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STANDBY GENERATOR

OWNER'S MANUAL

This manual should remain with the unit.

A new standard of reliability

Serial Number QT

6.8L

100kW

Models

Cover010 Rev. 0 08/05 Part No. 0F3605

Standby Generator Sets

Table of Contents

SECTION PAGE

SAFETY RULES ................................................ 1-1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Ignition Shutdown on Loss of Crank

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

Diagnostic Blink Patterns (Red LED Located

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Maintenance Performed by Authorized

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

30 kW - 150 kW Standby Gas Engine

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

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

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

NOTES

EXPLODED VIEWS & PARTS LISTS

WIRING DIAGRAMS & SCHEMATICS

WARRANTY

Content003 Rev. 0 08/05

Study these SAFETY RULES carefully before install-

ing, operating or servicing this equipment. Become

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

The generator can operate safely, efficiently and reli-

ably only if it is properly installed, operated and

maintained. Many accidents are caused by failing to

follow simple and fundamental rules or precautions.

The manufacturer cannot anticipate every possible

circumstance that might involve a hazard. The warn-

ings in this manual, and on tags and decals affixed

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

cedure, work method or operating technique is used

that the manufacturer does not specifically recom-

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

sure the procedure, work method or operating tech-

nique utilized does not render the generator unsafe.

DANGER

 Despite the safe design of this generator,

operating this equipment imprudently, neglect-

ing its maintenance or being careless can cause

possible injury or death. Permit only responsible

and capable persons to install, operate or main-

tain this equipment.

 Potentially lethal voltages are generated by

these machines. Ensure all steps are taken to

render the machine safe before attempting to

work on the generator.

 Parts of the generator are rotating and/or hot

during operation. Exercise care near running

generators.

 GENERAL HAZARDS 

• For safety reasons, the manufacturer recommends

that this equipment be installed, serviced and

repaired by an Authorized Service Dealer or other

competent, qualified electrician or installation tech-

nician who is familiar with applicable codes, stan-

dards and regulations. The operator also must

comply with all such codes, standards and regula-

tions.

• Installation, operation, servicing and repair of this

(and related) equipment must always comply with

applicable codes, standards, laws and regulations.

Adhere strictly to local, state and national electri-

cal and building codes. Comply with regulations

the Occupational Safety and Health Administration

(OSHA) has established. Also, ensure that the

generator is installed, operated and serviced in

accordance with the manufacturer’s instructions

and recommendations. Following installation, do

nothing that might render the unit unsafe or in

noncompliance with the aforementioned codes,

standards, laws and regulations.

• The engine exhaust fumes contain carbon monox-

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

if breathed in sufficient concentrations, can cause

unconsciousness or even death. For that reason,

adequate ventilation must be provided. Exhaust

gases must be piped safely away from any building

or enclosure that houses the generator to an area

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

This exhaust system must be installed properly, in

strict compliance with applicable codes and stan-

dards.

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

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

remove any drive belt or fan guard while the unit

is operating.

• Adequate, unobstructed flow of cooling and venti-

lating air is critical in any room or building hous-

ing the generator to prevent buildup of explosive

gases and to ensure correct generator operation.

Do not alter the installation or permit even partial

blockage of ventilation provisions, as this can seri-

ously affect safe operation of the generator.

• Keep the area around the generator clean and

uncluttered. Remove any materials that could

become hazardous.

• When working on this equipment, remain alert

at all times. Never work on the equipment when

physically or mentally fatigued.

• Inspect the generator regularly, and promptly

repair or replace all worn, damaged or defective

parts using only factory-approved parts.

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

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

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

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

WARNING:



This product contains or emits chemicals

known to the state of California to cause

cancer, birth defects or other reproductive harm.

WARNING:



1-1

Standby Generator Sets

Important Safety Instructions



Safety 001 Rev. 0 08/05

• Before performing any maintenance on the gen-

erator, disconnect its battery cables to prevent

accidental start-up. Disconnect the cable from the

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

first. Reconnect that cable last.

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

step. Stepping on the unit can stress and break

parts, and may result in dangerous operating con-

ditions from leaking exhaust gases, fuel leakage,

oil leakage, etc.

 ELECTRICAL HAZARDS 

• All generators covered by this manual produce

dangerous electrical voltages and can cause fatal

electrical shock. Utility power delivers extremely

high and dangerous voltages to the transfer switch

as well as the standby generator. Avoid contact

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

the generator as well as the transfer switch, if

applicable. Ensure all appropriate covers, guards

and barriers are in place before operating the gen-

erator. If work must be done around an operating

unit, stand on an insulated, dry surface to reduce

shock hazard.

• Do not handle any kind of electrical device while

standing in water, while barefoot, or while hands or

feet are wet. DANGEROUS ELECTRICAL SHOCK

MAY RESULT.

• If personnel must stand on metal or concrete while

installing, operating, servicing, adjusting or repair-

ing this equipment, place insulative mats over a

dry wooden platform. Work on the equipment only

while standing on such insulative mats.

• The National Electrical Code (NEC) requires the

frame and external electrically conductive parts

of the generator to be connected to an approved

earth ground. This grounding will help prevent

dangerous electrical shock that might be caused

by a ground fault condition in the generator set or

by static electricity. Never disconnect the ground

wire.

• Wire gauge sizes of electrical wiring, cables and

cord sets must be adequate to handle the maxi-

mum electrical current (ampacity) to which they

will be subjected.

• Before installing or servicing this (and related)

equipment, make sure that all power voltage

supplies are positively turned off at their source.

Failure to do so will result in hazardous and pos-

sibly fatal electrical shock.

• Connecting this unit to an electrical system nor-

mally supplied by an electric utility shall be by

means of a transfer switch so as to isolate the

generator electric system from the electric utility

distribution system when the generator is operat-

ing. Failure to isolate the two electric system power

sources from each other by such means will result

in damage to the generator and may also result

in injury or death to utility power workers due to

backfeed of electrical energy.

• Generators installed with an automatic transfer

switch will crank and start automatically when

normal (utility) source voltage is removed or is

below an acceptable preset level. To prevent such

automatic start-up and possible injury to person-

nel, disable the generator’s automatic start circuit

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

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

the generator control panel and on the transfer

switch.

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

diately shut down the source of electrical power.

If this is not possible, attempt to free the victim

from the live conductor. AVOID DIRECT CONTACT

WITH THE VICTIM. Use a nonconducting imple-

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

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

scious, apply first aid and get immediate medical

help.

• Never wear jewelry when working on this equip-

ment. Jewelry can conduct electricity resulting in

electric shock, or may get caught in moving com-

ponents causing injury.

 FIRE HAZARDS 

• Keep a fire extinguisher near the generator at all

times. Do NOT use any carbon tetra-chloride type

extinguisher. Its fumes are toxic, and the liquid

can deteriorate wiring insulation. Keep the extin-

guisher properly charged and be familiar with its

use. If there are any questions pertaining to fire

extinguishers, consult the local fire department.

 EXPLOSION HAZARDS 

• Properly ventilate any room or building housing

the generator to prevent build-up of explosive gas.

• Do not smoke around the generator. Wipe up any

fuel or oil spills immediately. Ensure that no com-

bustible materials are left in the generator com-

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

EXPLOSION may result. Keep the area surround-

ing the generator clean and free from debris.

• These generator sets may operate using one of

several types of fuels. All fuel types are potentially

FLAMMABLE and/or EXPLOSIVE and should be

handled with care. Comply with all laws regulat-

ing the storage and handling of fuels. Inspect the

unit’s fuel system frequently and correct any leaks

immediately. Fuel supply lines must be prop-

erly installed, purged and leak tested according to

applicable fuel-gas codes before placing this equip-

ment into service.

• Diesel fuels are highly FLAMMABLE. Gaseous

fluids such as natural gas and liquid propane

(LP) gas are extremely EXPLOSIVE. Natural gas

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

install leak detectors accordingly.

1-2

Standby Generator Sets

Important Safety Instructions

Safety 001 Rev. 0 08/05

1-3

INTRODUCTION

Thank you for purchasing this model of the standby

generator set product line.

Every effort was expended to make sure that the

information and instructions in this manual were

both accurate and current at the time the manual was

written. However, the manufacturer reserves the right

to change, alter or otherwise improve this product(s)

at any time without prior notice.

READ THIS MANUAL THOROUGHLY

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

tact the nearest Authorized Service Dealer for start-

ing, operating and servicing procedures.

Throughout this publication, and on tags and

decals affixed to the generator, DANGER, WARNING,

CAUTION and NOTE blocks are used to alert person-

nel to special instructions about a particular service

or operation that may be hazardous if performed

incorrectly or carelessly. Observe them carefully.

Their definitions are as follows:

DANGER

After this heading, read instructions that, if not

strictly complied with, will result in personal injury

or property damage.

After this heading, read instructions that, if not

strictly complied with, may result in personal

injury or property damage.

After this heading, read instructions that, if not

strictly complied with, could result in damage to

equipment and/or property.

NOTE:

After this heading, read explanatory statements

that require special emphasis.

These safety warnings cannot eliminate the hazards

that they indicate. Common sense and strict compli-

ance with the special instructions while performing

the service are essential to preventing accidents.

Four commonly used safety symbols accompany the

DANGER, WARNING and CAUTION blocks. The type

of information each indicates is as follows:

 This symbol points out important safety infor-

mation that, if not followed, could endanger

personal safety and/or property of others.

 This symbol points out potential explosion

hazard.



 This symbol points out potential fire hazard.

 This symbol points out potential electrical shock

hazard.

The operator is responsible for proper and safe use

of the equipment. The manufacturer strongly recom-

mends that the operator read this Owner's Manual

and thoroughly understand all instructions before

using this equipment. The manufacturer also strong-

ly recommends instructing other users to properly

start and operate the unit. This prepares them if they

need to operate the equipment in an emergency.

OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety

checks, to make sure that all maintenance for safe

operation is performed promptly, and to have the

equipment checked periodically by an Authorized

Service Dealer. Normal maintenance service and

replacement of parts are the responsibility of the

owner/operator and, as such, are not considered

defects in materials or workmanship within the terms

of the warranty. Individual operating habits and usage

contribute to the need for maintenance service.

Proper maintenance and care of the generator ensure

a minimum number of problems and keep operating

expenses at a minimum. See an Authorized Service

Dealer for service aids and accessories.

Operating instructions presented in this manual

assume that the standby electric system has been

installed by an Authorized Service Dealer or other

competent, qualified contractor. Installation of this

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

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs,

simply contact an Authorized Service Dealer for

assistance. Service technicians are factory-trained

and are capable of handling all service needs.

When contacting an Authorized Service Dealer or the

factory about parts and service, always supply the

complete model number of the unit as given on the

front cover of this manual or on the DATA LABEL

affixed to the unit.





AUTHORIZED SERVICE DEALER LOCATION

To locate the nearest AUTHORIZED

SERVICE DEALER, please call this number:

1-800-333-1322

or locate us on the web at:

www.generac.com

Standby Generator Sets

Important Safety Instructions

Safety 001 Rev. 0 08/05

IDENTIFICATION RECORD

DATA LABEL

Every generator set has a DATA LABEL that contains

important information pertinent to the generator. The

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

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

number and its rated voltage, amps, wattage capacity,

phase, frequency, rpm, power factor, etc.

WAUKESHA, WI

RATED KW

RATED VOLTAGE

POWER FACTOR

ENGINE RPM

ALTERNATOR SUBTRANSIENT REACTANCE

ALTERNATOR TRANSIENT REACTANCE

CLASS

MODEL

MADE IN USA

PRODUCTION DATE

GENERAC POWER SYSTEMS, INC.

HERTZ

RATED KVA

GENERATOR SET DATA

RATED AMPS

ALT RPM

PHASE

SERIAL

ROTOR STATOR WINDING INSULATION AT 25°C AMBIENT

NOTE:

For actual information related to this particular

model, please refer to the Manual Drawing Listing

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

label affixed to the unit.

Generator Model and Serial Number

This number is the key to numerous engineering and

manufacturing details pertaining to your unit. Always

supply this number when requesting service, order-

ing parts or seeking information.





Identification Code

Use this code to obtain important information about

the generator. For example, if the code is:

M — Designates generators capable of paralleling.

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

are currently available for this configura-

tion.

QT — Quiet Test Generator Series

100 — kw Rating

5.4 — Engine Size in Liters

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

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

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

L = 346/600, Three-phase

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

S — Enclosure Material: A = Aluminum; S

= Steel (Corrosion Resistant Aluminum

Enclosure Material, Steel is Standard)

N — Emission Equipment: N = No Equipment;

Y = Catalytic Converter and Air/Fuel Ratio

Controller

A — Industrial Dealer Product

Voltage Codes

The identification code letter following the unit’s

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

Groups and Assembly Numbers

The manual drawing listing lists the groups and cor-

responding assembly numbers for each unit. The

assembly numbers refer to exploded view drawing

numbers that are applicable to the specific generator

model. These drawings are located in the back half

of this manual.







2-1

Standby Generator Sets

General Information

Identy001 Rev. C 04/06

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

EQUIPMENT DESCRIPTION

This equipment is a revolving field, alternating cur-

rent generator set. It is powered by a gaseous fueled

engine operating at 1800 rpm for 4-pole direct drive

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

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

Specifications section for exact numbers. The unit

comes complete with a sound attenuated enclosure,

internally mounted muffler, control console, main-

line circuit breaker, battery charger, and protective

alarms as explained in the following paragraph.

All AC connections, including the power leads from

the alternator, 120 volt battery charger input and

control connections to the transfer switch are avail-

able in the main connection box.

The generator incorporates the following generator

features:

• Rotor and Stator insulation is Class H rated as

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

The generator is self ventilated and drip-proof con-

structed.

• The voltage waveform deviation, total harmonic

content of the AC waveform and telephone influ-

ence factor have been evaluated and are acceptable

according to NEMA MG1-32.

ENGINE OIL RECOMMENDATIONS

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

the factory. Use a high-quality detergent oil classified

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

engine cleaner and reduce carbon deposits. Use oil

having the following SAE viscosity rating, based on

the ambient temperature range anticipated before the

next oil change:

 Any attempt to crank or start the engine before

it has been properly serviced with the recom-

mended oil may result in an engine failure.

NOTE:

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

mended to use the optional Cold Weather Start Kit

(part number listed in the Specification Section).

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

30 synthetic oil.

COOLANT RECOMMENDATIONS

Use a mixture of half low silicate ethylene glycol

base anti-freeze and deionized water. Cooling system

capacity is listed in the specifications. Use only deion-

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

add a high quality rust inhibitor to the recommended

coolant mixture. When adding coolant, always add

the recommended 50-50 mixture.

 Do not use any chromate base rust inhibitor

with ethylene glycol base anti-freeze or chro-

mium hydroxide (“green slime”) forms and will

cause overheating. Engines that have been oper-

ated with a chromate base rust inhibitor must

be chemically cleaned before adding ethylene

glycol base anti-freeze. Using any high silicate

anti-freeze boosters or additives will also cause

overheating. The manufacturer also recommends

that any soluble oil inhibitor is NOT used for this

equipment.

DANGER

 Do not remove the radiator pressure cap while

the engine is hot or serious burns from boiling

liquid or steam could result.

 Ethylene glycol base antifreeze is poisonous.

Do not use mouth to siphon coolant from the

radiator, recovery bottle or any container. Wash

hands thoroughly after handling. Never store

used antifreeze in an open container because

animals are attracted to the smell and taste of

antifreeze even though it is poisonous to them.

Temperature Oil Grade (Recommended)

Above 80° F (27° C) SAE 30W or 15W-40

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

Below 32° F (0° C) See Note

3-1

Standby Generator Sets

Equipment Description

Equip001 Rev. 0 08/05

ENGINE PROTECTIVE DEVICES

The standby generator may be required to operate for

long periods of time without an operator on hand to

monitor such engine conditions as coolant tempera-

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

has several devices designed to protect it against

potentially damaging conditions by automatically

shutting down the unit when the oil pressure is too

low, the coolant temperature is too high, the coolant

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

NOTE:

Engine protective switches and sensors are men-

tioned here for the reader's convenience. Also refer

to the applicable control panel manual for addi-

tional automatic engine shutdown information.

COOLANT TEMPERATURE SENSING

An analog Water Temperature Sender (WTS) is locat-

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

nected to the panel and allows the panel to monitor

and display the temperature of the coolant system.

The WTS is a resistive device whose resistance chang-

es based on coolant temperature. The resistance of

the sender results in a voltage being developed across

the sender. As the Coolant temperature increases,

the resistance will decrease, causing the voltage to

decrease. This changing voltage is converted to 4-

20mA signal by a signal conditioner module. The

corresponding 4-20mA signal is read by the control

panel and displayed as the coolant temperature.

The control panel will monitor and display the cool-

ant temperature anytime the DC input to the control

panel is present.

If the temperature exceeds approximately 140° C

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

generator will automatically restart and the display

will reset once the temperature has returned to an

operating level.

LOW COOLANT LEVEL

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

generators coolant system. This sensor allows the

panel to detect a Low Coolant Level condition.

The LCL is a resistive device whose resistance changes

rapidly based on the presence or absence of coolant.

The resistance of the LCL results in a voltage being

developed across the LCL. This voltage changes as

the resistance changes. This changing voltage is con-

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

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

control panel and displayed as the low coolant level.

If the level of the engine coolant drops below the level

of the low coolant level sensor, the engine shutdown

will be initiated.





OIL PRESSURE SENSING

An analog Oil Pressure Sender (OPS) is used for

monitoring the engine oil pressure. This sender

allows the control panel to measure and display the

Engine oil pressure.

The OPS is a resistive device, whose resistance

changes based on engine oil pressure. The resistance

of the sender results in a voltage being developed

across the sender. As the oil pressure increases,

the resistance will decrease, causing the voltage to

decrease. This changing voltage is converted to 4-

20mA signal by a signal conditioner module. The

corresponding 4-20mA signal is read by the control

panel and displayed as the oil pressure.

The control panel will monitor and display oil pres-

sure anytime the DC input to the control panel is

present.

Should the oil pressure drop below the 8 psi range,

the engine shutdown is initiated. The unit should not

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

MANUAL switch to the OFF position, then back to

AUTO to restart.

OVERCRANK SHUTDOWN

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

tiates the programmed starting sequence. The start

sequence consists of the number of crank attempts,

the length of each crank attempt, and the rest time

between each crank attempt. If the engine has not

started by the end of the final crank attempt, an

Overcrank alarm is generated, the control panel will

sound the alarm and display the message "Failed to

start".

OVERSPEED SHUTDOWN

A speed circuit controls engine cranking, start-up,

operation and shutdown. Engine speed signals are

delivered to the circuit board whenever the unit is

running. Should the engine over speed above a safe,

preset value, the circuit board initiates an automatic

engine shutdown. Contact the nearest Authorized

Dealer if this failure occurs.

RPM SENSOR LOSS SHUTDOWN

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

shutdown will occur.

DC FUSE

This fuse is located inside of the control panel. It

protects the panel wiring and components from

damaging overload. Always remove this fuse before

commencing work on the generator. The unit will

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

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

the exploded views and parts lists at the end of this

manual for replacement part number.)











4-1

Standby Generator Sets

Engine Protective Devices

EngProt002 Rev. B 10/05

FUEL SYSTEM

FUEL REQUIREMENTS

The standby generator may be equipped with one of

the following fuel systems:

• Natural gas fuel system

• Propane vapor (PV) fuel system

• Liquid propane (LP) fuel system

The Manual Drawing Listing that is affixed to the

unit includes the “Identification Code,” which may be

used to identify the type of fuel system installed on

the unit.

Recommended fuels should have a Btu content of at

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

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

fuel supplier for the Btu content of the fuel.

Required fuel pressure for natural gas is 11 inches

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

liquid propane, 11 inches to 14 inches of water

column (0.4 to 0.5 psi).

NOTE:

Any piping used to connect the generator to the

fuel supply should be of adequate size to ensure

the fuel pressure NEVER drops below 11 inches

water column for natural gas or 11 inches water

column for liquid propane for all load ranges.

NOTE:

It is the responsibility of the installer to make sure

that only the correct recommended fuel is sup-

plied to the generator fuel system. Thereafter, the

owner/operator must make certain that only the

proper fuel is supplied.

NATURAL GAS FUEL SYSTEM

Natural gas is supplied in its vapor state. In most

cases, the gas distribution company provides piping

from the main gas distribution line to the standby

generator site. The following information applies to

natural gas fuel systems.

• Gas pressure in a building is usually regulated by

national, state and local codes.

• To reduce gas pressure to a safe level before

the gas enters a building, a primary regulator is

needed. The natural gas supplier may or may not

supply such a regulator.

• It is the responsibility of the gas supplier to make

sure sufficient gas pressure is available to operate

the primary regulator.

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

noid should not exceed approximately 14 inches

water column (0.5 psi). Optimum pressure at the

fuel shutoff solenoid is 11 inches water column

(0.4 psi).

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PROPANE VAPOR WITHDRAWAL FUEL SYSTEM

This type of system utilizes the vapors formed above

the liquid fuel in the supply tank. Approximately 10

to 20 percent of the tank capacity is needed for fuel

expansion from the liquid to the vapor state. The

vapor withdrawal system is generally best suited for

smaller engines that require less fuel. The installer

should be aware of the following:

• The natural gas and LP gas systems are similar.

However, the natural gas system delivers gas at a

pressure of approximately five inches water col-

umn to the carburetor.

• When ambient temperatures are low and engine

fuel consumption is high, the vapor withdrawal

system may not function efficiently.

• Ambient temperatures around the supply tank

must be high enough to sustain adequate vaporiza-

tion, or the system will not deliver the needed fuel

volume.

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

vaporization process itself provides an additional

cooling effect.

LP FUEL SYSTEM

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

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

the two gases. Propane tends to vaporize readily even

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

butane reverts to its liquid state when temperatures

drop below 32° F (0° C).

LP in a liquid withdrawal system must be converted

to its gaseous state before it is introduced into the

engine carburetor. A vaporizer-converter is generally

used to accomplish this. In such a converter, heated

engine coolant is ported through the converter to

provide the necessary heat for conversion of the fuel

from a liquid to a gaseous state.

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5-1

Standby Generator Sets

Fuel Systems

FuelSys002 Rev. A 05/06

SPECIFICATIONS

GENERATOR

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

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

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

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

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

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

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

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

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

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

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

gas.

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

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

120/240V, 1-phase, 1.0 pf 100 417 450

120/208V, 3-phase, 0.8 pf 100 347 400

277/480V, 3-phase, 0.8 pf 100 150 175

Generator Locked Rotor KVA Available @ Voltage Dip of 35%

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

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

ENGINE

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

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

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

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

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

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

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

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

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

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

Engine Parameters

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

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

Exhaust System

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

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

Combustion Air Requirements (Natural Gas)

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

Governor

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

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

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

Adjustments:

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

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Engine Lubrication System

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

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

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

COOLING SYSTEM

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

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

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

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

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

Air Flow (inlet air including alternator and

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

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

Heat Rejection to Coolant ..........................................342,000 Btu/h

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

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

FUEL SYSTEM

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

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

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

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

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

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

Exercise 25% 50% 75% 100%

Cycle Load Load Load Load

130/52 371/149 713/287 991/400 1260/507

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

factory set for the specific fuel.

ELECTRICAL SYSTEM

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

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

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

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

Voltage Regulator

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

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

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

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

V/F Adjustable, Adjustable

Voltage and Gain

Power Adjustment for Ambient Conditions

Temperature Deration

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

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

Altitude Deration

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

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

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

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6-1

Standby Generator Sets

Specifications

GenSpec009 Rev. C 11/05

COLD WEATHER KIT

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

ber 0F6148A) is recommended. The kit includes:

• Battery Warmer

• 4” Junction Box with hardware

• 700 Cold Cranking Amp Battery

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

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

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Figure 1 — Interconnections

6-2

Standby Generator Sets

Specifications

GenSpec009 Rev. C 11/05

5.4L & 6.8L IGNITION DESCRIPTION

This single-fire Ignition is intended to operate with

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

engine.

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

pickup CAM sensor and individual coil-on-plug coils

for each spark-plug.

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

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

for each spark-plug.

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

put is connected to one spark plug resulting in that

spark plug being fired only during the compression

cycle.

Engine Timing versus Engine Speed for the 6.8L

engine is:

RPM NG/LP Engine Timing (BTDC)

1800 rpm 22 degrees

3600 rpm 24 degrees

Engine Timing versus Engine Speed for the 5.4L

engine is:

RPM NG/LP Engine Timing (BTDC)

1800 rpm 26 degrees

3600 rpm 26 degrees

IGNITION POWER-UP INPUT ("56 LINE

INPUT")

When battery voltage is applied to this input the igni-

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

down, battery voltage must be removed from this

input.

IGNITION ENABLE ("14 LINE INPUT")

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

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

nected to battery ground the ignition will stop firing

the coils and will power down within approximately

2 seconds. In the event that an ignition fault has

occurred, however, the ignition will wait 60 seconds

before powering down. This allows time to view the

diagnostic LED located on the ignition board.

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NOTE:

The ignition cover does not need to be removed to

see the LED.

IGNITION SHUTDOWN ON LOSS OF CRANK

OR CAM SIGNALS

The ignition will stop firing the coils immediately fol-

lowing the loss of the crank signal. The ignition will

stop firing the coils after approx. 3 seconds following

the loss of the cam signal.

DIAGNOSTIC BLINK PATTERNS (RED LED

LOCATED ON THE IGNITION CONTROL

BOARD)

During normal ignition operation the RED LED

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

is considered one (1) blink.

LED Fault Code with Priority as shown:

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

3.0 seconds and then repeats

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

3.0 seconds and then repeats

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

exist then the highest priority fault must be resolved

prior to a lower priority fault being displayed. In the

event that an ignition fault has occurred the ignition

will wait 60 seconds before powering down.

NOTE:

The ignition cover does not need to be removed to

see the LED.

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6-3

Standby Generator Sets

Specifications

GenSpec009 Rev. C 11/05

GENERATOR AC LEAD CONNECTIONS

See “Voltage Codes”. This generator may be rated

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

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

nection (lower) panel should be installed according to

the number of leads and the voltage/phase required

for the application. If there are any questions regard-

ing lead connection, refer to the wiring diagrams at

the back of this manual.

Voltage codes apply to the type of stator assembly

installed on a particular generator.

FOUR-LEAD, SINGLE-PHASE STATOR

Four-lead generators are built to supply electrical

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

Electrical power is produced in the stator power

windings. These windings were connected at the fac-

tory to the main circuit breaker as shown in Figure

7.1.

The rated voltage between each circuit breaker ter-

minal is 240V. The rated voltage between each circuit

breaker terminal and the neutral point 00 is 120V.

Figure 7.1 — Four-lead, Single-phase Stator

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ALTERNATOR POWER WINDING

CONNECTIONS

3-PHASE ALTERNATORS

The generator is designed to supply 3-phase electri-

cal loads. Electric power is produced in the alterna-

tor power windings. These windings were connected

at the factory to the main circuit breaker with a “Y”

configuration as shown in Figures 7.2 and 7.3.

The rated voltage between circuit breaker terminals

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

depending on the model.

The rated voltage between each circuit breaker termi-

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

depending on the model.

Figure 7.2 — Stator Power Winding

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

E1

S1

S4

S7

S12 S11

S10

S8

S5

S2

E2

S9

S6

S3

E3 L - N

L - L

Figure 7.3 — Stator Power Winding

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

E1

S10

S12

S4

S5

S2

S8

S11

S6

S3

S9

S7 S1

E2

E3

L - N

L - L

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7-1

Standby Generator Sets

General Information

ACConn002 Rev. 0 08/05

INSTALLATION

Refer to the separate “Installation Guide QT Product

Line” supplied with the unit.

PREPARATION BEFORE START-UP

The instructions in this section assume that the

standby generator has been properly installed, ser-

viced, tested, adjusted and otherwise prepared for

use by a competent, qualified installation contractor.

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

safety information in this manual, before attempting

to operate this (and related) equipment.

Before starting the generator for the first time, the

installer must complete the following procedures. For

follow-up maintenance information and/or service

intervals, please refer to the “Maintenance” section

and the “Service Schedule”.

TRANSFER SWITCH

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

trical system normally powered by an electric utility,

the National Electrical Code requires that a transfer

switch be installed. The transfer switch prevents elec-

trical backfeed between two different electrical sys-

tems. (For additional information, see the applicable

transfer switch manual for this unit.) The transfer

switch, as well as the generator and other standby

components, must be properly located and mounted

in strict compliance with applicable codes, standards

and regulations.

FUEL SYSTEM

Make sure the fuel supply system to the genera-

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

sure and (b) is properly purged and leak tested

according to code. No fuel leakage is permitted. See

“Specifications” for more information.

GENERATOR SET LUBRICATION

Check the engine crankcase oil level before operating

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

mark. Never operate the engine with the oil level

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

and “Engine Oil Recommendations”.

NOTE:

This engine is shipped from the manufacturer

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

after 30 hours of operation.

Check the oil level in the generator gearbox (if so

equipped) prior to initial use and at the intervals

indicated by the “Service Schedule.” The recom-

mended oil is SAE 90 gear lubricant.

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

ernor, make sure the governor is properly lubricated

with clean engine oil.

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PRIOR TO INITIAL START-UP

 Prior to initially starting the generator, it must

be properly prepared for use. Any attempt to

crank or start the engine before it has been

properly serviced with the recommended types

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

etc.) may result in an engine failure.

ENGINE COOLANT

Have the engine cooling system properly filled with

the recommended coolant mixture. Check the system

for leaks and other problems. See “Specifications”

and “Coolant” sections.

BELT TENSION

Check-the engine-fan belt tension and condition prior

to placing the unit into service and at recommended

intervals. Belt tension is correct when a force of

approximately 22 pounds (10 kg), applied midway

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

inch (10 to 16 mm).

ELECTRICAL SYSTEM

Make sure the generator is properly connected to an

approved earth ground.

Make sure the generator battery is fully charged,

properly installed and interconnected, and ready for

use.

Check to ensure that there are no loose electrical con-

nections. Restrain any loose wires to keep them clear

of any moving generator set components.

INITIAL INSPECTION FOR QT GENSET

STARTUP

Inspect for the following.

• Freight Damage.

• Manuals present.

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

• Correct fuel piping.

• Correct muffler installation for external applica-

tion.

• Adequate air flow, clearances and ventilation per

installation drawings and applicable codes.

• Correct AC and DC wire size, connections and

grounding. Control and communication wiring to/

from the transfer switch must be run in a separate

conduit from the AC power leads.

• Battery charger connection to 120 VAC.

• Communication wires connected between transfer

switch and generator (HTS only).

• Unit secured to pad.

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8-1

Standby Generator Sets

Installation

Install001 Rev. C 05/06

START-UP CHECKLIST

 Before working on the generator, ensure the fol-

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 bat-

tery charger is open.

• Remove the fuse from the the control panel. For

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

control box and remove the 15 Amp ATO fuse in

the lower left-hand corner of the control box.

• Connect the battery cables to the battery. Attach

negative battery cable last.

• 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 dam-

age.

• Check all electrical plugs throughout the genera-

tor. Ensure each plug is seated correctly and fully

inserted into its receptacle.

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

position.

• Open the valve to the engine fuel line.

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

lines).

• Open the generator main line circuit breaker.

• Connect a manometer to the gas line and record

the static pressure. It must be as listed in the

Specifications.

• Insert the fuse into the control panel.

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

UAL position. The engine should now crank and

start.

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• Check voltage at the generator terminals.

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

transfer switch terminals. The generator phase

rotation must match the utility phase rotation.

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

• Close the generators main line circuit breaker.

• Turn the generator set off.

• Connect the UTILITY supply to the transfer

switch.

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

• Disconnect utility power before the transfer

switch.

Engine should start, transfer to load.

Run at least 15 minutes on generator power.

Make certain all 3-phase loads are functioning

correctly (correct phase rotation).

• Reconnect Utility power

Transfer switch will transfer back to Utility and

engine will shut down within the given time

parameters set up for the specific transfer switch

and controller.

• Install all covers, access plates and door panels.

• Put the Owners Manual in a safe and accessible

place.

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

the AUTO position.

START-UP INSPECTION

When a start-up is performed by an Authorized

Service Dealer, a standard three-part form titled

“Start-up Inspection for Standby Power Systems”

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

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

mation on locating the nearest Authorized Service

Dealer. The installer should complete the form and

disseminate copies as follows:

• White copy: Mail to Generac Warranty Department,

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

2062.

• Pink Copy: For service file of installing dealer.

• Yellow Copy: For the customer’s records.

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8-2

Standby Generator Sets

Installation

Install001 Rev. C 05/06

GENERATOR CONTROL AND

OPERATION

Refer to the appropriate control panel operator’s

manual for this unit.

OPERATING UNIT WITH MANUAL

TRANSFER SWITCH

If the generator was installed in conjunction with a

transfer switch capable of manual operation only, the

following procedure applies. A manually operated

transfer switch is one that will not provide automatic

start-up and does not include an intelligence circuit.

ENGINE START-UP AND TRANSFER

For additional information, refer to the applicable

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

erature pertaining to the specific transfer switch.

DANGER

 The Maintenance Disconnect Switch and the

AUTO/OFF/MANUAL switches (if so equipped)

must be set properly, or the generator will crank

and start as soon as the utility power to the

transfer switch is turned off. Refer to applicable

control panel and transfer switch manuals for

more information.

 Do not proceed until certain that utility source

voltage is available to the transfer switch and

the transfer switch main contacts are set to

UTILITY.

 Do not attempt manual operation until all power

supplies to the transfer switch have been posi-

tively turned off, or extremely dangerous - pos-

sibly lethal - electrical shock will result.

 Transfer switch enclosure doors should be kept

closed and locked. Only authorized personnel

should be allowed access to the transfer switch

interior. Extremely high and dangerous voltages

are present in the transfer switch.

In order to transfer load from the utility source to the

generator, follow these directions:

• Turn OFF or disconnect the utility power circuit

to the transfer switch, using the means provided

(such as the utility source main line circuit break-

er).

• Set the transfer handle to its UTILITY (NORMAL)

position with load circuits connected to the utility

power supply.

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

er to its OFF (or OPEN) position.

• Start the generator.

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 Do not crank the engine continuously for longer

than 30 seconds, or the heat may

damage the starter motor.

• Let engine stabilize and warm up.

• Check all applicable instrument and gauge read-

ings. When certain that all readings are correct,

move the transfer switch manual handle to its

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

cuits supplied by the generator.

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

er to its ON (or CLOSED) position.

• Load circuits are now powered by the standby

generator.

RETRANSFER AND SHUTDOWN

For additional information, refer to the applicable

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

erature pertaining to the specific transfer switch.

To transfer the load back to the utility power source

and shut down the generator, follow these direc-

tions:

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

er to its OFF (or OPEN) position.

• Manually move the transfer switch handle to its

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

connected to the utility.

• Turn ON the utility power supply to the transfer

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

ity power source main line circuit breaker).

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

to stabilize internal temperatures.

• Shut down the generator.

OPERATING UNIT WITH AUTOMATIC

TRANSFER SWITCH

If the generator has been installed with an automatic

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

transfer switch, the engine may be started and

stopped automatically or manually.

NOTE:

Refer to the applicable manual for your trans-

fer switch and to “Transfer Switch Start Signal

Connections”. In addition, please note the dangers

under “Engine Start-up and Transfer.”

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9-1

Standby Generator Sets

Operation

Oper001 Rev. 0 08/05

MAINTENANCE PERFORMED BY

AUTHORIZED SERVICE FACILITIES

 Before working on the generator, ensure the fol-

lowing:

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

position.

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

trol box.

• The 120VAC supply to the battery charger is

switched OFF.

EVERY THREE MONTHS

1. Check battery state of charge and condition.

2. Inspect and test fuel system.

3. Check transfer switch.

4. Inspect exhaust system.

5. Check engine ignition system.

6. Check fan belts.

ONCE EVERY SIX MONTHS

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

coolant level, high coolant temperature).

ONCE ANNUALLY

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

2. Clean, inspect generator.

3. Flush cooling system.

FIRST 100 OPERATING HOURS

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

change, service engine oil and filter at 150 operat-

ing hours or 6 months, whichever comes first.)

EVERY 500 OPERATING HOURS

1. Service air cleaner.

2. Check starter.

3. Check engine DC alternator.

COOLING SYSTEM

Air intake and outlet openings in the generator com-

partment must be open and unobstructed for contin-

ued proper operation. This includes such obstruc-

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

Without sufficient cooling and ventilating air flow, the

engine/generator quickly overheats, which causes it

to shut down.

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 The exhaust system parts from this product get

extremely hot and remain hot after shutdown.

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

remain clear of the exhaust. Such materials may

ignite and burn from the heat of the exhaust

system.

CHECKING FLUID LEVELS

CHECK ENGINE OIL

Check engine crankcase oil level (Figure 10.1) at least

every 20 hours of operation, or prior to use.

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

free cloth.

• Install oil dipstick, then remove again.

• Oil should be between FULL and ADD marks.

• If oil level is below the dipstick ADD mark,

remove oil fill cap. Add the recommended oil to

bring oil level up to the FULL mark. DO NOT

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

Recommendations” for recommended oils.

Figure 10.1 - Oil Dipstick and Oil Fill Cap

Oil Filter

Oil Fill

Oil

Dipstic

k

BATTERY FLUID

Check battery electrolyte fluid at least once weekly.

Fluid should cover separators in all battery cells. If

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

separators. DO NOT USE TAP WATER IN BATTERY.

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10-1

Standby Generator Sets

Maintenance

Maint004 Rev. 0 08/05

ENGINE COOLANT

Check coolant level in coolant recovery bottle. See the

“Specifications” section.

• Add recommended coolant mixture as necessary.

• Periodically remove radiator pressure cap to make

sure the coolant recovery system is functioning

properly. Coolant should be at bottom of radiator

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

radiator pressure cap. Replace cap, if necessary.

To have pressure cap tested, contact an Authorized

Service Dealer. Inspect cooling system and coolant

recovery system for leaks.

MAINTENANCE OWNER/

OPERATOR CAN PERFORM

CHECK ENGINE OIL LEVEL

Refer to the “Checking Fluid Levels” section.

CHECK BATTERY

• Check battery fluid level each week as outlined

under “Check Fluid Levels”.

• Check battery cables for condition, tightness, cor-

rosion 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. See the

“Weekly Exercise Cycle” section.

INSPECT COOLING SYSTEM

• Inspect engine cooling system at least once each

month.

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

Correct any discrepancies found.

• Check hose clamps for tightness.

CHECK ENGINE COOLANT LEVEL

See the “Checking Fluid Levels” section.

PERFORM VISUAL INSPECTION

Complete a thorough visual inspection of the entire

engine-generator monthly. Look for obvious damage,

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

teners. Look for fuel, oil or coolant leaks.

INSPECT EXHAUST SYSTEM

Inspect the exhaust system at least once every three

months. Check all exhaust system pipes, mufflers,

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

damage.

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

CHECK FAN BELT

• Inspect fan belts every three months. Replace any

damaged, deteriorated, worn or otherwise defec-

tive belt.

• Check fan belt tension. Thumb pressure, exerted

midway between pulleys, should deflect about 3/8

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

INSPECT ENGINE GOVERNOR

Visually inspect electronic governor.

DANGER

 Do not attempt to adjust the governor. Only

qualified service facilities should adjust the gov-

ernor. Excessively high operating speeds are dan-

gerous and increase the risk of personal injury.

Low speeds impose a heavy load on the engine

when adequate engine power is not available

and may shorten engine life. Correct rated fre-

quency and voltage are supplied only at the

proper governed speed. Some connected electri-

cal load devices may be damaged by incorrect

frequency and/or voltage. Only qualified service

technicians should adjust the governed speed.

CHANGING ENGINE OIL

Refer to maintenance performed by authorized ser-

vice facilities for engine oil and filter change frequen-

cies.

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

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

and drain immediately as follows:

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 4.0 U.S. quarts (3.8 liters).

 After refilling the crankcase with oil, always

check oil level on dipstick. NEVER OPERATE

ENGINE WITH OIL BELOW THE DIPSTICK “ADD”

MARK.







Standby Generator Sets

Maintenance

10-2

Maint004 Rev. 0 08/05

7. Start engine and check for oil leaks.

Figure 10.2 - Oil Filter

Oil Filter

Oil Fill

Oil

Dipstic

k

CHANGING THE ENGINE AIR CLEANER

To replace the engine air cleaner, (part number

0A4637), remove the air cleaner cover and replace

the air filter making sure it is positioned properly

before reattaching the cover.

Figure 10.3 — Engine Air Filter

Air Filter

See the “Service Schedule” section for air cleaner

maintenance.

SPARK PLUGS

Reset the spark plug gap or replace the spark plugs

as necessary.

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

to keep dirt and debris out of the engine. Clean

by scraping or washing using a wire brush and

commercial solvent. Do not blast the spark plugs

to clean.





2. Remove the spark plugs and check the condition.

Replace the spark plugs if worn or if reuse is

questionable. See the “Service Schedule” section

for recommended inspection.

3. Check the spark plug gap using a wire feeler

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

by carefully bending the ground electrode (Figure

10.4).

Figure 10.4 – Setting the Spark Plug Gap

COOLANT CHANGE

Every year, have an Authorized Service Facility

drain, flush and refill the cooling system. See the

“Specifications” section for cooling system recom-

mendations.

MISCELLANEOUS MAINTENANCE

CLEANING THE GENERATOR

Keep the generator as clean and as dry as possible.

Dirt and moisture that accumulates on internal gen-

erator windings have an adverse effect on insulation

resistance.

Periodically clean generator exterior surfaces. A soft

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

vacuum system or dry, low pressure air to remove

any accumulations of dirt. The generator is housed

inside an all-weather enclosure, clean the enclosure

with a soft, damp cloth or sponge and water.

Once each year, have the generator cleaned and

inspected by an Authorized Service Dealer. That

dealer will use dry, low pressure air to clean internal

windings. Parts inside the control console should be

cleaned and inspected at this time as well.

Finally, have the insulation resistance of stator and

rotor windings checked. If insulation resistances are

excessively low, the generator may require drying.





SET PLUG GAP AT 1.14 mm

(0.045 inch)

Standby Generator Sets

Maintenance

10-3

Maint004 Rev. 0 08/05

BATTERY

All lead-acid storage batteries discharge when not in

use. Refer to specific instructions and warnings that

accompany the battery. If such information is not

available, observe the following precautions when

handling a battery:

• DO NOT use jumper cables and a booster battery

to crank or start the generator engine.

• DO NOT recharge a weak battery while it is

installed in the generator. Remove battery from

generator and recharge in a well-ventilated area,

away from fuel vapors, sparks, heat or flames.

• Battery electrolyte fluid is an extremely caustic

sulfuric solution that can cause severe burns. DO

NOT permit fluid to contact eyes, skin, clothing,

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

tery fluid is spilled, flush the affected area with

clear water immediately.

• Always wear safety glasses, rubber apron and

gloves when handling a battery.

• Batteries give off explosive hydrogen gas while

charging. The gas can form an explosive mixture

around the battery for several hours after charging.

Any spark, heat or flames can ignite the gas and

cause an explosion which can shatter the battery,

causing blindness or other serious injury.

BATTERY MAINTENANCE

The battery should be inspected per the “Service

Schedule” section. The following procedure should

be followed for inspection:

1. Inspect the battery posts and cables for tightness

and corrosion. Tighten and clean as necessary.

2. Check the battery fluid level of unsealed batteries

and, if necessary, fill with DISTILLED WATER

ONLY. DO NOT USE TAP WATER IN BATTER-

IES.

3. Have the state of charge and condition checked.

This should be done with an automotive-type bat-

tery hydrometer.

DANGER

 Storage batteries give off explosive hydrogen

gas. This gas can form an explosive mixture

around the battery for several hours after charg-

ing. The slightest spark can ignite the gas and

cause an explosion. Such an explosion can shat-

ter the battery and cause blindness or other

injury. Any area that houses a storage battery

must be properly ventilated. Do not allow smok-

ing, open flame, sparks or any spark producing

tools or equipment near the battery.





 Battery electrolyte fluid is an extremely caus-

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 any jumper cables or booster battery

to crank and start the generator engine. If the

battery has completely discharged, remove it

from the generator for recharging.

 Be sure the AUTO/OFF/MANUAL switch is set to

the OFF position before connecting the battery

cables. If the switch is set to AUTO or MANUAL,

the generator can crank and start as soon as the

battery cables are connected.

 Be sure the 120VAC power supply to the battery

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

tery posts as the cables are attached and cause

an explosion.

BATTERY REPLACEMENT

When replacing batteries, use the same number and

the type of battery that follows:

NOTE:

The BCI number should be located directly on the

battery.

REPAIR PARTS

The latter portion of this manual consists of exploded

views, parts lists and electrical data pertaining to this

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

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

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

corresponds to an identical number on the exploded

view drawing.



BCI Group No. CCA

24F-6 525 @ 0 deg. F

Standby Generator Sets

Maintenance

10-4

Maint004 Rev. 0 08/05

SERVICE SCHEDULE

30 KW - 150 KW STANDBY GAS ENGINE DRIVEN GENERATOR SETS

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

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

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

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

maintenance interval.

Service Maintenance Interval Information:

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

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

tial problem areas.

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

the engine from starting automatically without warning:

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

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

Manual switch to the “OFF” position.

• Remove the 15 amp control panel fuse.

• Turn off the battery charger.

• Remove the negative battery cable.

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

from burning out sensitive control panel components and circuits.

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

operation when required.

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

required, and to identify any potential problem areas.

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

the unit.

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

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

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

and to identify any potential problem areas.

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

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

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

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

and to identify any potential problem areas.

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

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

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

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

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

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

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

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

11-1

Standby Generator Sets

Service Schedule

SrvSchd001 Rev. A 09/05

Maintenance Level 1 Level 2 Level 3 Level 4 Level5

Tasks Recom- Task Required Task Required Task Task Required Task

mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.

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

monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) annually/ Initials)

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

1. Disable the unit

from operating

per the first page

warning.

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

Standby Generator Sets

Service Schedule

SrvSchd001 Rev. A 09/05

Maintenance Level 1 Level 2 Level 3 Level 4 Level5

Tasks Recom- Task Required Task Required Task Task Required Task

mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.

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

monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) annually/ Initials)

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

10. Check the engine

accessory drive

belts and fan

coupling device

if equipped for

correct tension,

wear, weather

cracking, and

damage. Replace

as necessary.

11. Check the engine

valve clearance.

Adjust as

necessary.

12. Visually inspect

the unit looking

for leaks, wear or

damage, loose

connections or

components, and

corrosion. Correct

as necessary.

13. Test the engine

and transfer

switch safety

devices. Correct

and/or adjust as

necessary.

14. Initiate an

automatic start

and transfer of

the unit to site

load and exercise

it for at least 1

hour looking for

leaks, loose

connections or

components, and

abnormal

operating

conditions.

Correct as

necessary.

15. Replace the

engine

accessory

drive belts.

16. Check gearbox

oil level (if

equipped).

17. Change gearbox

oil (if equipped).

11-3

Standby Generator Sets

Service Schedule

SrvSchd001 Rev. A 09/05

Maintenance Level 1 Level 2 Level 3 Level 4 Level5

Tasks Recom- Task Required Task Required Task Task Required Task

mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.

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

monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) annually/ Initials)

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

Standby Generator Sets

Service Schedule

SrvSchd001 Rev. A 09/05

TROUBLESHOOTING GUIDE

PROBLEM CAUSE CORRECTION

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

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

battery cables. battery cables as necessary.

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

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

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

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

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

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

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

circuit board.

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

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

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

damaged.

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

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

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

recommended in SPECIFICATIONS.

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

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

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

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

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

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

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

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

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

AUTO/OFF/MANUAL switch and Control

Module circuit board.

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

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

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

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

4. Generator internal failure. 4. *

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

attempt restart.

*Contact the nearest Authorized Dealer for assistance.

12-1

Standby Generator Sets

Troubleshooting

Trblsht001 Rev. 0 08/05

Standby Generator Sets

Notes

Standby Generator Sets

Notes

Standby Generator Sets

Notes

Standby Generator Sets

Notes

1 0F2885 1 PANEL CB CONN BOX

2 0F2883 1 STAND RH CONTROL

0F9637 (4) 1 STAND RH CONTROL, TWO HOLE (FOR 5.4L 100KW &

4.6L 80KW 1PHASE)

3 0F3685 1 STAND LH CONTROL C5 GRBX

4 023484N 1 BUSHING SNAP SB-2.5-31

023484N 2 BUSHING SNAP SB-2.5-31 (FOR 5.4L 100KW & 4.6L

80KW 1PHASE)

5 086961 1 INTERFACE 1PH 240V

067617030A - INTERFACE 3PHS 416/480V

067617030B - INTERFACE 3PHS 208/240V

6 043180 4 WASHER FLAT M4

7 022264 4 WASHER LOCK #8-M4

8 0C3990 4 SCREW PHTT M4-0.7 X 10 ZYC

(1) 9 057701 REF. BLOCK TERM 20A 8 X 6 X 1100V

10 022155 2 WASHER LOCK #6

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

12 0F3618 1 DECAL CPL CUST CONN H CTRL

13 0A9457 1 DECAL NEUTRAL

14 057073 2 JUNCTION BLOCK 3/8-16

(2) 15 0D5466 REF. BUS BAR NEUTRAL BLOCK 390

(2) 16 0A7822 REF. LUG SLDLSS 600/250-1/0 X 1/4-28

17 022237 4 WASHER LOCK 3/8

18 022241 4 NUT HEX 3/8-16 STEEL

19 049226 6 WASHER LOCK M5

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

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

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

23 022473 12 WASHER FLAT 1/4-M6 ZINC

24 022097 8 WASHER LOCK M6-1/4

25 049813 4 NUT HEX M6 X 1.0 G8 YEL CHR

(1) 26 0D4698 1 BLOCK TERM 20A 6 X 3 X 1100V

27 0F4464 1 DECAL CUST CONN 120V UTILITY

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

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

30 067210A 1 DECAL GROUND LUG

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

32 051713 2 WASHER FLAT M5

33 081008 1 GROMMET 1.25 X .25 X .75

34 077043J 3 CONDUIT FLEX 2.0" ID

077043J 4 CONDUIT FLEX 2.0" ID (FOR 5.4L 100KW & 4.6L 80KW

1 PHASE)

35 0F6156 1 PLATE WIRE SNGL GALV

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

(3) 37 0F8656 REF ASSY PCB 4.6L IGNITION MODULE

0F3113 REF ASSY PCB HSB CTRL IGN MODULE (ALL OTHER

APPLICATIONS EXCEPT 4.6L G3)

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

39 036943 2 SCREW PPHM #10/32 X 2

40 023897 2 WASHER FLAT #10 ZINC

41 022152 2 WASHER LOCK #10

42 022158 2 NUT HEX #10-32 STEEL

1.) UL CIRCUIT BREAKER (FD)

A 0F2887 1 COVER FD FRM CB

B 065469 1 DECAL DANGER HIGH VOLTAGE

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

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

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

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

D 0F0199 1 INSULATOR CB FD FRAME 30MIL

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

F 022473 4 WASHER FLAT 1/4-M6 ZINC

G 022097 4 WASHER LOCK M6-1/4

H 022127 4 NUT HEX 1/4-20 STEEL

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

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

L 0F1733 1 DECAL CUSTOMER CONNECT INSIDE

2.) UL CIRCUIT BREAKER (JD+LD)

A 0F2721 1 COVER CIR BRKR JD/LD

B 065469 1 DECAL DANGER HIGH VOLTAGE

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

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

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

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

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

D 0F2353 2 INSULATOR CIRCUIT BR. JD/LD

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

F 022473 4 WASHER FLAT 1/4-M6 ZINC

G 022097 4 WASHER LOCK M6-1/4

H 022127 4 NUT HEX 1/4-20 STEEL

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

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

L 0F1733 1 DECAL CUSTOMER CONNECT INSIDE

(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.) UL CIRCUIT BREAKER (225AF)

A 0F4173 1 COVER CB C5 225AF

B 065469 1 DECAL DANGER HIGH VOLTAGE

C 0F4165$ REF CIRCUIT BREAKERS 200A FRAME

D 0F4186 1 COVER CB DISH 225AF

E 036261 4 RIVET POP .125 X .275 SS

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

G 038150 4 WASHER FLAT #8 ZINC

H 022264 4 WASHER LOCK #8-M4

J 022471 4 NUT HEX #8-32 STEEL

K 029289 2 TAPE ELEC 1/2 FOAM

L 0F1733 1 DECAL CUSTOMER CONNECT INSIDE

M 022129 9 WASHER LOCK M8-5/16

N 0F8432 1 INSULATOR CB 225AF

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

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

S 049897 9 SCREW SHC M8-1.25 X 20 G8

T 022145 6 WASHER FLAT 5/16-M8 ZINC

U 045771 3 NUT HEX M8-1.25 G8 CLEAR ZINC

V 0F8843 3 BUS BAR 200A LUG ADAPTOR

(1) W W/CB 2 TERMINAL COVER CB

4.) UL CIRCUIT BREAKER (400AF)

A 0F4175 1 COVER CB C5 400AF

B 065469 1 DECAL DANGER HIGH VOLTAGE

C 0F4166$ REF CIRCUIT BREAKERS 400A FRAME

D 0F1733 1 DECAL CUSTOMER CONNECT INSIDE

E 042419 4 SCREW RHM 10-32 X 4

F 023897 4 WASHER FLAT #10 ZINC

G 022152 4 WASHER LOCK #10

H 022158 4 NUT HEX #10-32 STEEL

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

K 029289 1 TAPE ELEC 1/2 FOAM

(2) L 052647 2/3 SCREW SHC M10-1.5 X 25 G12.9

(2) M 046526 2/3 WASHER LOCK M10

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

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

R 022131 3 WASHER FLAT 3/8-M10 ZINC

(1) S W/CB 2 TERM COVER CB

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

U 022097 6 WASHER LOCK M6-1/4

V 022473 6 WASHER FLAT 1/4-M6 ZINC

(2) W W/CB 2/3 SCREW SHC M10-1.5 X 25 G12.9

(2) X W/CB 2/3 WASHER LOCK M10

5.) UL CIRCUIT BREAKER (800AF)

A 0F4176 1 COVER CB C5 800AF

B 065469 1 DECAL DANGER HIGH VOLTAGE

C 0F4167$ REF CIRCUIT BREAKERS 800A FRAME

D 0F8433 2 INSULATOR CB 800AF

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

F 022473 4 WASHER FLAT 1/4-M6 ZINC

G 022097 4 WASHER LOCK M6-1/4

H 022127 4 NUT HEX 1/4-20 STEEL

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

K 029289 2 TAPE ELEC 1/2 FOAM

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

M 022131 9 WASHER FLAT 3/8-M10 ZINC

N 022237 6 WASHER LOCK 3/8

P 045772 6 NUT HEX M10-1.5 G8 YEL CHR

R 0F8452 3 LUG SLDLSS 500-750 X 2 MCM AL/CU

S 097950 3 SCREW SHC M10-1.25 X 70 G8.8

T 0F1733 1 DECAL CUSTOMER CONNECT INSIDE

(1) U W/CB 2 TERM COVER VITZROTECH 400AF CB

6.) NEUTRAL BLOCK 390 / 200-400A

A 0D5466 2 BUS BAR NEUTRAL BLOCK 390

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

C 022145 1 WASHER FLAT 5/16-M8 ZINC

D 022129 1 WASHER LOCK M8-5/16

E 045771 1 NUT HEX M8-1.25 G8 YEL CHR

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

G 022097 2 WASHER LOCK M6-1/4

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

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

WITH CIRCUIT BREAKERS.

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

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

2 022129 6 WASHER LOCK M8-5/16

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

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

6 0A3009 1 HUB DRIVE 390 SAE GB

7 0F5564D 1 RTR 390 100KB3 GB SAE TECHUM

0F5563D 1 RTR 390 130KB4 GB SAE TECHUM

0A3881D 1 RTR 390 80GB BR BRLSS

0A3881B 1 RTR 390 80GB 1P BRLSS

0A3882B 1 RTR 390 100GB 1P BRLSS

0A3883B 1 RTR 390 125GB 1P BRLSS

8 * 052624 1 BEARING BALL 6212 SEALED

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

10 0A1633 4 WASHER 390 SAE ALT.

11 0F7351 1 STR 390 130 GB4 CPL

0F7349 1 STR 390 80 AB3 CPL

0F7348 1 STR 390 100 AB3 CPL

0F7350 1 STR 390 130 AB4 CPL

12 068113 1 CARRIER REAR BRG 15"

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

14 043123 4 WASHER LOCK M14

15 051779 4 NUT HEX M14-2.0 G8 YEL CHR

16 052259 2 WASHER FLAT M12

17 051769 3 WASHER LOCK M12

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

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

20 087272 1 ASSY EXCITER 2.00" STK

21 068405C 1 EXITER FIELD 2" LG SPD CONN

22 092950 1 COLLAR SLIP FIT 390 MM

25 090063 1 BRIDGE SUPPORT DIODE 15"

26 090152 1 ASSY BRIDGE RECTIFIER

27 023365 3 WASHER SHAKEPROOF INT #8

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

29 090064 1 CAP END ROTOR 390MM

30 083485 2 PLATE NUT

31 031980 2 TIE WRAP UL 14.6 X .14 NATL

32 083401 1 BRACKET-STATOR WIRE

33 042561 1 CLAMP HOSE #36 1.88-2.7

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

35 083549 1 SLEEVE RUBBER

40 0A4089 1 ASSY SCROLL 390 SAE

KIT PARTS I/N’S: 41 THRU 49

41 0A2491 2 SHROUD ALT SHEET METAL

42 0A2497 2 SCREEN SHROUD SAE

43 0A2496 2 BRKT TENSIONER SAE SCROLL

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

45 022307 6 WASHER LOCK M6-1/4

46 022473 6 WASHER FLAT 1/4-M6 ZINC

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

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

49 0A2110 12 SCREW SWAGE 1/4-20 X 1/2 ZYC

* ROTOR REPLACEMENT PART

1 0F2885 1 PANEL CB CONN BOX

2 0G0171 1 STAND, RH CONTROL CPL C5

0G0171A 1 STAND RH CONTROL CPL C5 2 HOLE

3 0G0172 1 STAND, LH CONTROL CPL C5

4 023484N 1 BUSHING SNAP SB-2.5-31

5 0F4677 1 ASSY PCB INTERFACE 1PH 240V

067617030A - INTERFACE 3PHS 416/480V

067617030B - INTERFACE 3PHS 208/240V

6 043180 4 WASHER FLAT M4

7 022264 4 WASHER LOCK #8-M4

8 0C3990 4 SCREW PHTT M4-0.7 X 10 ZYC

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

10 022155 2 WASHER LOCK #6

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

12 0F3618 1 DECAL CPL CUST CONN H CTRL

13 0A9457 1 DECAL NEUTRAL

14 057073 2 JUNCTION BLOCK 3/8-16

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

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

17 022237 4 WASHER LOCK 3/8

18 022241 4 NUT HEX 3/8-16 STEEL

19 049226 6 WASHER LOCK M5

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

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

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

23 022473 12 WASHER FLAT 1/4-M6 ZINC

24 022097 8 WASHER LOCK M6-1/4

25 049813 4 NUT HEX M6 X 1.0 G8 YEL CHR

26 * 0D4698 1 BLOCK TERM 20A 6 X 3 X 1100V

27 0F4464 1 DECAL CUST CONN 120V UTILITY

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

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

30 067210A 1 DECAL GROUND LUG

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

32 051713 2 WASHER FLAT M5

33 081008 1 GROMMET 1.25 X .25 X .75

34 077043J 3 CONDUIT FLEX 2.0" ID

35 0F6156 1 PLATE WIRE SNGL GALV

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

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

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

39 036943 2 SCREW PPHM #10/32 X 2

40 023897 2 WASHER FLAT #10 ZINC

41 022152 2 WASHER LOCK #10

42 022158 2 NUT HEX #10-32 STEEL

1.) UL CIRCUIT BREAKER (800AF)

A 0G0173 1 COVER, CB 803 C5

B 065469 1 DECAL DANGER HIGH VOLTAGE

C 0F4167$ REF CIRCUIT BREAKERS 800A FRAME

D 0F8433 2 INSUL CB 800AF

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

F 022473 4 WASHER FLAT 1/4-M6 ZINC

G 022097 4 WASHER LOCK M6-1/4

H 022127 4 NUT HEX 1/4-20 STEEL

J 0F1733 1 DECAL CUSTOMER CONNECT INSIDE

K 029289 2 TAPE ELEC 1/2 FOAM

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

M 022131 9 WASHER FLAT 3/8-M10 ZINC

N 022237 6 WASHER LOCK 3/8

P 045772 6 NUT HEX M10-1.5 G8 YEL CHR

R 0F8452 3 LUG SLDLSS 500-750X2 MCM AL/CU

S 0D2576 3 SCREW SHC M10-1.5 X 70 G10.9

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

2.) NEUTRAL BLOCK 390 / 200-400A

A 0D5466 1 BUS BAR NEUTRAL BLOCK 390

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

C 022145 1 WASHER FLAT 5/16-M8 ZINC

D 022129 1 WASHER LOCK M8-5/16

E 045771 1 NUT HEX M8-1.25 G8 YEL CHR

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

G 083896 2 WASHER LOCK 1/4-M6 SS

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

* ITEM INCLUDED WITH HARNESS

** ITEM INCLUDED WITH 0D5464B

*** ITEM IS PART OF 9R.

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

SUPPLIED WITH CIRCUIT BREAKERS.

1 0F2687 1 WELDMENT RADIATOR SUPPORT150

2 0F2611 1 RADIATOR 680 X 680 X 70 CPL

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

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

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

4 046526 12 WASHER LOCK M10

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

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

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

8 076749 1 TANK COOLANT RECOVERY

9 0F2573 1 PULLEY FAN V-GROOVE 9"

10 0F2610 1 FAN 26" LH ROTATION

11 0F2572 1 ARM TENSIONER

12 0F5689 1 SCREW SHC SHLDR LKG M8 X 16 LG

13 0F2862 1 SPRING TENSION CPL

14 0F2560 1 PULLEY V-BELT 4" FLANGED

15 022131 14 WASHER FLAT 3/8-M10 ZINC

16 039414 1 SCREW HHC M8-1.25 X 35 G8.8

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

18 0F2561 1 HUB FLEX PLATE

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

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

21 0C7043 12 DISK FLEX

22 0E8909 1 COUPLING HUB FLEX (MACH)

23 048031C 1 CLAMP HOSE BAND 1/4

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

25 082774 2 KEY WOODRUFF 4 X 19D

26 0F2686 1 HOSE RADIATOR UPPER CPL

27 0F5463 1 HOSE LOWER RAD CPL C5 6.8L

28 0F8695 1 ASSY BRG/SHAFT CPL FANDRIVE

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

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

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

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

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

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

32 022304 2 WASHER FLAT 1/2 ZINC

33 022195 1 WASHER LOCK 1/2

34 022196 1 NUT HEX 1/2-13 STEEL

35 049813 8 NUT HEX M6 X 1.0 G8 YEL CHR

36 049820 1 NUT HEX LOCK M8-1.25 NY INS

39 022145 1 WASHER FLAT 5/16-M8 ZINC

40 022129 1 WASHER LOCK M8-5/16

42 035685 4 CLAMP HOSE #28 1.32-2.25

43 045764 1 SCREW HHTT M4-0.7 X 8 BP

44 065852 1 SPRING CLIP HOLDER .37-.62

45 0C7649 1 CLAMP HOSE .38-.87

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

47 069860E 1 HOSE DRAIN ASSY 28"

48 * 069811 REF CAP HEX 1/4 NPT BRASS

49 080713 1 BRACKET COOLANT TANK

50 022473 16 WASHER FLAT 1/4-M6 ZINC

51 022097 16 WASHER LOCK M6-1/4

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

53 0F5050 1 SHIELD RADIATOR C5

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

55 051769 1 WASHER LOCK M12

56 0C8145 8 WASHER FLEX (THIN)

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

58 090283 1 CAP RADIATOR 13 PSI

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

60 0F2776A 1 BRACKET, SIGNAL CONDITIONER

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

* ITEM 48 IS INCLUDED WITH 47.

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

2 065852 1 SPRING CLIP HOLDER .37-.62

3 052252 4 DAMPENER VIBRATION

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

5 052259 8 WASHER FLAT M12

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

7 052251A 4 DAMPENER VIBRATION 50 WHITE

8 052860 4 NUT LOCKING M12-1.75

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

10 045764 1 SCREW HHTT M4-0.7 X 8 BP

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

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

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

14 022473 1 WASHER FLAT 1/4-M6 ZINC

15 049813 1 NUT HEX M6 X 1.0 G8 YEL CHR

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

17 022131 8 WASHER FLAT 3/8-M10 ZINC

18 046526 8 WASHER LOCK M10

19 0536210360 1 WIRE ASSEM #4GA GRD

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

21 022261 2 WASHER SHAKEPROOF INT 3/8

22 022129 1 WASHER LOCK M8-5/16

23 022145 2 WASHER FLAT 5/16-M8 ZINC

24 045771 2 NUT HEX M8-1.25 G8 YEL CHR

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

26 0F2591 2 TOWER GB COMPROD C5

27 0F2910 1 SUPPORT ENGINE 6.8L LH SIDE

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

29 022097 1 WASHER LOCK M6-1/4

30 022447 1 WASHER SHAKEPROOF INT 1/4

1 0F3408A 1 TRAY BATTERY 27F

2 0F3411A 1 STRAP BATTERY RETAINMENT 27F

3 058665 1 BATTERY 12VDC 90-AH 27F

4 022131 1 WASHER FLAT 3/8-M10 ZINC

5 050331A 1 BATTERY POST COVER RED +

6 050331 1 BATTERY POST COVER BLK -

7 038805Z 1 CABLE BATTERY BACLK #1 X 26.00

8 038804U 1 CABLE BATTERY RED #1 X 28.00

9 045771 1 NUT HEX M8-1.25 G8 YEL CHR

10 022129 1 WASHER LOCK M8-5/16

11 027482 1 WASHER SHAKEPROOF EXT 5/16 STL

12 075763 1 BOOT BATTERY CABLE

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

14 0F3409 1 SUPPORT BATTERY TRAY

15 022097 2 WASHER LOCK M6-1/4

16 049813 2 NUT HEX M6 X 1.0 G8 YEL CHR

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

18 0G0783 1 SUPPORT 27F BATTERY

1 0F2123 1 GEAR CASE ENG. MACHINED

2 0F2122 1 GEAR CASE ALT. MACHINED

3 095613 1 SEAL OIL

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

5 046526 44 WASHER LOCK M10

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

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

8 0F2097 1 GASKET 390 GEARBOX

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

10 097557B 1 KEY 10 X 16 X 46

11 097785 1 GEAR OUTPUT 1.65:1

095970 1 GEAR OUT 390-50H 37T

095968 1 GEAR OUT 390-60H 35T

0E6866 1 GEAR OUTPUT 2:1 50HZ 390

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

13 057019 2 BALL BRG 65 X 120 X 23

14 026847 1 BREATHER

15 097784 1 GEAR INPUT 1.65: 1

095969 1 GEAR INPT 390-50 25T

095967 1 GEAR INPT 390-60 27T

0E6865 1 GEAR INPUT 2:1 50HZ 390

16 095966 1 SHAFT 390 INPUT GEAR

17 095976 1 COLLAR HARDENED

18 095971 1 SEAL OIL

19 096777 1 SNAP RING INT 120MM

20 057019S 1 BEARING #6213 SEALED

22 096379 1 PLATE INTRNL BRG RET

23 048189 2 PIN DOWEL M8 X 24

24 095979 1 PLATE BEARING THRST

25 021159 1 SPACER STRESSPROOF

26 097557A 1 KEY 10 X 16 X 40

27 057163 1 PLUG PIPE 3/8" MAGNETIC

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

29 0F3201 1 COVER GEARBOX GUARD

30 020443 1 COUPLING INNER DRAWN

31 094666A 1 COUPLING OUTER MACHN

32 099828 8 DAMPER GB CPLR VIBRA

33 099828A 8 DAMPER GB CPLR VIBRA

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

35 097557C 1 KEY 10 X 16 X 50

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

37 025066 1 COUPLING FULL 3/8-18

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

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

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

40 0A1786 2.5cc RETAINING COMPOUND

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

44 045772 10 NUT HEX M10-1.5 G8 YEL CHR

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

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

47 0F6487 4 WASHER FLAT M10 SEALING COPPER

48 0F6355 1 GASKET SEAL PLATE 390 GB

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

50 0F6557 0.4cc THREADLOCK AND SEALANT

COMPONENTS INCLUDED IN 0F1826E

1 0F1823 1 ENCL H CONTROL PANEL

2 0F1824 1 COVER CONTROL PANEL

3 0F2606 1 HINGE CONTINUOUS H-PNL

4 036261 6 RIVET POP .125 X .275 SS

5 0F5763 1 ASSY PROGRAMMED PM H-100

6 0F1732 1 DECAL FUSES LOCATED INSIDE

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

8 0F1725C 1 ASSY PCB 2AMP 12V UL BATT CHGR

9 0F1958 1 PLATE HARNESS CLAMP

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

11 0E3161 1 ASSY PCB BOSCH GOV DRIVER

12 029673 1 DIO BRIDGE 25A 600V

13 049226 8 WASHER LOCK M5

14 079224 4 SCREW PPHM M5-0.8 X 30 SS

15 051713 8 WASHER FLAT M5

16 0F5886 3 SCREW HHPM M5-0.8 X 12

17 051716 5 NUT HEX M5-0.8 G8 CLEAR ZINC

18 0C3990 3 SCREW PHTT M4-0.7 X 10 ZYC

19 043280 3 WASHER FLAT M4

20 055014 10 SCREW PPHM M4-0.7 X 8 BLK OX

21 043184 10 WASHER LOCK M4

22 0F2557 1 DECAL WARNING BATT CHRG 12/24V

23 0F5884 1 SCREW PHTT M3.5-0.6 X 10

24 0C2265 4 SCREW PHTT M4-0.7 X 12 ZYC

25 0F4333 1 CONN DUST CAP W/CHAIN DB9

26 0F5883 1 WASHER FLAT M3.5

27 0F6305 2 SEAL COVER 3.18 X 12.7 X 382

28 0F6305A 1 SEAL COVER 3.18 X 12.7 X 283

29 0F6277 1 ASSY HARNESS H-PNL SW (NOT SHOWN)

COMPONENTS INCLUDED IN WIRE HARNESS

A 0F1263 1 ADPTR RH SIDE WICKMAN 178.6191

B 0F1262 4 HOLDER FUSE WICKMANN 178.6150

C 0F1264 1 ADPTR LH SIDE WICKMAN 178.6192

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

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

COMPONENTS NOT INCLUDED IN 0F1826E OR WIRE HARNESS

50 056739 1 RELAY SOLENOID 12VDC PNL MNT

51 - 1 DPE BREAKER SEE DRAWING 0F9280

52 - 1 BOOST RESISTOR SEE DRAWING 0F9280

53 0F2627A 1 COVER CONTROL PANEL SIDE

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

55 022473 4 WASHER FLAT 1/4-M6 ZINC

56 022097 2 WASHER LOCK M6-1/4

57 043182 3 WASHER LOCK M3

58 051714 3 NUT HEX M3-0.5 G8 YEL CHR

59 052777 3 WASHER FLAT M3

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

61 0F5459 1 DECAL CPL CONTROL PANEL FUSES

62 0F5461 1 DECAL 5.4/6.8L TB3

63 022127 2 NUT HEX 1/4-20 STEEL

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

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

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

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

68 091526 4 SCREW PPHM M5-0.8 X 12 ZNC

69 0C2699 2 SCREW PHTT #6-32 X 3/8 ZYC

70 051713 4 WASHER FLAT M5

71 049226 4 WASHER LOCK M5

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

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

0F9207 1 PIPE EXH MANIFOLD 4.6L RH

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

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

0F9208 1 PIPE EXH MANIFOLD 4.6L LH

3 0F4505 REF GLASS PACK 23.5" LG 2.5" IN/OUT

4 0A6765 2 RING GASKET 2.5 DIA

50F4710 6WASHER LOCK M10 SS

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

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

8 0F2809 1 PIPE EXHAUST CROSSOVER

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

10 0F2962 2 MUFFLER STRAP

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

12 022097 8 WASHER LOCK M6-1/4

13 0F2830 2 MUFFLER BRACKET STIFFENER

14 0F4462 REF RAIN CAP ALUM FOR 2-1/2" PIPE

15 0C2454 REF SCREW THF M6-1 X 16 N WA Z/JS

16 0F4367 REF HEAT SHIELD EXHAUST STACK

17 0F4368 REF CAP HEAT SHIELD EXHAUST STACK

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

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

19 0D3159 2 FLANGE EXHAUST

20 088775 6 WASHER FLAT 3/8 SS

21 0F2808 2 EXHUAST OUTLET PIPE CPL

22 0F5447 1 BRKT MUFFLER

23 022473 12 WASHER FLAT 1/4-M6 ZINC

24 0F6214 2 PIPE ELBOW EXHAUST MUFFLER

25 080762 REF BOLT U 3/8-16 X 2.62

26 0F6803 4 MUFFLER STRAP UPPER/LOWER

27 049813 4 NUT HEX M6 X 1.0 G8 YEL CHR

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

29 088510 6 NUT HEX M10-1.5 SS

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

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

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

3 022129 4 WASHER LOCK M8-5/16

4 022145 4 WASHER FLAT 5/16-M8 ZINC

5 ** 0D5419 REF OIL FILTER, FORD V-10 ENGINE

6 0D7055 1 DIPSTICK TUBE, FORD 6.8L

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

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

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

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

8 057795A 1 BARBED EL 90 3/4 PLASTIC

9 0A6283 1 HOSE PREFORMED BLOCK HEATER

10 0F3287 1 BRACKET DC ALTERNATOR UPPER

11 0F5990 1 HARN ENG 6.8L H-100 (NOT SHOWN)

12 0E9868A 1 ALTERNATOR DC W/OUT PULLEY

13 057796 1 GROMMET

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

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

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

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

15 055476 1 BUSHING REDUCER 3/8 TO 1/8 GAL

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

17 0D6658 1 DIPSTICK 6.8L FORD

18 * 029333A 2 TIE WRAP UL 7.4" X .19" BLK (NOT SHOWN)

19 022097 3 WASHER LOCK M6-1/4

20 022473 3 WASHER FLAT 1/4 ZINC

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

22 0D8027 4 BOLT WATER PUMP PULLEY

23 0D8025 1 BOLT GROOVED IDLER PULLEY

24 0D8026 3 BOLT BELT TENSIONER

25 0D8030 1 TENSIONER ENG. AUTOMATIC BELT

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

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

27 0D8028 1 PULLEY GROOVED ENGINE IDLER

28 045771 1 NUT HEX M8-1.25 G8 YEL CHR

29 0D3454 1 ENGINE 6.8L FORD (V-10)

30 022131 2 WASHER FLAT 3/8-M10 ZINC

31 046526 1 WASHER LOCK M10

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

33 045772 1 NUT HEX M10-1.5 G8 YEL CHR

34 0F3217 1 SPACER DC ALTERNATOR PULLEY

35 0F2776A 1 BRACKET SIGNAL CONDITIONER

36 0F6151 1 CAP RUBBER

37 0F4308 1 BRACKET DC ALT STABILIZER

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

39 057823 1 CLAMP HOSE #10 .56-1.06

40 0E0502 1 TEMPERATURE SENDER DELPHI

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

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

43 0F4355 1 ADAPTOR 1/2" NPT - 3/8" NPT (150KW 3600RPM)

44 0G0153 1 BARBED EL 90 1/2 NPT X 3/4 HOSE (150KW 3600RPM)

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

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

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

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

2 0D5418 1 STARTER MOTOR FORD V-10 ENGINE

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

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

5 0D5623 2 HEAT SHIELD EXHAUST

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

7 070006 30 WASHER LOCK M8 SSTL

8 070008 10 WASHER FLAT M8 SS

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

10 047290 1 HOSE 3/8 ID SINGLE BRAID (15”)

11 046526 23 WASHER LOCK M10

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

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

14 049340 1 BARBED EL 90 1/4 NPT X 3/8

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

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

17 022129 4 WASHER LOCK M8-5/16

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

19 0F2776A 1 BRACKET SIGNAL CONDITIONER

20 022097 1 WASHER LOCK M6-1/4

21 048191 2 DOWEL PIN M10 X 24

22 022473 1 WASHER FLAT 1/4 ZINC

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

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

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

26 069860E 1 HOSE DRAIN ASSY 28"

27 0D4255 2 GASKET EXHAUST MANIFOLD

28 057772 1 WASHER NYLON .565

29 0D6686 1 ASSEMBLY 6.8L G-BOX FLYWHEEL

30 0F3131 1 HOUSING FLYWHEEL 6.8L FORD MCH

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

32 021113 1 PLATE DAMPNER RETNR

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

34 022131 7 WASHER FLAT 3/8-M10 ZINC

35 048031J 1 HOSE CLAMP BAND 5/8"

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

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

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

39 0F5114 1 DECAL REFER TO OWNERS MANUAL

40 0F5454 1 PLATE MAG PICK-UP ADAPTOR

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

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

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

2 0F5419 1 ELEMENT AIR FILTER

3 0F4268 1 TOP PLATE VENTURI

4 0F4270A 1 HOLD DOWN AIR CLEANER PLATED

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

6 037561 1 NUT WING 1/4-20 NYLK

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

8 022097 4 WASHER LOCK M6-1/4

9 049811 4 WASHER FLAT M6

10 0F4269 1 GASKET MIXER BODY

11 022473 1 WASHER FLAT 1/4-M6 ZINC

1 049721 4 SCREW HHC M6-1.0 X 35 G8.8 BLK

2 065908 1 SUPPORT NAT GAS SOLENOID

3 0F6261G 1 REGULATOR ASSM 5.4L 80KW NG

0F6261C 1 REGULATOR ASSM 5.4L 100KW NG

0F6261D 1 REGULATOR ASSM 6.8L 100KW NG

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

5 022304 2 WASHER FLAT 1/2 ZINC

6 022129 4 WASHER LOCK M8-5/16

7 045773 2 NUT HEX M12-1.75 G8 YEL CHR

8 022195 2 WASHER LOCK 1/2

9 040173 2 CLAMP HOSE #5.5 .62-.62 (5.4L)

0C7649 2 CLAMP HOSE .38-.87 (6.8L 100KW)

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

11 031015 1 NIPPLE PIPE 1-1/4 NPT X 3

12 039130 1 NIPPLE CLOSE 1.25 NPT X 1.625

13 057822 9 CLAMP HOSE #8 .53-1.00

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

15 0A8064 2 BSHG RDCR HEX 1-1/4-3/4

16 0D1509 1 DECAL INLET PRESSURE

17 050279 1 DECAL FUEL INLET NG

18 0F2756A 1 MACHINING, INTAKE ADAPTOR 60MM (5.4L FORD)

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

19 0E4390 1 GASKET GOVERNOR ACTUATOR

20 0E4392 1 ACTUATOR BOSCH 60 GOVERNOR

21 0F0960 1 REDUCER 3.0" TO 2.75" TURBO

22 0F3885 1 MIXER 40/60MM ACTUATOR ASSY

23 0F3694 2 O-RING 2-7/8 X 3-1/16 X 3/32

24 0F3691C 1 VENTURI THROTTLE 38MM (5.4L 80KW)

0F3691D 1 VENTURI THROTTLE 40MM (5.4L FORD 2-POLE 100KW)

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

25 026915 2 NIPPLE CLOSE 3/4 X 1.375

26 059057 1 HOSE 3/4 ID SAE-30R2 (42” LG)

27 035461 1 BARBED STR 1/4 NPT X 3/8 (5.4L 80KW & 100KW NG)

081017 1 BARBED STR 1/4 NPT X 1/2 (6.8L 100KW NG)

28 046580 4 SCREW SHC M6-1.0 X 45 G12.9

29 039294 2 CLAMP HOSE #44 2.31-3.25

30 022097 4 WASHER LOCK M6-1/4

31 047290 1 HOSE 3/8 ID SINGLE BRAID (42” LG)

052223 1 HOSE 1/2 ID SAE-30R2 FUELOIL (42” LG) (6.8L 100KW)

32 0D2698 1 GASKET ADAPTER THROT BODY (6.8L FORD ONLY)

33 059057 1 HOSE 3/4 ID SAE-30R2 (42” LG)

34 064346 1 PIPE TEE 1-1/4 NPT

35 0F4408 1 Y CONNECTOR 500 SERIES BARBS

36 0F6279 1 HARNESS FUEL JUMPER DUAL REG

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

2 065908 1 SUPPORT NAT GAS SOLENOID

3 0F6261H 1 REGULATOR ASSM 5.4L 80KW LPV (5.4L 80KW)

0F6261J 1 REGULATOR ASSM 5.4L 100KW LPV (5.4L 100KW)

0F6261K 1 REGULATOR ASSM 6.8L 100KW LPG (6.8L 100KW)

0F6261L 1 REGULATOR ASSM 6.8L 130KW LPV (6.8L 130KW)

0F6261M 1 REGULATOR ASSM 6.8L 150KW LPV (6.8L 150KW)

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

5 022304 2 WASHER FLAT 1/2 ZINC

6 022129 4 WASHER LOCK M8-5/16

7 045773 2 NUT HEX M12-1.75 G8 YEL CHR

8 064346 1 PIPE TEE 1-1/4 NPT

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

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

11 031015 1 NIPPLE PIPE 1-1/4 NPT X 3

088963 1 NIPPLE PIPE 1.25 NPT X 5.5 BL IRN (6.8L 150KW ONLY)

12 026915 2 NIPPLE CLOSE 3/4 X 1.375

13 057823 4 CLAMP HOSE #10 .56-1.06

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

15 0D2698 1 GASKET ADAPTER THROT BODY

16 0D1509 1 DECAL INLET PRESSURE

17 050280 1 DECAL FUEL INLET LPG (LP VAPOR APPLICATION)

18 0D2696B 1 ADAPTOR THROTTLE BODY (BOSCH) (6.8L)

0F2756A 1 MACHINING INTAKE ADAPTOR 60MM (5.4L)

19 0E4390 1 GASKET GOVERNOR ACTUATOR

20 0E4392 1 ACTUATOR BOSCH 60 GOVERNOR

21 0F0960 1 REDUCER 3.0" TO 2.75" TURBO

22 0F3885 1 MIXER 40/60MM ACTUATOR ASSY

23 0F3694 2 O-RING 2-7/8 X 3-1/16 X 3/32

24 0F3691B 1 VENTURI THROTTLE 36MM (5.4L 80KW)

0F3691D 1 VENTURI THROTTLE 40MM (5.4L 100KW)

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

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

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

25 022195 2 WASHER LOCK 1/2

26 0F6279 1 HARNESS FUEL JUMPER DUAL REG

27 081017 1 BARBED STR 1/4 NPT X 1/2

28 046580 4 SCREW SHC M6-1.0 X 45 G12.9

29 039294 2 CLAMP HOSE #44 2.31-3.25

30 022097 4 WASHER LOCK M6-1/4

31 047290 1 HOSE 3/8 ID SINGLE BRAID (42” LG)

32 040173 2 CLAMP HOSE #5.5 .62-.62

33 039130 1 NIPPLE CLOSE 1.25 NPT X 1.625

(2) 1 0F5873 1 REAR WRAP C5

(2) 2 0F5868 4 DOOR C5

(2) 3 0F5872 2 CENTER SUPPORT C5

(2) 4 0F5871 2 DISCHARGE DUCT LH & RH SIDE C5

(2) 5 0F5869 2 FRONT CORNERS C5

(2) 6 0F5870 1 DISCHARGE CENTER DUCT C5

(2) 7 0F5867 1 ROOF C5 ALUM

11 0C2454 78 SCREW THF M6-1 X 16 N WA Z/JS

12 0F2766 2 SPLITTER

13 0F3181 4 SPLITTER SHORT

14 0F3185 2 STRINGER SPLITTER C3

15 0F3416 2 SUPPORT SPLITTER C5 130KW

16 0F3949 2 INSULATION CORNER POST

17 0C2634A 1 ASSEMBLY COVER ACCESS

18 022473 5 WASHER FLAT 1/4-M6 ZINC

19 022097 1 WASHER LOCK M6-1/4

20 022127 1 NUT HEX 1/4-20 STEEL

21 0F3072 20 INSULATION RETAINMENT HANGER

22 078115 70 WASHER SELF LOCKING DOME

23 0F3949B 3 INSULATION SPLITTER

24 0F3949A 4 INSULATION SHORT LOUVER

25 0F5048D 4 VISE-ACTION LATCH SLOTTED CIR

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

27 0F5049 4 TAB PULL

28 0F3949L 2 INSULATION SPLITTER SML

29 0F3949E 1 INSULATION ROOF TOP REAR

30 0F3890A 8 RETAINER INSULATION (740)

31 087233 2 RIVET POP .1875 X .450 SS

32 0F3949C 1 INSULATION ROOF TOP

33 0F3949D 4 INSULATION DOOR

34 0F3949G 1 INSULATION DISCHARGE DUCT

35 0F3949J 2 INSULATION CENTER SUPPORT

36 0F3949K 1 INSULATION DISCHARGE DUCT TOP

37 0F3949F 2 INSULATION INNER DUCT SIDE

38 0F3890B 4 RETAINER INSULATION (820)

39 0F3890 14 RETAINER INSULATION (450)

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

41 0912970088 2 ASSY WIRE 14 AWG 20.9" GRN/YEL

42 022447 4 WASHER SHAKEPROOF INT 1/4

43 049813 4 NUT HEX M6 X 1.0 G8 YEL CHR

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

45 0912970094 2 ASSY WIRE 14 AWG 34.8" GRN/YEL

46 0F2766A 1 SPLITTER C5

47 0F3949M 1 INSULATION SPLITTER SHRT MPS

48 0F8869D 1 KEY VISE-ACTION LATCH SLOT CIR

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

(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

Printed in U.S.A.

GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR

COMMERCIAL PRODUCT 50kW AND ABOVE

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

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

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

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

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

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

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

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

ranty period.

WARRANTY SCHEDULE

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

• - ALL COMPONENTS

YEAR TWO — Limited comprehensive coverage on parts listed.

• - ALL COMPONENTS

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

Guidelines:

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

branch thereof.

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

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

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

Manual.

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

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

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

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

applicable).

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

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

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

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

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

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

warranty.

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

normally exist.

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

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

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

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

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

defective part(s).

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

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

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

13. Overtime, holiday, or emergency labor.

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

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

cause of the problem.

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

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

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

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

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

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

DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.

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

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

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

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

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

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