plugged fuel line.
3. Defective spark plugs.
4. Fuel pressure incorrect.

1. Clean or replace as needed.

Engine starts hard, runs rough.

2. Unclog fuel line.
3. Clean, regap or replace plugs.
4. Confirm fuel pressure to regulator is as
recommended in SPECIFICATIONS.

Engine starts then shuts down.

1.
2.
3.
4.
5.
6.
7.

AUTO/OFF/MANUAL Switch at OFF,
engine continues to run

1. Defective AUTO/OFF/MANUAL switch
2. Open/disconnected wire #15A between
AUTO/OFF/MANUAL switch and Control
Module circuit board.
3. Defective Control Module circuit board

3. Replace board.*

1.
2.
3.
4.
5.

Check main line circuit breaker.
Check circuit breaker & fuses.
Transfer switch set to NORMAL position
Generator internal failure.
Thermal circuit breaker open.

1.
2.
3.
4.
5.
6.
7.

Check oil and add oil as needed.
Check cooling system for leaks.
Replace switch.*
Replace switch.*
Replace board.*
Repair leak - Add coolant.
Replace Switch.*

1. Replace switch.*
2. Reconnect/close wire.

Reset to ON or CLOSED.
Reset and replace, if necessary.
Set to GENERATOR position.
*
Auto-reset - Wait 5 min. and
attempt restart.

*Contact the nearest Authorized Dealer for assistance.

12-1

Trblsht001 Rev. 0 08/05

No AC output from generator.

Engine oil level is low.
Engine is overheated.
Defective Low Oil Pressure Switch
Defective Coolant Temperature Switch
Defective Control Module circuit board.
Coolant Level is Low.
Defective Low Coolant Level Switch

4. Clean, regap or replace plugs.
5. Close door on tank.

Standby Generator Sets
Notes

3
4
5
6
7
8
9
10
11
12
13
14
15

0F9952
0F3417
0F2984
0F9949
0F3418
0F2985
0F9950
0F9951
0F6183
0F6187
0F6184
0F6212
0G2023
068405C
0F3013
072878
0C9708
0F3726B
0F2689
023454
0F8408
046526
0A2601
0A2602
022473
022097

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
REF
1
1
1
4
4
1
1
8/12
4/6

ASSY ROTOR 2390 80KB3 CPL
ASSY ROTOR 390 2P 100K BRSHLS
ASSY ROTOR 390 2P 150K BRSHLS
ASSY STATOR 80KW 1PH 2P BRSHLS
ASSY STATOR 390 2P 100K BRSHLS
ASSY STATOR 390 2P 150K BRSHLS UL
STATOR 2390 80 GB3 CPL
STATOR 2390 80 KB3 CPL
ASSY STR 390 100KW 2P 3PH 208V
ASSY STR 100KW 1PH 2P BRSHLS
ASSY STR 390 150KW 2P 3PH 208V
ASSY STR 150KW 1PH 2P BRSHLS
ASSY STR 390 150KW 2P 3PH 240V
EXITER FIELD 2" LG SPD CONN
ASSY EXCITER 2.0" STACK 2P
KEY SQ 3/8 X 3-1/4 STEEL
HYPOT TEST PROCEDURE (NOT SHOWN)
ASSY FLYWHEEL CPL
RING PRESSURE 390 STATOR CAN
KEY WOODRUFF #E
SCREW HHC M10-1.50 X 16 G10.9
WASHER LOCK M10
SCREW HHC M16-2.0 X 45 G8.8
WASHER FLAT .688 ID X 3.25 OD
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4

16
17
18
19
20
21
22
23
24
25
26

44
45
46
47
48
49
50 *
51
52
53

0C2454
092950
04576100CF
052646
043123
051779
022392
052259
051769
0E7230
0F3033
0F9492
0F2722
077043F
020151
023365
033133
033143
086032
090063
090064
090152
022661L
028739A
085662D
068113
068406
0F7272
023484N
023484N
0F6819
REF.
0C2428
022155
042568
049813
052624
0F7030
0F7047
0F7029

11
1
4
4
4
4
2
2
3
3
1
1
1
1
1
3
1
2
2
1
1
1
1
2
1
1
1
6
1
2
1
2/3
2
2
4/6
4/6
1
1
1
1

0F3834

61
62
63
64
65
66
67
68
69

KIT PARTS
0F3846B
0F3892
0A2496A
056326
022097
022473
045757
047411
0A2110

2
2
2
8.4 FT.
6
6
2
4
12

27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43

SCREW THF M6-1 X 16 N WA Z/JS
COLLAR SLIP FIT 390 MM
STUD M14-2.0 X 760 G5 ZINC
WASHER FLAT M14
WASHER LOCK M14
NUT HEX M14-2.0 G8 YEL CHR
PIN DOWEL 1/2 X 1-1/4
WASHER FLAT M12
WASHER LOCK M12
SCREW HHC M12-1.75 X 80 G10.9
SHIELD ALT EXCITER 390
SHIELD ALT EXCITER 5.4/6.8 (1 PHASE)
COVER EXCITER SHIELD
CONDUIT FLEX 1.25” ID
CLAMP VINYL .312 X .203 Z
WASHER SHAKEPROOF INT #8
SCREW HHM #8-32 X 3/8
SCREW HHM #8-32 X 7/8
LUG RT-ANG #10/10-12
BRIDGE SUPPORT DIODE 15"
CAP END ROTOR 390MM
ASSY BRIDGE RECTIFIER
SLEEVING UL #0 .330 ID (3” LG)
TIE WRAP UL 3.9" X .10" BLK
TIE WRAP UL 17.7 X .35 BLK HT
CARRIER REAR BRG 15" (BRUSHLESS)
SCREW HHC M12-1.75 X 60 G10.9
SCREW 1/4-20 X 5/8" TAPTITE SS
BUSHING SNAP SB-2.5-31
BUSHING SNAP SB-2.5-31 (FOR 5.4/6.8 1 PHASE)
MOUNT CT'S 5.4L 100KW
TRANSFORMER
SCREW PHTT #6-32 X 1/2 ZYC
WASHER LOCK #6
SCREW HHC M6-1.0 X 20 G8.8
NUT HEX M6 X 1.0 G8 YEL CHR
BEARING BALL 6212 SEALED
SHROUD UPPER ALTERNATOR EXCITR
SHROUD CENTER ALTERNATR EXCITR
SHROUD LOWER ALTERNATOR EXCITR
ASSY SCROLL 390 X 60MM CPL
I/N’S: 61 THRU 69
SHROUD ALT SHEET METAL CPL 2P
SCREEN, 390 SAE ALT 60MM WIDE
BRACKET SAE SCROLL TENSIONER
VINYL TRIM 1/8” GAP
WASHER, SPLIT 1/4”-M6
WASHER FLAT 1/4 ZINC
SCREW HHC M6-1.0 x 25 LONG
SCREW HHC M6-1.0 X 16 G8.8
SCREW SWAGE 1/4-20 X 1/2 Z/YC

* ROTOR REPLACEMENT PARTS.
** 1 PHASE UNITS REQUIRE SEPERATION OF LEADS.
QTY. REQ: 1 PHASE / 3 PHASE

1
2

0F2885
0F2883
0F9637 (4)

1
1
1

3
4

0F3685
023484N
023484N

1
1
2

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
077043J

1
4
4
4
REF.
2
2
1
1
2
REF.
REF.
4
4
6
6
10
4
12
8
4
1
1
1
1
1
4
2
1
3
4

35
36
(3) 37

0F6156
029289
0F8656
0F3113

1
1
REF
REF

38
39
40
41
42

047411
036943
023897
022152
022158

4
2
2
2
2

6
7
8
(1) 9
10
11
12
13
14
(2) 15
(2) 16
17
18
19
20
21
22
23
24
25
(1) 26
27
28
29
30
31
32
33
34

PANEL CB CONN BOX
STAND RH CONTROL
STAND RH CONTROL, TWO HOLE (FOR 5.4L 100KW &
4.6L 80KW 1PHASE)
STAND LH CONTROL C5 GRBX
BUSHING SNAP SB-2.5-31
BUSHING SNAP SB-2.5-31 (FOR 5.4L 100KW & 4.6L
80KW 1PHASE)
INTERFACE 1PH 240V
INTERFACE 3PHS 416/480V
INTERFACE 3PHS 208/240V
WASHER FLAT M4
WASHER LOCK #8-M4
SCREW PHTT M4-0.7 X 10 ZYC
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
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
SCREW HHTT M6-1.0 X 16 ZYC
WASHER FLAT M5
GROMMET 1.25 X .25 X .75
CONDUIT FLEX 2.0" ID
CONDUIT FLEX 2.0" ID (FOR 5.4L 100KW & 4.6L 80KW
1 PHASE)
PLATE WIRE SNGL GALV
TAPE ELEC 1/2 FOAM (AS REQ’D)
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

1.)
A
C

D
E
F
G
H
J
K
L
2.)
A
C

D
E
F
G
H
J
K
L

0F2887
0D5572
0D5573
0D5575
0D5576
0F0199
065960
022473
022097
022127
0C2454
029289
0F1733

UL CIRCUIT BREAKER (FD)
1
COVER FD FRM CB
CB 0150A 3P 600V S FD6 LL
CB 0175A 3P 600V S FD6 LL
CB 0225A 3P 600V S FD6 LL
CB 0250A 3P 600V S FD6 LL
1
INSULATOR CB FD FRAME 30MIL
4
SCREW SHC 1/4-20 X 4 G8.8 NZ
4
WASHER FLAT 1/4-M6 ZINC
4
WASHER LOCK M6-1/4
4
NUT HEX 1/4-20 STEEL
4
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE

0F2721
0D5577
0D5578
0D5579
0D5581
0D5585
0F2353
022770
022473
022097
022127
0C2454
029289
0F1733

UL CIRCUIT BREAKER (JD+LD)
1
COVER CIR BRKR JD/LD
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
CB 0450A 3P 600V S LD6 LL
2
INSULATOR CIRCUIT BR. JD/LD
4
SCREW RHM 1/4-20 X 3
4
WASHER FLAT 1/4-M6 ZINC
4
WASHER LOCK M6-1/4
4
NUT HEX 1/4-20 STEEL
7
SCREW THF M6-1 X 16 N WA Z/JS
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
1
DECAL CUSTOMER CONNECT INSIDE

(1) ITEM INCLUDED WITH HARNESS.
(2) ITEM INCLUDED WITH 0D5464B.
(3) ITEM IS PART OF 9R.
(4) ROUTE ONE SET (11, 22, 33, 44) THROUGH ONE HOLE; AND
ROUTE THE SECOND SET (11, 22, 33, 44) THROUGH THE OTHER
HOLE.

3.)
A
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
(1) W
X
4.)
A
C
D
E
F
G
H
J
K
(2) L
(2) M
N
P
R
(1) S
T
U
V
(2) W
(2) X
Y

0F4173
0F4165$
0F4186
036261
053640
038150
022264
022471
029289
0F1733
022129
0F8432
0C2454
0F8451
049897
022145
045771
0F8843
W/CB
0G3259
0F4175
0F4166$
0F1733
042419
023897
022152
022158
0C2454
029289
052647
046526
W/CB
0A7822
022131
W/CB
023334
022097
022473
W/CB
W/CB
0G3259

1
REF
1
4
4
4
4
4
2
1
9
1
7
3
9
6
3
3
2
1
1
REF
1
4
4
4
4
7
1
2/3
2/3
3
3
3
2
6
6
6
2/3
2/3
1

UL CIRCUIT BREAKER (225AF)
COVER CB C5 225AF
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
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
DECAL TERMINAL SHOCK HZD BI
UL CIRCUIT BREAKER (400AF)
COVER CB C5 400AF
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
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
DECAL TERMINAL SHOCK HZD BI

5.)
A
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
(1) U
V

0F4176
0F4167$
0F8433
024196
022473
022097
022127
0C2454
029289
060619
022131
022237
045772
0F8452
097950
0F1733
W/CB
0G3259

1
REF
2
4
4
4
4
7
2
3
9
6
6
3
3
1
2
1

UL CIRCUIT BREAKER (800AF)
COVER CB C5 800AF
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
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
DECAL TERMINAL SHOCK HZD BI

6.)
A
B
C
D
E
F
G
H

0D5466
039287
022145
022129
045771
045335
022097
0A7822

2
1
1
1
1
2
2
1

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

(1) HARDWARE FOR MTG. CB TERMINAL COVERS IS SUPPLIED
WITH CIRCUIT BREAKERS.
(2) 2/3 QTY. 2POLE & 3 POLE CB.

1
2
3

4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

30
31
32
33
34
35
36
39
40
42
43
44
45
46
47
48 *
49
50
51
52
53
54
55
56
57
58
59
60
61
62

0F2687
0F2611
0F5254
0F5253
0F7077
046526
051756
0C2454
052250
076749
0F2573
0F2610
0G51580ST03
0G2990
0F2862
0F2560
022131
039414
052625
0F2561
0C8165
0D6795
0C7043
0E8909
048031C
0C8146
082774
0F2686
0F5463
0F8695
0F4028
0F4030
0F4032
0F4496
042911
0F2872
022304
022195
022196
049813
070015
022145
022129
035685
045764
065852
0C7649
055596
069860E
069811
080713
022473
022097
042568
0F5050
039253
051769
0C8145
0E2507
090283
0C8566
0F2776A
052644
0G4376

1
1
1
1
1
12
8
2
2
1
1
1
1
1
1
1
15
1
3
1
5
1
12
1
1
4
2
1
1
1
1
1
1
1
1
1
2
1
1
8
1
1
1
4
1
1
1
1
1
REF
1
16
16
8
1
1
1
8
1
1
8
1
1
1

WELDMENT RADIATOR SUPPORT150
RADIATOR 680 X 680 X 70 CPL
V-BELT 31/64" X 62-3/8"
V-BELT 31/64" X 61-3/8" (5.4L 100KW ONLY)
V-BELT 1/2" X 63-3/8" (6.8L 100 130KW)
WASHER LOCK M10
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
TENSIONER ARM, PULLER SYSTEM
SHOULDER BOLT 3/8 X 1/2"
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
WASHER LOCK 1/2
NUT HEX 1/2-13 STEEL
NUT HEX M6 X 1.0 G8 YEL CHR
NUT HEX LOCK 5/16-18 NY INS SS
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
WASHER BELLEVILLE .75X.38X.028

* ITEM 48 IS INCLUDED WITH 47.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26

0F3099
065852
052252
052257
052259
055597
052251A
052860
0F2895
045764
022447
061383
043107
022473
049813
057192
022131
046526
0536210360
042909
022261
022129
022145
045771
038750
022097

1
1
5
5
5
5
5
4
2
1
1
1
1
1
1
8
8
8
1
1
2
1
2
2
1
1

MTG BASE CP 5.4L 100KW DD
SPRING CLIP HOLDER .37-.62
DAMPENER VIBRATION
SPACER .49 X .62 X 1.87 PWDR/ZINC
WASHER FLAT M12
SCREW HHC M12-1.75 X 85 G8.8
DAMPENER VIBRATION 50 WHITE
NUT LOCKING M12-1.75
SUPPORT ENG 5.4L LH/RH 6.8L RH
SCREW HHTT M4-0.7 X 8 BP
WASHER SHAKEPROOF INT 1/4
LUG SOLDERLESS 3/0-#4 X 13/32 CU
SCREW HHC M8-1.25 X 25 G8.8
WASHER FLAT 1/4-M6 ZINC
NUT HEX M6 X 1.0 G8 YEL CHR
SCREW SHC M10-1.5 X 30 G12.9
WASHER 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 M6-1.0 X 30 G8.8
WASHER LOCK M6-1/4

1
2
3
4
5
6
7
8
9
10
11
12
13
14

0F3408
0F3411
058208
022131
050331A
050331
038805U
038804U
045771
022129
027482
075763
0C2454
0F3409

1
1
1
1
1
1
1
1
1
1
1
1
8
1

TRAY BATTERY
STRAP BATTERY RETAINMENT
BATT 12VDC 24F 625
WASHER FLAT 3/8-M10 ZINC
BATT POST COVER RED +
BATT POST COVER BLK CABLE BATT BLK #1 X 18.00
CABLE BATT 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 M6-1X16 N WA Z/JS
SUPPORT BATTERY TRAY

1
2
(1) 3
4
5
6
7
8
9
10
11
12
13
(1) 14
(1) 15
(1) 16
(1) 17
18
19
20
21
22
23
24
(1) 25
26
27
28
29

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

1
1
1
1
1
1
REF
2
6
6
8
1
2
2
4
8
2
REF
REF
REF
REF
2
2
2
6
2
1
12
2
REF
4
4
8
6

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
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

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

1
2
3
4
5
6
7
8
9
10
11

0D2513D
0F5419
0F4268
0F4270A
0F6977
037561
047411
022097
049811
0F4269
022473

1
1
1
1
1
1
4
4
4
1
1

AIR CLNR BTM PLT W/CPLR 8.1L
ELEMENT AIR FILTER
TOP PLATE VENTURI
HOLD DOWN AIR CLEANER PLATED
PLATE AIR CLEAN TOP 5.4L/6.8L
NUT WING 1/4-20 NYLK
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
WASHER FLAT M6
GASKET MIXER BODY
WASHER FLAT 1/4-M6 ZINC

1*
2*
3
4
5 **
6
7

8
9
10
11
12 *

0F3883
0F1960
0F2842
0F2843
0D5419
0F2849
0D3488G
0D3488L
0D3488K
057795A
059057
0F2844
0F2847
0F2839

1
1
8
1
1
1
1
1
1
1
1
1
1
1

TUBE HEATER WATER
ENGINE 5.4L FORD
IGNITION COIL ASSY FORD
GASKET THERMOSTAT HOUSING FORD
OIL FILTER FORD V-10 ENGINE
TUBE OIL LEVEL INDICATOR FORD
BELT SERPENTINE 65.0" (1800 RPM)
SERPENTINE BELT (66.0") (2650 RPM)
SERPENTINE BELT (68.3") (3600 RPM)
BARBED EL 90 3/4 PLASTIC
HOSE 3/4 ID SAE-30R2 (16.75”LG)
THERMOSTAT ASSY FORD
PULLEY FAN BELT FORD
GASKET INTAKE MANIFOLD RIGHT

13 *
14 *
15
16
17
18
19
20
21
22
23
24
25
26
27

28
29
30
31
32
33
34 *
35 *
36 *
37 *
38 *
39 *
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55 ***
56
57
58
59

0F2840
0F1959
055476
0F2851
0F2848
055440
022097
022473
042568
022129
0F4612
0E9868A
022145
057796
0F3216
0F3216B
0F3216D
0F3217
0F3287
0F3017
0F5991
051713
042914
051731
022129
022145
051756
046526
022131
039253
064416
022131
046526
0D8027
0D8025
0D8026
0D8030
0F2846
0D8029
0D8028
0F2776A
045772
045771
0E0992A
057823
029333A
0F6151
0E0502
0F4308
036277

1
1
1
1
1
8
3
3
3
6
1
1
7
1
1
1
1
1
1
1
1
8
2
9
9
9
2
2
2
3
1
2
1
4
2
3
1
1
1
1
2
1
2
8
3
2
2
1
1
1

GASKET INTAKE MANIFOLD LEFT
INTAKE MANIFOLD 5.4L (PLASTIC)
BUSHING REDUCER 3/8 TO 1/8 GAL
CONNECTION WATER OUTLET FORD
INDICATOR ASSY OIL LEVEL FORD
SCREW HHC M5-0.8 X 25 G8.8
WASHER LOCK M6-1/4
WASHER FLAT 1/4 ZINC
SCREW HHC M6-1.0 X 20 G8.8
WASHER LOCK M8-5/16
SENDER OIL PRESSURE 1/8"NPT
ALTERNATOR DC W/OUT PULLEY
WASHER FLAT 5/16 ZINC
GROMMET
PULLEY 80 OD DC ALTERNATOR (1800RPM)
PULLEY 117 OD DC ALTERNATOR (2650 RPM)
PULLEY 160 OD DC ALTERNATOR (3600 RPM)
SPACER DC ALTERNATOR PULLEY
BRKT DC ALTERNATOR UPPER
BRKT DC ALTERNATOR LOWER
HARN ENG 5.4L H-100 (NOT SHOWN)
WASHER FLAT M5
SCREW HHC M8-1.25 X 90 G8.8
SCREW HHC M8-1.25 X 50 G8.8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
SCREW HHC M10-1.5 X 20 G8.8
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
SCREW HHC M8-1.25 X 20 G8.8
SCREW HHC M10-1.5 X 45 G8.8 FT
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
SCREW WP PULLEY M8-1.25 X 19
BOLT HEX FL HD M8-1.25 X 28
BOLT HEX FL HD M8-1.25 X 31
TENSIONER ENG. AUTOMATIC BELT
PULLEY WATER PUMP FORD (1800RPM)
PULLEY ENGINE WATER PUMP (2650 & 3600RPM)
PULLEY GROOVED ENGINE IDLER
BRACKET SIGNAL CONDITIONER
NUT HEX M10-1.5 G8 YEL CHR
NUT HEX M8-1.25 G8 YEL CHR
PLUG EXPANSION 14 OD
CLAMP HOSE #10 .56-1.06
TIE WRAP UL 7.4" X .19" BLK (NOT SHOWN)
CAP RUBBER
TEMPERATURE SENDER, DELPHI
BRACKET DC ALT STABILIZER
ELBOW 90D STREET 1/8

* NOTE: PART OF ENGINE MAKE P/N 0F3902.
** NOTE: I/N 5 IS PART OF I/N 2.
*** NOTE: I/N 55 IS FOR HOLDING SENSOR TO I/N 50.

1
2
3
4
5
6
7
8*
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
41
42
43

0D9913
0E9747
0F3514
0F3903C
0F3903C
0F2776A
0D5417
0F3844
029333A
022131
055596
057772
057823
057765
0F3534
069860E
049821
022129
039253
0D2244M
044118
055934M
047411
071623
0D6742
022097
0F1820
0F1818
022473
048031J
0F2929
077996
046526
070008
070006
0D2608
0F5114
0F5454
047290
059057
040173

16
1
1
1
2
1
8
8
1
1
1
1
2
1
2
1
2
4
1
1
REF
1
1
4
1
1
2
2
1
1
1
2
6
8
24
8
1
1
1
1
1

SCREW SHC M8-1.25 X 35 SS
STARTER 12 VOLT
SPACER FLEXPLATE 5.4L/6.8L (1800 RPM ONLY)
FLEX PLATE 2 POLE 5.4L & 6.8L (1800 RPM UNITS ONLY)
FLEX PLATE 2 POLE 5.4L & 6.8L (3600 RPM UNITS ONLY)
BRACKET, SIGNAL CONDITIONER
SCREW HHC M10-1.0 X 25 G10.9
WASHER FLAT .43 X 1.00
TIE WRAP UL 7.4" X .19" BLK (NOT SHOWN)
WASHER FLAT 3/8-M10 ZINC
BARBED STR 3/8 NPT X 3/8
WASHER NYLON .565
CLAMP HOSE #10 .56 - 1.06
ADAPTER M14-1.50 X 3/8 NPT
HEAT SHLD EXHAUST MANIFOLD
HOSE DRAIN ASSY 28"
SCREW SHC M8-1.25 X 30 G12.9
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 20 G8.8
ASSY MAGPICKUP(3/8-24 MALE)
BARBED STR 1/2 NPT X 5/8
CLAMP VINYL .75 X .343 Z
SCREW HHC M6-1.0 X 16 G8.8
SCREW SHC M10-1.5 X 55 G12.9
VALVE PCV (FORD 6.8L)
WASHER LOCK M6-1/4
MACHINED MANIFOLD EXHAUST 5.4L
GASKET EXHAUST MANIFOLD
WASHER FLAT 1/4-M6 ZINC
HOSE CLAMP BAND 5/8"
ENGINE ADAPTER 5.4L/6.8L
CAP HOSE
WASHER LOCK M10
WASHER FLAT M8 SS
WASHER LOCK M8 SSTL
SCREW HHC 5/16-18 X 1/2 SSTL
DECAL REFER TO OWNERS MANUAL
PLATE MAG PICK-UP ADAPTOR
HOSE 3/8 ID SINGLE BRAID (15” LG)
HOSE 3/4 ID SAE-30R2
CLAMP HOSE #5.5 .62-.62

* NOTE: I/N 8 IS FOR HOLDING SENSOR TO I/N 5.

COMPONENTS INCLUDED IN 0G4139E
1
ENCL H/G CONTROL PANEL
1
COVER CONTROL PANEL
1
HINGE CONTINUOUS H PANEL
6
RIVET POP .125 X .275 SS
1
ASSY PROGRAMMED H-100
1
DECAL FUSES LOCATED INSIDE
1
RAIL SNAPTRACK PCB HOLDER BULK (12”LG)
1
ASSY PCB 2AMP 12V UL BATT CHGR
1
PLATE HARNESS CLAMP
1
ASSY PCB PWR AVR W/AMP HEADER
1
ASSY PCB BOSCH GOV DRIVER
1
DIO BRIDGE 25A 600V
7
WASHER LOCK M5
4
SCREW PPHM M5-0.8 X 30 SS
7
WASHER FLAT M5
2
SCREW HHPM M5-0.8 X 12
5
NUT HEX M5-0.8 G8 YEL CHR
3
WASHER FLAT M4
3
SCREW PHTT M4-0.7 X 10 ZYC
1
CONN DUST CAP W/CHAIN DB9
1
WASHER FLAT M3.5
1
SCREW PHTT M3.5-0.6 X 10
10
SCREW PPHM M4-0.7 X 8 BLX OX
10
WASHER LOCK #8-M4
1
DECAL WRN BATT CHRG 12/24V BI
4
SCREW PHTT M4-0.7 X 12 ZYC
1
M5-0.8 CAPTIVE PANEL KNLD HD
2
SEAL COVER 3.18 X 12.7 X 382
1
SEAL COVER 3.18 X 12.7 X 283
1
HARNESS H-PNL INTEGRATED SW (NOT SHOWN)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

0F1823CST06
0F1824AST06
0F2606
036261
0F5763
0F1732
0E9764
0F1725C
0F1958
0F2256
0E3161
029673
049226
079224
051713
0F5886
051716
043180
0C3990
0F4333
0F5883
0F5884
055014
022264
0G3546
0C2265
0G3648
0F6305
0F6305A
0G4329

A
B
C
D
E

0F1263
0F1262
0F1264
0E9049B
055911

COMPONENTS INCLUDED IN WIRE HARNESS
1
ADPTR RH SIDE WICKMANN 178.6191
4
HOLDER FUSE WICKMANN 178.6150
1
ADPTR LH SIDE WICKMANN 178.6192
1
ASSY PCB G-PANEL RELAY 12VDC
1
BLOCK TERM 20A 12 X 6 X 1100V

50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71

056739
0F2627A
022287
022473
022097
043182
051714
052777
0C2323
0F5459
0F5461
022127
0F5460
0E7403C
0E7403B
0F6145
091526
0C2699
051713
049226

COMPONENTS NOT INCLUDED IN 0G4139E OR WIRE HARNESS
1
RELAY CONTACTOR 12VDC
1
DPE BREAKER SEE DRAWING 0F9280
1
BOOST RESISTOR SEE DRAWING 0F9280
1
COVER CONTROL PANEL SIDE
2
SCREW HHC 1/4-20 X 3/4 G5
4
WASHER FLAT M6-1/4
2
WASHER LOCK M6-1/4
3
WASHER LOCK M3
3
NUT HEX M3-0.5 G8 YEL CHR
3
WASHER FLAT M3
2
SCREW PHTT #6-32 X 5/8 ZYC
1
DECAL CPL CONTROL PANEL FUSES
1
DECAL CPL 5.4/6.8L TB3
2
NUT HEX 1/4-20 STEEL
1
DECAL CPL 5.4/6.8L RELAY BOARD
1
FUSE ATO TYPE 15 AMP (BLUE)
2
FUSE ATO TYPE 10 AMP (RED)
A/R
SEAL WEATHER .45"DIA
4
SCREW PPHM M5-0.8 X 12 ZNC
2
SCREW PHTT #6-32 X 3/8 ZYC
4
WASHER FLAT M5
4
WASHER LOCK M5

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
(1) 38
(1) 39
(1) 40
(1) 41

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
0G3167
0F3691C
0F3691D
0F3691E
026915
059057
035461
081017
046580
039294
022097
047290
052223
0D2698
059057
064346
0F4408
0F6279
066212
0G46350ST03
042568
022097
049811

4
1
1
1
1
2
2
4
2
2
2
2
1
1
1
9
2
2
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
4
1
4
1
1
1
1
1
1
1
1
1
2
2
2

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 2-3/4 X 3/32 X 2-15/16
VENTURI THROTTLE 38MM (5.4L 80KW)
VENTURI THROTTLE 40MM (5.4L FORD 2-POLE 100KW)
VENTURI THROTTLE 42MM (6.8L FORD GEARBOX 100KW)
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
CLAMP HOSE #52 2.81-3.75
BRACKET, HOSE RISER
SCREW HHC M6-1.0 X 20 G8.8
WASHER LOCK M6-1/4
WASHER FLAT M6
(1) G6.8L UNITS ONLY

1
2
3

4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

25
26
27
28
29
30
31
32
33
34
(1) 35
(1) 36
(1) 37
(1) 38

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
0G3167
0F3691B
0F3691D
0F3691E
0F3691F
0F3691J
022195
0F6279
081017
046580
039294
022097
047290
040173
039130
066212
0G46350ST03
042568
022097
049811

4
1
1
1
1
1
1
2
2
4
2
1
2
1
1
1
2
4
2
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1
4
1
4
1
2
1
1
1
2
2
2

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 2-3/4 X 3/32 X 2-15/16
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
CLAMP HOSE #52 2.81-3.75
BRACKET, HOSE RISER
SCREW HHC M6-1.0 X 20 G8.8
WASHER LOCK M6-1/4
WASHER FLAT M6
(1) G6.8L UNITS ONLY

(2) 1
(2) 2
(2) 3
(2) 4
(2) 5
(2) 6
(2) 7

0F5873
0F5868
0F5872
0F5871
0F5869
0F5870
0F5867

1
4
2
2
2
1
1

REAR WRAP C5
DOOR C5
CENTER SUPPORT C5
DISCHARGE DUCT LH & RH SIDE C5
FRONT CORNERS C5
DISCHARGE CENTER DUCT C5
ROOF C5 ALUM

11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
42
43
(1) 44
45
46
47
48
49
50

0C2454
0F2766
0F3181
0F3185
0F3416
0F3949
0F4487A
022473
022097
022127
0F3072
078115
0F3949B
0F3949A
0F5048D
0E5968
0F5049
0F3949L
0F3949E
0F3890A
087233
0F3949C
0F3949D
0F3949G
0F3949J
0F3949K
0F3949F
0F3890B
0F3890
042568
022447
049813
077992
0912970094
0F2766A
0F3949M
0F8869D
0E3257
078115A

86
2
4
2
2
2
1
5
1
1
20
58
3
4
4
1
4
2
1
8
2
1
4
1
2
1
2
4
14
4
4
4
28
4
1
1
1
6
12

SCREW THF M6-1 X 16 N WA Z/JS
SPLITTER
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 #4-40
INSULATION SPLITTER
INSULATION SHORT LOUVER
VISE-ACTION LATCH SLOTTED CIR
GASKET EXTRUDED TRIM (566” LG)
TAB PULL
INSULATION SPLITTER SML
INSULATION ROOF TOP REAR
RETAINER INSULATION (740)
RIVET POP .1875 X .450 SS
INSULATION ROOF TOP
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
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
INSULATION SPLITTER SHRT MPS
KEY VISE-ACTION LATCH SLOT CIR
SCREW TH-FRM M6 W/CAP SHKPRF W
WASHER SELF LOCKING DOME #8-32

(1) ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO
THE BASE FRAME MUST BE SECURED USING ITEM 11 & 49 THREAD FORMING
FASTENER AND ITEM 44 LOCK NUT. LOCK NUT IS TO BE INSTALLED AFTER THREAD
FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS.
ALL ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER.
(2) I/N’S 1 THRU 7, REFER TO CHART BELOW FOR ENCLOSURE COLOR & MATERIAL TYPE.

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 warranty period.

WARRANTY SCHEDULE
YEAR ONE — Limited comprehensive coverage on mileage, labor, and parts listed.
• - ALL COMPONENTS
YEAR TWO — Limited comprehensive coverage on parts listed.
• - ALL COMPONENTS
*Start-up and/or On-line Registration, or Registration Card, along with Proof of Purchase, must be performed and/or sent in.

Guidelines:
• Any and all warranty repairs and/or concerns, must be performed and/or addressed by an Authorized/Certified Generac Power Systems Dealer, or
branch thereof.
• A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a Non - Generac Power
Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the genset, no warranty coverage shall apply.
• All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty, Policies, and Procedures Flat Rate
Manual.
• Units that have been resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable.
• 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.
2.
3.
4.

5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

Any unit built/manufactured prior to March 1, 2005.
Costs of normal maintenance (i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up).
Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze.
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.
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.
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.
Products that are modified or altered in a manner not authorized by Generac Power Systems in writing.
Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing.
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).
Failure due to misapplication, misrepresentation, or bi-fuel conversion.
Telephone, facsimile, cell phone, satellite, internet, or any other communication expenses.
Rental equipment used while warranty repairs are being performed (i.e. rental generators, cranes, etc.).
Overtime, holiday, or emergency labor.
Planes, ferries, railroad, busses, helicopters, snowmobiles, snow-cats, off-road vehicle or any other mode of transportation deemed abnormal.
Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct
cause of the problem.
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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Cover084 RevA 05 07 QT 5.4L 100 K W Generator Owners Manual 0G2814

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