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GENERAC®
Model: 13694330200
Type: SDI00
Engine: D6. 7.1

Owner's Manual
Stationary Emergency Generator

c@us
LISTED
This manual should remain with the unit.

Table of Contents
Introduction

1

Installation

13

Read This Manual Thoroughly

1

STATIONARY EMERGENCY GENERATOR INSTALLATION

.13

Operation and Maintenance

1

NFPA Standards...

. 13

How to Obtain Service

1

Other Published Standards..

. .. 13

Authorized Service Dealer Locator Number. . '... 1

BASIC STATIONARY EMERGENCY ELECTRIC SYSTEM..

Safety Rules

TOTAL CIRCUIT ISOLATION METHOD

. 13

EMERGENCY CIRCUIT ISOLATION METHOD

2

GROUNDING THE GENERATOR...

Generallnformation

4

IDENTIFICATION RECORD

.4

Standard Generator Features

.
;)

.

.

5

ENGINE PROTECTIVE DEViCES..

5

Coolant Temperature Sender

.

14

.

Overspeed Shutdown
Overcrank Shutdown

TRANSFER SWITCH START SIGNAL CONNECTIONS.

. 14

.

.

14

Vented Batteries.....

..15

PREPARATION BEFORE START-UP

..

.. 15

Prior to Initial Start-up..

... 15

Start-up Inspection

.. 16

5

Operation

16

0

GENERATOR CONTROL AND OPERATION

16

;)

OPERATING UNIT WITH MANUAL TRANSFER SWITCH

5
.

5

., .. 17

5

FUEL SYSTEM
Diesel Fuel System...

6
6

Maintenance

6

SERVICE SCHEDULE..............

.

Generator

6

Engine Oil Recommendations
Coolant.

6
6
6

.

7

Test Stationary Emergency Generator System Operation
and Components..
.. ..

7

Inspect Battery...

8

Check F l u i d s .

8
8

Inspect Exhaust System..
.
Inspect/Test Fuel Supply System..

GENERATOR AC LEAD CONNECTIONS
Four-lead, Single-phase Stator..

.

12-lead, Broad Range Stators

9

Six-lead, 600 VAC, Three-phase Stator
FIELD WIRING CONNECTIONS REQUIREMENTS
Field Wiring Connections to Buss Bars..

..... 10
.

GENERATOR AND LOAD COMPATIBILITY

10
11
11

.

11

Engine Coolant Heaters.. ..

.

11

Engine Oil Heater (Optional) ..

.

11

Battery Warmers (Optional)..
Battery Chargers.. .

.
.

12
12

17
17

Authorized Service Technician Maintenance Functions
PERIODIC MAINTENANCE

.

THE BATTERY...

.

Authorized Operator Maintenance Functions

Gearbox Lubrication..

.

.... 17

17

Fuel System Requirements and Recommendations.....
BATTERY INSTALLATION..

16

Retransfer and Shutdown..

DC FUSES..

SPECIFICATIONS

... 16

Start-up and Transfer...
OPERATING UNIT WITH AUTOMATIC TRANSFER SWITCH

STARTING AIDS

..14

5

Low Coolant Level Sensor...
Oil Pressure Sender

RPM Sensor Loss Shutdown...

14
... 14

GENERATOR AC NEUTRAL CONNECTIONS..............
BATTERY INSTALLATION.....

Data Label ...
Generator Set XPL Label
EQUIPMENT DESCRIPTION

..

. 18
.. 18

REPAIR P A R T S . . . . . . . .
How to Order Parts.. .

. 17
18

..

19
19
.

.

500 I\VV TO 600 I\VV STATIONARY EMERGENCY DIESEL
ENGINE DRIVEN GENERATOR SETS..
.
SERVICE MAINTENANCE INTERVAL INFORMATION . .

19

19
19

..

20
,,20

Notes

27

Warranty

29

Introduction

INTRODUCTION
Thank you for purchasing this model of the stationary emergency
generator set product line by Generac Power Systems, Inc"
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, contact the nearest Authorized Service Dealer for starting, 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 personnel to special instructions about a particular
service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are
as follows:

~
INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF
NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.

IAWARNING!I
Indicates a hazardous situation or action which, if not
avoided, could result in death or serious injury.
ACAUTIONI
Indicates a hazardous situation or action which, if not
avoided, could result in minor or moderate injury.
NOTE:
Notes contain additional information important to a procedure
and will be found within the regular text body of this manual.

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

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
stationary emergency 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, 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 about parts and
service, always supply the complete model number of the unit
as given on the front cover of this manual or on the DATA LABEL
affixed to the unit.

These safety warnings cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the special
instructions while performing the action or 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:

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

A

This symbol points out potential explosion hazard.

£

This symbol points out potential fire hazard.

Lh

This symbol points out potential electrical shock hazard.

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

1·800·333·1322
DEALER LOCATION INFORMATION
CAN BE OBTAINED AT THIS NUMBER
or visit the website at

www.generac.com.

Safety Rules
It.. 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.
It.. SAVE THESE INSTRUCTIONS - This manual contains Important Instructions that should be followed
"'durlng Installation and maintenance of the generator and batteries.
Study these SAFETY RULES carefully before installing, operating
or servicing this equipment. Become familiar with this Owner's
Manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and
maintained. Many accidents are caused by failing to follow simple
and fundamental rules or precautions.
The manufacturer cannot anticipate every possible circumstance
that might involve a hazard. The warnings in this
and on
tags and decals affixed to the unit are, therefore, not all-inclusive.
If using a procedure, work method or operating technique that the
manufacturer does not specifically recommend, ensure that it is
safe for others. Also make sure the procedure, work method or
operating technique utilized does not render the generator unsafe.

~
It.. Despite the safe design of this genera·
. . .tor, operating this equipment Imprudently,
neglecting Its maintenance or being careless
can cause possible Injury or death. Permit
only responsible and capable persons to
Install, operate or maintain this equipment.
~

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.

It.. 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 technician who is familiar with applicable codes,
standards and regulations. The operator also must comply with
all such codes, standards and regulations.
• Installation, operation, servicing and
of this (and related)
equipment must always comply with applicable codes, standards, laws and regulat'lons. Adhere strictly to local, state and
national electrical and building codes. Comply with regulations
the Occupational Safety and Health Administration (OSHA) has
established. Also, ensure that the generator is installed, operated and serviced in accordance with the manufacturer's instructions and recommendations. Following installation, do nothing
that might render the unit unsafe or in noncompliance with the
aforementioned codes, standards, laws and regulations.

2

• The engine exhaust fumes contain carbon monoxide gas,
which can be DEADLY. This dangerous gas, if breathed in
sufficient concentrations, can cause unconsciousness or even
death. For that reason, adequate ventilation must be provided.
Exhaust gases must be piped safely away from any building or
enclosure that houses the generator to an area where people,
animals, etc., will not be harmed. This exhaust system must be
installed properly, in strict compliance with applicable codes
and standards.
• Keep hands, feet, clothing, etc, away from drive belts, fans,
and other moving or hot parts. Never remove any drive belt or
fan guard while the unit is operating.
• Adequate, unobstructed flow of cooling and ventilating air is
critical in any room or building housing the generator to prevent
buildup of explosive gases and to ensure correct generator
operation. Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seriously affect
safe operation of the generator.
• Keep the area around the generator clean and uncluttered.
Remove any materials that could become hazardous.
• When working on this equipment, remain alert at all times.
Never work on the equipment when physically or mentally
fatigued.
• Inspect the generator regularly, and promptly repair or replace
all worn, damaged or defective parts using only factoryapproved parts.
• Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start-up. Disconnect
the cable from the battery post indicated by a NEGATIVE, NEG
or
first. Reconnect that cable last.
• Never use the generator or any of its parts as a step. Stepping
on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel
leakage, oil leakage, etc.

Safety Rules

ELECTRICAL HAZARDS

FIRE 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 stationary emergency generator. Avoid
contact with bare Wires, terminals, connections, etc., on the
generator as well as the transfer switch, if applicable. Ensure all
appropriate covers, guards and barriers are in place before operating the generator. If work must be done around an operating
unit, stand on an insulated, dry surface to reduce shock hazard.
• Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
• If people must stand on metal or concrete while installing,
operating, servicing, adjusting or repairing this equipment,
place insulative mats over a dry wooden platform. Work on the
equipment only while standing on such insulative mats.
• The generator set must be grounded in accordance with the
National Electrical Code and any state or local requirements.
• Wire gauge sizes of electrical wiring, cables and cord sets
must be adequate to handle the maximum electrical current
(ampacity) to which they will be subjected. See the Field Wiring
Requirements Table.
• Before installing or servicing this (and related) equipment, make
sure that all power voltage supplies are positively turned off at
their source. Failure to do so will result in hazardous and possibly fatal electrical shock.
• Connecting this unit to an electrical system normally supplied
by an electric utility shall be by means of atransfer switch so as
to isolate the generator electric system from the electric utility
distribution system when the generator is operating. Failure to
isolate the two electric system power sources from each other
by such means will result in damage to the generator and may
also result in injury or death to utility power workers due to
backfeed of electrical energy.
• Generators installed with an automatic transfer switch will
crank and start automatically when NORMAL (UTILITY) source
voltage is removed or is below an acceptable preset level. To
prevent such automatic start-up and possible injury to personnel, disable the generator's automatic start circuit (battery
cables, etc.) before working on or around the unit. Then, place
a "Do Not Operate" tag on the generator control panel and on
the transfer switch.
• In case of accident caused by electric shock, immediately
shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID
DIRECT CONTACT WITH THE VICTIM. Use a nonconducting
implement, such as a dry rope or board, to free the victim from
the live conductor. If the victim is unconscious, apply first aid
and get immediate medical help.
• Never wear jewelry when working on this equipment. Jewelry
can conduct electricity resulting in electric shock, or may get
caught in moving components causing injury.

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

EXPLOSION HAZARDS
• Properly ventilate any room or building housing the generator to
prevent bUild-Up of explosive gas,
• Do not smoke around the generator, Wipe up any fuel or oil
spills immediately. Ensure that no combustible materials are left
in the generator compartment, or on or near the generator, as
FIRE or EXPLOSION may result. Keep the area surrounding the
generator clean and free from debris.
• All fuel types are potentially FLAMMABLE and/or EXPLOSIVE
and shOUld be handled with care, Comply with all laws regulating the storage and handling of fuels, Inspect the unit's fuel
system frequently and correct any leaks immediately, Fuel
supply lines must be properly installed, purged and leak tested
according to applicable fuel-gas codes before placing this
equipment into service,
• Diesel fuels are highly FLAMMABLE.

CALIFORNIA PROPOSITION 65 WARNING
Engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects
and other reproductive harm.
CALIFORNIA PROPOSITION 65 WARNING
This product contains or emits chemicals known to the
State of California to cause cancer, birth defects and
other reproductive harm

3

General Information

IDENTIFICATION RECORD

Figure 1.2 - XPL Label

DATA LABEL

GENERAC POWER SYSTEMS

Every generator set has a DATA LABEL that contains important
information pertinent to the generator (Figure 1,1), The data label,
which can be found attached to the generator's lower connection
box, lists the unit's serial number and its rated voltage, amps, wattage capacity, phase, frequency, rpm, power factor, etc

Figure 1.1 - Data Label

MODEL NO OOA 00000 S
GROUP
A
B

C
D

E
F
G
H

DATE 00/00/05

DESCRIPTION
Generator
Control Panel
Mounting Base
Engine & Accy,
Fuel Systems
Compartments
Wiring Diagrams
Kits

ASSEMBLY NUMBERS
00000 00000
00000 00000 00000
00000 00000 00000
00000 00000
00000
00000 00000
00000 00000 00000
00000 00000

WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE ABOVE
INFORMATION

NOTE:
The above is a generic representation of an XPllabel. For actual information related to this particular model, please refer to
the "construction document" located at the end of this manual,
or to the data cards affixed to the unit.

NOTE:

Identification Code

The above is a generic representation of a data label. For actual
information related to this particular model, please refer to the
"construction document" located at the end of this manual, or
to the data labels affixed to the unit.

Use this code to obtain important information about the generator,
For example, if the code is '"

GENERATOR SET XPL LABEL

- identify the generator as follows:
• SO - Stationary emergency diesel generator ("58" indicates a
stationary emergency gaseous fuel unit),
• 0100 - Rated output is 100,000 watts (100 kW),
• A- Voltage code (see "Voltage Codes"),
• G17 -Indicates engine MFG (for Generac use).
• 4,5 - Engine is 4,5 liter.
• 0 - Unit has diesel fuel system ("N" indicates natural gas;
'T' indicates LP Liquid Withdrawal; "v" indicates LP Vapor
Withdrawal),
• 18 - Alternator rpm rating (1,800 rpm); "36" indicates 3,600
rpm.
• H - Unit has an option "H" control panel ("G" panels are also
available on some units).
• B- Indicates a brushless unit ("P" indicates a permanent magnet excitation).
• Y - Unit is equipped with a standard enclosure ("N" indicates
no enclosure; "5' indicates Level 1 sound attenuation; "L" indicates Level 2 sound attenuation),
• "Y" indicates a muffler has been mounted; N - Unit does not
have an exhaust muffler; "L:' indicates a muffler has been
shipped loose with the unit),
• 3 - Emission designation (for factory use),

Every generator set has a XPL LABEL affixed to the lower connection box (Figure 1,2), Additionally, a printed CONSTRUCTION
DOCUMENT containing identical information can be found at the
end of this manual.
When requesting information, ordering replacement parts, asking
for service, etc" one or more of the following may be needed:
•
•
•
•

Generator Model Number
Date of Manufacture
Generator Identification Code
Generator Assembly Groups

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

4

SO 0100 A617 4.5 0 18 H BY Y 3

General Information
Groups and Assembly Numbers

ENGINE PROTECTIVE DEVICES

The XPL label lists the groups and corresponding 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.

The stationary emergency generator may be required to operate
for long periods of time without an operator on hand to monitor
such engine conditions as coolant temperature, oil pressure or
rpm. For that reason, the engine has several devices designed to
protect it against potentially damaging conditions by automatically
shutting down the unit when the oil pressure is too low, the coolant
temperature is too high, the coolant level is too low, or the engine
is running too fast.

Voltage Codes
The identification code letter following the unit's kilowatt rating is
the generator's "voltage code." Anyone of the following voltage
codes may be listed.
A

-

o G
J
K
L
M
N
P
R
S

-

120/240 volts, single-phase, four-lead, 60 Hz
120/240 volts, single- and three-phase, 12-lead, 60 Hz
120/208 volts, three-phase, 12-lead, 60 Hz Broad Range
120/240 volts, three-phase, 12-lead, 60 Hz Broad Range
277/480 volts, three-phase, 12-lead, 60 Hz Broad Range
346/600 volts, three-phase, six-lead, 60 Hz
110/220 volts, single-phase, four-lead, 50 Hz
115/200 volts, three-phase, 12-lead, 50 Hz Broad Range
100/200 volts, three-phase, 12-lead, 50 Hz Broad Range
231/400 volts, three-phase, 12-lead, 50 Hz Broad Range
277/480 volts, three-phase, six-lead, 50 Hz

EQUIPMENT DESCRIPTION
This equipment is a revolving field, alternating current generator
set. The generator was designed to supply electrical power for the
operation of compatible electrical loads-when the UTILITY power
supply is not available or has dropped to an unacceptable level.

NOTE:

Engine protective switches and sensors are mentioned here for
the reader's convenience. Also refer to the applicable control
panel manual for additional automatic engine shutdown information.

COOLANT TEMPERATURE SENDER
This sender automatically shuts down the engine if the engine
coolant temperature rises above a safe level.

LOW COOLANT LEVEL SENSOR
Should the engine coolant level drop below the level of the high
coolant temperature switch, it is possible for the engine to overheat
without automatic shutdown. To prevent such overheating, the
engine has alow coolant level sensor. If the level of engine coolant
drops below the level of the low coolant level sensor, the engine
automatically shuts down.

OIL PRESSURE SENDER

The generator's revolving field is directly connected to and driven
by an engine by means of flexible discs. Generators with a fourpole rotor are driven at rated speeds of 1,800 rpm to supply a
frequency of 60 Hertz.

This sender monitors oil pressure in the engine. If oil pressure
drops below a safe level, the control system automatically shuts
down the engine.

Refer to the data label on this specific generator or to the data label
affixed to the unit for rated AC voltage, wattage, amperage, number
of phases, etc. See "Identification Code" for an explanation of the
way to identify the unit's features.

OVERSPEED SHUTDOWN

STANDARD GENERATOR FEATURES

A speed circuit controls engine cranking, start-up, operation and
shutdown. Engine speed signals are delivered to the circuit board
whenever the unit is running. Should the engine overspeed above
a safe, preset value, the circuit board initiates an automatic engine
shutdown.

This generator incorporates the following generator features:
• The rotor insulation system is Class "H" rated, and the stator
insulation is Class "H" rated as defined by NEMA MG1-22.4
and NEMA MG1-1.65.
• The generator is self-ventilated and drip-proof constructed.
• The voltage waveform deviation, total harmonic content of
the AC waveform and "telephone influence factor" have been
evaluated and are acceptable according to NEMA MG1-22.
• All prototype tested models have passed three-phase symmetrical short circuit test to ensure system protection and
reliability.

OVERCRANK SHUTOOWN
After a prespecified duration of cranking, this function ends the
cranking if the engine has failed to start.

RPM SENSOR LOSS SHUTDOWN
If the speed signal to the control panel is lost, engine shutdown
will occur.

DC FUSES
These fuses are located inside the front panel of the control system. They protect the panel wiring and components from damaging overload.

5

General Information
COOLANT

FUEL SYSTEM

Use only de-ionized water and Ethylene glycol antifreeze (Propylene
glycol can also be used but should not be mixed with Ethylene glycol - see DANGER below). When adding coolant, always add the
recommended 50-50 mixture.

DIESR FUEL SYSTEM
Diesel fuel is supplied to the generator set from a base-mounted
fuel tank or external source.

~

Diesel fuels are less volatile than gaseous fuels, however, careless
installation can lead to safety hazards and/or serious problems
with engine/generator performance and reliability.

A. Do not remove the radiator pressure cap
.... while the engine is hot or serious burns from
boiling liquid or steam could result.
A. 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.

NOTE:
Appropriate care should be taken in applications where
extremely low ambient temperatures are possible to ensure the
temperature of the diesel fuel is not allowed to fall below levels
where "gelling" could occur.

SPECIFICATIONS
GENERATOR

ACAUTIONI

Refer to the data plate on the generator for rated watts, amperes,
frequency, voltage, phase and other pertinent information. Refer to
the drawings in the back of this manual for engine, cooling system,
and exhaust system specifications.

A. Do not use any chromate base rust Inhibitor
.... with propylene glycol base antifreeze. Using
any high silicate antifreeze boosters or additives also will cause overheating. We also
recommend that any soluble 011 Inhibitor Is
NOT USED for this equipment.

ENGINE OIL RECOMMENDATIONS
The unit has been filled with 15W-40 engine oil at the factory. Use
a high-quality detergent oil classified "For Service SJ and CG/CH".
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
(Figure 1.3).

GEARBOX LUBBICATION
If the generator set is equipped with a gearbox, the appropriate
lubricant is SAE 90 gear oil.

Figure 1.3 - Engine Oil Recommendations
-35

-30

-25

-20

-15

-10

·5

15

I

SAE lOW

20

25

30

35

40

45

50'C

95

104

113

122 'F

I

SAE 20W
SAE 30

I

I

SAE 40

SAE 1OW -30
SAE lOW -40
SAE 10W ·60
SAE l5W -40 mineral base
SAE 15W -40 semisynthetic base
SAE 20W ·60 semisynthetic base
SAE 5W -30 synthetic base
SAE OW ·30 synthetic base
-31
6

-22

-13

14

23

32

41

50

59

68

77

86

General Information
FUEL SYSTEM REDUIREMENTS AND RECOMMENDATIONS
Diesel Fuel System: See Chapter 8 of Engine-Generator Stationary
Emergency Electric Power Systems Installer's Guide and Reference
Manual (part no. 046622).
1.

Beginning October 1, 2007, owners and operators that use
diesel fuel must use diesel fuel that meets:
A. Sulfur content of 500 parts per million (ppm) maximum.
B. Cetane index or aromatic content as follows:

Before installing and connecting the battery, complete the following steps:
1.
2.
3.

Set the generator's AUTO/OFF/MANUAL switch to OFF.
Turn off utility power supply to the transfer switch.
Remove the 10A and 15A fuses from the generator control
panel.
Battery cables were factory connected at the generator (Figure
1.4). Connect cables to battery posts as follows:

• A minimum cetane index of 40 or;
• A maximum aromatic content of 35 volume percent.

2.

Figure 1.4 - Battery Cable Connections

Beginning October 1, 2010, owners and operators that use
diesel fuel must use diesel fuel that meets:
A. Sulfur content of 15 parts per million (ppm) maximum.
B. Cetane index or aromatic content as follows:

BLACK LEAD
FRAME)

~ (FROM
---<~~

• A minimum cetane index of 40 or;
• A maximum aromatic content of 35 volume percent.

___________

BATTERY INSTALLATION
When a unit is supplied with out a battery or during replacement
use the following table to properly select the battery size and minimum Cold Cranking Ampere required for a particular unit.

Diesel Engine
2.4L
3.4L

Battery Size

Minimum CCA

GRP 27 or GRP 31

650 or 925

4.5L

925

6.7L (100, 130Kw)
6.7L (150, 175Kw)

1 or 2 X GRP 31

925

2 X GRP 31

925

10.3L

4.
5.

Connect the red battery cable (from starter contactor) to the
battery post indicated by a positive, pas or (+).
Connect the black battery cable (from frame ground) to the
battery post indicated by a negative, NEG or (-).
NOTE:

Damage will result if battery connections are made in reverse.
NOTE:

12.9L
13.0L
16.0L
18.0L

+
BATTERY
BLACK

GRP 31 or GRP
31E

8.7L

RED LEAD
(FROM STARTER
CONTACTOR)

2 x GRP 31 or 2 x
GRP 80

925 or 1155

22.0L
Fill the battery with the proper electrolyte fluid if necessary and
have the battery fUlly charged before installing it.

The generator is equipped with a battery trickle charger that is
active when the unit is set up for automatic operation. With the
battery installed and utility power source voltage available, the
battery receives a trickle charge while the engine is not running, to prevent self-discharge. The trickle charger is designed
to help extend the life of the battery by maintaining the battery
when the unit is not running. The trickle charge feature cannot
be used to recharge a discharged battery.

7

General Information
THE BATTERY
~
A Do not dispose of the battery In a fire. The
tAbattery Is capable of exploding.

/r\ A battery presents a risk of electrical shock
illand high short circuit current. The following
precautions are to be observed when working on batteries:
• Remove the 10A and 15A fuses from the generator control panel.
• Remove watches, rings or other metal objects;
• Use tools with Insulated handles;
• Wear rubber gloves and boots;
• Do not lay tools or metal parts on top of the
battery; and
• Disconnect charging source prior to connecting
or disconnecting battery terminals.

IA WARNING!1
Jt.. Do not open or mutilate the battery. Released
.... electrolyte has been known to be harmful to
the skin and eyes, and to be toxic.

A The electrolyte Is a dilute sulfuric acid that Is
.... harmful to the skin and eyes. It is electrically
conductive and corrosive.
The following procedures are to be observed:
• Wear full eye protection and protective clothing;
• Where electrolyte contacts the skin, wash It off
Immediately with water;
• Where electrolyte contacts the eyes, flush
thoroughly and Immediately with water and
seek medical attention; and
• Spilled electrolyte Is to be washed down with
an acid neutralizing agent. A common practice
Is to use a solution of 1 pound (500 grams)
bicarbonate of soda to 1 gallon (4 liters) of
water. The bicarbonate of soda solution is to
be added until the evidence of reaction (foaming) has ceased. The resulting liquid Is to be
flushed with water and the area dried.
&. lead-acid batteries present a risk of fire
Lmbecause they generate hydrogen gas. The
following procedures are to be followed:
• DO NOT SMOKE when near the battery;
• DO NOT cause flame or spark in battery area;
and
• Discharge static electricity from body before
touching the battery by first touching a grounded metal surface.
A 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.
8

A Be sure the utility power supply is turned off
tAand the 10A and 15A fuses are removed from
the generator control panel, or sparking may
occur at the battery posts as the cables are
attached and cause an explosion.
Servicing of the battery is to be performed or supervised by personnel knowledgeable of batteries and the required precautions.
Keep unauthorized personnel away from batteries.
A negative ground system is used. Battery connections are shown
on the wiring diagrams. Make sure the battery is correctly connected and terminals are tight. Observe battery polarity when connecting the battery to the generator set.

GENERATOR AC LEAD
CONNECTIONS
See "Voltage Codes". This generator may be rated at anyone of
several voltages, either single-phase or three-phase. The electrical
wires in the unit's AG connection (lower) panel should be installed
according to the number of leads and the voltage/phase required
for the application. If there is any question regarding lead connection, refer to Figures 1.4 through 1.9.
Voltage codes apply to the type of stator assembly installed on a
particular generator.

fOUR-LEAD, SINGLE-PHASE STATOR
Four-lead generators are dual voltage coils or windings (Figure
1.5). Units may be assigned any of the following voltage codes:
• "{:>:.' units are rated 120/240 VAG, single-phase, 60 Hertz.
• "M" units are rated 110/220 VAG, single-phase, 50 Hertz.
Each stator winding in this case delivers a 110 VAG or 120 VAG
output; connecting the two windings series results in a 220 VAG
or 240 VAC output.

The neutral line is formed by a junction of stator leads 22 and
33. Therefore, connection of 120 VAG (60 Hertz) or 110 VAC (50
Hertz) loads across leads 11 and neutral, or across leads 44 and
neutral can be made.

Figure 1.5 - Four-lead, Single-phase Stator

E

44~EJ
I

I

I
I

II

JJ ]

I

:

22

II

I NEUTRAL:lloLTS

I
I
I

:

E

I
I

110/120
VOLTS
00

b20h40
110/120
VOLTS

11~E1
l
_
CIRCUIT BREAKER

General Information

Figure 1.9 - Single-/Three-phase
Delta Stator Connection

Figure 1.10 - Six-lead Stator Connection
51

E2

1 1
277V 50HZ 480V 50 HZ
346V60HZ 600V 60 HZ

240V

!

240V

I

S6

S3~

SII

S2
- - 240V - - - - J

SIX-LEAD. 600 VAG, THREE-PHASE STATOR
This type of stator has three coils and six leads (Figure 1.10). Units
may be assigned any of the following voltage codes:
• "1.:' units are rated 346/600 VAG, three-phase, 60 Hertz.
• "5" units are rated 277/480 VAG, three-phase, 50 Hertz.

FIELD WIRING CONNECTIONS
REQUIREMENTS
The table should be used as a reference for: wire type, temperature
rating, and size range of output wires to be connected to the circuit
breakers. Wire sizes should be in accordance with table 310.16 of
the National Electric Gode (NEG).

FIELD WIRING REQUIREMENTS TABLE
Wire Type

Wire Temperature
Rating

Circuit Breaker
Lug AWG Wire
Range / (Number of
Gonductors)

Torque to Wire

20 - 250

Cu

75 c C

4-350 kemil (1)

180 in-Ib

160 - 600

Cu/AI

75 C

2-500 kemil (2)

3751n-lb

Breaker Frame

Gircuit Breaker Range
(A)

Series G- JG Frame
Series G- LG Frame

C

(#14-10) 35 In-Ib
15 - 100

Cu/AI

75 c C

14-1/0 (1)

Series C- FFrame

Series C- K Frame

Series C- L Frame
Series C- M Frame
Series C- N Frame

CulAl

75 c C

4-4/0 (1)

120 in-Ib
120 in-Ib
275 in-Ib

100 - 225

Cu/AI

75°C

6-300 kemll (1)

250

Cu

75°C

4-350 kemll (1)

225

CulAl

75°C

3-350 kemll (1)

275 in-Ib

300

CulAl

75 C
D

250-500 kemll (1)

375 In-Ib

350 - 400

Cu/AI

75 C

3/0-250 kemil (2)

2751n-lb

450 - 500

Cu/AI

75°C

3/0-350 kemil (2)

275 in-Ib

600

Cu/AI

75°C

400-550 kemll (2)

275 in-Ib

3/0-400 kemll (3)

3751n-lb

D

700 - 800

Cu/AI

WC

900 - 1000

Cu/AI

75°C

4/0-500 kemll (4)

375 In-Ib

Cu/AI

WC

500-750 kemil (3)

450 In-Ib

500-1000 kemil (4)

550 in-Ib

1200

Series C- R Frame
1400 - 1600
75°C
Cu/AI
NOTE: All field installations must meet the National Electric Code for wire size and bending space requirements.
10

(#6-4) 45 in-Ib
(#3-1/0) 50 in-Ib

60 - 200
Series C- J Frame

(#8) 40 In-Ib

General Information

FIELD WIRING CONNECTIONS TO BUSS BARS

ENGINE COOLANT HEATERS

500Kw Volvo and 500/600Kw Doosan powered units supplied
with Series C - R Frame Breakers rated 1400, 1600, 2000 and
2500A have Buss Bars supplied in the connection Module for the
connection of the Field Conductors. The following information
should be followed in order to obtain a suitable electrical connection to the Buss Bars.

If the unit is equipped with an engine coolant (block) heater (Figure
1.11), it is powered by a circuit normally fed by the utility power
supply. This heats the engine coolant when the unit is not operating, This action keeps the engine warm even in cold weather,
helping to ensure quicker starts, Heated coolant in the engine
rises continuously drawing cold coolant into the heater, creating a
constant flow of warm coolant through the engine.

• Conductor Lugs - The Buss Bars have been configured to
accept Aluminum Compression Lugs suitable for copper or
aluminum stranded wire .
• Suggested Manufacturer - PENN UNION CORP
• Manufacturers Part No. - BLUA060D2
• Type - Dual Rated (Al/CU), Two
Studs spaced 1 3/4" Apart
• Wire Size - 600 kcmil

Figure 1.11- Typical Engine Coolant Heaters
OUTLET

Required Hardware
Below is the recommended hardware required to attach the Lugs
to the Buss Bars,
• M12 x 65mm Grade 8,8 Hex Head Cap Screw, M12 Flat
Washers, Lock Washer and Nut
or
Flat
• 1/2"-20 x 2.5" Grade SAE 5 Hex Head Cap Screw,
Washers, Lock Washer and Nut
Required Torque - Tighten fasteners to:
M12

Dry 75 Ft-Lbs

Lubed 58 FHbs

1/2"

Dry 85 FHbs

Lubed 65 FHbs

GENERATOR AND LOAD
COMPATIBILITY
The generator must be fully compatible with the rated voltage,
phase and frequency of the connected electrical loads. The generator, connected electrical devices, or both, can be damaged if
voltage, phase and frequency are not compatible,

NOTE:
This manual assumes that the stationary emergency generator
has been properly selected, installed and interconnected by a
competent, qualified electrician or installation contractor. Once
the installation is complete, do nothing that may result in noncompatibility between the generator and connected electrical
loads.

TYPE A

TYPES

ENGINE OIL HEATER (OPTIONAL)
The engine oil heater is designed for installations where the engine
oil must be kept near operating temperature at all times. If included
with this unit, alow-watt density heater and thermostat are mounted in the engine's oil sump or on the sump pan (Figure 1.12). The
heater and thermostat do not require maintenance.
1.
2.
3.

STARTING AIDS

The stationary emergency generator may be equipped with one or
more starting aids that serve to provide quicker, easier starts under
varying climactic conditions.
This generator may have been mounted with (a) an engine coolant
heater, (b) an engine oil heater, (c) a battery warmer or (d) a battery charger. These aids are powered by a normal (utility) power
source during nonoperating periods.

4.
5.

Disconnect battery cables to prevent accidental start-up.
Disconnect the negative battery cable first from the battery
post indicated by (-) or NEG,
Make sure power is off from the appropriate power source.
To connect the wires, hold the bare metal leads together and
place awire nut over them, then twist clockwise until tight. For
all these connections, use the wire nuts provided.
Connect the ground wire from 120V power source to the
ground wire from oil heater,
Using wire nuts provided connect the white wire and black
wire from the oil heater as follows:
• The white (common) power wire from 120V power source
to 1st wire from the oil heater.
• The wire from load side of thermostat to 2nd wire from the
oil heater.

11

-------_.

__

_ - - _ _------..

General Information

FIELD WIRING CONNECTIONS TO BUSS BARS

ENGINE COOLANT HEATERS

Units supplied with Series C- RFrame Breakers rated 1600, 2000
and 2500A have Buss Bars suppled in the connection Module for
the connection of the Field Conductors. The following information
should be followed in order to obtain a suitable electrical connection to the Buss Bars.

If the unit is equipped with an engine coolant (block) heater (Figure
1.11), it is powered by a circuit normally fed by the utility power
supply. This heats the engine coolant when the unit is not operating. This action keeps the engine warm even in cold weather,
helping to ensure quicker starts. Heated coolant in the engine
rises continuously drawing cold coolant into the heater, creating a
constant flow of warm coolant through the engine.

• Conductor lugs - The Buss Bars have been configured to
accept Aluminum Compression Lugs suitable for copper or
aluminum stranded wire.
• Suggested Manufacturer - PENN UNION CORP
• Manufacturers Part No. - BLUA060D2
• Type - Dual Rated (AL/CU), Two 1/2" Studs spaced 1 3/4" Apart
• Wire Size - 600 kcmil

Figure 1.11- Typical Engine Coolanl Healers
OUTLET

Required Hardware
Below is the recommended hardware required to attach the Lugs
to the Buss Bars.
• M12 x 65mm Grade 8.8 Hex Head Cap Screw, M12 Flat
Washers, Lock Washer and Nut
or
TYPE A

• 1/2"-20 x 2.5" Grade SAE 5 Hex Head Cap Screw, 1/2" Flat
Washers, Lock Washer and Nut
Required Torque - Tighten fasteners to:
M12

Dry 75 Ft-Lbs

Lubed 58 Ft-Lbs

1/2"

Dry 85 Ft-Lbs

Lubed 65 Ft-Lbs

1~'_KE__~

GENERATOR AND LOAD
COMPATIBILITY

TYPEB

The generator must be fully compatible with the rated voltage,
phase and frequency of the connected electrical loads. The generator, connected electrical devices, or both, can be damaged if
voltage, phase and frequency are not compatible.

ENGINE OIL HEATER (OPTIONALl

NOTE:
This manual assumes that the stationary emergency generator
has been properly selected, installed and interconnected by a
competent, qualified electrician or installation contractor. Once
the installation is complete, do nothing that may result in noncompatibility between the generator and connected electrical
loads.

1.

STARTING AIDS
The stationary emergency generator may be equipped with one or
more starting aids that serve to provide quicker, easier starts under
varying climactic conditions.
This generator may have been mounted with (a) an engine coolant
heater, (b) an engine oil heater, (c) a battery warmer or (d) a battery charger. These aids are powered by a normal (utility) power
source during nonoperating periods.

The engine oil heater is designed for installations where the engine
oil must be kept near operating temperature at all times. If included
with this unit, alow-watt density heater and thermostat are mounted in the engine's oil sump or on the sump pan (Figure 1.12). The
heater and thermostat do not require maintenance.

2.
3.
4.
5.

Disconnect battery cables to prevent accidental start-up.
Disconnect the negative battery cable first from the battery
post indicated by (-) or NEG.
Make sure power is off from the appropriate power source.
To connect the wires, hold the bare metal leads together and
place awire nut over them, then twist clockwise until tight. For
all these connections, use the wire nuts provided.
Connect the ground wire from 120V power source to the
ground wire from oil heater.
Using wire nuts provided connect the white wire and black
wire from the oil heater as follows:
• The white (common) power wire from 120V power source
to 1st wire from the oil heater.
• The wire from load side of thermostat to 2nd wire from the
oil heater.

11

General Information

ACAUTIONI

ACAUTIONI

A. Be sure no bare wire or wire strands are vis~Ible after making connections.
6. Push all wires and wire nuts into junction box.
7. Assemble junction box cover to junction box
8. Reconnect battery cables to battery posts. Connect the positive cable first to the battery post indicated by (+) or POS.

A. Be sure no bare wire or wire strands are vis~ Ible after making connections.
6. Push all wires and wire nuts into junction box,
7. Assemble junction box cover to junction box,
8, Reconnect battery cables to battery posts, Connect the positive cable first to the battery post indicated by (+) or POS,

Figure 1.12 - Oil Heater Kit

Figure 1.13 - Battery Warmer Kit

BATTERY CHARGERS
There are two types of battery chargers available: 2,5-amp and
10-amp (nine-amp UL) rated, The 2,5-amp charger is 12 VDC
only. The 1Q-amp is available as 12 VDC or 24 VDC, as appropriate for the engine's DC system voltage, These chargers are UL
component recognized for use on these generator sets.

BATTERY WARMERS (OPTIONAL)
When used in conjunction with a coolant (block) heater, battery
warmers (Figure 1.13) aid in ensuring that the engine will reach
maximum cranking speed.
1,
2.
3,
4,
5,

12

Disconnect battery cables to prevent accidental start-up.
Disconnect the negative battery cable first from the battery
post indicated by (-) or NEG,
Make sure power is off from the appropriate power source,
To connect the wires, hold the bare metal leads together and
place awire nut over them, then twist clockwise until tight. For
all these connections, use the wire nuts provided.
Connect the ground wire from 120V power source to the
ground wire from battery heater.
Using wire nuts provided connect the white wire and black
wire from the battery heater as follows:
• The white (common) power wire from 120V power source
to 1st wire from the battery heater,
• The wire from load side of thermostat to 2nd wire from the
battery heater,

Both of the chargers are fully automatic float types and are fully
fuse protected (input and output), They have automatic current
limiting to reduce risk of overcharging, and have automatic maintenance of charge voltage. Therefore, they can be connected to the
batteries continuously,
The chargers require the connection of a battery in order to turn
on, The battery provides boost voltage for the charger, so a completely dead battery will not allow the charger to operate. The boost
required is approximately nine to 11 volts for a 12 VDC system
and 18 to 22 volts for a 24 VDC system, If the battery is below the
boost voltage, it needs to be replaced.
They are not water resistant, so they must be installed within arain
resistant enclosure.

Installation

STATIONARY EMERGENCY
GENERATOR INSTALLATION
~
k.. Connecting this generator to an electrical
illsystem normally supplied by an electric utility shall be by means of a transfer switch
(such as the "GTS" type transfer switch),
so as to isolate the electric system from the
utility distribution system when the generator is operating. Failure to isolate the electric
system by these means will result in damage
to the generator and may also result in injury
or death to utility workers due to backfeed of
electrical energy.

t

ACAUTIONI

If an open bottom is used, the engine-generLmator is to be installed over non-combustible
materials and should be located such that
combustible materials are not capable of
accumulating under the generator set.
Only qualified, competent installation contractors or electricians
thoroughly familiar with applicable codes, standards and regulations should install this stationary emergency electric power system. The installation must comply strictly with all codes, standards
and regulations pertaining to the installation.

This genset must be installed on a level surface. The base frame
must be level within two (2) inches all around.

ACAUTIONI
A After the system has been installed, do noth..... ing that might render the installation in non·
compliance with such codes, standards and
regulations.
NOTE:
For more information about the installation of a stationary
emergency system, order Engine-Generator Stationary emergency Electric Power Systems Installer's Guide and Reference
Manual (part #046622) from an Authorized Service Dealer.

NFPA STANDARDS
The following published standards booklets pertaining to stationary emergency electric systems are available from the National Fire
Protection Association (NFPA), Batterymarch Park, Quincy, MA
02269 or www.nfpa.org.
o

o

o
o

o

NFPA No. 37, STATIONARY COMBUSTION ENGINES AND GAS
TURBINES.
NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS FOR
HEALTH CARE FACILITIES.
NFPA No. 220, STANDARD TYPES OF BUILDING CONSTRUCTION
NFPA No. 68, GUIDE FOR EXPLOSION VENTING
NFPA No. 70, NATIONAL ELECTRICAL CODE.

• NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS
CODE.
• NFPA No. 10, INSTALLATION, MAINTENANCE AND USE OF
PORTABLE FIRE EXTINGUISHERS.

OTHER PUBLISHED STANDARDS
In addition to NFPA standards, the following information pertaining to the installation and use of stationary emergency electric
systems is available:
• Article X, NATIONAL BUILDING CODE, available from the
American Insurance Association, 85 John Street, New York,
NY 10038,
o AGRICULTURAL WIRING HANDBOOK, obtainable from the Food
and Energy Council, 909 University Avenue, Columbia, MO,
65201.
• ASAE EP-364.2, INSTALLATION AND MAINTENANCE OF FARM
STANDBY ELECTRIC POWER, available from the American
Society of Agricultural Engineers, 2950 Niles Road, St. Joseph,
M149085.
• A52.1, AMERICAN NATIONAL STANDARD FOR CHIMNEYS,
FIREPLACES AND VENTING SYSTEMS, available from the
American National Standard Institute, 1430 Broadway, New
York, N.Y 10018.

BASIC STATIONARY EMERGENCY
ELECTRIC SYSTEM

Figure 2.1 shows a schematic diagram of a basic stationary
emergency electric system. Both the UTILITY power supply and
the STANDBY (GENERATOR) output are connected to an approved
transfer switch. The transfer switch is required by electrical code
and serves the following functions:
o Permits the LOAD circuits to be connected to only one power
supply at a time.
o Prevents electrical backfeed between the generator and the
UTILITY power circuits.
Notice that both the STANDBY and the UTILITY power supplies to
the transfer switch are protected against overload by a main line
circuit breaker.

Figure 2.1 - Basic Stationary Emergency Electric
System
MAIN UNE
CIRCUIT BREAKER
UTIUTY
POWER - - t - /
SUPPLY
'- - - - -TRANSFER r---+-~
SWITCH
I-

,
,,
I

. _ J

TO LOAD
c--f---CIRCUITS

'- STANDBY
--- -GENERATOR --~'
,..;.-'
OUTPUT
,
~
MAIN UNE
CIRCUIT BREAKER

--1

13

Installation

EMERGENCY CIRCUIT ISOLATION
METHOD
This prevents overloading the generator by keeping electrical
loads below the wattage/amperage capacity of the generator, If
the generator is powering only critical loads, within the wattage/
amperage capacity, during utility power outages, consider using
the emergency circuit isolation method,
Critical electrical loads are grouped together and wired into a separate "Emergency Distribution Panel." Load circuits powered by that
panel are within the wattage/amperage capacity of the generator
set. When this method is used, it is difficult to overload the generator, The transfer switch must meet the
requirements:
• It must have an ampere rating equal to the total amperage rating
of the emergency distribution panel circuit.
• Have it installed between the building's main distribution panel
and the emergency distribution panel.

TOTAL CIRCUIT ISOLATION
METHOD

When a generator capable of powering all electrical loads in the
circuit is to be installed, use the "Total Circuit Isolation Method," It
is possible for the generator to be overloaded when this isolation
method is employed, The following apply to the transfer switch in
this type of system,
• Ampere rating of the transfer switch must
the ampere
rating of the normal incoming utility service,
• The transfer switch is installed between the utility service
entrance and the building distribution panel.

GROUNDING THE GENERATOR
The generator set must be grounded in accordance with the
National Electrical Code and any state or local requirements,

~
A

Do not connect the ground wire to any pipe

~that carries a flammable or explosive sub-

stance - FIRE or an EXPLOSION may result.

Figure 2.2 - Grounding Electrode Terminal (typical)

Base Frame

GENERATOR AC NEUTRAL
CONNECTIONS
Grounding is recommended only at one point in the system,
Consult local building codes for proper neutral grounding requirements,

TRANSFER SWITCH START SIGNAL
CONNECTIONS
If the generator is to be installed with a standard automatic transfer
switch, such as a GTS type switch, it will be necessary to connect
the two-wire start control system,
Connect the two-wire start signal from the automatic transfer
switch to the automatic start connection, which is located in the
lower rear of the AC connection panel. Match wires 178 (0) and
183 In the transfer SWitch to 178 (0) and 183 on the terminal strip
In the connection box, The conductors for the two-wire start circuit
must be in their own conduit.
If the generator is to be installed with an HTS-type transfer switch
a different connection method is needed, Use shielded 2-wir~
communications cable (such a Belden #9460) to make the connection from the HTS transfer switch to the engine generator
connection panel. This cable is to be routed in a separate conduit
between the HTS transfer switch and the generator, The cable is to
be connected as follows:
HTS transfer switch - 4 position terminal block, in the bottom of the
transfer switch enclosure (labeled "comm, Ports"),
Engine generator - terminal strip located in the lower rear of the
AC connection panel. Connect the RS485+ and RS485- to the
respective terminals in switch and generator. Do not connect the
shield at the transfer switch end.

BATTERY INSTALLATION
~

A Stationary emergency generators installed
.... with automatic transfer switches will crank
and start automatically when NORMAL (UTILITY) source voltage is removed or is below
an acceptable preset level. To prevent such
automatic start-up and possible injury to personnel, do not connect battery cables until
certain that normal source voltage at the
transfer switch is correct and the system Is
ready to be placed Into operation.

A Storage batteries give off explosive hydrogen

~gas. This gas can form an explosive mixture

Grounding Electrode Terminal
14

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

Operation
A Battery electrolyte fluid is an extremely
....caustic 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 fluid
is spilled, flush the affected area immediately with clear water.
IAWARNINGII
A Do not dispose of the battery in a fire. The

~battery is capable of exploding.

A Do not open or mutilate the battery.
.... Released electrolyte can be toxic and harmful to the skin and eyes.
Ir\ The battery represents a risk of high short
illcircuit current. When working on the battery,
always remove watches, rings or other metal
objects, and only use tools that have insulated handles.

VENTED BATTERIES
ACAUTIONI

A The electrolyte is a dilute sulfuric acid that is
.... harmful to the skin and eyes. It is electrically
conductive and corrosive. The following procedures are to be observed:
o Wear full eye protection and protective clothing,
o Where electrolyte contacts the skin, wash it off
immediately with water,
o Where electrolyte contacts the eyes, flush thoroughly and immediately with water and seek
medical attention, and
o Spilled electrolyte is to be washed down with
an acid-neutralizing agent. A common practice
is to use a solution of one pound (500 grams)
bicarbonate of soda to one gallon (4 liters) of
water. The bicarbonate of soda solution is to be
added until the evidence of reaction (foaming)
has ceased. The resulting liquid is to be flushed
with water and the area dried.
A Lead acid batteries present a risk of fire
~because they generate hydrogen gas. The
following procedure are to be followed:
o DO NOT SMOKE when near batteries,
o DO NOT cause flame or spark in battery area,
and
o Discharge static electricity from body before
touching batteries by first touching a grounded
metal surface.

Servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions, Keep
unauthorized personnel away from batteries.
For recommended batteries, see "Specifications," All batteries
must be at 100 percent state-of-charge before they are installed
on the generator.
When using maintenance-free batteries, it is not necessary
to check the specific gravity or electrolyte level. Have these
procedures performed at the intervals specified in Section 4,
"Maintenance," A negative ground system is used. Battery connections are shown on the wiring diagrams, Make sure all batteries
are correctly connected and terminals are tight. Observe battery
polarity when connecting batteries to the generator set.
NOTE:

Damage will result if the battery connections are made in
reverse.

PREPARATION BEFORE START-UP
The instructions in this section assume that the stationary emergency generator has been properly installed, serviced, tested,
adjusted and otherwise prepared for use by acompetent, qualified
installation contractor. Be sure to read the" Safety Rules" on Pages
2 and 3, as well as all other safety information in this manual,
before attempting to operate this (and related) equipment.

PRIOR TO INITIAL START-UP
ACAUTIONI

A 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.
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 Section 4,
"Maintenance," and the "Service Schedule",

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

15

Operation
Fuel System

Rodent Protection

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

Make sure the four, 3-inch diameter cap plugs are properly
installed in the tie-down holes in the side rails of the unit's base
frame (Figure 2.3). The cap plugs are shipped in a plastic bag
located in the lower connection box. These plugs are needed to
prevent rodents from accessing the interior of the generator set
On acoustic units, cap plugs also are needed to stay within noise
specification limits.

If the unit has been idle for a long period of time, or if the fuel lines
or system components have been removed and reinstalled, the fuel
system may require bleeding to remove air from the system. Air in
the fuel system causes hard starting and rough operation. All fuel
system lines must be installed and must be tight A loose line may
show no sign of leakage, but may draw air into the system.

Figure 2.3 - Base Frame Cap Plugs

ACAUTIONI

A Use a suitable container to catch the fuel
.... that will spill during system bleeding process. Clean up all spilled fuel after bleeding.

BASE
FRAME

3-INCH CIA.
PLUG

Generator Set Lubrication
Check the engine crankcase oil level befol'e 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"
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 recommended oil is SAE 90 gear lubricant
Also, if the engine is equipped with a mechanical governor, make
sure the governor is properly lubricated with clean engine oil.

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"

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 aforce of approximately 22 pounds (10 kg), applied
midway between pulleys, deflects the belt about 3/8- to 5/8-inch
(10 to 16 mm). This does not apply to automatic belt tensioning
systems.

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 connections,
Restrain any loose wires to keep them clear of any moving generator set components.

STA8r-UP INSPECTION
Astandard form titled "Start-up Inspection for Stationary Emergency
Power Systems" (part no. 067377) should be completed by the
installation technician or engineer. As stated on the form, inspections are to be accomplished only by factory-trained personnel.
The technician performing the install should then scan and e-mail
the completed form to service@generac.com. The form can also
be filled out at a dealer's Generac website.

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 atransfer 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 STA8T-UP AND TRANSFE8
For additional information, refer to the applicable control panel
manual for this unit, as well as any literature pertaining to the
transfer switch.
16

Maintenance

~
A 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.
A 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.
/r\ Do not attempt manual operation until all
illpower supplies to the transfer switch have
been positively turned off, or extremely dangerous - possibly lethal - electrical shock
will result.

/i). 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 manually transfer load from the utility source to the
generator, follow these directions:

• Turn OFF or disconnect the utility power circuit to the transfer
switch, using the means provided (such as the utility source
main line circuit breaker).
• Set the transfer handle to its UTILITY (NORMAL) position with
load circuits connected to the utility power supply.
• Set the stationary emergency generator's main line circuit
breaker to its OFF (or OPEN) position.
• Start the generator.
• Let engine stabilize and warm up.
• Check all applicable instrument and gauge readings. When
certain that all readings are correct, move the transfer switch
manual handle to its STANDBY (GENERATOR) position, i.e,
load circuits supplied by the generator.
• Set the stationary emergency generator's main line circuit
breaker to its ON (or CLOSED) position.
• Load circuits are now powered by the stationary emergency
generator.

RETRANSFER AND SHUTDOWN
For additional information, refer to the applicable control panel
manual for this unit, as well as any literature pertaining to the
transfer switch.
To manually transfer the load back to the utility power source and
shut down the generator, follow these directions:
• Set the stationary emergency generator's main line circuit
breaker to its OFF (or OPEN) position.
• Manually move the transfer switch handle to its UTILITY (NORMAL) position, i.e., load cirCUits connected to the utility.

• Turn ON the utility power supply to the transfer switch, using
the means provided (such as the utility power source main line
circuit breaker) .
• Let the generator run at no-load for a few minutes to stabilize
internal temperatures.
• Shut down the generator.

OPERATING UNIT WITH AUTOMATIC
TRANSFER SWITCH
If the generator has been installed along with an automatic transfer
switch, such as a GTS-type switch, the engine may be started and
stopped automatically or manually.
NOTE:
Refer to the applicable manual for the transfer switch and to
"Transfer Switch Start Signal Connections". In addition, please
note the dangers under "Engine Start-up and Transfer."

SERVICE SCHEDULE
AUTHORIZED OPERATOR MAINTENANCE FUNCTIONS

Every Month or 100 Hours (whichever comes first)
•
•
•
•
•
•
•

Test stationary emergency generator system.
Inspect battery (batteries) and cables.
Check engine oil level.
Check gearbox oil level (if so equipped).
Check engine coolant level.
Check generator ground connections.
Test/inspect starting aids.

Every Three Months or Every 120 Hours (whichever comes first)
• Inspect and test fuel system and connections.
• Inspect exhaust system.
• Inspect/test fuel supply system.

AUTHORIZED SERVICE TECHNICIAN MAINTENANCE
FUNCTIONS

After First 30 Hours of Operation
•
•
•
•

Inspect Wiring.
Change engine crankcase oil and oil filter.
Inspect engine fan belts.
Inspect battery (batteries) and cables.

Every Six Months or Every 200 Hours (whichever comes first)
•
•
•
•
•
•
•
•

Lubricate engine controls.
Service engine air cleaner.
Service engine fuel filter.
Inspect AC generator.
Test engine safety controls.
Inspect fan belts.
Check engine coolant level.
Inspect engine cooling system hoses.
17

Maintenance

•
•
•
•
•
•

Check optional starting aids.
Check battery (batteries).
Check engine compression.
Check electrical connections.
Check/test annunciator panel.
Perform operational test

Annually or Every 600 Hours (whichever comes first)
•
•
•
•
•
•

Change engine oil and filter.
Inspect all wiring.
Test engine starter operation.
Drain water from fuel tank.
Retorque fan bolts.
Drain and refill gearbox (if so equipped).

Every Two Years
•
•
•
•

Replace all rubber hoses.
Replace engine fan belts.
Inspect the Stationary Emergency Generator System.
Drain, flush, refill cooling system.

Every 1,000 Operating Hours
•
•
•
•
•

Inspect engine DC alternator.
Inspect engine starter.
Retorque engine mounting brackets.
Remove/test fuel injection pump.
Remove/test cooling system thermostat.

As Required
• Bleed engine fuel system.

PERIODIC MAINTENANCE
A rigorous program of scheduled periodic maintenance should
be established and maintained. Such a program, if adhered to
diligently, will provide added assurance that the power system
functions properly when it is needed.
Keeping a "Maintenance Log" is highly recommended. Such a
log should be a continuous record of repairs, parts replacements,
gauge and instrument readings during operational tests, etc.
The manufacturer requires that a "Scheduled Maintenance Plan"
be established between the user of this equipment and the installing Authorized Service Dealer. Under this agreement, (Part No.
053263), an Authorized Service Technician performs prestart and
engine running tests and checks at six-month and one-year intervals. Ask an Authorized Service Dealer about this agreement
The tasks listed in the "Service Schedule" cover the minimum
recommended maintenance requirements for this equipment.
Note that many of the tests and checks listed in the schedule are
to be performed only by an Authorized Service Technician. Fluid
capacities and recommendations, as well as other applicable
specifications, are listed in "Specifications".

18

TEST STATIONARY EMERGENCY GENERATOR SYSTEM
OPERATION AND COMPONENTS
An authorized operator should test the operation of the stationary emergency generator system and inspect its components
monthly (or 100 hours). This should include inspecting the transfer switch for evidence of arcing, and pitted or burned contacts;
inspecting wiring and grounding connections (see "Grounding the
Generator"); and ensuring that starting devices are operational.
During this operational test, all instrument and gauge readings
should be recorded in a "Maintenance Log." The transfer system
also should be tested at this time; the engine should be run at least
30 minutes and any discrepancies corrected immediately.
Every six months (or 200 hours), an Authorized Service Technician
should perform a system operational test

INSPECT BAUERY
A Stationary emergency generators Installed
.... with automatic transfer switches will crank
and start automatically when NORMAL (UTILITY) source voltage Is removed or Is below
an acceptable preset level. To prevent such
automatic start-up and possible Injury to
personnel, do not connect battery cables
until certain that normal source voltage at
the transfer switch Is correct and the system
Is ready to be placed Into operation.
A Storage batteries give off explosive hydrogen
~gas. This gas can form an explosive mixture
around the battery for several hours after
charging. The slightest spark can Ignite the
gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other Injury. Any area that houses a
storage battery must be properly ventilated.
Do not allow smoking, open flame, sparks or
any spark producing tools or equipment near
the battery.
A Battery electrolyte fluid Is an extremely
.... caustic 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 fluid
Is spilled, flush the affected area Immediately with clear water.

IAWARNINGII

A

Do not dispose of the battery In a fire. The

~battery Is capable of exploding.

A Do not open or mutilate the battery.
.... Released electrolyte can be toxic and harmful to the skin and eyes.

Maintenance

/;\ The battery represents a risk of high short
illcircuit current. When working on the battery,
always remove watches, rings or other metal
objects, and only use tools that have insulated
handles.
An authorized operator should inspect the engine battery system
monthly (or 100 hours). At this time, the battery fluid level should
be checked and distilled water added if needed. Battery cables
and connections also should be inspected for cleanliness and
corrosion.

Once every six months (or 200 hours), an Authorized Service
Technician 'should inspect the battery system. At this time the
battery condition and state of charge should be checked using a
battery hydrometer. The battery should be recharge or replaced as
required.

CHECK FLUIDS
An authorized operator should check the levels of engine oil, and
engine coolant monthly (or 100 hours). The oil level should be
maintained between the "FULl:' and "ADD" marks on the engine
dipstick. Recommended fluids are listed are in the "Specifications"
section.
Once annually (or at every 600 hour intervals), an authorized service technician should completely drain and refill the gearbox (if so
equipped) using the following procedure (Figure 4.1):
1.
2.
3.
4.
5.

Remove panel fuse and negative battery cable.
Remove the oil filler/Vent cap.
Remove the drain plug and drain the oil into an appropriate
container. Dispose of or recycle the oil properly.
Reinstall the oil drain plug.
To add oil to the gearbox, remove the oil level check plug.

Figure 4.1 - Gearbox Oil Servicing Points
OIL FILLERNENT CAP

OIL LEVEL
CHECK PLUG

6.
7.
8.

Add the recommended oil until it just starts to flow from the
oil level check plug opening.
Finally, install and tighten the oil filler/Vent cap and oil level
check plug.
Re-install negative battery cable and panel fuse. Start unit and
check for leaks.

INSPECT EXHAUST SYSTEM
Every three months (or 120 hours), an authorized operator should
inspect the entire exhaust system. Abnormal noise levels heard
during each operational test may indicate a defective exhaust pipe
or muffler. Any defective or leaking component should be repaired
or replaced immediately by an Authorized Service Technician.

INSPECT/TEST FUEL SUPPLY SYSTEM
Every three months (or 120 hours), an authorized operator should
inspect and test the fuel supply system, as well as all fuel system
connections. All connections must be tight and in good condition.
A loose fuel system line may show no signs of leakage, but may
draw air into the system causing rough operation and starting difficulties. Any defective or leaking component should be repaired or
replaced immediately by an Authorized Service Technician.

REPAIR PARTS
The latter portion of this manual consist 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.

HOW TO ORDER PARTS
To order a replacement part, locate the part in the applicable
exploded view. Contact an Authorized Service Dealer (call 800333-1322 to locate one in the area) and provide the following
information:
• The generator model number.
• The generator identification code, which indicates the specific
generator assembly for each unit.
• The part number and corresponding description from the applicable parts list in this manual.
• The applicable exploded view "Group" letter (A-H) and drawing number (five-digit number), which can be found on the
exploded view drawing.
NOTE:

In most cases, repair parts can be obtained by providing the
Authorized Service Dealer with the data label information and
a description of the required part. If unable to locate either
the data label or the construction document, describe the part
needed and provide the unit's model number. This number can
be found on the DATA LABEL attached to the generator's lower
connection box.

19

Maintenance

500 KW TO 600 KW STATIONARY EMERGENCY DIESEL ENGINE DRIVEN
GENERATOR SETS
Following Is a recommended maintenance schedule for stationary emergency diesel engine driven generator sets from 500 kW to 600 kW in
size. The established intervals in the schedule are the maximum required 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 the unit hour meter or calendar time, whichever
occurs first, from the previous maintenance interval to determine the next required maintenance interval.

NOTE: Add 20% to all times noted for 12 cylinder or larger engines.

14 WARNINGll
A

To prevent injury, disable the generator set from starting and/or connecting to the load by setting the
~ control panel Auto-Oft-Manual switch to the "Off' position, removing the control panel fuse, turning
oft the battery charger, and removing the negative battery cable before performing any maintenance.
NOTE: The battery charger must be turned oft 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.

SERVICE MAINTENANCE INTERVAL INFORMATION
The various service maintenance intervals are designated by interval numbers as follows:
1.

An early inspection of the generator set to insure it is ready to operate when required and to identify any potential problem areas. Performed
monthly or following each 10 hours of operation of the unit and requires approximately .5 man-hours per unit to complete.
1A. A break-in service inspection of the generator set to insure it is ready to operate, transfer to, and carry the load when required, and to
identify any potential problem areas. Performed ONLY ONCE following the first six months or the first 50 hours of operation after purchase
of the unit and requires approximately 2.5 man-hours per unit to complete.
2. 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 and requires approximately 1.5 man-hours
per unit to complete.
3. A mid-level inspection of the generator set to insure it is
to operate and carry the load when required, and to identify any potential
problem areas. Performed annually or
each 100 hours of operation of the unit and requires approximately 4. a man-hours per
unit to complete.
4. 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 biannually or following each 250 hours of operation of the unit and requires
approximately 8.0 man-hours per unit to complete.

20

Maintenance

Maint
level

Maintenance
Interval

Task Completed
Date/Initials

Maintenance Tasks

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.
Every month
or
10 hours
of operation.

4. Check the battery electrolyte level if accessible. Adjust as necessary.

1
(Requires
approximately

5. Check the diesel fuel supply level. Adjust as necessary.

0.5 man hours
per unit)
6. Check the air inlets and outlets for debris. Clean as necessary.

7. Visually inspect the unit looking for leaks, wear or damage, loose
connections or components, and corrosion. Correct as necessary.

8. Return the unit to operational condition.

Technician's Signature

Date Inspection Completed

Unit Hour Meter Reading at Completion of the Inspection

21

Maintenance

Maint
Level

Maintenance
Interval

Task Completed
Date/lnitials

Maintenance Tasks

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 battery electrolyte level if accessible, Adjust as necessary,

5, Check the diesel fuel supply level. Adjust as necessary.

First 6 months
or
50 hours of
operation
ONLY

6, Drain water and sediment from the diesel fuel tank.

7. Drain water from the diesel fuel line water separator if unit is equipped
with one,

1A
(Requires
approximately
2,5 man hours
per unit)

8, Check the air inlets and outlets for debris, Clean as necessary,

g, Visually inspect the unit looking for leaks, wear or damage, loose
connections or components, and corrosion, Correct as necessary,
1O, Initiate an automatic start and transfer to load of the unit, and exercise it
for at least 1 hour looking for leaks, loose connections or components,
and abnormal operating conditions, Correct as necessary,

11, Change the engine oil.

12, Replace the engine oil

13. Replace the engine fuel filter(s),
14, Return the unit to stand-by setup for operation when required,

Technician's Signature

Unit Hour Meter Reading at Completion of the Inspection

22

Date Inspection Completed

Maintenance

Maint
Level

Maintenance
Interval

Task Completed
Date/Initials

Maintenance Tasks

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 battery electrolyte level if accessible. Adjust as
necessary.
Every 6 months
or
50 hours of
operation

5. Check the diesel fuel supply level. Adjust as necessary.
6. Drain water and sediment from the diesel fuel tank.

2
(Requires
approximately
1.5 man hours
per unit)

7. Drain water from the diesel fuel line water separator if unit is equipped
with one.

8. Check the air inlets and outlets for debris. Clean as necessary.
9. Visually inspect the unit looking for leaks, wear or damage, loose connections or components, and corrosion. Correct as necessary.
10. Initiate an automatic start and transfer to load of the unit, and exercise it for at least 1 hour looking for leaks, loose connections or components, and abnormal operating conditions. Correct as necessary.
11. Return the unit to standby setup for operation when required.

Technician's Signature

Date Inspection Completed

Unit Hour Meter Reading at Completion of the Inspection

23

Maintenance

Maint
level

Maintenance
Interval

Task Completed
Date/lnitials

Maintenance Tasks
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 diesel fuel supply level. Adjust as necessary.
6. Drain water and sediment from the diesel fuel tank.

Every 12 months
or
100 hours of
operation
3
(Requires
approximately
4,0 man hours
per unit)

7. Drain water from the diesel fuel line water separator if unit is equipped
with one.
8. Check the air inlets and outlets for debris. Clean as necessary.
9. Check the battery electrolyte level if accessible. Adjust as
necessary.
10. Check the battery posts, cables, and charger for loose connections,
corrosion, and proper operation. Correct as necessary.
11. Check the unit wiring for loose connections, corrosion, and damage.
Correct as necessary.
12. Check the engine accessory drive belts for wear, weather cracking,
and damage. Replace as necessary.
13. Test the unit safety devices (alarms, shutdowns, etc.) for proper
operation. Correct and/or adjust as necessary.
14. Perform an oil analysis (send a sample to a lab for results). Change the
engine oil and filters if the analysis results indicate this is required.
15. Visually inspect the unit looking for leaks, wear or damage, loose
connections or components, and corrosion. Correct as necessary.
16. Start and exercise the unit under full rated load for at least 2 hours looking for leaks, loose connections or components, and abnormal operating
conditions. Correct as necessary.

17. Return the unit to standby setup for operation when required.
Technician's Signature
Unit Hour Meter Reading at Completion of the Inspection
24

Date Inspection Completed

Maintenance

Maint
level

Maintenance
Interval

Task Completed
Datellnitials

Maintenance Tasks
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 diesel fuel supply level. Adjust as necessary.
6. Drain water and sediment from the diesel fuel tank.
Every 24 months
or
250 hours of
operation

7. Drain water from the diesel fuel line water separator if unit is equipped

with one.
8. Check the air inlets and outlets for debris. Clean as necessary.

4
(Requires
approximately
8.0 man hours
per unit)

9. Check the battery electrolyte level if accessible. Adjust as necessary.
10. Check the battery posts, cables, and charger for loose connections,
corrosion, and proper operation. Correct as necessary.

11. Check the unit wiring for loose connections, corrosion, and damage.
Correct as necessary.
12. Check the engine accessory drive belts for wear, weather cracking, and
damage. Replace as necessary.
13. Check the engine valve clearance. Adjust as necessary.
14. Visually inspect the unit looking for leaks, wear or damage, loose connections or components, and corrosion. Correct as necessary.
15. Start and exercise the unit under full rated load for at least 2 hours looking for leaks, loose connections or components, and abnormal operating
conditions. Correct as necessalY
16. Change the engine oil.

17. Replace the engine oil filter(s).

Maintenance Level 4 continued on next page.

25

Maintenance

Maint
Level

Maintenance
Interval

Task Completed
Date/lnitials

Maintenance Tasks

18. Replace the engine fuel filter(s).
19. Replace the
Every 24 months
or
250 hours of
operation

air filter(s).

20. Replace Engine Coolant.
21 Replace Coolant Hoses.

4
(Requires
approximately
8.0 man hours
per unit)

22. Visibly inspect flexible fuel lines and flexible air lines, if applicable, on
this unit. Replace them if they seem worn, spongy or brittle.
23. Start the unit and exercise it for at least 15 minutes looking for leaks,
loose connections or components, and abnormal operating conditions.
Correct as necessary.
24. Return the unit to standby setup for operation when required.

Technician's Signature

Unit Hour Meter Reading at Completion of the Inspection

26

Date Inspection Completed

Warranty

EPA EMISSION-RELATED CI GENERATOR MODEL WARRANTY
Effective 01/01/2011, applicable to CI generator models equal to and larger than SD80
Effective 01/01/2012, applicable to CI generator models equal to and larger than SD35.
Effective 01/01/2013, applicable to all CI generator models.
Your emission-related warranty covers only components whose failure would increase an engine's emissions of any regulated pollutant where they are designed,
built, and equipped to be free from defects in materials and workmanship under applicable regulations of section 213 of the clean air act. To receive information about how to make an emission-related warranty claim, and how to make arrangements for authorized repairs call 1-800-333-1322 or wwwgenerac.com.
Emission-related warranty claims may be denied without proof of proper maintenance or use, accidents beyond the control of the manufacturer, or acts of God.
Proper maintenance is specified in the owners manual. Usage is limited to stationary emergency operations and 100 hours per year for maintenance and readiness testing. The warranty period begins when the engine is placed into service. Warranty periods: Compression ignition engines rated> 25 HP is 5 years.

27

Warranty
Effective 01/01/2011, applicable to CI generator models eguilila ilnd smilllQ[ than S060.
Effective 01/01/2012, applicable to CI generator models eguiliia and smallQr than S030.
Effective 01/01/2013, not applicable to CI generator models.
NOTE: This Emission Control Warranty Statement applies only to mobile (trallerlzed) non-road diesel engine powered
generators (model year 2000) as follows: The EPA portion of this statement pertains to this product; The CARB portion of
this statement pertains to this product only IF the generator size Is (1) 15 kW or below OR (2) 130 kW or greater.

CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with Generac Power Systems, Inc.
(Generac), are pleased to explain the Emission Control System Warranty on your new non-road diesel engine.* New non-road diesel engines must be
designed, built and equipped to meet stringent anti-smog standards for the state of California and the federal government. Generac will warrant the emission
control system on your non-road diesel engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modification or
improper maintenance of your non-road diesel engine.
Your emission control system may include such parts as the fuel injection system and the air induction system. Also included may be hoses, belts, connectors and other emission-related assemblies Generac will repair your non-road diesel engine al no cost to you for diagnosis, replacement paris and
labor, should a warrantable condition occur.

MANUFACTURER'S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:
Emission control systems on 1996 and later model year non-road diesel engines are warranted for five years, or 3,000 hours of use, whichever occurs
first. In the absence of an hourmeter, the said coverage is five years If, during said warranty period, any emission-related component or system on your
engine is found to be defective in materials or workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Facility.

PURCHASER'S/OWNER'S WARRANTY RESPONSIBILITIES:
As the non-road diesel engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory supplied
Owner's Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance of your non-road diesel engine. However,
Generac cannot deny warranty solely due to lack of receipts or for your failure to ensure the completion of all scheduled maintenance.
As the non-road diesel engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or responsibility
if your non-road diesel engine, or a parVcomponent
has failed due to abuse, neglect, improper maintenance or unapproved modifications., or the
use of counterfeit and/or "grey market" parts not made, supplied or approved by Generac.
Your engine is designed to operate on diesel fuel only Use of any other fuel may result in your engine no longer operating in compliance with federal or
California emission requirements.
You are responsible for contacting a Generac Authorized Warranty Service Facility as soon as a problem occurs. The
warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility. To locate the Generac
Authorized Warranty Service Facility nearest you, call our toll-free number:

1·800·333·1322
IMPORTANT NOTE: This
statement explains your rights and obligations under the Emission Control System Warranty (ECS Warranty),
which is provided to you by Generac pursuant to federal and California law. See also the "Generac Limited Warranties for Generac Power Systems, Inc.,"
which is enclosed herewith on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission control system of your
new non-road diesel engine. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in
circumstances where the Generac Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac describe important I'ights and
obligations with respect to your new non-road diesel engine

Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service, evidence must be presented
showing the date of sale to the original purchaser/owner.
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the
following address:

ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
211 MURPHY DRIVE
EAGLE, WI 53119
Part 1
28

........................

~ ~ ~ ~ ~ - - - - ~ ~ _ . _ - ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ -

Warranty

GENERAC POWER SYSTEMS STANDARD TWO-YEAR BASIC
LIMITED WARRANTY FOR STANDBY POWER SYSTEMS
NOTE: ALL UNITS MUST HAVE A START·UP INSPECTION PERFORMED BY AN AUTHORIZED GENERAC DEALER.
For a period of two (2) years or two thousand (2,000) hours of operation from the date of start up, which ever occurs first, Generac Power Systems, Inc
will, at its option,
repair or replace any part(s) which, upon examination, inspection, and testing by Generac or an Authorized/Certified Generac Dealer, or branch thereof, is
to
defective under
normal use and service, in accordance with the warranty schedule set forth below. Repair or replacement pursuant to this limited warranty shall not renew or extend the original warranty
period. Any repaired product shall be warranted for the remaining original warranty period only. Any equipment that the purchaser/owner claims to be defective must be examined by the
nearest Authorized/Certified Generac Dealer, or branch thereof. This warranty applies only to Generac Generators used In "Standby" applications, as Generac has defined Standby, provided
said generator has been initially installed and/or Inspected on-site by an Authorized/Certified Generac Dealer, or branch thereof. It is highly recommended that scheduled maintenance, as
outlined by the generator owner's manual, be performed by an Authorized/Certified Generac Dealer, or branch thereof. This will verify service has been performed on the unit throughout
the warranty period. This warranty Is limited to and available only on liquid-cooled units.
"'This warranty only applies to units sold for use in the US and Canada.'"

WARRANTY SCHEDULE
YEAR ONE - Limited comprehensive coverage on mileage, labor, and parts listed .
• ALL COMPONENTS - ENGINE. ALTERNATOR AND TRANSFER SWITCH
YEAR TWO - Limited comprehensive coverage on parts listed .
• ALL COMPONENTS - ENGINE, ALTERNATOR AND TRANSFER SWITCH PARTS ONLY

GEARBOX EQUIPPED UNITS· LIMITED GEARBOX COVERAGE
YEARS ONE THROUGH FIVE - Parts and labor coverage on gearbox and components.
YEARS SIX THROUGH TEN - Parts only coverage on gearbox and components

GUIDELINES:
1. Travel allowance is limited to 300 miles maximum, and 7.5 hours maximum (per occurrence), round trip. to the nearest authorized Generac Service Facility.
2. Warranty only applies to permanently wired and mounted units.
3.
4.
5.

6.
7.
8.
9.

10.
11.
12.

13
14.

All warranty repairs, must be performed and/or addressed by an Authorized/Certified Generac Dealer, or branch thereof.
A Generac Transfer Switch is highly recommended to be used In conjunction with the generator set. If a Non-Generac Transfer Switch IS substituted for use and directly causes damage to the generator set, no warranty coverage shall apply.
All warranty expense allowances are subject to the conditions defined in Generac's General Service Policy Manual.
Units that have been resold are not covered under the Generac Warranty, as this Warranty is not transferable
Unit enclosure Is only covered during the first year of the warranty provision
Use of Non-Generac replacement part(s) wiil 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.
Generac may chose to Repair, Replace or Refund a piece of equipment.
Warranty Labor Rates are based on normal working hours Additional costs for overtime, holiday or emergency labor costs for repairs outside of normal business hours will be the
responsibility of the customer
Warranty Parts shipment costs are reimbursed at ground shipment rates. Costs related to requests for expedited shipping will be the responsibility of the customer
Batteries are warranted by the battery manufacturer
Verification of required maintenance may be required for warranty coverage.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
Any unit builVmanufactured prior to Juiy 1, 2004.
1. Costs of normal maintenance (ie. tune-ups, associated
adjustments, loose/leaking ciamps, installation and start-up).
2. Any failure caused by contaminated fuels, oiis.
or lack of proper fuels. oils or coolants/antifreeze
3. Units sold, rated or used for "Prime Power", "Trailer Mounted" or "Rental Unit" applications as Generac has defined Prime Power,Trailer Mounted or Rental Unit. Contact a Generac
Distributor for Prime Power, Trailer Mounted or Rental Unit definition and warranty.
4. 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
5. Products that are modified or altered in a manner not authorized by Generac in writing.
6. Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation. maintenance, or SIZing.
7. 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).
8. Damage related to rodent and/or insect infestation
9. Failure due to misapplication, misrepresentation, or bi-fuel conversion.
10. Telephone, facsimile, cellular phone, satellite, Internet, or any other communication expenses.
11. Rental equipment used while warranty repairs are being performed (I e. rental generators, cranes, etc).
12, Modes of transportation deemed abnormal (refer to Generac General Service Policy Manual).
13. Steel enclosures that are rusting due to improper installation, location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised.
14. Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct cause of the problem.
15. Starting batteries, fuses, light bulbs, engine fluids, and overnight freight cost for replacement part(s).
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSEO OR IMPLIED, SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE. Any Implied warranties which are allowed by law, shall be limited in duration to the terms ot the express warranty provided herein, Some states
do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to purchaser/owner
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL, OR
CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC'S. 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 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
Part No. OJ4298

Manual Part No. OJ5019

Rev. B 08.11

Revision C(11/01/11)

GROUPB
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, ion', H·9805·C
RevIs
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Date: 1r'

Page 1

EXPLODED VIEW: EV H-PNL lOA BC NO E-GOV DSL24

GROUPB

DRAWING #: OJ0288
APPLICABLE TO:
ITEM
(1) 1
2

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

PART#

QTY.

OH84230STOR
OH4733E
OG4140E
OG4141E
OE9764
055911
057701
OJ01360STOR
OH96870STOR
OJ5462
OJ5464
051713
049226
OC2454
022097
047411
022145
022129
026850
039253
OG6962A
OG6962B
OJ0392
OJ0398
OJ0393
OJ0545
OJ0575
OC3168
022206
OH9845
OC8065
OJ5349

1
1
1
1
1
REF
REF
1
1
6
3
1
1
2
4
4
4

4
1
4
1
1
1
1
1
1
1
1
1
REF
1
REF

DESCRIPTION
BRACKET H-PNL MOUNTIN CCIIND
ASSY H-PANEL 2.5A BATC 12V
ASSY H-PANEL 10A BATC 12V
ASSY H-PANEL NO BATC NO E-GOV
RAIL SNAPTRACK PCB HOLDER BULK
BLOCK TERM 20A 12 X 6 X 1100V
BLOCK TERM 20A 8 X 6 X 11 OOV
PLATE, WIRE HARN BLOCKOFF
COVER, COSTOMER CONN H-PNL
SCREW THTT M4-0.7 X 16 ZP
SCREW THTT M5-0.8 X 16 ZP
WASHER FLAT M5
WASHER LOCK M5
SCREW HWHT M6-1 X 16 N WA Z/JS
WASHER LOCK M6-1/4
SCREW HHC M6-1.0 X 16 C8.8
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
WASHER LOCK EXT 1/4 STL
SCREW HHC M8-1.25 X 20 C8.8
ASSY PCB RELAY 24VDC
ASSY PCB RELAY 12VDC
DECAL, TB1 LV CUSTOMER CONN
DECAL, CONTACT RAT 30VAC/30VDC
DECAL, TB2 LV CUSTOMER CONN
DECAL, LV CUSTOMER CONN INSIDE
DECAL, CUSTOMER WIRE #14
WASHER LOCK SPECIAL 5/16
FITTING CONDUIT STR 3/8
HARN 390/520 CON BOX H-PANEL
DIODE ASSEMBLY
HARN 390/520 CONBOX 12V GAS H (NOT SHOWN)

(1) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR).
•
MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
CUSTOMER: FOR CORRECT MATERIAL AND COLOR OF REPLACEMENT PARTS REFER TO "REPLACEMENT SHEET
METAL PARTS ORDERING GUIDE-OH7169" INCLUDED IN THE MANUAL OR AVAILABLE ON THE GENERAC WEBSITE.
(2) PART OF CONNECTION BOX HARNESS
(3) HARNESS GETS WIRED TO LOAD CENTER IF EQUIPPED.
(4) REFERENCE WIRE DIAGRAM FOR PROPER LOCATION.

REVISION H-9805-C
DATE 10110111

PAGE 2 OF 2

225AF

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Date: 9"
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Drawing No. : OJ1027

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SCROLL DETAIL "A"

Exploded View: EV ALTCOMPRT <80KW DD PME G17
Drawing No. : OJ1481

EXPLODED VIEW: EV ALTCOMPRT <80KW DD PME G17

GROUP A

DRAWING #: OJ1481
APPLICABLE TO:
ITEM

PART#

QTY.

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

063837
051769
PIN VARIES
055173
022129
037554C
OG0724
OA2601
OA2602
OA1138
021941
VARIES
OA1786
OA5580
OA1633
VARIES
022131
046526
057642
097485
OH8394
043123
051779
094511
080934
022473
022097
082460
OH7626
084828B
088367
042558
OH7625A
OH7625C
OA2110
OE8771
OE8782
087271
087272
OG2829
OA1138
04576100CN
022131
046526
045772
022145
OH7393
OF1965
089520
043180
090152
0A4089
OE9107
023365

6
6
REF
6
6
1
1
1
1
1
1
REF
.5CC
4
4
REF
18
12
12
1
1
4
4
1
1
4
4
4
1
1
1
1
1
1
2
1
1
1
1
1
1
4
8
8
8
6
1
1
2
2
1
1
1
2

34
35
36
37
38
39
40
41
42
43
44
46
51
54
55
56
57

REVISION H-9012-C
DATE 5/20111

DESCRIPTION
SCREW HHC M12-1.75 X 30 C10.9
WASHER LOCK M12
FLEX PLATE
SCREW HHC M8-1.25 X 20 G10.9
WASHER LOCK M8-5/16
SLEEVING UL #2 .2681D 3"PRECUT
FAN MACHINED 390 SAE ALTERATOR
SCREW HHC M16-2 X 45 G8.8
WASHER FLAT .6881D X 3.25 OD
KEY SO 3/8 X 2-1/2 STEEL
COUPLER 390 SAE
ROTOR PER ORDER (SEE BOM)
ADH LOCTITE #8931 AA WIS
SCREW HHC M14-2.0 X 140 G8.8
WASHER 390 SAE ALT.
STATOR PER ORDER (SEE BOM)
WASHER FLAT M10-3/8 ZINC
WASHER LOCK M10
SCREW HHC M10-1.5 X 40 G8.8
BEARING CARRIER 390 PMG REAR
390. BOARD SOLID LEAD TERM PME
WASHER LOCK M14
NUT HEX M14-2
ASSY STATOR PME
RING PME STATOR RETAINING
WASHER FLAT M6-1/4 ZINC
WASHER LOCK M6-1/4
SCREW SHC M6-1.0 X 65 G10.9
COLLAR SLIP FIT 122.65MM
HOUSING 520 PME MAGNET
FAN MAGNETIC HOUSING
KEY SO 3/8 X 1 STEEL
COLLAR SLIP FIT 71.12
COLLAR SLIP FIT 90.17
SCREW SWAGE 1/4-20 X 1/2 lYC
EXCITER FIELD 1.25" WICAN 25KW-35KW
EXCITER FIELD 2.00" 40KW-125KW
ASSEMBLY EXCITER 25KW-35KW
ASSEMBLY EXCITER 40KW-125KW
KEY SO 3/8 X 1-3/4 STEEL
KEY SO 3/8 X 2-1/2 STEEL
STUD M10-1.5 X 280 G5 ZINC
WASHER FLAT M10-3/8 ZINC
WASHER LOCK M10
NUT HEX M10-1.5
WASHER FLAT 5/16-M8 ZINC
M20 RIBBED LOCK WASHER
SCREW HHC M20-1.5 X 55 C8.8
SCREW PFILHM M4-0.7 X 16
WASHER FLAT M4
ASSEMBLY BRIDGE RECTIFIER
ASSEMBLY SCROLL 390 SAE
MOUNT RECTIFIER
WASHER SHAKEPROOF INT #8

Page 2 of 4

EXPLODED VIEW: EV ALTCOMPRT <80KW DD PME G17

GROUP A

DRAWING #: OJ1481
APPLICABLE TO:

ITEM

PART#

QTY.

60
61
62
63
64
65
66
67
68

OA2491
OA2497
OA2496
056326
022097
022473
OA2110
047411
045757

KIT 0A4089 PARTS
2
2
2
8.4 FT
6
6
12
4
2

REVISION H-9012-C
DATE 5/20/11

DESCRIPTION
SHROUD ALT SHEET METAL
SCREEN SHROUD SAE
BRACKET TENSIONER SAE SCROLL
TRIM VINYL BLACK 1/8 GP
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
SCREW SWAGE 1/4-20 X 1/2 ZlYC
SCREW HHC M6-1,O X 16 G8,8
SCREW HHC M6-1,O X 25 G8,8

Page 3 of 4

EXPLODED VIEW: EV ALTCOMPRT <80KW DD PME G17
DRAWING #: OJ1481
APPLICABLE TO:

GROUP A

THIS PAGE LEFT INTENTIONALLY BLANK

REVISION H-9012-C
DATE 5/20/11

Page 4 of 4

GROUP A
y--11
I

2

DUAL MODULE OPTION

20

3

Revl's'lon'" H-9332-C
Date: 71'

, w'
EV ALT-TOWER SPC PRT 390 ALT
Exploded Vie,
Oj1584

Drawing No..

EXPLODED VIEW: EV 390 ALTERNATOR TOWER ASM

GROUP A

DRAWING #: OJ1584
APPLICABLE TO:
ITEM
(1 )1
(1)2
(1)2A
(1)3
(3)4

5
(1)6

7
8
9
(2)10
11
(3)12
(3)13
14
15
16
(3)17
18
19
20

PART#

QTY.

OH9429ASTOR
OH94310STOR
OH9431ASTOR
OH94320STOR
OJ0481
OJ0481A
OJ0481B
OJ0481C
OJ0481D
OJ0481 E
OJ0481 F
OJ0481G
NIA
OJ01360STOR
OJ5464
022097
022473
056326
OC2454
022145
022129
042907
045771
024983
OJ1857
OJ1857A
OC1229
OH9845
052250

1
1
1
1
2/3
2/3
2/3
2/3
2/3
2/3
2/3
2/3

1
2
4
4
2/4
12
4/8
2/3
2/3
2/3
4
2/3
2/3
1

1
1

DESCRIPTION
MAIN, ALT TOWER 390 LONG
TOP, ALT TOWER 390 SINGLE CB
TOP, ALT TOWER 390 DUAL CB
COVER, ALT TOWER 390
XFMR CURRENT 50A W/BRKT UL RCG
XFMR CURRENT 100A W/BRKT UL G
XFMR CURRENT 150A W/BRKT UL
XFMR CURRENT 200A W/BRKT UL
XFMR CURRENT 300A W/BRKT UL
XFMR CURRENT 400A W/BRKT UL
XFMR CURRENT 500A W/BRKT UL
XFMR CURRENT 600A W/BRKT UL
PLATE, WIRE HARN BLOCKOFF
SCREW THTT M5-0.8 X 16 ZP
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
TRIM VINYL BLACK 1/8GP (6"LG)
SCREW HWHT M6-1 X 16 N WA Z/JS
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 16 C8.8
NUT HEX M8-1.25 G8 CLEAR ZINC
SCREW HHTT 1/4-20 X 3/4 CZ
CTBRKT 1.1"WINDOWFRAME
CT BRKT 2.25" WINDOW FRAME
DECAL WARNING ELECTRICAL SHOCK
HARN 390/520 CON BOX H-PANEL (NOT SHOWN)
TAPE FOAM 1X1 (49" LG)

NOTES (UNLESS OTHERWISE SPECIFIED):
(1) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
•
MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE
SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE OH7169).
(3) QTY. REQUIRED FOR 1 PHASE 1 QTY. REQUIRED FOR 3 PHASE.

REVISION H-9332-C
DATE 7/19/11

PAGE20F2

GROUP A

3

4
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I

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10

3

4

Y

12

390 ALTERNATOR SINGLE CIS

V

390/520 ALTERNATOR DUAL CIS

520 ALTERNATOR SINGLE CIS

Revision: H·9670·B
Date: 9'- •

Page 1 ' • ~

Exploded View: EV, LOAD CENTER KIT 390/520
Drawing No. : OJ5190

EXPLODED VIEW: EV, LOAD CENTER KIT 390/520

GROUP A

DRAWING #: OJ5190
APPLICABLE TO:

ITEM

(1)2
3
4
5
6
7
8
9
10

11
12
13

2
3
4
5
6
7
8
9

10
11

(1)2
3
4
5
6
7
8
9
10
11
12

PART#

QTY.

DESCRIPTION

390 ALTERNATOR SINGLE C/B
OD8602
1
LOAD CENTER,125A,SIEMENS 8 BAY\
OD8602A
1
LOAD CTR, 125A,SIEMENS NEMA 3R
OJ51820STOR
1
390 ALT LOAD CENTER MOUNT
039253
4
SCREW HHC M8-1.25 X 20 CB.B
022145
8
WASHER FLAT 5/16-MB ZINC
022129
4
WASHER LOCK MB-5/16
045771
4
NUT HEX MB-1.25 GB CLEAR ZINC
OC2454
2
SCREW HWHT M6-1 X 16 N WA Z/JS
OE6523
1
GROUND BAR (5)4-14 AWG CONN
036920
2
SCREW PPHM #B-32 X 3/4
03B150
2
WASHER FLAT #8 ZINC
022264
2
WASHER LOCK #8-M4
022471
2
NUT HEX #B-32 STEEL
OF1735
1
DECAL AUXILIARY LOAD PANEL
520 ALTERNATOR SINGLE C/B
ODB602
1
LOAD CENTER,125A,SIEMENS B BAY
ODB602A
1
LOAD CTR, 125A,SIEMENS NEMA 3R
OF1735
1
DECAL AUXILIARY LOAD PANEL
039253
4
SCREW HHC M8-1.25 X 20 CB.B
022145
8
WASHER FLAT 5/16-MB ZINC
022129
4
WASHER LOCK MB-5/16
045771
4
NUT HEX MB-1.25 G8 CLEAR ZINC
OE6523
1
GROUND BAR (5)4-14 AWG CONN
036920
2
SCREW PPHM #B-32 X 3/4
03B150
2
WASHER FLAT #B ZINC
022264
2
WASHER LOCK #B-M4
022471
2
NUT HEX #B-32 STEEL
390/520 ALTERNATOR DUAL C/B
ODB602
1
LOAD CENTER,125A,SIEMENS 8 BAY
ODB602A
1
LOAD CTR, 125A,SIEMENS NEMA 3R
OJ27960STOR
2
BRACKET, LOAD CENTER DUAL MOD
039253
4
SCREW HHC M8-1.25 X 20 CB.B
022145
8
WASHER FLAT 5/16-MB ZINC
022129
4
WASHER LOCK MB-5/16
045771
4
NUT HEX M8-1.25 GB CLEAR ZINC
OE6523
1
GROUND BAR (5)4-14 AWG CONN
036920
2
SCREW PPHM #8-32 X 'l:;
038150
2
WASHER FLAT #B ZINC
022264
2
WASHER LOCK #8-M4
022471
2
NUT HEX #B-32 STEEL
OF1735
1
DECAL AUXILIARY LOAD PANEL

NOTES (UNLESS OTHERWISE SPECIFEID):
(1) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
•
MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE
SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE OH7169).

REVISION H-9670-B
DATE 9/13/11

Page 2 of 2

EXPLODED VIEW: TABLE H-100 FIELD RES & OPE CB
DRAWING #: OF9280
APPLICABLE TO:

GROUP B

OPE Breaker and Field Boost Resistor Table for Gensets with H-Panel Control & 12V Battery
VOLTAGE

120/240 1$

FREQUENCY

FIELD BOOST RESISTOR
PART NO.
SIZE

EX

OF5752E

5 ohm

PME/brushless

OF5752B

25 ohm

direct

OF5752E

5 ohm

OF5752B

25 ohm

390 mm or
smaller

60 Hz

7

120/2083$

60 Hz
PME/brushless

390 mm or
smaller

7 20
direct

120/2403$

390 mm or
smaller

60 Hz
PME/brushless

direct

277/4803$

60 Hz
PME/brushless

390 mm or
smaller

7

h

OF5752E

5 ohm

OF5752B

25 ohm

OF5752E

5 ohm

OF5752B

25 ohm

7
direct

346/6003$

60 Hz

OF5752E

5 ohm

390 mm or
smaller

OF5752B

25 ohm

390 mm or
smaller

OF5752B

25 ohm

OF5752E

5 ohm

OF5752B

25 ohm

OF5752E

5 ohm

OF5752B

25 ohm

OF5752E

50hm

OF5752B

25 ohm

PME/brushless

direct

110/220 1$

50 Hz
PME/brushless

direct

100/2003$

390 mm or
smaller

50 Hz
PME/brushless

direct

115/200 3$

50 Hz
PME/brushless

390 mm or
smaller

direct

231/4003$

390 mm or
smaller

50 Hz
PME/brushless

mm

REVISION:
DATE: 10131105

20

PAGE 1 OF 2

7

hm

EXPLODED VIEW: TABLE H-100 FIELD RES & DPE CB
DRAWING #: OF9280
APPLICABLE TO:

GROUP B

BLANK

PAGE

REVISION:
DATE: 10/31/05

PAGE20F2

GROUPB
1f',. '

277,

fTO"A"

:~12
:

~6

25

Vy
1 ~
28
1 29
Y

¥

USE EXISTING
30
(2)NOTE: THRU 520
ALTERNATOR TO
ENGINE

OIL TEMP KIT
PIN OH5427

9

,

17;1\\" ,

<..

1

8

17 ~"--~h
~ ~..--

50 33 '-.

Y

1
143

e

~

)I
16

~

34

16

,.j

7

HARNESS
GROUND

33

49

~

)

20 10'
19 ,- ';:;.>

Y

JtIJ

,

'~

1

~

3

31

~

_..;;;::--.\V

20'''--''--

V..--.-

18 19

\/ .....

4

6

Revision: H·9325·
Date: 7/""
D

Page 1 " •

Exploded View' ENG
Drawing No.: OH2124 COM PARTS 6.7L LO G17

EXPLODED VIEW: EV ENGCOMPRT 6.7L LO G17

GROUPB

DRAWING #: OH2124
APPLICABLE TO:
ITEM

PART#

QTY.

1

OJ2730
021322A
(1) 020604
OH2119A
OF2610
OH21450ST03
OH21460ST03
OH3201
OH22980ST03
021325
055934P
055934M
OH5182A
OH51420SS0R
OH51410SS0R
051756
046526
081816
063837
051769
049808
OD2244M
OH5002
045757
022097
022473
043116
052857
022129
022145
042907
090502

REF

(2)2

3

4
5
6
7
8
(2)9
(4)10
(3)11
12
(5)13
(5014
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

33
(2)34
(1)35
36
37
38
39
40
(5)41
42
43

44
45
46
47
(2)48
49

OJ4574
022131
052647
057642
OA4707A
052648
OF4612
030418
OE0502
OH61800SS0R
OF2776
051768
039253
055934B
086292
OH4195
045773
025507

REVISION H-9325-0
DATE 7/27//11

5
3
1

1
1
1
1
2
1
1

1
1
1
1
4
27
16
10
34
43

1
1
1
1
2
1
1
5
5
4
4
8
21
12
12
1

4
1
1
1
1
1

7
2
1

1
1
12

1

DESCRIPTION
ENGINE D6.7L G17 100/130KW
FLEX PLATE, 520ALT
PLATE FLEX 11-112 SAE 390
FAN SPACER 6.7L G17
FAN COOL 26" LH ROTATION
FOOT ENGINE LF D6.7L G17
FOOT ENGINE RF D6.7L G17
ENGINE FOOT SPACER
REAR ENGINE FEET 4.5L G17
ADAPTER SAE3X520 ALT (MACHO)
CLAMP STLNNL 1.62 X .486
CLAMP STLNNL .75 X .343 Z
ASSY. MECH BOSCH ACTUATOR
HEAT SHEILD TURBO 6.7L LO G17
HEAT SHEILD 6.7L 100-130KW G17
SCREW HHC M10-1.5X 20 C8.8
WASHER LOCK M10
SCREW HHC M12-1.75 X 55 C10.9
SCREW HHC M12-1.75 X 30 C10.9
WASHER LOCK M12
WASHER FLAT M12
ASSY MAGPICKUP(3/8-24 MALE)
ADAPTER MAG PICKUP 6.7L LO G17
SCREW HHC M6-1.0 X 25 C8.8
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
SCREW HHC M6-1.0 X 12 G8.8
NUT TOP LOCK FL M6-1.0
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
SCREW HHC M8-1.25 X 16 C8.8
SCREW SHC M10-1.5 X 60 C12.9
SCREW SHC M10-1.5 X 25 C8.8
WASHER FLAT 3/8-M10 ZINC
SCREW SHC M10-1.5 X 25 C12.9
SCREW HHC M10-1.5 X 40 C8.8
ADPATER 1/8NPT X M10-1.0
SCREW SHC M10-1.5 X 20 C12.9
SENDER OIL PRESSURE 1/8"NPT
BSHG RDCR HEX 1/2 TO 3/8
TEMPERATURE SENDER, DELPHI
HEAT SHEILD 6.7LG17 100/130 LH
BRACKET, SIGNAL CONDITIONER
SCREW HHC M12-1.75 X 25 C8.8
SCREW HHC M8-1.25 X 20 C8.8
CLAMP STLNNL 1 X .281 Z (NOT SHOWN)
SCREW HWHSD #10-16 X 3/4 SEMS (NOT SHOWN)
HARN ENG D4.5L1D6.7L G17 H-PNL (NOT SHOWN)
NUT HEX M12-1.75 G8 YEL CHR
WASHER LOCK EXT 7/16 STL

Page 2 of 4

EXPLODED VIEW: EV ENGCOMPRT 6.7L LO G17

GROUPB

DRAWING #: OH2124
APPLICABLE TO:

ITEM

PART#

50
51

049814
055934M

A
B
C
D

E
F
G
(1)
(2)
(3)
(4)
(5)

QTY.

1
OIL TEMP KIT PIN OH5427
OA4707L
1
OE0502
1
OF2776A
1
022145
1
022129
1
042907
1
OG0349
1

DESCRIPTION
SCREW HHC M10-1.5 X 25 C8.8
CLAMP STLNNL .75 X .343 Z
ADAPTER 3/8NPT X M14-1.5
TEMPERATURE SENDER, DELPHI
BRACKET, SIGNAL CONDITIONER
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 16 C8.8
HARN OIL TEMP SENDER OPTION

W 1390 ALTERNATOR ONLY
W I 520 ALTERNATOR ONLY
FOR ENGINE HARNESS
FOR BLOCK HEATER
SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR).
•
MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
•
CUSTOMER: FOR CORRECT MATERIAL AND COLOR OF REPLACEMENT PARTS REFER TO "REPLACEMENT SHEET
METAL PARTS ORDERING GUIDE-OH7169" INCLUDED IN THE MANUAL OR AVAILABLE ON THE GENERAC WEBSITE.

REVISION H-9325-D
DATE 7/271/1 I

Page 3 of 4

EXPLODED VIEW: EV ENGCOMPRT 6.7L LO G17
DRAWING #: OH2124
APPLICABLE TO:

GROUPB

THIS PAGE LEFT INTENTIONALLY BLANK

REVISION H-9325-D
DATE 7/27//11

Page 4 of 4

GROUP B

NOTE 1: ITEM 29 ATTACHES TO CONTACT ON REAR Of ITEM 5

EXPLODED VIEW:
REVISION: J-1 """-D
DATE: IZIZt

PAG!

2

H-PANEL 10A BATIERY CHARGER E-GOV DSL 12V
DRAWINO #: OH5043D

EXPLODED VIEW: H-PANEL 10A BATIERY CHARGER E-GOV DIESEL 12V
DRAWING #: OH5043D

GROUP B

APPLICABLE TO:

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

PART #

18
19
20
21
22
23
24
25
26
27
28
29

OF1823CST03
OF 1824AST03
OF2606
036261
OF5763
OF1732
OE9764
OF1740C
OF1958
OF2256
OE3161
029673
049226
079224
051713
OF5886
051716
043180
OC3990
OF4333
OF5883
OF5884
055014
022264
003546
OG3648
OF6305
OF6305A
OG4329

A
B
C
D
E

OF1263
OF1262
OF1264
OE9049B
055911

17

9BieQN~J 0G'14QE
1
1
1
7
1
1
1FT.
1
1
1
1
1
11
4
11
6
5
3
3
1
1
1
10
10
1
1
1
1
1

ENCL H/G CONTROL PANEL
COVER CONTROL PANEL
HINGE CONTINUOUS H·PANEL
RIVET POP .125 X .275 SS
ASSY PROGRAMMED H·100
DECAL FUSES LOCATED INSIDE
RAIL SNAPTRACK PCB HOLDER BULK
ASSY PCB 10A UL BAn CHRGR 12V
PLATE HARNESS CLAMP
ASSYPCB PWR AVRW/AMP HEADER
ASSY PCB BOSCH GOV DRIVER
DIO BRIDGE 25A 600V
WASHER LOCK M5
SCREW PPHM M5-0.8 X 30 SS
WASHER FLAT M5
SCREW HHPM Ms-D.8 X 12
NUT HEX Ms-D.8 G8 YEL CHR
WASHER FLAT M4
SCREW PHTT M4-0.7 X 10 rYC
CONN DUST CAP WICHAIN DB9
WASHER FLAT M3.5
SCREW PHTT M3.5-0.6 X 10
SCREW PPHM M4-0.7 X 8 BLK OX
WASHER LOCK #8·M4
DECAL WRN BATT CHRG 12124V BI
M5-0.8 CAPTIVE PANEL KNLD HD
SEAL COVER 3.18 X 12.7 X 382
SEAL COVER 3.18 X 12.7 X 283
HARNESS H·PNL INTEGRATED SW (NOT SHOWN)

ITEM
50
51
52

53
54

PART
056739
022287
022473
022097
022127

55
56
57
58

59
60
61
62
63
64
65
66
67
68

043182
051714
052777
OC2323
OC2699
OE7403B
OE7403C
OJ7646
OF5461
OF5752A
OF6145
OF7473

1
2
4
2
2
REF.
REF.
4
4
4
2
2
1
1
1
1
1

AIR
1

RELAY CONTACTOR 12VDC
SCREW HHC 1/4·20 X 3/4 G5
WASHER FLAT M6 ·1/4
WASHER LOCK M6· 1/4
NUT HEX 1/4-20 STEEL
DPE BREAKER SEE DRAWING OF9280
BOOST RESISTOR SEE DRAWING OF9280
WASHER LOCK M3
NUT HEX M3·0.5 G8 YEL CHR
WASHER FLAT M3
SCREW PHn #6-32 X 5/8rYC
SCREW PHTT #6-32 X 3/8rYC
FUSE ATO TYPE 10 AMP (RED)
FUSE ATO TYPE 15 AMP (BLUE)
DECAL CONTROL BOX FUSES
DECAL CPL 5.416.8L TB3
RES WW 10R 5% 15W OK CONN
SEAL WEATHER AS' DIA
DECAL H·100 RELAY BD 12V RB1

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

REVISION: J-I00I-D
DATE: 12/2/11

PAGE20F2

GROUP H

Revision: H·6096·C
Date:

zr

Page 1 --

Exploded View: KIT FAN GUARD
Drawing No.: OG4310

GROUP B

SEE DETAIL "A"

NOTE 1: ITEM 29 ATTACHES TO CONTACT ON REAR OF ITEM 5

EXPLODED VIEW:
REVISION: J-IOOI-D
DATE: 12/2/II

PAGE 1 OF2

H-PANEL 10A BATIERY CHARGER E-GOV DSL 12V
DRAWING #: OH5043D

EXPLODED VIEW: H-PANEL 10A BATIERY CHARGER E-GOV DIESEL 12V
DRAWING #: OH5043D

GROUP B

APPLICABLE TO:

ITEM

PART #

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

OF1823CST03
OF1824AST03
OF2606
036261
OF5763
OF1732
OE9764
OF1740C
OF1958
OF2256
OE3161
029673
049226
079224
051713
OF5886
051716
043180
OC3990
OF4333
OF5883
OF5884
055014
022264
003546
OG3648
OF6305
OF6305A
OG4329

A
B
C

OF1263
OF1262
OF1254
OE9049B
055911

0
E

9HieQN~" OG',4QF

REVISION: J-I001-0
DATE: 1212/11

1
1
1
7
1
1
1 FT.
1
1
1
1
1
11
4
11
6
5
3
3
1
1
1
10
10
1
1
1
1
1

ENCL H/G CONTROL PANEL
COVER CONTROL PANEL
HINGE CONTINUOUS H·PANEL
RIVET POP .125 X .275 SS
ASSY PROGRAMMED H·100
DECAL FUSES LOCATED INSIDE
RAIL SNAPTRACK PCB HOLDER BULK
ASSY PCB 10A UL BAn CHRGR 12V
PLATE HARNESS CLAMP
ASSY PCB PWR AVR W/AMP HEADER
ASSY PCB BOSCH GOV DRIVER
010 BRIDGE 25A 600V
WASHER LOCK 1.45
SCREW PPHM 1.45-0.8 X 30 SS
WASHER FLAT 1.45
SCREW HHPM 1.45-0.8 X 12
NUT HEX 1.45-0.8 G8 YEL CHR
WASHER FLAT 1.44
SCREW PHTT 1.44-0.7 X 10 ZYC
CONN DUST CAP W/CHAIN DB9
WASHER FLAT 1.43.5
SCREW PHn 1.43.5-0.6 X 10
SCREW PPHM 1.44-0.7 X 8 BLK OX
WASHER LOCK #8-1.44
DECAL WRN BAn CHRG 12124V BI
1.45-0.8 CAPTIVE PANEL KNLD HD
SEAL COVER 3.18 X 12.7 X 382
SEAL COVER 3.18 X12.7 X 283
HARNESS H·PNL INTEGRATED SW (NOT SHOWN)

ITEM
50
51
52
53

54
55

PART
056739
022287
022473
022097
022127

56

57
58
59
60
61

62
63
54
65
66
67

68

043182
051714
052777
OC2323
OC2699
OE7403B
OE7403C
OJ7646
OF5461
OF5752A
OF6145
OF7473

1
2
4
2
2
REF.
REF.
4
4
4
2
2
1
1
1
1
1

AIR
1

RELAY CONTACTOR 12VDC
SCREW HHC 1/4·20 X 3/4 G5
WASHER FLAT 1.46 • 1/4
WASHER LOCK 1.46 ·1/4
NUT HEX 1/4-20 STEEL
OPE BREAKER SEE DRAWING OF9280
BOOST RESISTOR SEE DRAWING OF9280
WASHER LOCK 1.43
NUT HEX 1.43·0.5 G8 YEL CHR
WASHER FLAT 1.43
SCREW PHTT #6-32 X 5/8l:'fC
SCREW PHTT #6·32 X 3/8l:'fC
FUSE ATO TYPE 10 AMP (RED)
FUSE ATO TYPE 15 AMP (BLUE)
DECAL CONTROL BOX FUSES
DECAL CPL 5A/6.8L TB3
RES WW 10R 5% 15W QK CONN
SEAL WEATHER .45" DIA
DECAL H·100 RELAY BD 12V RB1

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

PAGE 2 OF 2

GROUP H

Revision: H·6096·C
Date: 2/25/10

Page 1 of 2

Exploded View: KIT FAN GUARD
Drawing No.: OG4310

EXPLODED VIEW: KIT FAN GUARD 4.5L G4

GROUPH

DRAWING #: OG4310
APPLICABLE TO:

ITEM

PART#

QTY.

1
2
3
4

OG29160ST03
OG29170ST03
090388
OG24170ST03

1
1
24
2

REVISION. H-6096-C

DATE 2/25/10

DESCRIPTION
FAN GUARD R/H SIDE
FAN GUARD LlH SIDE
SCREW HHTI M6-1.0 X 12 ZINC
SUPPORT BRACKET, FAN GUARD

PAGE20F 2

GROUpe

8~

7 --.!

6

/

TO"B"

1

12V. SINGLE BATTERY

Revision: ·A·
Date: 9/17109

12V. DUAL BATTERY

Page 1 of 2

Exploded View: BAIT HOLD OWN 3112V G17
Drawing No.:OH5386

EXPLODED VIEW: BATT HOLD OWN 31 12V G17

GROUpe

DRAWING #: OH5386
APPLICABLE TO:
ITEM

PART#

QTY.

DESCRIPTION

GROUP 31 SINGLE BATIERY KIT 12V. PIN OH5473
1
2
3
4
5
6
7
8
9
10
11
12
13
14

061119
061119A
OH4637
OH4637
099049
059568H
058653
022129
045771
OH4637
OH4637
0A4456
022131
046526
049814

1 (REF)
1 (REF)
1
1
2
1
2
2
2
1
1
1
1
1
1

BATTERY BCI GRP 31 925 CCA
31E BATTERY SERVICE DRY 925CCA
BATTERY CABLE SET 6.7L G17
BATTERY CABLE SET 6.7L G17
JBOLT,BATTERYTRAY
BATT HOLD-DOWN BAR 390 MM
WASHER FLAT M8
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 CLEAR ZINC
BATTERY CABLE SET 6.7L G17
BATTERY CABLE SET 6.7L G17
WASHER LOCK SPECIAL 3/8
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK MiD
SCREW HHC M10-1.5 X 25 C8.8

GROUP 31 DUAL BATTERY KIT 12V. PIN OH5474
1
2
3
4
5
6
7
8
9
10
11
12
13
14

REVISION-A-

DATE 9117/09

061119
061119A
OH5206
OH5206
099049
059568H
058653
022129
045771
OH5206
OH5206
0A4456
022131
046526
049814

2 (REF)
2 (REF)
1
1
4
2
4
4
4
1
1
1
1
1
1

BATTERYBCIGRP31
31E BATTERY SERVICE DRY
DUAL BATT CABLE SET D6.7L G17
DUAL BATT CABLE SET D6.7L G17
JBOLT,BATTERYTRAY
BATT HOLD DOWN BAR 390MM
WASHER FLAT M8
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 CLEAR ZINC
DUAL BATT CABLE SET D6.7L G17
DUAL BATT CABLE SET D6.7L G17
WASHER LOCK SPECIAL 3/8
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
SCREW HHC M10-1.5 X 25 C8.8

PAGE 2 OF 2

111
/(f)

35

l

21

1\
1"1

"" ~ i

~

2-$
I
I

TO
ENGINE
BLOCK

14

29

33

.,

I

I
I
I

ENGINE
MOUNTING
21
LEG
20

23

/' /'
(/'

~~

:
I
I
I
I

/'

21

22

TO

~ FUEL RETURN
~~

j:;V

21
20

/' /'

I / ' / ' /'

~~

tv

/':#
/'

~

27

';4P~~

~
17 34
24

/'

/'

26
/J
I

\ ~

1 17 ~ ~
OIL PAN ~ ~ ~«
A~ ~18
/'/'
19
/' "

TO

16

GROUpe

TO
FUEL SUPPLY

/' /' /'

)
/' /'

/'

15~

~" J

~/~

\

"~,'f(.• .>•.'l7"";;;'/REAR BEARING

30
~
37
;./'

.til

~~

CARRIER

13~

5--0
)

~"

31

(

36~
10~
Revision: ·A·
Date: 3/17/11

11--1
Page 1of2

Exploded View EV BASEFRAME 6.7L G17 390ALT:
Drawing No. : OH9939

---------~~~~

EXPLODED VIEW: EVBASEFRAME 6.7L G17 390ALT

GROUpe

DRAWING #: OH9939
APPLICABLE TO:

ITEM

PART#

QTY.

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

OH99410STOR
059675
059676
056727
052257
049869
050277
056726
060079
052259
059983
055597
052251A
027482
052860
056460
OG0015
065386
0A4707H
007020
OC7649
007532
007532
077043E
024310
039413
078944
OA8258
022145
022129
OC3168
045771
0536210292
044118
022132
052252
039253

1
4
4
1
2
4
1
1
4
2
4
2
2
1
2
1
2
1
1
2
4
1
1
1
3
1
1
1
3
2
1
1
1
1
4
2
1

DESCRIPTION
MTG BASE 6.7L G17 C-GRP 390ALT
MOUNT UPPER VIBRATION
MOUNT LOWER VIBRATION
DECAL-FUEL INLET DES
SPACER .49X.62X1.87 PWORIZINC
WASHER FLAT M16
DECAL OIL DRAIN
DECAL-FUEL RETURN
NUT HEX LOCK M14-2.0 NY INS
WASHER FLAT M12
SCREW HHC M14-2.0 X 110 C8.8
SCREW HHC M12-1.75 X 85 C8.8
DAMPENER VIB 50 WHITE
WASHER SHAKEPROOF EXT 5116 STL
NUT TOP LOCK FL M12-1.75
BARBED EL 90 112 NPT X 518
CLAMP HOSE 718" 00 DOUBLE WIRE
HOSE COOL 51810 100R6 (12.5"LG)
ADAPTER 112NPT X M22-1.5
BARBED STR 1/2NPT X 318"
CLAMP HOSE .38-.87
HOSE DIESEL 318" FC598-06 (66"LG)
HOSE DIESEL 318" FC598-06 (66"LG)
CONDUIT FLEX 1.0"10 (17"LG)
HD
PLUG STD PIPE 112 STEEL
NIPPLE PIPE 112 NPT X 2
VALVE BALL
SCREW HHC M8-1.25 X 25 C10.9
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5116
WASHER LOCK SPECIAL 5/16
NUT HEX M8-1.25 G8 CLEAR ZINC
ASSY WIRE #1 18.00"
BARBED STR 112NPT X 518
WASHER FLAT 9/16 ZINC
DAMPER VIBRATION
SCREW HHC M8-1.25 X 20 C8.8

sa

(1) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR).
MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
•
CUSTOMER: FOR CORRECT MATERIAL AND COLOR OF REPLACEMENT PARTS REFER TO "REPLACEMENT SHEET
METAL PARTS ORDERING GUIDE-OH7169" INCLUDED IN THE MANUAL OR AVAILABLE ON THE GENERAC WEBSITE.

REVISION-ADATE 3/l7/l1

Page 2 of 2

GROUpe
OPTIONAL
EMERGENCY VENT
(PRIMARY TANK)

~20A

35
11

10

2

~3

~

BASE
FRAME

15

~16

L,~

)

I
I

20

~

/'
/'

I

/'

I

/'

I

)

I
I
I

/'

18"0;

/'

/'

I

19--j

I
I
I
I
I
I

3

v./

I
I
)

./

./

20

~
I

~

OPTIONAL
EMERGENCY VENT
(SECONDARY TANK)

20A

~

(

29"+

4-1

14

140

14A

"'4C
,:~j
~" -J

14F~

1

/'

v/'
5

Revision: ·A·
Date: 4/21/11

N.O. ARROW MUST
POINT UP

Page 1 of 4

Exploded View: EV, BASE TANK 6.7L C·GRP 1·3FT
Drawing No.: OJ1126

1---------

EXPLODED VIEW: EV, BASE TANK 6.7L C-GRP I-3FT

GROUpe

DRAWING #: OJ1126
APPLICABLE TO:
ITEM

PART#

QTY.

11
(3)12
13
14

OJ18460STOR
OJ 18480STOR
OJ 18500STOR
OC6789
087171
051548
OD3747
OD3747A
OD3747B
050190
051754
48031E
021623
021623B
021623D
070327
021825
OD3038A
OH5761

1
1
1
10
20
10
1
1
1
6
6
1
1
1
1
2
1
1
1

14A
14B
14C
140
14E
14F
14

OG8010A
OD2668
052829
097962
OE4351
OE4352
OH5761A

1
1
3
4
1
1
1

14A
14B
14C
140
14E
14F
14

OG8010B
002668
052829
097962
OE4351
OE4352
OH5761B

1
1
3
4
1
1

1
1
3
4
1
1
1
1
1
1
1
1
1

(1)20
(2)20

OG8010C
OD2668
052829
097962
OE4351
OE4352
OA1492
002670
(2) 002737
(2) 002739
(2) 002740
021824
021178
OA7238
(2) 002737
(2) OD2739
(2) 002740
028619B
OD2450

20A
20B
21
22
23
24

OA1380
028667
096500V
025655
021821
021823

2
1
1
1
1
1

(4)1

2
3
4
5

6
7
9
10

14A
14B
14C
140
14E
14F
15
(1)16

(3)17
18
(1 )19

REVISION-ADATE 9iI 5/I 0

1

1
1
1
2
1

DESCRIPTION
BASETANK CD0095U1N TYPE 1
BASETANK CD0225U2N TYPE 1
BASETANK CD0355U3N TYPE 1
SCREW HHC M12-1.75 X 30 SS FT
WASHER FLAT 1/2 SS
NUT HEX M12-1.75 G8 SS
COVER, STUB-UP (1FT)
COVER, STUB-UP (2FT
COVER, STUB-UP (3FT
WASHER FLAT .344 ID X 1.0 OD
SCREW HHC M8-1.25 X 12 G8.8
CLAMP HOSE BAND .66
FUEL DIP PIPE 233MM
FUEL DIP PIPE 538MM
FUEL DIP PIPE 843MM
VALVE CHECK 3/8 NPT
DECAL RELIEF VENTING
BARBED STR FE 3/8 NPT X 3/8
FUEL LEVEL GAUGE KIT-1 FT ELECTRICAL
(TO INCLUDE ITEMS 14A, 14B, 14C, 14D, 14E & 14F)
ELEC FUEL GAUGE 1FT DW
PLATE ADAPTOR
SCREW SHC M8-1.25 X 14 G 12.9
SCREW SHC M6-1.0 X 25 G12.9
GASKET,ROCHESTER FUEL LEVGAUGE
GASKET, ADAPTER PLATE
FUEL LEVEL GAUGE KIT-2 FT ELECTRICAL
(TO INCLUDE ITEMS 14A, 14B, 14C, 140, 14E & 14F)
FUEL LEVEL GAUGE
PLATE ADAPTER
SCREW SHC M8-1.25 X 14 G12.9
SCREW SHC M6-1.0 X 25 G12.9
GASKET,ROCHESTER FUEL LEVGAUGE
GASKET, ADAPTER PLATE
FUEL LEVEL GAUGE KIT-3 FT ELECTRICAL
(TO INCLUDE ITEMS 14A, 14B, 14C & 14D, 14E & 14F)
FUEL LEVEL GAUGE
PLATE ADAPTOR
SCREW SHC M8-1.25 X 14 C12.9
SCREW SHC M6-1.0 X 25 C12.9
GASKET,ROCHESTER FUEL LEVGAUGE
GASKET, ADAPTER PLATE
CAP FUEL FILL
NECK FUEL FILL (STANDARD-4")
FUEL FILL AND PRIMARY VENT EXT. KIT 8"
FUEL FILL AND PRIMARY VENT EXT. KIT 13"
FUEL FILL AND PRIMARY VENT EXT. KIT 19"
WARNING LABEL
VENT OEM 2" NPT
NIPPLE PIPE 2 NPT X 3.5 BL IRON
FUEL FILL AND PRIMARY VENT EXT. KIT 8"
FUEL FILL AND PRIMARY VENT EXT. KIT 13"
FUEL FILL AND PRIMARY VENT EXT. KIT 19"
PLUG PIPE 4" SQ. HD.
VENT EMERGENCY KIT 4" NPT
(TO INCLUDE ITEM 20A)
VENT EMERGENCY 4" NPT
ELBOW 90D STREET 4
ASSY FUEL LEAK DET ALARM WICON
PLUG STD PIPE 3/4" STEEL SQ HO
PLATE GENERAC
PLATE UL

Page 2 01'4

EXPLODED VIEW: EV, BASE TANK 6.7L C-GRP 1-3FT

GROUpe

DRAWING #: OJ1126
APPLICABLE TO:

ITEM

PART#

QTY.

(3)25
(3)26
(3)27
(3)28
29
(3)30
(3)31
(3)32
(3)33
34
35

OA1478
OA1477
OA1476
OA1546
083215
OA1479
021826
OA1481
OA1482
048031N
055596

1
1
1
1
10
1
2
1
1
1

1

DESCRIPTION
DECAL FUEL RETURN
DECAL FUEL SUPPLY
LABEL FUEL FILL
LABEL FUEL LEVEL
WASHER LOCK 1/2 SS
LABEL VENT
DECAL EMERGENCY VENT
LABEL LEAK DETECTOR
LABEL DRAIN
CLAMP HOSE BAND .53
BARBED STR 3/8NPT X 3/8

NOTES (UNLESS OTHERWISE SPECIFEID):
(1) ITEMS ARE STANDARD COMPONENTS
(2) ITEMS ARE OPTIONAL COMPONENTS
(3) UL STICKER KIT PIN OA1493.
(4) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE
SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE OH7169).

REVISION-ADATE 9115/10

Page 3 of4

EXPLODED VIEW: EV, BASE TANK 6.7L C-GRP I-3FT
DRAWING #: OJ1l26
APPLICABLE TO:

GROUpe

THIS PAGE LEFT INTENTIONALLY BLANK

REVISION-ADATE 9/J5/IO

Page 4 of 4

GROUPD
39

~I
I

<

II

33 " " /' /,
32
~ /'"

35

Y

V

"

"

/'

"-./ 33
32
"- /'

35

::. .Jfl

V

47

Revision: H·8526·E
Date: 4/14/11

Page 1 of 2

Exploded View' COO
Drawing No.: OH2157LING PACK 6.7L LO G17

EXPLODED VIEW: COOLING PACK6.7L LO G17

GROUPD

DRAWING #:OH2157
APPLICABLE TO:
ITEM

PART#

QTY.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
(1)44
(1)45
(1)46
47

OG1286G
OG1404AST03
OG14040ST03
OH1901
049814
046526
022131
OG25960ST03
007975
076749
OC2454
OH2246
084294B
OH2316
051756
048031C
051768
049808
OA5398B
OH2321
OH1827
OH1985
086133C
052250
OG3269
OG3263
0861330
OH2288
OG3266
0A4456
039287
022129
022145
OF2776C
039253
OG7895A
077043H
029032
OE4162
052860
035461
OC7649
047290
OH31940191
OH31940138
OH31940137
050276

1
1
1
1
1
10
10
1
1
1
1
1
1
1
9
2
6
6
1
1
1
1
4
1
2
2
4
1
1
1
4
15
15
1
12
1
1
1
1
6
1
2
1
REF
REF
REF
1

DESCRIPTION
RAD RH-INIOUT DEAERATN BAFFL
SUPPORT, R/H SIDE RADIATOR
SUPPORT, UH SIDE RADIATOR
ASSY CAC 4.5L (IN=LWR/RT)
SCREW HHC M10-1.5 X 25 C8.8
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
VENTURI, 26"FAN 6.8L C-GRP
WATER BOTILE BRACKET
TANK COOLANT RECOVERY
SCREW HWHT M6-1 X 16 N WA ZIJS
HOSE LOWER RAD 6.7L G17 LO
HOSE 2.5"10 X 4.0"LG
PIPE, CAC OUT 6.7L LO G17
SCREW HHC M10-1.5 X 20 C8.8
CLAMP HOSE BAND .50
SCREW HHC M12-1.75 X 25 C8.8
WASHER FLAT M12
HOSE 2.5"10 X 4.0"LG
PIPE ASSY, CAC IN 6.7L LO G17
PROBE COOLANT LEVEL 3/8-18NPTF
HOSE UPPER RADIATOR
CLAMP HI TORQUE 1.75 - 2.625
TAPE FOAM 1X1 (184"LG)
DECAL WARNING FAN BI
DECAL WARNING HOT SURFACES BI
CLAMP HI TORQUE 2.25 - 3.125
GASKET G171NTAKE MANIFOLD
DECAL WARNING COOLANT EGLY BI
WASHER LOCK SPECIAL 3/8
SCREW HHC M8-1.25 X 45 C8.8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
BRACKET, SIGNAL CONDo 2 PLACE
SCREW HHC M8-1.25 X 20 C8.8
HARN RADIATOR GND 80"
CONDUIT FLEX .25"10 (80"LG)
HOSE 9132 10 (75"LG)
CAP RADIATOR 20 PSI
NUT TOP LOCK FL M12-1.75
BARBED STR 114NPT X 3/8
CLAMP HOSE .38-.87
HOSE 318 10 SINGLE BRAID (27"LG)
CLIP
NUT, HEX
O-RING
DECAL RADIATOR DRAIN

(1) SUPPLIED WITH ENGINE

REVISION. H-8526-E

DATE 4/14/1 I

PAGE 20F 2

~14

KIT AIR MINDER
OA4256A
(OPTIONAL)

TO
ENGINE ~
CRANKCASE
~

13
5

73

l

"

~

15

12

12

11

2

11

6

USE EXISTING

Revision: H-5883-B
Date: 1/29/10

Page 1of2

Exploded View: AIR CLEANER 06.7 LO G17
Drawing No.:OH3251

EXPLODED VIEW: AIR CLEANER D6.7 LO G17

GROUPD

DRAWING #:OH3251
APPLICABLE TO:
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

PART#

QTY.

084725
OH2573B
084288
026073
084289
OH32570ST03
OH32620ST03
022131
052859
051756
058612
OC5209
057824
0A4256A
057648

1
1
1
1
2
1
1
5
5
5
2
1
2
REF
1

REVISION H-5883-B
DATE 1/29110

DESCRIPTION
REDUCER HUMP
WELDMENT, AIR INTAKE TUBE
AIR CLEANER ECO SE
HD
PLUG STD PIPE 1/8 STEEL
MOUNTING CLAMP
BRACKET, AIR CLEANER
BRACKET, AIR CLEANER SUPPORT
WASHER FLAT 3/8-M10 ZINC
NUT TOP LOCK FL M10-1.50
SCREW HHC M10-1.5 X 20 C8.8
CLAMP HOSE #88 5.12-6.00
HOSE 110 LOW PRES OILlWATER (9"LG)
CLAMP HOSE #16 .87-1.50
KIT AIR FILTER RESTRICTION IND
CLAMP HOSE #64 3.56-4.50

sa

PAGE 2 OF 2

GROUPF

10

4
I,
I "
I
I

16

18\\)

I

I
I
I

24

l

----

3

I

,

I
I
...

7

..
.. ..

----

----

----

1

I
I
'--.]

----

----

/

; , ~21
~ 20
19

18

16

17

\

~;

Revision: J·1124-C
Date: 12/6/11

\

----

..
.. .
..
Page 1of 2

TO
COMPARTMENT

1

Exploded View: EXHAUST 6.7L G17100·135KW
Drawing No.: OH2765

EXPLODED VIEW: EXHAUST 6.7L G17100-135KW

GROUPF

DRAWING #:OH2765
APPLICABLE TO:
ITEM

PART#

QTY.

1

OC2933
OC57370STOR
OC5665
OC9653
OC9643
065805
OC8403AASOR
OC9647D
OA5215D
OH3281
OC3433C
OH6348
OF9911A
083468
OC5668
051756
046526
022131
055173
022129
022145
049820
039287
OC2454

2
2
4
1

(2)2

3
4

5
6
(2)7

8
9
10

11
(1)12
13
14
15
16
17
18
19
20
21

22
23
24

1

1
1
1

1
1
2
REF

1
1

1
8
8
8
4
4
12
4

4
2

DESCRIPTION
BRACKET, MUFFLER MOUNTING
BRACKET, HEAT SHIELD
CLAMP OVAL MUFFLER
MUFFLER 4"INLET/5"OUTLET
TUBE, STRAIGHT
RAINCAP 5.00115.19
SHIELD R/H C-GRP MUFFLER HEAT
TUBE, 90 DEG ELBOW 4" DIA
FLEX PIPE 4"
TURBO EXHAUST PIPE
BAND CLAMP 4 DIA
CLIP 6.7L G17
BLANKET EXHAUST 1090 LG
BOLT U 3/8-16 X 4
BOLT U 5/16-18 X 5
SCREW HHC M10-1.5 X 20 G8.8
WASHER LOCK M10
WASHER FLAT M10-3/8 ZINC
SCREW HHC M8-1.25 X 20 G10.9
WASHER LOCK M8-5/16
WASHER FLAT M8-5/16 ZINC
NUT LOCK HEX M8-1.25 NYL INS
SCREW HHC M8-1.25 X 45 G8.8 FT
SCREW TH-FRM M6-1 X 16 N WA ZlJS

(1) SUPPLIED WITH ENGINE
(2) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE
SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE OH7169).

REVISION J-1124-C
DATE 12/6/1 ]

PAGE20F2

o,

GROUPF

STATES FOAM IS ON NEAR SIDE

.....

\

) STATES FOAM IS ON FAR SIDE

, ,
, ,
,
'1

<

---, ---

---

, ,
, ,

'--- ---

--tJ@

(
I
I

I::l-- 53

I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I

29

19

(
36

30

Revision: H·9744-B
Date: 10/6/11

18

Page 1 of4

Exploded View: EV ENCL SAE C·GRP
Drawing No. : OJ0433

EXPLODED VIEW: EV ENCL SAE C-GRP

GROUPF

DRAWING #:OJ0433
APPLICABLE TO:
PART#

QTY.

DESCRIPTION

(1 )1
(1)2
(1)3
(1)4
(1)5
(1)6
(1)7
(1)8
(1)9
10
11
12
13
(1)14
(1 )15
16
(1)17
18
19
20
21
22
23
(1)24
(1)25
(1)26
(1)27
28
(1)29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
(1)49
(1)50
51
(1)52
53
54

OH98290STOR
OH98300STOR
OH98340STOR
OH98310STOR
OH98320STOR
OG63850STOR
OH27690STOR
OH97910STOR
OJ 19690ALOR
OC7990
OC7989
OC8391
OC7987
OH28160ALOR
OG14150STOR

CORNER POST LH REAR
CORNER POST RH REAR
SIDE BRACE TOP&BTM C-GRP
CORNER POST LH FRONT C-GRP
CORNER POST RH FRONT C-GRP
LOWER RADIATOR BLOCK OFF
FRONT BRACE TOP 6.7L G17
CENTER DOOR SUPPORT
ASSY, ROOF C-GRP
DUCT, FRONT LH
DUCT, FRONT RH
DUCT, BOTTOM
DUCT, FRONT PANEL
DUCT FRONT TOP R/H ALUM
RADIATOR BLOCK OFF 6.8L 135KW

OH98350STOR
OC7984
OC7983
OC7985
OC8392
OC3595
OC3595A
OJ00780STOR
OJ00790STOR
OJ00800STOR
OJ00810STOR
OJ0992
OJ16010STOR
OJ0993
OA5991
OC3393
022145
022129
042907
OC6749
022769
080490
OC6748
022473
022097
049813
026311
OC2454
OE3257
OA9881
066760
027529
OJ29770STOR
OJ02700STOR
087233
OC53560STOR
OE7222

1
1
4
1
1
1
1
2
1
1
1
2
1
1
2
1
1
1
1
1
1
8
8
2
2
2
2
4
8
8
64
4
4
4
4
16
4
16
16
17(REF)
17
16
1
112
14
1
1
8(REF)
2
2
16
1
2

OC3948

8

SPACER DOOR (NOT SHOWN)

60
61
62
63
64
65
66
67
68
69

OJ0553EG
OJ0553EF
OJ0553EE
OJ0553ED
OJ0553BJ
OJ0553EH
OJ0553BI
OJ0553BL
OJ0553BM
OJ0621N

1
2
1
1
2
1
8
1
1
1

INSUL REAR DUCT SIDE
INSUL REAR DUCT SIDE
INSUL REAR DUCT LH SIDE
INSUL REAR DUCT RH SIDE
INSUL REAR CORNER POST
INSUL REAR DUCT TOP
INSUL SIDE SUPPORT RAIL
INSUL ROOF REAR
INSUL ROOF MID
INSUL HIGH HEAT FRONT ROOF

ITEM

OC2634A

REVISION H-9744-B
DATE 10/6111

ASSY ACCESS COVER
REAR SOUND BAFFLE, C-GRP
DUCT, REAR LH
DUCT, REAR RH
DUCT, REAR PANEL
DUCT,REAR TOP
ASSY M8 HINGE
ASSY M8 HINGE LH
DOOR LH LOUVERED
DOOR RH LOUVERED
DOOR LH SOLID
DOOR RH SOLID
T-HANDLE, 2-POINT DBL DOOR
BRACKET, ROD GUIDE
ROLLER ROD, T-HANDLE
SCREW 8HSC M8-1.25 X 16 SS
SCREW SHOULDER M8-1.25 X 20
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5116
SCREW HHC M8-1.25 X 16 C8.8
SCREW PPHM M4-0.7 X 12 SS
WASHER LOCK INT #10
WASHER FLAT #8 SS
NUT HEX LOCK M4-0.7 S5 NYL INS
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX M6-1.0 G8 CLEAR ZINC
NUT LOCK HEX JAM 1/4-20 NYL IN
SCREW HWHT M6-1 X 16 N WA Z/JS
SCREW HWHTF M6-1.0 X 16
TRIM VINYL SEAL
STRIP SEALANT 118 X 1 (NOT SHOWN)
NUT HEX LOCK 114-20 NY INS
DOOR BAFFLE
DOOR BAFFLE
RIVET POP .1875 X .450 SS
PLATE VARMINT BLOCKOFF
RAIN SHIELD,DOOR JAMB

Page 2of4

----------------

EXPLODED VIEW: EV ENCL SAE C-GRP

GROUPF

DRAWING #:OJ0433
APPLICABLE TO:
ITEM
70
71
72

73
74

75
76

77

78
79

80

81
82

83
84

85
86

PART#

QTY.

OJ0621G
OJ0553BG
OJ0621H
OJ0553K
OJ0553L
OJ0553E
OJ0553Y
OJ0553M
OJ0553N
OJ0553EJ
OJ0553BH
OJ0553EA
OJ0553DZ
OJ0553CD
OJ0553EB
OJ0553EC
OJ0553EI

2
2
1
2
2
2

2
2
2

2
1
1
1
1

2

1
1

DESCRIPTION
INSUL HIGH HEAT FRNT CNR POST
INSUL FRONT CORNER POST
INSUL HIGH HEAT FRNT CTR SPT
INSUL RH SOLID DOOR
INSUL LH SOLID DOOR
INSUL CTR DOOR SUPPORT
INSUL DOOR BAFFLE
INSUL RH LOUVERED DOOR
INSUL LH LOUVERED DOOR
INSUL DOOR BAFFLE
INSUL BOTTOM FRONT SUPPORT
INSUL FRONT DUCT LH SIDE
INSUL FRONT DUCT RH SIDE
INSUL FRONT DUCT BTM
INSUL FRONT DUCT SIDE
INSUL FRONT DUCT SIDE
INSUL REAR DUCT BAFFLE

(1) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR).
MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
•
CUSTOMER: FOR CORRECT MATERIAL AND COLOR OF REPLACEMENT PARTS REFER TO "REPLACEMENT SHEET
METAL PARTS ORDERING GUIDE-OH7169" INCLUDED IN THE MANUAL OR AVAILABLE ON THE GENERAC WEBSITE.

REVISION H-9744-B
DATE 10/6/11

Page 3 of4

----------~

__

.
_
~
_
.
_
-

.

EXPLODED VIEW: EV ENCL SAE C-GRP
DRAWING #:OJ0433
APPLICABLE TO:

GROUPF

This page left blank intentionally

REVISION H-9744-B
DATE IO/61l1

Page 40f4

GROUP G
1-.-------

10,24

-----------------1-1

9,52

~---------

---------~

f--- 0,35

----

~-+-+--------+--+---.~
0,35 -

~
~
I

~~

~" Dia Hole (0.236")

Dia Drill
4 places for
cutout

gOO

For mounting to wall
4 holes

-,'
f
----t---t---.+

7,09

\
6,39

Cutout along this
line

Template for OG7879
Flush Mount 21 Light
-'----+----\-

6,75

REF

CB
-j-

~nnunciatorBOX_ _

INSTALLATION TEMPLATE
DRAVING~ OG8762 REV A

1-.----------

REVISION:
DATE: 03/26/08

9,88

REF

-----------1-.]

EXPLODED VIEW:
INSTALLATION TEMPLATE

PAGE 1 OF 2

DRAWING #: OG8762

EXPLODED VIEW: INSTALLATION TEMPLATE
DRAWING #: OG8762
APPLICABLE TO:

GROUP G

THIS PAGE IS LEFT INTENTIONALLY BLANK

REVISION:
DATE: 03/26/08

PAGE20F2

GROUPG
1-------------------------------- ----------------,
I
I
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OPTION 1 - SINGLE PHASE, H-PANEL OR G·PANEL CONTROL PANEL

LEGEND
AR
AS
AVR
CL
EF
MLCB
NB
PME

-

ALTERNATOR ROTOR
ALTERNATOR STATOR
AUTOMATIC VOLTAGE REGULATOR
CURRENT TRANSFORMER
EXCITER FIELD
MAIN CIRCUIT BREAKER
NEUTRAL BLOCK
PERMANENT MAGNET EXCITER

...J

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l5
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o

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AS
'NOTE:
#5 WIRE (OPTIONAL) USED TO BYPASS
STATOR THERMAL PROTECTOR

E3
GENERATOR OUTPUT
CUSTOMER CONNECTION
El-E3 '240VAC
El-N OR E3-N '120VAC
'NOTE: THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE ON
UNITS BEFORE 2010
THE 7TH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE ON UNITS
2010 TO PRESENT
"A" = 120/240VAC 60HZ
"M" = 110/220VAC 50HZ

AGE 1 OF 10
L-

_

--------------------------------------~

WIRING - DIAGRAM

ALTERNATOR GIH-PANEL

REVISION: J-1048-B
DATE: 1I115111

PAGE 1 OF 10

DRAWING #: OH9846

GROUPG

,---

----------------------- ---------------,

I

OPTION 2 - THREE PHASE, H-PANEL OR G-PANEL CONTROL PANEL, DIRECT DRIVE, 6 LEAD

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AVR
CT_
EF
MLCB
NB
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I

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-

ALTERNATOR ROTOR
ALTERNATOR STATOR
AUTOMATIC VOLTAGE REGULATOR
CURRENT TRANSFORMER
EXCITER FlELD
MAIN CIRCUIT BREAKER
NEUTRAL BLOCK
PERMANENT MAGNET EXCITER

d

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ii ------ ii

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GENERATOR OUTPUT
CUSTOMER CONNECTION
E1 TO E2J
E2 TO E3 *208VAC OR *480VAC
E1 TO E3
E1, E2 OR E3 TO NB = *120VAC OR *277VAC
*NOTE: THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE ON
UNITS BEFORE 2010
THE 7TH DIGIT OF THE MODEL NUMBER SPECIFlES OUTPUT VOLTAGE ON UNITS
2010 TO PRESENT
"G" = 120!208VAC 60HZ
"K" = 277/480VAC 60HZ

L__________

I

~

~

_

I
PAGE 2 OF 10

I

~

WIRING - DIAGRAM
ALTERNATOR GIH-PANEL

REVISION: J-I048-8
DATE: 11/15/11

PAGE 2 OF 10

DRAWING #: OH9846

GROUPG

,-----

-----,

I

OPTION 3 - THREE PHASE, H-PANEL OR G-PANEL CONTROL PANEL, GEARBOX (REVERSE ROTATION)

LEGEND
AR
AS
AVR
CT_
EF
MLCB
NB
PME

-

ALTERNATOR ROTOR
ALTERNATOR STATOR
AUTOMATIC VOLTAGE REGULATOR
CURRENT 1RANSFORMER
EXCITER FIELD
MAIN CIRCUIT BREAKER
NEU1RAL BLOCK
PERMANENT MAGNET EXCITER

--------------,
: _

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--!J

1 -BLACK

4 _-:: RED

!~I:l -:-a~

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AR

0

BRU:~LESS

2
6

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E2

E3

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S12

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~S7
/

S5
.S8

l.-/

GENERATOR OUTPUT
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S6 S9

o

El TO E2J
E2 TO E3 *480VAC
El TO E3
E1, E2 OR E3 TO NB = *277VAC
"NOTE: THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE ON
UNITS BEFORE 2010
THE 7TH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE ON UNITS
2010 TO PRESENT
"K- = 277/480VAC 60HZ
L

"AGE 3 OF 10

_

-----------------------------------------~
WIRING - DIAGRAM

REVISION: J-1048-B
DATE: lI/IS/II

ALTERNATOR G/H-PANEL
PAGE 3 OF 10

DRAWING #: OH9846

GROUPG

--------,

r

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OPTION 4 - THREE PHASE DELTA, H-PANEL OR G-PANEL CONTROL PANEL, DIRECT DRIVE, 7 LEAD

I

LEGEND
AR
AS
AItR
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MLCB
NB
PME

I
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- ALTERNATOR ROTOR
- ALTERNATOR STATOR
- AUTOMATIC VOLTAGE REGULATOR
- CURRENT TRANSFORMER
- EXCITER FJELD
- MAIN CIRCUIT BREAKER
- NEUTRAL BLOCK
- PERMANENT MAGNET EXCITER

CT

~ [-+(~~+-

I ===~

G:l

~ ~398A-WHITE
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!--+++-

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Ul

_

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f

OO-OO

HB

GEARBOX DRIVE

AS

o

GENERATOR OUTPUT
CUSTOMER CONNECTION
E1 TO E2J
E2 TO E3 "240VAC
E1 TO E3
E1-N OR E3-N '" "120VAC
"NOTE: THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE ON
UNITS BEFORE 2010
THE 7TH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE ON UNITS
2010 TO PRESENT
"J" '" 120!240VAC 60HZ

L

PAGE 4 OF 10
~

WIRING - DIAGRAM
ALTERNATOR G/H-PANEL

REVISION: J-I048-B
DATE: 11/15/11

PAGE 4 OF 10

DRAWING #: OH9846

GROUPG
r------------------------------------------------- i
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OPTION 5 - THREE PHASE SERIES WYE, H-PANEL OR G-PANEL CONTROL PANEL, DIRECT DRIVE, 12 LEAD

I

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LEGEND
AR
AS
AVR
CT_
EF
MLCB
NB

-

I
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AL1ERNATOR ROTOR
AL1ERNATOR STATOR
AUTOMATIC VOLTAGE REGULATOR
CURRENT TRANSFORMER
EXCI1ER FlELD
MAIN CIRCUIT BREAKER
NEUTRAL BLOCK

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G:J ~399B:----------..,

;
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±
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X1

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I---l-+-l- S1

a..

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---+-+---+4--l
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S3

--+-+----1
X1

~

S3

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"
Z

~[N3
w -N2----+--"
(f)

_

N1

~

~
~

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MLCB

000
E1

E2

E3

~

~~~-------~~~

S12

S12
~

NB

o

C

GENERATOR OUTPUT
CUSTOMER CONNECTION
E1 TO E2]
E2 TO E3 *480VAC
E1 TO E3

E1 TO E2]
E2 TO E3 *400VAC
E1 TO E3

E1-N OR E2-N OR E3-N = *277VAC
E1-N OR E2-N OR E3-N = *231VAC
*N01E: THE 8TH DIGIT OF THE MODEL NUMBER SPECIFlES OUTPUT VOLTAGE ON UNITS BEFORE 2010
THE 7TH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE ON UNITS 2010 TO PRESENT
"K" = 277/480VAC 60HZ
"R" = 231/400VAC 50HZ

S7

AS

S5
/
.S8
~
S6 S9

o

I
I
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i'AGE 5 OF 10
I
~-------------------------------------------------~
WIRING - DIAGRAM

ALTERNATOR GIH-PANEL

REVISION: J-I048-B
DATE: 11/15/11

PAGE 5 OF 10

DRAWING #: OH9846

,-------I
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GROUPG
----------------,

-------------- ----

OPTION 6 - THREE PARALLEL ZIG ZAG, H·PANEL OR G·PANEL CONTROL PANEL, DIRECT DRIVE, 12 LEAD

LEGEND
AR
AS
AVR
CL
EF
MLCB
NB

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-

ALTERN ATOR ROTOR
ALTERNATOR STATOR
AUTOMATIC VOLTAGE REGULATOR
CURRENT TRANSFORMER
- EXCITER FIELD
- MAIN CIRCUIT BREAKER
- NEUTRAL BLOCK

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P

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2
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F

1 --BLACK
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1
1

BRUSHLESS

---- - --- -- ---- ---2

I

6

6 [~398A-WHITE
15
~399A,----------------,

g< # 1398C-WHITE----------,
399C------------,
0-

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(J)
(J)

w

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DIRECT DRIVE

511

NB

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GENERATOR OUTPUT
CUSTOMER CONNECTION

I
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DO-{~~

<~S658S12

AS

~

El TO 00l'115VAC OR '120VAC
E3 TO OOJ
El TO E3] '200VAC OR '240VAC
'NOTE: THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE ON UNITS BEFORE 2010
THE 7TH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE ON UNITS 2010 TO PRESENT
"A" - 120!240VAC 60HZ
"N" a 115/200VAC 50HZ

_

PAGE 6 OF 10

---------------~

WIRING - DIAGRAM

ALTERNATOR G/H-PANEL

REVISION: J-I048-B
DATE: 11/15/11

PAGE 6 OF 10

DRAWING #: OH9846

GROUPG
,-------------------------------------------------,
I

OPTION 7 - THREE PHASE SERIES DELTA, H-PANEL OR G-PANEL CONTROL PANEL, DIRECT DRIVE, 12 LEAD

I
I
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LEGEND
AR
AS
AVR
CL
EF
MLCB
NB

-

I

ALTERNATOR ROTOR
ALTERNATOR STATOR
AUTOMATIC VOLTAGE REGULATOR
CURRENT TRANSFORMER
EXCITER FlELO
MAIN CIRCUIT BREAKER
NEUTRAL BLOCK

I

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15 ~398B-WHITE

r;l ~399B-------------,

~ 398C-WHITE:-------,
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±
399C:---------,

X1

0.

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N1 ----l'--l----+-+----l

N1

X1

N2 --1-+--1

1--+'--1-'--1--- N2

X1

CT2

N3

S3
S10

~
o

000
E1

E2

E3

~j - - - - - - - ~j

NB

~

~S8

S6
S9

AS

6

GENERATOR OUTPUT
CUSTOMER CONNECTION
E1 TO E2J
E2 TO E3 "2400VAC

E1 TO E2J
E2 TO E3 "200VAC

8TO~

8TO~

E1-N OR E2-N OR E3-N = "120VAC
E1-N OR E2-N OR E3-N = "100VAC
"NOTE: THE 8TH DIGIT OF THE MODEL NUMBER SPECIFlES OUTPUT VOLTAGE ON UNITS BEFORE 2010
THE 7TH DIGIT ON THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE ON UNITS 2010 TO PRESENT
"0" = 120/2400VAC 10/30 60HZ
"J" = 120/240VAC 60HZ
"p" = 100/200VAC 50HZ

II
I
I

I

I
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L ?AGE 7 OF 10

~

WIRING - DIAGRAM
REVISION: J-1048-B
DATE: 11115/11

ALTERNATOR G/H-PANEL
PAGE 7 OF 10

DRAWING #: OH9846

GROUPG

r-----------I
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OPTION 8 - THREE PHASE PARALLEL WYE, H-PANEL OR G-PANEL CONTROL PANEL, DIRECT DRIVE,12 LEAD

I

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LEGEND
AR
AS

- ALTERN ATOR ROTOR
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A~
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CT_ - CURRENT TRANSFORMER
EF
- EXCITER FlELD
MLCB - MAIN CIRCUIT BREAKER
NB
- NEUTRAL BLOCK

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Nl

GENERATOR OUTPUT
CUSTOMER CONNECTION

li -------!~
S11
S12

DIRECT DRIVE

S l l - -.....
S12 --.........;::....-_--

NB

El TO E2J
E2 TO E3 "208VAC
El TO E3
El-N OR E2-N OR E3-N = "120VAC
"NOTE: THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOlTAGE ON UNITS BEFORE 2010
THE 7TH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE ON UNITS 2010 TO PRESENT
"G"
120/208VAC 60HZ

=

I

IL

PAGE 8 OF 10
~

WIRING - DIAGRAM
REVISION: J-1048-8
DATE: 11/15/11

ALTERNATOR GIH-PANEL
PAGE 8 OF 10

DRAWING #: OH9846

----~~~

~----

GROUPG

r------------ ------------------- ----------------,
OPTION 9 - THREE PHASE SERIES DELTA, H-PANEL OR G-PANEL CONTROL PANEL, GEARBOX (REVERSE ROTATION), 12 LEAD

LEGENp
AR
AS
AVR
CL
EF
MLCB
NB

-

ALlERNATOR ROTOR
ALlERNATOR STATOR
AUTOMATIC VOLTAGE REGULATOR
CURRENT TRANSFORMER
EXCllER FIELD
MAIN CIRCUIT BREAKER
NEUTRAL BLOCK

I

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~ ~398A-WHllE--------------,
c1 ~399A----------------,

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~ 398C-WHllE-----_,
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a.

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I---+_+_-+-- Nl

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r"<:l--T"<:I---i'd-,

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El

E2

E3

GENERATOR OUTPUT
CUSTOMER CONNECTION

~
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S6
S10
S11
S12

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S10
S l l - -.....
S12 -----''''''-----

NB

AS

I
I
I
I
I
I
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El TO E2J
E2 TO E3 *208VAC
El TO E3
El-N OR E2-N OR E3-N = *120VAC
*NOlE: THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE ON UNITS BEFORE 2010
THE 7TH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE ON UNITS 2010 TO PRESENT
"G" = 120j208VAC 60HZ

_'AGE 9 OF 10

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~-------------------------------------------------~
WIRlNG - DIAGRAM
ALTERNATOR G/I~HANEL

REVISION: J-1048-8
DATE: 11/15/11

PAGE 9 OF 10

DRAWING #: OH9846

GROUPG

....,

1---

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PAGE LEFT BLANK INTENTIONALLY

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IL

PAGE 10 OF 10
~

WIRING - DIAGRAM
REVISION: J-1048-B
DATE: 11115/11

ALTERNATOR GIR-PANEL
PAGE IOOF 10

DRAWING #: OH9846

GROUPG
-----------------l

r-------------------------------I

Will:iQ.
AH1
ALT
AVR
BCC
BCH
CB
CO
COM
CT_
DB
ECM
ES1
EXC
F_
FLS_
GA_
GO
GFCI
GND
1FT

-

ALARM HORN
DC CHARGE ALTERNATOR
AUTO VOLTAGE REGULATOR
BATTERY CHARGER CONNECTOR
BATTERY CHARGER
CIRCUIT BREAKER OPE
CROSSOVER CONNECTOR
COMMUNICATION CONNECTOR
CURRENT TRANSFORMER
DIODE BRIDGE
ELECTRONIC CONTROL MODULE
EMERGENCY STOP SWITCH
EXCITER
FUSE
FUEL LEVEL SENDER
GOVERNOR ACTUATOR
GOVERNOR DRIVER
GROUND FAULT CIRCUIT INTERRUPT
GROUND BAR CONNECTION
INTERFACE TRANSFORMER

IP

-

L
LD
MLCB
MOD
MPU1
NB
OPS1
OTS_
R_
RB_
RB_A
SC
SM
SW1
SWC
T8_
WlLS_
WTS_

-

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I

NOTE: ALL WIRES 18 AWG
300V UL LISTED UNLESS
SHOWN OTHERWISE

INJECTOR PUMP
ENGINE CONTROL MODULE CONN.
LEAK DETECTOR
MAIN LINE CIRCUIT BREAKER
MODEM CONNECTOR
MAGNETIC PICKUP
NEUTRAL BLOCK
OIL PRESSURE SENDER
OIL TEMPERATURE SENDER
RESISTOR
RELAY BOARD
RELAY BOARD CONNECTOR
STARTER CONTACTOR
STARTER MOTOR
OFF/AUTO/MANUAL SWITCH
SWITCH CONNECTOR
TERMINAL BLOCK
COOLANT LEVEL SENDER
COOLANT TEMPERATURE SENDER

COMPONENTS LOCATED IN ALTERNATOR CONNECTION BOX
. - - - - - - - - W H I T E - - - - - - - - H f ' 7 > 1 1 - 398A
r----------------t-'-~>t_399A

r=

~~

~~

J2-12
J2-11

I

cn

CT2

AVR-3-- 6
CB-- 2

-----.:-T.

~-

IWHITE~ 398C - - J2-10

I ~399C--J2-9

i ~~

L-~T3

AVR-5-- 4
1

I

[

i

~ ~! ~~~~.i'O'"
I
I-- --

EXC

WHITE
2
398B - - J2-35
_ _ _ _ _ _1-'-1~>+- 399B - - J2-34

4
1

PERMANENT
MAGNET
EXCITER

+

-./-

AVR-1--

~

3
2

EXCITER
FIELD

TB2-7X

SEE DRAWING OH9846 FOR CT WIRING.

--I
I
I

COMPONENTS LOCATED IN HIGH VOLTAGE CUSTOMER CONNECTION MODULE
CONNECTIONS
FOR 10 UNIT

I

CONNECTIONS
FOR 30 UNIT

NOTE: ALL WIRES IN THIS
SECTION ARE 600V RATED

I
I
I

TO GENERATOR

------S1

r-r-

-

31

31

32

32

33

S3

..-- 00

00

2

------S2

3

S3

4

------00

1FT

J2-6--224

5

J2-29--225

6

r l r l ri

J2-17--226

7

MLCB

J2-7--227

8

L1

~

9

L2

L3

Q

-

J2-6--224

N

J2-29--225

0
0
0
0
0

J2-17--226

NB

J2-7--227

-,

,----

2

3
4

5

1FT

6

7

8
'---

9
~

l,Jl,Jl,J

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I
I

CUSTOMER
CONNECTIONS
AGE1~~

~

WIRING - DIAGRAM
D4.5L/D6.7L G17 12V

REV1SION: H-9136-D
DATE: 6/8111

PAGE 1 OF 6

DRAWING #: OH9862

GROUPG

r--------------------------------------------------------------l
COMPONENTS LOCATED IN HIGH VOLTAGE CUSTOMER CONNECTION MODULE

I

TB4

x
BCC-1

Y

L1

120/240 VAC
UTILITY SUPPLY
(BY CUSTOMER)

GND
N

L1

125A

OR

LOAD CENTER
L1
GND
L2

BCC-2-- N

VERIFY COMPONENT
RATINGS FOR PROPER
SUPPLY VOLTAGE
TO BE PROVIDED.

BCC-3-- GND -l.J..:i:J.-1l:'~

-

L1

o
NOTE:
FOR FIELD WIRING TO CUSTOMER CONNECTIONS
(TERMINAL STRIP)
MAXIMUM WIRE SIZE: #10 AWG
RECOMMENDED TIGHTENING TORQUE: 14 LB-IN

-GND--~I

RUN RELAY

,---I--{J.;:s'l

W

2

L2-------.....J

f - - 14

_ _ _ _O~T~O~

14~r~,00~O,,:\
00 8110,::«

RR-3

COM1--RR-1

@2

-'
w
<>::

@3

NC1--RR-4

z

@4

N02

::>

<>::

@5

OM2--RR-8

@6

NC2--RR-5

0

_TIGHTENIN~ ~ORQUE: _1~

LB-IN

BLACK

~~~~WHtjITEt=~(= D

I

~

GREEN

THERMOSLTAT

i :

RR-6

NOTE:
FOR FIELD WIRING TO CUSTOMER CONNECTIONS
:
(TERMINAL STRIPS AND RELAY BOARD)
MAXIMUM WIRE SIZE: #14 AWG
LCOMMENDED

I

I

0

TB4 OR
LOAD CENTER

i :
N01

@1

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I

I

i :
I
i :
I
I

I
I

N
SUPPLIED WITH
3- WIRE

-o GND

L-

JUNCTION BOX

I

1

FOR
CUSTOMER
CONNECTIONS
(BATTERY
WARMER AND
OIL HEATER)

TEF:MI~IATlcDIN

BOX
-- - -

I
II

I
I
I
I
I

GROUNDED
PW~
TYPICALLY
PLUG IS
REMOVED
BY THE
INSTALLER
AND WIRES
ARE

-

II

COMMON
- -- - -

- - --

OPTI~

- - - -PAGE 2 OF 8

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---------------------------------~
WIRING - DIAGRAM
D4.5L1D6.7L 017 12V

REVISION: H-9136-D

DATE: 6/8/11

PAGE 20F6

DRAWING #: OH9862

GROUPG
r-------------------------------------------- -----------------l
COMPONENTS LOCATED ON LOW VOLTAGE CUSTOMER CONNECTION PANEL

I

GRN-@ GROUND STUD

"

.[C~

S

NC

li--15A_2--0C5-3--0C6-4--15A-5--0C7-6--0C8--

TB2-1X
J2-23
J2-22
TB2-1X
J2-33
J2-21

<{

RB3A

NO

U1

t-

::>
0..

t-

::>
0

w

0::

<{

0..
U1

f'

NC

x

::>
<{

K310

NO

"['~
S

RB3

NC

<{

NO

st~NC
0«

NO

TB1

~(J)

z

0

F
u
w

X

0

0

o - - TB2-8X
0
183-- J2-4

0@1

W
t- [
b~
:::;;t-

(J)

Y

183 @2
@3@

z
z

["~~
uo..

0

390-- J2-13

@4

:::;;t-

U

is

0::

w

:::;;

I I
I I

~ RS485- @5

SHLD @6

a
t(J)

391

J2-1

SHLD

J2-24

@7@

::>

u

ffi

~-1 ~-

--.J 0..

_____

w

~1S'L

DI3-- J2-3

8
9

0
0

zW
W5:

11

DI4

0..

12

0

:::;;U1

at-

Eo«

0::

00

0

0

TB2

8

u [

Y

X

o

0

u..

@ 1
15A-- RB3A-1
15A-- RB3A-4
@ 2 N I - - - 1 5 A - - CO-7

~ z [

@ 3 N I - - - 1 4 - - CO-8



r5

@ 4
5D

0::

*

*

D

~

~

@ 6

~

@ 7 NI---

NOTE: ENSURE LINE OF DIODE
(CATHODE) IS CLOSEST TO
TB2-4X FOR CORRECT
POLARIZATION.
EXC-1

[
@8NI::--- 0

o

o

TB1-1X
CO-6

L ,'AGE 3 OF 6

NOTE:
FOR FIELD WIRING TO CUSTOMER CONNECTIONS
(TERMINAL STRIPS AND RELAY BOARD)
MAXIMUM WIRE SIZE: #14 AWG
RECOMMENDED TIGHnENING TORQUE: 12 LB-IN

I
JI

WIRING - DIAGRAM
D4.5L/D6.7L 017 12V

REVISION: H-9136-D

DATE: 6/8/11

PAGE 3 OF6

DRAWING #: OH9862

GROUPG

r----------

COMPONENTS LOCATED IN CONTROL PANEL
COM

MOD

0",
0

387
388
389

J2-14
J2-2
J2-25

ALT

49

TB3-8X

14

--------------------l

-809
812~
810
8_1_1]
Jl-14-811
J1-26 - 812 - - - - - -

0

49

AVR

1
2
3
4
5
6
7
8

1
1 -TB2-4X
194--+------Hl4--J2-31
6
6 -PME-3
4
4 ------- 4
PME-4
403
4 0 3 - J2-8
404
4 0 4 - J2-20

9

10
11
12
13
14

406-------406-J2-30
405
405-J2-19
162

PME-2

2

J1-23 - - - - 5 f ; A - - - - - - - - - - - - - - - - - - - - - J
J1-34
445------------------------f--+--+------44:i-

swc

J2-5~174

J2-28~175-+.~+-----,

r---:r

o
-

+

AH1

H

229

56

10
9

15A

2
I

'---

«


N
N

@8

:R

.~tlI

FLS1

------~

_

WTSl

WLSl

OPS1

----------------------------------~~~~~~
WIRING - DIAGRAM

D4.5L/D6.7L Gl7 12V

REVISION: H-9136-D
DATE: 6/8111

PAGE60F6

DRAWING #: OH9862

GROUPG
r-------------------------------I-----------I

------------------1

ALTERNATOR

STATOR

MAIN TERMINALS

:

~1L
~......---'-'-+--"---+---'~-------_>----T1

L1

L1

ALTERNATOR
MAIN TERMINALS

STATOR

I

CT1

T2

L3

K

CT2

I
I

L

00
N

co

U

....



>
<{

'"

t')

<{w

<{

>-

""c;::

co
ro

<{

ro

a

~

U;

'"

'"

N
U1

I

I

N


<{

227 -

L2

K

ro

co 0
'" ro

t')

t')

<{

>
<{

I

CT3

L3

L

'" '"

'"

t')

""c;::

224

1FT

225

~~

225 -

J2

L3

1FT

-

L

k I

co

U

--,

224

CT2

PME
OR
DPE

N

z

K

I ,+-_-+_+-_-1_+°_°_-+-_ _+-';-_-11--+-_-+_+---+--+_ 00 I
I
I

0
0

t')

t')

t')

13

I
I

00

L2

k I

L31

k I

PME
OR
DPE

L1

k I

k I

13

L

J2

[

226
227

AL TERNA TOR CONNECTIONS FOR 1¢ UNITS

AL TERNA TOR CONNECTIONS FOR 3¢ UNITS

N

--,

n

j

a...J
'"
,....

02
0

L

!2!

05

0..

r+-+--l-I
I

I

I
:01

I
I

-02
'--03
04

~
0

I

: Ir~ :
I~ ~

i~I

: OT51

I

>

N.C.

t:J
"'01
-0

0

N(I)[7j

W

Z

390
391

J2 [
J2 [

RS485+ ]
RS485SHLD

0
013

0013 ]
o COM

014
0

0014 ]
COM

NOTE 5 15A

z

LOU1

0

(/)0
n::o

n::
w

co:::E
.... :::E

d]
::::>0

"n::
i5~

°0
CL

0

:::E

U1

>n::::::>
w":::EZ
0>-...J
U1«
::::>>-

f2U1

::::>

0

013

0

FUSED DC
ENGINE
RUNNING

t; ]

----..-~-:----:--~~~-=-=.--::_g_
I-.GIN~D----_i_-l_-'---~..____o ~ND
o
Ll

>...Jo
"-«
0..>
::::>0
U1..,.

~~
_0
---'N

F-

::::>

~

oz

r')

SC

I
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I
I

I

UTILITY POWlERED_ _
OPTIONAL

I
--.J

I
I

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I
I
I
I
I
I
I
I
I
I
I
I
I
I

L-------+---O--~--O--+------'

NOTE:
FOR FIELD WIRING TO CUSTOMER CONNECTIONS
(TERMINAL STRIPS AND RELAY BOARDS)
MAXIMUM WIRE SIZE #14 AWG
RECOMMENDED TIGHTENING TORQUE 12 LB-IN

L________________ _

Y~~l~~J

SCHEMATIC - DIAGRAM
D4.5L1D6.7L G17 12V

REVISION: -A-

DATE: 7/12110

PAGE 20F4

DRAWING #: OH9863

GROUPG
r--------------------------------------------------------------l
I

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RB1
r-_pA-::=2 445 J1

AH1 229 1

-::::":"::"':"""T1~T--~-

0 NOTE 1

J

NOTEl 0 ~3f--_---'
j - - _pA--'.' 15B NOTE 6
ES1 15E '

ALARM
RB1 229

NOTE 5 15A ...:5+-_---'

AH1 BJ--+---15A NOTE 5

,--_pA-....::3 R15B J1/ES1

I
E-STOP

r - -pA-:;.e5 256 J1

NOTE 3 14 7

J1 R15B
ES1--+-RB1 15E---L-La

R15 J2
15 NOTE 4

NOTE 5 15A ...:9+-_---'
j----pA--C.'15 NOTE 4
SC 56

F

'0

11

NOTE 2 13

NOTE 5 l5A ""2+-_---'

'----pA--"5 56A J1

NOTE 2

F1"v154

15A NOTE 5

13~15B

NOTE 6

L1

COM

<'.:-5"-3-+-_---_-~~:]J2

UTILITY

N
[

"""'2-+-*-----\:1-387

GND

R2

,1'50::

505 J2

o

: ~~

GND

+ (POS) :

NOTE 1 0

__ ~~~~.U
CHARGE CURRENT

I

I
I

NOTE 1

, i3C;:

NOTE 2 13

4~~:B

ALT 49 --ANv-49A

, lOA
L1 (HOT) : CHARGER
, ONLY
N (NEUT) : O::w

I
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I
I

BCH

9 PIN
D-SUB

r-

I
I
I
I
I
I
I

I
I
I
I

803 J1

!

DB

I
I
I
I
I
I
I
I
I
I
I
I
CB
I
I
OPE---'~'----162
I
I
I
I
I
I
1f-1 FIELDI
I
2f-194 J2
3f-6 OPE
I
I
,
I
I
51-- 4 FIELO+
51-- 403 J2
I
I
71-- 404 J2
AVR
I
I
8
9
I
I
10f- 406 J2
I
I
llf- 405 J2
12
I
I
13
,
I
I
I
I
I
I
I
I
:' L - E - G - E N - D - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - , :
I

I
I
I
I
I
I
I

00
AH1
ALT
AVR
BAT
BCH
CB
COM
CT_

-

NEUTRAL
ALARM HORN
DC CHARGE ALTERNATOR
AUTO VOLTAGE REGULATOR
- BATTERY
BA TTERY CHARGER
- CIRCUIT BREAKER
- COMMUNICATION CONNECTOR
- CURRENT TRANSFORMER

DB
DPE
ES1

-

DIODE BRIDGE
EXCITER
EMERGENCY STOP SWITCH
FUSE
FUEL LEVEL SENDER
GA_ - GOVERNOR ACTUATOR
GD
GOVERNOR DRIVER
GFCI
GROUND FAULT CIRCUIT INTERRUPT
1FT - INTERFACE TRANSFORMER

IP

-

L

- ENGINE CONTROL MODULE CONN. SC

LD
MLCBMPU1
OPS1 OTS_
PME R_
-

INJECTION PUMP
LEAK DETECTOR
MAIN LINE CIRCUIT BREAKER
MAGNETIC PICKUP
OIL PRESSURE SENDER
OIL TEMPERATURE SENDER
PERMANENT MAGNET EXCITER
RESISTOR

RB_ - RELAY BOARD
- STARTER CONTACTOR
SM
- STARTER MOTOR
SW1 - OFF/AUTO/MANUAL Sv.1TCH
\\1LS_ - COOLANT LEVEL SENSOR
WTS_ - COOLANT TEMPERATLRE SENDER

I

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L . 'AGE 3 OF 4

SCHEMATIC - DIAGRAM
REVISION: -A-

DATE: 7/12/10

D4.5L1D6.7L GI7 12V
PAGE 3 OF4

DRAWINO #: OH9863

GROUPG

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---------l
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AVR CONNECTOR
PIN
1
2
3
4
5
6
7
10
11
13

WIRE
1
194
6
4
4
403
404
406
405
162

TO
~ELD

J2-31
DPE
Rl FIELD
Rl FIELD

GD CONNECTOR
PIN
1
4

8
9
10
12

WIRE
0
14
771
770
0
769

ENGINE CONTROL MODULE CONNECTIONS
J1
PIN
3
6
7
8
9
10
11
12
14
15
16
17
18
19
20
23
24
25
26
29
30
31
32
33
34
35

J2
WIRE
810
575R
575V
523R
523V
R15B
256

o

811
68V
803
766R
766V
69R
69V
56A

o

79
812
573R
573V
68R
809
769
445
158

TO
MOD-2
FLS-2
FLS-l
OTS-2
OTS-l
RB1A-3 E
RB1A-5
GND
MOD-3
WTS-l
BCH
GA-2
GA-l
OPSI-3
OPSI-2
RB1A-6
MPUI-2
MPUI-3
MOD-4
WLS-2
WLS-l
WTS-2
MOD-l
GD-12
RB1A-2
F2

PIN

2
3
4

5
6
7

8
9
10
11
12
13
14
15
16
17
19
20
21

TO
GND
R81-7
GA1-l
GAI-4
GND
JI-33

FUNCTION
NOTE 1
NOTE
THRO
THRO
NOTE 1
THROTTLE PWM

LO
HI

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I

22
23
24
25

26
27
28
29
30
31

33

NOTES:

34
35

1) WIRE# 0 IS CHASSIS GROUND (BATTERY-)
UNLESS NOTED OTHERWISE.

I
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I
I

2) WlRE# 13 IS UNFUSED +12VDC (BATTERY+).
3) WlRE# 14 IS FUSED +12VDC WHEN
GENERATOR IS CRANKING OR RUNNING.
4) WlRE# 15 IS FUSED + 12VDC WHEN
E-STOP IS !:lQI ACllVATED.
5) WlRE# 15A IS FUSED + 12VDC FOR
GENERAL USE.
6) WlRE# 15B IS FUSED +12VDC FOR THE
ENGINE CONTROL MODULE.

I

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I

L

~~~2~~

SCHEMATIC - DIAGRAM
REVISION: -ADATE: 7/12/10

D4.5L/D6.7L 017 12V
PAOE40F4

DRAWING #: OH9863

GROUP H

lIN

NOTE:
DECAL TO BE PLACED IN
VISIBLE AREA WHEN
FILUNG TANK.

NOTE:
WHEN USING EXTERNAL FUEL SOURCE
DECAL MUST BE APPLIED IN VISIBLE
AREA OF FUEL FILL.

OPEN SET APPLICATION

BASE TANK APPLICATION
NOTE:
DECAL TO BE PLACED IN
VISIBLE AREA WHEN
FILLING TANK.

NOTE:
DECAL TO BE PLACED
ON DOOR USED TO FILL
FUEL.

e

CLOSED SET APPLICATION
BASE TANK W / EXTENSION
APPLICATION

EXPLODED VIEW:
REVISION: H-6666-B
DATE: 05111110

PAGE 1 OF 2

LOW SULFUR FUEL
DRAWING #: OG8716

~--------

--------------

EXPLODED VIEW: LOW SULFUR FUEL
DRAWING #: OG8716
APPLICABLE TO:

~ - -

GROUP H

THIS PAGE IS LEFT INTENTIONALLY BLANK

REVISION: H-6666-B
DATE: 05/11/10

PAGE20F2

GROUPH

1

1
/

/
/

~//
2

Revision: H-6171-B
Date: 3/5/10

Page 1 of 2

ASSEMBY VIEW FOR
SHROUD OH78890ST03 ONLY

Exploded View: KIT, 390 ALT SHROUD
Drawing No.:OH5179

EXPLODED VIEW: EV 390 ALT SHROUD KIT

GROUPH

DRAWING #: OH5179
APPLICABLE TO:

ITEM

PART#

QTY.

(1) 1

OH47970ST03
OH4797AST03
OH4797BST03
OH78890ST03
OC2454
OE1534A

2
2
2
2
8/10
4

(2)2
3

DESCRIPTION
SHROUD 390 ALT X 76MM
SHROUD 390 ALT X 50MM
SHROUD 390 ALT X 100MM
SHROUD 390 ALT X 150MM
SCREW HWHT M6·1 X 16 NWAZlJS
PLUG PLASTIC 1.50"

(1)NOTE:
OH47970ST031NCLUDED IN KIT#OH5178
OH4797AST03 INCLUDED IN KIT #OH5178A
OH4797BST03 INCLUDED IN KIT #OH5178B
OH78890ST031NCLUDED IN KIT#OH5178C
(2) QTY DETERMINED BY SHROUD MOUNTING REQUIREMENTS.

REVISION H-6I71-B
DATE 3/5/10

Page 2 of 2

GROUPH

8

~

~/
7

10

Revision:H-6657-C
Date: 5/12/10

Page 1of 2

Exploded View: BLOCK HEATER D6.7L G17 100/130KW
Drawing No.: OH5980

EXPLODED VIEW: BLK HTR D6.7L GI7 IOO/I30KW

GROUPH

DRAWING #: OH5980
APPLICABLE TO:

ITEM

PART#

QTY.

1
2
3
4
5
6
7
8
9
10
11

077043E
022473
022097
047411
077043E
OA4707E
034339
050967
050967
OG0015
084918H
084918L
084427
042568
049813
055934P
051768
051769
049808

1
6
4

12
13
14
15
16
17
18

REVISION H-6657-C
DATE 5/\2/\0

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

DESCRIPTION
CONDUIT FLEX 1.0" 10 (23"LG)
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
SCREW HHC M6-1.0 X 16 C8.8
CONDUIT FLEX 1.0" 10 (46" LG)
ADAPTER 3/8NPT X M18-1.5
BARBED EL 90 3/8NPT X 5/8
HOSE COOL 5/8 10 20R3 (46" LG)
HOSE COOL 5/8 10 20R3 (23" LG)
CLAMP HOSE 7/8" 00 DOUBLE WIRE
HEATER BLOCK 1500W 240V
HEATER BLOCK 1500W 120V
BRACKET HEATER WIWELONUTS
SCREW HHC M6-1.0 X 20 C8.8
NUT HEX M6 X 1.0 G8 YEL CHR
CLAMP STLNNL 1.62 X .486
SCREW HHC M12-1.75 X 25 C8.8
WASHER LOCK M12
WASHER FLAT M12

PAGE 2 OF 2

GROUPH

REMOVE AND
DISCARD EXISTING
FlntNGS

~

Revision: -ADate: 2/12/10

Page 1 of 2

Exploded View: ENGINE KIT 6.7 LO G17
Drawing No.: OH6009B

EXPLODED VIEW: 4.5L 60KW G17 ENGINE KIT

GROUPH

DRAWING #: OH6009B
APPLICABLE TO:
ITEM

PART#

QTY.

1
2
3
4
S
6

OH6298
OH6299
OH6297
OH629S
OH6296
OH6349

3
1
1
1
1
1

REVISION -ADATE 1/20/10

DESCRIPTION
WASHER
THREADED UNION
SWIVEL COUPLING
BANJO BOLT M12-1.S X 2S
ELBOW COUPLING
PIPE SOCKET

PAGE20F2

GROUPH
8

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11
6

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1
7

2

4
3

Revision: -ADate: 3/21/10

Page 1 of 2

Exploded View: HEATER PREP KIT
Drawing No.: OH8028

EXPLODED VIEW: EV HEATER PREP KIT

GROUPH

DRAWING #: OH8028
APPLICABLE TO:

ITEM

PART#

QTY.

1
2
(2)3
4
(1)5
6
7
8
9
10
11
12

OH55060ST03
OH55070ST03
OG5704B
OG3546
OG5704
022206
OE3257
OE6187
027959
052010
036261
OH8147

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

DESCRIPTION
JUNCTION BOX
JUNCTION BOX COVER
DECAL OIL WARMER CONNECTION
DECAL WRN BATI CHRG 12/24V
DECAL BATIWARMER CONNECTION
FITIING CONDUIT STR 3/8
SCREW HWHTF M6-1.0 X 16
CORD,POWER SUPPLY 16 AWG X 9'
WIRE NUT #30-451 YEL
ASSY THERMOSTAT AND LEAD
RIVET POP .125 X .275 SS
DECAL HEATER PREP KIT

(1)PARTS INCLUDED IN OPTIONAL BATIERY WARMER KIT.
(2)PARTS INCLUDED IN OPTIONAL OIL WARMER

REVISION -ADATE 3/2/10

Page 2 of 2

GROUPH

JUNCTION BOX

ALTERNATE DUAL BATTERY CONFIGURATION

Revision: ·A·
Date: 3/5/10

Page 1 of 2

Exploded View: KITS 36" SATIERY WARMER
Drawing No.: OH8060

EXPLODED VIEW:

GROUPH

DRAWING #:OH8060
APPLICABLE TO:

ITEM

PART#

QTY.

1
2
3

057148A
022206
OG5704

2

1
1

DESCRIPTION
BATIERY WARMER 36" 80W 120V
FITIING CONDUIT STR 3/8
DECAL BATIWARMER CONNECTION

Battery Heater Connection
1.
2.
3.
4.
5.

Disconnect battery cables to prevent accidental start-up. Disconnect the negative battery cable first from the battery post indicated by (-) or
NEG.
Make sure power is off from the appropriate power source.
To connect the wires, hold the bare metal leads together and place a wire nut over them, then twist clockwise until tight. For all these
connections, use the wires nuts provided.
Connect the ground wire from 120V power source to the ground wire from battery heater.
Using wire nuts provided connect the white wire and black wire from the battery heater as follows:
•
The white (common) power wire from 120V power source to 1st wire from the battery heater.
•
The wire from load side of themnostat to 2nd wire from the battery heater.

CAUTION: Be sure no bare wire or wire strands are visible after making connections.
6.
7.
8.

Push all wires and wire nuts into junction box.
Assemble junction box cover to junction box.
Reconnect battery cables to battery posts. Connect the positive cable first to the battery post indicated by (+) or POS.

REVISION-ADATE 3/4/10
PAGE 2 OF 2

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Revision: H-8638-B
Date: 4/5/11

Page 1 of 2

Exploded View: EV, NEUTRAL BLOCK 0-250OA
Drawing No. : OJ1047

EXPLODED VIEW: EV, NEUTRAL BLOCK 0-250A

GROUPH

DRAWING #: OJI047
APPLICABLE TO:

ITEM

PART#

1
2
3
4

057073
OH9690
OF8451
OC2266
022131
022237
022241
067989
043107

5
6
7
8
9

1
2
3
4
5

6
7
8
9
10

5
6
7
8

NEUTRAL BLOCK (250A)
2

1
1
4
2
2
2
1

1

DESCRIPTION
JUNCTION BLOCK 318-16
NEUTRAL, BRACKET (60-100A)
LUG SLDLSS 300 MCM-6 AUCU
SCREW PHTT M5-0.8 X 16 ZP
WASHER FLAT 318-M10 ZINC
WASHER LOCK 318
NUT HEX 318-16 STEEL
NUT HEX FL WHIZ M8-1.25
SCREW HHC M8-1.25 X 25 C8.8

NEUTRAL BLOCK (300A - 600A)
057073
2
JUNCTION BLOCK 318-16
OH9689A
1
BUS BAR, NTRL BLK 520 0-600A
OA7822
2
LUG SLDLSS 6001250-110X114-28
OC2266
4
SCREW PHTT M5-0.8 X 16 ZP
022511
2
SCREW HHC 318-16 X 1-114 G5
022237
4
WASHER LOCK 318
022241
4
NUT HEX 318-16 STEEL
022131
2
WASHER FLAT 318-M10 ZINC
045335
4
SCREW HHC 114-28 X 314 G5
022097
4
WASHER LOCK M6-114
NEUTRAL BLOCK (700A -1200A)
057073
2
JUNCTION BLOCK 318-16
OH9689
1
BUS BAR, NTRL BLK 520 600-1600
OA7822
4
LUG SLDLSS 6001250-110X114-28
OC2266
4
SCREW PHTT M5-0.8 X 16 ZP
022511
5
SCREW HHC 318-16 X 1-114 G5
022237
7
WASHER LOCK 318
022241
7
NUT HEX 318-16 STEEL
022131
2
WASHER FLAT 3/8-M10 ZINC
045335
8
SCREW HHC 114-28 X 3/4 G5
022097
8
WASHER LOCK M6-114

1
2
3
4
5
6
7
8
9
10
1
2
3
4

QTY.

NEUTRAL BLOCK (1400A - 2500A)
OC6937M
2
INSULATOR, STANDOFF 600V3/8-16
OJ4583
2
BUS BAR, 114"X6"X10"
031578
3
SCREW HHC 318-16 X 1-11288
10
WASHER FLAT 3/8-M10 ZINC
022131
022237
7
WASHER LOCK 3/8
022241
3
NUT HEX 318-16 STEEL
023152
2
SCREW HHC 318-16 X 314 G5
029745
2
SCREW HHC 318-16 X 1 G5

REVISION H-8638-B
DATE 415/11

PAGE20F 2

Notes

6 I,. 1,.89 1M '318'113
01,.8 X08 'O'd " 'l:::lO AHdl:::lnV\l I,. 1,.(3

":JNI ISWEU.SAS t:l3MOd ,,:J'dt:l3N3EJ



---

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