13370 1 Generac Qt06024Ansx Owners Manual Power Systems, Inc. User

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User Manual: Pump 13370 1 Generac Qt06024Ansx Owners Manual

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2.4L

60kW Models

EPA Certified

Owner's Manual

Stationary Emergency Generator

Cover195 Rev. A 04/10 Part No. 0H7320

n NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT

APPLICATIONS.

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST

FUMES! OUTDOOR INSTALLATION ONLY!

SECTION PAGE

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

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

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

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

SAFETY RULES ............................................................ 1-2

GENERAL INFORMATION ............................................ 2-1

Identification Record ........................................................................2-1

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

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

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

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

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

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

Engine Protective Devices ................................................................4-1

High Coolant Temperature Sender ................................................4-1

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

Low Oil Pressure Switch ..............................................................4-1

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

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

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

DC Fuses .....................................................................................4-1

FUEL SYSTEM .............................................................. 5-1

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

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

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

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

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

Stationary Emergency Generator ..................................................6-1

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

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

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

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

Weather and Maintenance Kits .....................................................6-2

Reconfiguring the Fuel System .........................................................6-2

Fuel System .................................................................................6-2

Control Panel ...............................................................................6-2

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

Alternator AC Lead Connections .......................................................7-1

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

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

3-phase Alternators ("Y" Configuration) ........................................7-1

3-phase Alternators ("Delta" Configuration)...................................7-2

CONTROL PANEL ......................................................... 8-1

Control Panel Interface .....................................................................8-1

Using the Auto/Off/Manual Switch ................................................8-1

Activate the Generator ......................................................................8-1

Display Interface Menus ...................................................................8-1

Activation Chart ...........................................................................8-2

Setting the Exercise Timer ................................................................8-3

Low Speed Exercise .....................................................................8-3

User Adjustable Settings ..................................................................8-3

Fuel Conversion ...............................................................................8-3

Operation ......................................................................................... 8-3

Automatic Transfer Operation .......................................................8-3

Sequence of Automatic Operation ................................................8-4

Crank Cycles and Overcrank Shutdown ........................................8-4

Auto Start ........................................................................................8-4

Manual Start ....................................................................................8-4

Alarm and Warning Messages ..........................................................8-4

Low Oil Pressure Shutdown Alarm ...............................................8-4

High Coolant Temperature Shutdown Alarm ..................................8-4

Overcrank Shutdown Alarm ..........................................................8-4

Overspeed Shutdown Alarm .........................................................8-4

RPM Sensor Failure Shutdown Alarm ...........................................8-4

Under-frequency Shutdown Alarm ................................................8-5

Low Battery Alarm .......................................................................8-5

Low Battery Warning....................................................................8-5

Low Coolant Level Alarm .............................................................8-5

Missing Cam Pulse Alarm ............................................................8-5

Missing Crank Pulse Alarm ..........................................................8-5

Low Fuel Pressure Warning ..........................................................8-5

Governor Sensor Fault Alarm ........................................................8-5

Wiring Error Alarm .......................................................................8-5

Undervoltage Alarm .....................................................................8-5

Overvoltage Alarm .......................................................................8-6

Internal Failure Shutdown Alarm ...................................................8-6

Canbus Alarm ..............................................................................8-6

Ignition Alarm ..............................................................................8-6

Maintenance Warning ...................................................................8-6

Alarm Cancel ...............................................................................8-6

Common Alarm Relay ......................................................................8-6

Maintenance Alerts ..........................................................................8-6

Menu System ...................................................................................8-7

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

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

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

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

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

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

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

General Maintenance ......................................................................10-1

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

Changing Engine Oil ...................................................................10-1

Cooling Intake/Outlet ..................................................................10-1

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

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

Coolant Change .........................................................................10-2

Overload Protection for Engine DC Electrical System ..................10-2

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

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

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

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

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

Changing the Engine Air Filter .....................................................10-2

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

Battery Maintenance ..................................................................10-3

Battery Replacement ..................................................................10-3

Battery Fluid ...............................................................................10-3

Cleaning the Stationary Emergency Generator ............................10-3

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

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

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

EMISSIONS WARRANTY ............................................ 13-1

NOTES

EXPLODED VIEWS & PARTS LISTS

WIRING DIAGRAMS & SCHEMATICS

Content048 Rev. A 05/10

Table of Contents

INTRODUCTION

Thank you for purchasing this model of the stationary emergency

generator product line.

Every effort was expended to make sure that the information and

instructions in this manual were both accurate and current at the

time the manual was written. However, the manufacturer reserves

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

any time without prior notice.

READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, contact the nearest

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 incor-

rectly 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.

Indicates a hazardous situation or action which, if not

avoided, could result in death or serious injury.

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.

These safety warnings cannot eliminate the hazards that they

indicate. Common sense and strict compliance with the special

instructions while performing the service are essential to prevent-

ing accidents.

Four commonly used safety symbols accompany the DANGER,

WARNING and CAUTION blocks. The type of information each

indicates is as follows:

n This symbol points out important safety information that,

if not followed, could endanger personal safety and/or

property of others.



This symbol points out potential explosion hazard.

This symbol points out potential fire hazard.

This symbol points out potential electrical shock hazard.

The operator is responsible for proper and safe use of the equip-

ment. The manufacturer strongly recommends that the operator

read this Owner's Manual and thoroughly understand all instruc-

tions before using this equipment. The manufacturer also strongly

recommends instructing other users to properly start and operate

the unit. This prepares them if they need to operate the equipment

in an emergency.

For safety reasons, the manufacturer recommends that this

equipment be installed, serviced and repaired by a Service

Dealer or other competent, qualified electrician or installation

technician who is familiar with applicable codes, standards and

regulations. The operator also must comply with all such codes,

standards and regulations.

OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety checks, to

make sure that all maintenance for safe operation is performed

promptly, and to have the equipment checked periodically by a

Service Dealer. Normal maintenance service and replacement of

parts are the responsibility of the owner/operator and, as such,

are not considered defects in materials or workmanship within the

terms of the warranty. Individual operating habits and usage con-

tribute to the need for maintenance service.

Proper maintenance and care of the generator ensure a minimum

number of problems and keep operating expenses at a minimum.

See a Service Dealer for service aids and accessories.

Operating instructions presented in this manual assume that the

generator electric system has been installed by a Service Dealer or

other competent, qualified contractor. Installation of this equipment

is not a “do-it-yourself” project.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs, simply contact

a Service Dealer for assistance. Service technicians are factory-

trained and are capable of handling all service needs.

When contacting a dealer about parts and service, always supply

the complete Model Number, Serial Number and Type Code (where

applicable) from the DATA LABEL that is affixed to the unit.

1-1

Safety004 Rev. F 05/10

Safety Instructions

n

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.

SAFETY RULES

Study these SAFETY RULES carefully before installing, operating

or servicing this equipment. Become familiar with this Owner’s

Manual and with the unit. The generator can operate safely, effi-

ciently and reliably only if it is properly installed, operated and

maintained. Many accidents are caused by failing to follow simple

and fundamental rules or precautions.

The manufacturer cannot anticipate every possible circumstance

that might involve a hazard. The warnings in this manual, and on

tags and decals affixed to the unit are, therefore, not all inclusive.

If a procedure, work method or operating technique is used that

the manufacturer does not specifically recommend, ensure that it

is safe for others. Also make sure the procedure, work method or

operating technique utilized does not render the generator unsafe.

n

Despite the safe design of this generator,

operating this equipment imprudently, neglect-

ing its maintenance or being careless can cause

possible injury or death. Permit only respon-

sible and capable persons to install, operate or

maintain this equipment.



Potentially lethal voltages are generated by

these machines. Ensure all steps are taken to

render the machine safe before attempting to

work on the generator.

n

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 a Service

Dealer or other competent, qualified electrician or installation

technician who is familiar with applicable codes, standards

and regulations. The operator also must comply with all such

codes, standards and regulations.

Installation, operation, servicing and repair of this (and related) •

equipment must always comply with applicable codes, stan-

dards, laws and regulations. Adhere strictly to local, state and

national electrical and building codes. Comply with regulations

the Occupational Safety and Health Administration (OSHA) has

established. Also, ensure that the generator is installed, operat-

ed and serviced in accordance with the manufacturer’s instruc-

tions and recommendations. Following installation, do nothing

that might render the unit unsafe or in noncompliance with the

aforementioned codes, standards, laws and regulations.

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. This should

be considered prior to installing the generator. The unit should

be positioned to direct exhaust gasses safely away from any

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

exhaust stacks that ship loose with the unit must be installed

properly per the manufacturer's instruction, and in strict compli-

ance with applicable codes and standards.

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

and other moving or hot parts. Never remove any drive belt or

fan guard while the unit is operating.

Adequate, unobstructed flow of cooling and ventilating air is •

critical in any room or building housing the generator to prevent

buildup of explosive gases and to ensure correct generator

operation. Do not alter the installation or permit even partial

blockage of ventilation provisions, as this can seriously affect

safe operation of the generator.

Keep the area around the generator clean and uncluttered. •

Remove any materials that could become hazardous.

When working on this equipment, remain alert at all times. •

Never work on the equipment when physically or mentally

fatigued.

Inspect the generator regularly, and promptly repair or replace •

all worn, damaged or defective parts using only factory-

approved parts.

Before performing any maintenance on the generator, discon-•

nect its battery cables to prevent accidental start-up. Disconnect

the cable from the battery post indicated by a NEGATIVE, NEG

or (–) first. Reconnect that cable last.

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

on the unit can stress and break parts, and may result in dan-

gerous operating conditions from leaking exhaust gases, fuel

leakage, oil leakage, etc.

ELECTRICAL HAZARDS

All stationary emergency generators covered by this manual •

produce dangerous electrical voltages and can cause fatal

electrical shock. Utility power delivers extremely high and dan-

gerous voltages to the transfer switch as well as the generator.

Avoid contact with bare wires, terminals, connections, etc.,

on the generator as well as the transfer switch, if applicable.

Ensure all appropriate covers, guards and barriers are in place

before operating the generator. If work must be done around

an operating unit, stand on an insulated, dry surface to reduce

shock hazard.

Do not handle any kind of electrical device while stand-•

ing in water, while barefoot, or while hands or feet are wet.

DANGEROUS ELECTRICAL SHOCK MAY RESULT.

1-2

Safety004 Rev. F 05/10

Safety Instructions

If personnel must stand on metal or concrete while installing, •

operating, servicing, adjusting or repairing this equipment,

place insulative mats over a dry wooden platform. Work on the

equipment only while standing on such insulative mats.

The National Electrical Code (NEC) requires the frame and •

external electrically conductive parts of the generator to be con-

nected to an approved earth ground. This grounding will help

prevent dangerous electrical shock that might be caused by a

ground fault condition in the generator or by static electricity.

Never disconnect the ground wire.

Wire gauge sizes of electrical wiring, cables and cord sets must •

be adequate to handle the maximum electrical current (ampac-

ity) to which they will be subjected.

Before installing or servicing this (and related) equipment, make •

sure that all power voltage supplies are positively turned off at

their source. Failure to do so will result in hazardous and pos-

sibly fatal electrical shock.

Connecting this unit to an electrical system normally supplied •

by an electric utility shall be by means of a transfer switch so as

to isolate the generator electric system from the electric utility

distribution system when the generator is operating. Failure to

isolate the two electric system power sources from each other

by such means will result in damage to the generator and may

also result in injury or death to utility power workers due to

backfeed of electrical energy.

Stationary emergency generators installed with an automatic •

transfer switch will crank and start automatically when normal

(utility) source voltage is removed or is below an acceptable

preset level. To prevent such automatic start-up and possible

injury to personnel, disable the generator’s automatic start cir-

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

Then, place a “Do Not Operate” tag on the generator control

panel and on the transfer switch.

In case of accident caused by electric shock, immediately •

shut down the source of electrical power. If this is not pos-

sible, attempt to free the victim from the live conductor. AVOID

DIRECT CONTACT WITH THE VICTIM. Use a nonconducting

implement, such as a dry rope or board, to free the victim from

the live conductor. If the victim is unconscious, apply first aid

and get immediate medical help.

Never wear jewelry when working on this equipment. Jewelry •

can conduct electricity resulting in electric shock, or may get

caught in moving components causing injury.

FIRE HAZARDS

Keep a fire extinguisher near the generator at all times. Do NOT •

use any carbon tetra-chloride type extinguisher. Its fumes are

toxic, and the liquid can deteriorate wiring insulation. Keep the

extinguisher properly charged and be familiar with its use. If

there are any questions pertaining to fire extinguishers, consult

the local fire department.

EXPLOSION HAZARDS

Properly ventilate any room or building housing the generator to •

prevent build-up of explosive gas.

Do not smoke around the generator. Wipe up any fuel or oil •

spills immediately. Ensure that no combustible materials are left

in the generator compartment, or on or near the generator, as

FIRE or EXPLOSION may result. Keep the area surrounding the

generator clean and free from debris.

These generators may operate using one of several types •

of fuels. All fuel types are potentially FLAMMABLE and/or

EXPLOSIVE and should be handled with care. Comply with all

laws regulating the storage and handling of fuels. Inspect the

unit’s fuel system frequently and correct any leaks immediately.

Fuel supply lines must be properly installed, purged and leak

tested according to applicable fuel-gas codes before placing

this equipment into service.

Diesel fuels are highly FLAMMABLE. Gaseous fluids such •

as natural gas and liquid propane (LP) gas are extremely

EXPLOSIVE. Natural gas is lighter than air, and LP gas is heavier

than air; install leak detectors accordingly.

1-3

Safety004 Rev. F 05/10

Safety Instructions

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.

IDENTIFICATION RECORD

DATA LABEL

Every generator set has a DATA LABEL that contains important

information pertinent to the generator. The data label, which can be

found attached to the generator’s lower connection box, lists the

unit’s serial number and its rated voltage, amps, wattage capacity,

phase, frequency, rpm, power factor, production date, etc.

NOTE:

For actual information related to this particular model, please

refer to the Manual Drawing Listing located at the end of this

manual, or to the data label affixed to the unit.

Stationary Emergency Generator Model and Serial

Number

This number is the key to numerous engineering and manufactur-

ing details pertaining to your unit. Always supply this number

when requesting service, ordering parts or seeking information.

2-1

Identy005 Rev. D 05/10

General Information

Data Label

EQUIPMENT DESCRIPTION

This equipment is a revolving field, alternating current Stationary

Emergency Generator. It is powered by a gaseous fueled engine

operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for

2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear

units. See the Specifications section for exact numbers. The unit

comes complete with a sound attenuated enclosure, internally

mounted muffler, control console, mainline circuit breaker, bat-

tery charger, and protective alarms as explained in the following

paragraph.

All AC connections, including the power leads from the alterna-

tor, 120 volt battery charger input and control connections to the

transfer switch are available in the main connection box.

The Stationary Emergency Generator incorporates the following

alternator features:

Rotor and Stator insulation class is rated as defined by NEMA •

MG1-32.6, NEMA MG1-1.66. The generator is self ventilated

and drip-proof constructed. Refer to the Specifications section

or the data label for the class ratings.

The voltage waveform deviation, total harmonic content of the •

AC waveform and telephone influence factor have been evalu-

ated and are acceptable according to NEMA MG1-32.

ENGINE OIL RECOMMENDATIONS

The unit has been filled with 5W-20 engine oil at the factory. Use

a high-quality detergent oil classified “For Service SJ or SH.”

Detergent oils keep the engine cleaner and reduce carbon deposits.

When changing the engine oil, be sure to use 5W-30 engine oil.

n

Any attempt to crank or start the engine before

it has been properly serviced with the recom-

mended oil may result in an engine failure.

NOTE:

If not already equipped, it is strongly recommended to use the

optional Cold Weather Start Kit for temperatures below 32° F.

The part number for the Cold Weather Start Kit can be found

in the Specifications section or by contacting an authorized

dealer. The oil grade for temperatures below 32° F is 5W-30

synthetic oil.

COOLANT RECOMMENDATIONS

Use a mixture of half low silicate ethylene glycol base anti-freeze

and deionized water. Cooling system capacity is listed in the

specifications. Use only deionized water and only low silicate

anti-freeze. If desired, add a high quality rust inhibitor to the rec-

ommended coolant mixture. When adding coolant, always add the

recommended 50-50 mixture.

n

Do not use any chromate base rust inhibitor

with ethylene glycol base anti-freeze or chro-

mium hydroxide (“green slime”) forms and will

cause overheating. Engines that have been

operated with a chromate base rust inhibitor

must be chemically cleaned before adding eth-

ylene glycol base anti-freeze. Using any high

silicate anti-freeze boosters or additives will

also cause overheating. The manufacturer also

recommends that any soluble oil inhibitor is

NOT used for this equipment.

n

Do not remove the radiator pressure cap while

the engine is hot or serious burns from boiling

liquid or steam could result.

n

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.

3-1

Equip001 Rev. G 05/10

Equipment Description

ENGINE PROTECTIVE DEVICES

The Stationary Emergency Generator may be required to operate

for long periods of time without an operator on hand to monitor

such engine conditions as coolant temperature, oil pressure or

rpm. For that reason, the engine has several devices designed to

protect it against potentially damaging conditions by automatically

shutting down the unit when the oil pressure is too low, the coolant

temperature is too high, the coolant level is too low, or the engine

is running too fast.

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 infor-

mation.

HIGH COOLANT TEMPERATURE SENDER

An analog coolant temperture sender, located in the engine's

cooling system will cause an engine shutdown if the temperature

should exceed approximately 125° C (257° F). The generator will

automatically restart once the temperature has returned to a safe

operating level.

LOW COOLANT LEVEL SENSOR

To prevent overheating, the engine has a low coolant level sensor.

If the level of engine coolant drops below the level of the low cool-

ant level sensor, the engine automatically shuts down.

LOW OIL PRESSURE SWITCH

This switch has normally closed contacts that are held open by

engine oil pressure during cranking and operating. Should oil pres-

sure drop below the 8 psi range, switch contacts close, and the

engine shuts down. The unit should not be restarted until oil is

added, and the AUTO/OFF/MANUAL switch must be turned to OFF

and then back to AUTO.

OVERCRANK SHUTDOWN

After a prespecified duration of cranking, this function ends the

cranking if the engine has failed to start. The overcrank message

will turn ON. Turn OFF the AUTO/OFF/MANUAL switch, then turn

switch back to AUTO to reset the generator control board.

NOTE:

If the fault is not corrected, the overcrank feature will continue

to activate.

Approximate Crank Cycle Times

15 seconds ON•

7 seconds OFF•

7 seconds ON•

7 seconds OFF•

Repeat for 45 seconds•

Approximately 90 seconds total.•

OVERSPEED SHUTDOWN

A speed circuit controls engine cranking, start-up, operation and

shutdown. Engine speed signals are delivered to the circuit board

whenever the unit is running. Should the engine overspeed above

a safe, preset value, the circuit board initiates an automatic engine

shutdown. Contact the nearest Authorized Dealer if this failure

occurs.

RPM SENSOR LOSS SHUTDOWN

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

will occur.

DC FUSES

A fuse (7.5 amp) is located on the control panel. It protects the

panel components from damaging overload. Always remove this

fuse before commencing work on the generator. The unit will not

start or crank if the fuse is blown.

A fuse (25 amp) is located in the engine wire harness adjacent

to the DC alternator. It is used to prevent circuit failure due to DC

alternator falure. It will also protect the system in the event of a

wiring short-dircuit. If this fuse is blown, the generator will not

operate. Replace these fuses with the same size, type, and rating.

4-1

EngProt003 Rev. B 05/10

Engine Protective Devices

FUEL SYSTEM

FUEL REQUIREMENTS

The Stationary Emergency Generator may be equipped with one of

the following fuel systems:

• Natural gas fuel system

• Propane vapor (LPV) fuel system

Recommended fuels should have a Btu content of at least 1,000

Btu's per cubic foot for natural gas; or at least 2,520 Btu's per

cubic foot for LP gas. Ask the fuel supplier for the Btu content of

the fuel.

NOTE:

The fuel consumption requirements are identified in the

Specifications section of the Owner's Manual. Refer to the

Installation Manual if assistance is required for the sizing of

the pipe diameter for the generator. Any piping used to connect

the generator to the fuel supply should be of adequate size to

achieve the 100% load fuel consumption requirements identi-

fied in the Specifications section regardless of actual load.

NOTE:

The recommended fuel pressure is identified in the Specifications

section this manual.

NOTE:

It is the responsibility of the installer to make sure that only

the correct recommended fuel is supplied to the generator fuel

system. Thereafter, the owner/operator must make certain that

only the proper fuel is supplied.

NATURAL GAS FUEL SYSTEM

Natural gas is supplied in its vapor state. In most cases, the gas

distribution company provides piping from the main gas distribu-

tion line to the standby generator site. The following information

applies to natural gas fuel systems.

• Gas pressure in a building is usually regulated by national, state

and local codes.

• To reduce gas pressure to a safe level before the gas enters a

building, a primary regulator is needed. The natural gas supplier

may or may not supply such a regulator.

• It is the responsibility of the gas supplier to make sure sufficient

gas pressure is available to operate the primary regulator.

• Gas pressure at the inlet to the fuel shutoff solenoid must never

exceed approximately 14 inches water column (0.5 psi).

PROPANE VAPOR WITHDRAWAL FUEL SYSTEM

This type of system utilizes the vapors formed above the liquid

fuel in the supply tank. Approximately 10 to 20 percent of the tank

capacity is needed for fuel expansion from the liquid to the vapor

state. The vapor withdrawal system is generally best suited for

smaller engines that require less fuel. The installer should be aware

of the following:

• When ambient temperatures are low and engine fuel consump-

tion is high, the vapor withdrawal system may not function

efficiently.

• Ambient temperatures around the supply tank must be high

enough to sustain adequate vaporization, or the system will not

deliver the needed fuel volume.

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

process itself provides an additional cooling effect.

5-1

FuelSys001 Rev. F 04/11

Fuel System

SPECIFICATIONS

GENERATOR

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

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

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

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

Alternator Output Leads 3-phase ..................................... 4-wire

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

Coupling ................................................................Flexible Disc

Load Capacity (Standby Rating) .....................................60kW*

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

J1349, ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate

with natural gas.

Excitation System ............................................................Direct

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

120/240V, 1-phase, 1.0 pf 60 250 300

120/208V, 3-phase, 0.8 pf 60 208 250

120/240V, 3-phase, 0.8 pf 60 180 200

277/480V, 3-phase, 0.8 pf 60 90 100

Generator Locked Rotor KVA Available @ Voltage Dip of 35%

Single-phase or 208, 3-phase (60kW) ...................... 120 KVA

480V, 3-phase (60kW) .............................................. 141 KVA

ENGINE

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

Model .............................................................................In Line

Cylinders and Arrangement .....................................................4

Displacement ............................................................... 2.4 Liter

Bore..............................................................................3.41 in.

Stroke ...........................................................................3.94 in.

Compression Ratio....................................................... 9.5-to-1

Air Intake System ........................... Turbo Charged/After Cooled

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

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

Spark Plug Gap ........................................0.17mm (0.028 inch)

Engine Parameters

Rated Synchronous RPM .......................................60 Hz, 3600

Exhaust System

Exhaust Flow at Rated Output 60 Hz (60kW) ................494 cfm

Exhaust Temp. at Rated Output (60kW) .........................1050° F

Combustion Air Requirements (Natural Gas)

Flow at rated power, 60 Hz (60kW) ..............................180 cfm

Governor

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

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

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

Engine Lubrication System

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

Oil Filter ......................................... Full Flow Spin-on, Cartridge

Crankcase Oil Capacity ....5.25 U.S. qts. (including filter capacity)

COOLING SYSTEM

Type............................................. Pressurized Closed Recovery

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

Fan Speed ..................................................................2050 rpm

Fan Diameter ..............................................................22 inches

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

Air Flow (inlet air including alternator and

combustion air) ................................................. 3280 ft3/min.

Coolant Capacity ................................................. (2.5 U.S. gal.)

Heat Rejection to Coolant (60kW) .......................270,000 Btu/h

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

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

FUEL SYSTEM

Type of Fuel ....................................Natural Gas, Propane Vapor

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

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

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

Operating Fuel Pressure .................5 in. - 14 in. Water Column

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

Exercise 25% 50% 75% 100%

Cycle Load Load Load Load

60kW 123/49.3 267/101 483/183 672/255 862/327

ELECTRICAL SYSTEM

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

Static Battery Charger ..................................................2.5 Amp

Recommended Battery .................................Group 26, 525CCA

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

Voltage Regulator

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

Sensing ................................................................ Single-phase

Regulation ........................................................................± 1%

Features ......................................... Adjustable Voltage and Gain

Power Adjustment for Ambient Conditions

Temperature Deration

3% for every 10° C above °C (60kW) ..................................25

1.65% for every 10° above °F (60kW) .................................77

Altitude Deration

1% for every 100 m above m (60kW) ...............................915

3% for every 1000 ft. above ft. (60kW) ...........................3000

Controller ................................................................. Nexus

6-1

GenSpec088 Rev. A 05/10

Specifications

WEATHER AND MAINTENANCE KITS

To keep the generator running at its peak, the following kits are

offered:

Cold Weather Kit•

~ Recommended for climates with temperatures below 32° F.

Extreme Cold Weather Kit•

~ Recommended Block Heater Kit for protection in tempera-

tures below 32° F.

Scheduled Maintenance Kit•

~ Kit includes the recommended parts to maintain the genera-

tor. Refer to the Service Schedule for regular maintenance

intervals.

For additional information, or to order any of these kits, please

contact an Authorized Service Dealer or Customer Service

Representative.

6-2

GenSpec088 Rev. A 05/10

Specifications

ALTERNATOR AC LEAD

CONNECTIONS

The electrical wires in the unit’s AC connection (lower) panel

should be installed according to the number of leads and the

voltage/phase required for the application. The voltage and phase

are described on the generator data label. The number of lead

wires can be identified using the Specifications section and the

power output rating on the generator data label. For example, if

the generator produces 130kW, 277/480 Volt, 3-phase power, the

generator has 12 alternator output leads. Figure 7.3 describes the

stator power winding connection for the generator.

FOUR-LEAD, SINGLE-PHASE STATOR

Four-lead alternators (see Figure 7.1) are designed to supply elec-

trical loads with voltage code “A” (240V, 1-phase, 60 Hz). Electrical

power is produced in the stator power windings. These windings

were connected at the factory to the main circuit breaker as shown

in Figure 7.1.

The rated voltage between each circuit breaker terminal is 240V.

The rated voltage between each circuit breaker terminal and the

neutral point 00 is 120V.

Figure 7.1 — Four-lead, Single-phase Stator

ALTERNATOR POWER WINDING

CONNECTIONS

3-PHASE ALTERNATORS ("Y" CONFIGURATION)

The Stationary Emergency Generator is designed to supply

3-phase electrical loads. Electric power is produced in the alterna-

tor power windings. These windings were connected at the factory

to the main circuit breaker with a “Y” configuration as shown in

Figures 7.2 through 7.6.

The rated voltage between circuit breaker terminals E1-E2, E1-E3

and E2-E3 is 480V, 208V or 600V depending on the model.

The rated voltage between each circuit breaker terminal and the

neutral point 00 is 277V, 120V, or 346V depending on the model.

Figure 7.2 — Stator Power Winding

Connections - 3-phase, 277/480V (6 Lead)

E1

S1

S6

S5

S4

S2

E2

S3

E3 L - N

L - L

INTERNAL

CONNECTIONS

00 (NEUTRAL)

Figure 7.3 — Stator Power Winding

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

E1

S1

S4

S7

S12

S11

S10

S8

S5

S2

E2

S9

S6

S3

E3 L - N

L - L

7-1

ACConn007 Rev. B 05/10

General Information

Figure 7.4 — Stator Power Winding

Connections - 3-phase, 120/208V (6 Lead)

E3 E2

00 (NEUTRAL)

INTERNAL CONNECTIONS E1

L-L

L-N

S1 S1

S4 S4

S6

S6

S3

S3

S5

S5 S2

S2

Figure 7.5 — Stator Power Winding

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

E3 E2

E1

L-L

L-N

S7 S1

S10 S4

S12

S6

S9

S3

S5

S11 S2

S8

Figure 7.6 — Stator Power Winding

Connections - 3-phase, 346/600V (6 Lead)

E1

S1

S6

S5

S4

S2

E2

S3

E3 L - N

L - L

INTERNAL

CONNECTIONS

00 (NEUTRAL)

3-PHASE ALTERNATORS ("DELTA" CONFIGURATION)

The Stationary Emergency Generator is designed to supply

3-phase electrical loads. Electric power is produced in the alterna-

tor power windings. These windings were connected at the factory

to the main circuit breaker with a “Delta” configuration as shown

in Figures 7.7 and 7.8.

The rated voltage between circuit breaker terminals E1-E2, E1-E3

and E2-E3 is 240V.

The rated voltage between E1 or E3 and the neutral point 00 is

120V.

Figure 7.7 — Stator Power Winding

Connections - 3-phase, 120/240V (6 Lead)

E2

E1 E3

INTERNAL

CONNECTIONS

S1

S6

S5

S4

S2

S3

L - N

L - L

00 (NEUTRAL)

Figure 7.8 — Stator Power Winding

Connections - 3-phase, 120/240V (12 Lead)

E2

E1 E3

S1

S12

S11

S8 S6

S5 S9

S10

S2

S3

L - N

L - L

00 (NEUTRAL)

7-2

ACConn007 Rev. B 05/10

General Information

CONTROL PANEL INTERFACE

USING THE AUTO/OFF/MANUAL SWITCH

 With the switch set to AUTO, the engine may

crank and start at any time without warning.

Such automatic starting occurs when utility

power source voltage drops below a preset

level or during the normal exercise cycle. To

prevent possible injury that might be caused

by such sudden starts, always set the switch

to OFF and remove the fuse before work-

ing on or around the generator or transfer

switch. Then, place a “DO NOT OPERATE”

tag on the generator panel and on the trans-

fer switch.

1. “AUTO” Position – Selecting this switch activates fully auto-

matic system operation. It also allows the unit to automati-

cally start and exercise the engine every seven days with the

setting of the exercise timer (see the Setting the Exercise

Timer section).

2. “OFF” Position – This switch position shuts down the engine.

This position also prevents automatic operation.

3. “MANUAL” Position – Set the switch to MANUAL to crank

and start the engine. Transfer to standby power will not occur

unless there is a utility failure.

ACTIVATE THE GENERATOR

When battery power is applied to the generator during the instal-

lation process, the controller will turn ON and the LCD screen will

illuminate. However, the generator still needs to be activated before

it will automatically run in the event of a power outage.

Activating the generator is a simple one time process that is guided

by the controller screen prompts. Once the product is activated,

the controller screen will not prompt you again, even if you discon-

nect the generator battery.

To obtain the activation code, record the generator serial number

and log onto www.activategen.com or call 1-888-9ACTIVATE and

follow the steps to retrieve the activation code.

After obtaining your activation code, please complete the following

steps at the generator’s control panel in the Activation Chart on the

following page.

NOTE:

The generator will only run in manual until the passcode has

been entered.

Upon power up, this controller will go through a system self test

which will check for the presence of utility voltage on the DC

circuits. This is done to prevent damage if the installer mistakenly

connects AC utility power sense wires into the DC terminal block.

If utility voltage is detected, the controller will display a warning

message and lock out the generator, preventing damage to the

controller. Power to the controller must be removed to clear this

warning.

Utility voltage must be turned on and present at the N1 and N2

terminals inside the generator control panel for this test to be

performed and pass.

NOTE:

DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT

WIRES IS NOT WARRANTABLE!

This test will be performed each time the controller is powered

up.

Next, the user must enter the minimum settings to operate. These

settings are current date and time and exercise day and time. The

maintenance intervals will be initialized (i.e. started) the first time

the clock is set. If the clock is never set at power up, the mainte-

nance intervals will be reset every time power is applied.

If a subsequent power loss (loss of battery power) occurs the

Installation assistant will operate upon power restoration. The self

test routine will be run and then the customer will be required to

re-enter the time and date, as this is not retained during a power

loss. The unit will not require re-activation.

DISPLAY INTERFACE MENUS

The LCD display is organized as detailed below:

• The “Home” page, this page is the default page which will be

displayed if no keys are pressed for 30 seconds. This page

normally shows the current Status message and the current

date and time. The highest priority active Alarm and/or Warning

will be automatically posted on this page as well as flashing

the backlight when such an event is detected. In the case of

multiple Alarms or Warnings, only the first message will be

displayed. To clear an Alarm or Warning, see the Protection

Systems section - Clear Alarm.

• The display backlight is normally off. If the user presses any

key, the backlight will come on automatically and remain on for

30 seconds after the last key was pressed.

• The “Main Menu” page will allow the user to navigate to all other

pages or sub-menus by using the Left/Right and Enter keys.

This page can be accessed at any time with several presses of

the dedicated Escape key. Each press of the Escape key takes

you back to the previous menu until the main menu is reached.

This page displays the following options: HISTORY; STATUS;

EDIT; AND DEBUG. (See the Appendix - "Menu System".)

8-1

CntrlNexusus001 Rev. D 04/11

Control Panel

8-2

CntrlNexus001 Rev. D 04/11

Control Panel

ACTIVATION CHART

CHOOSE LANGUAGE TROUBLESHOOTING

Display Reads: Use ARROW keys to scroll to desired lan-

guage. Press ENTER to select.

If the wrong language is chosen, it can be

changed later using the “edit” menu.

Display Reads: Press ENTER to begin the activation pro-

cess.

If ESCAPE is pressed instead of ENTER,

your generator will only run in manual mode

(for test purposes) and NOT ACTIVATED will

be displayed. You will need to remove the

generator control panel fuse AND disconnect

the T1, N1 and N2 connector in the external

connection box (if equipped); or disconnect

utility input (main breaker) to the transfer

switch for 3-5 seconds and reconnect, then

begin with Step 1.

Display Reads: If you do not have your activation code,

go to www.activategen.com or call

1-888-9ACTIVATE (922-8482).

If you already have your activation code,

wait 3-5 seconds for the next display.

ENTER ACTIVATION CODE (Passcode) TROUBLESHOOTING

Display Reads: Use ARROW keys to scroll and find the first

number of your Activation Code.

Press ENTER to select.

Repeat this step until all digits have been

entered.

Use ESCAPE to correct previous digits.

Display Reads: Activation is complete when all digits are

entered above and your screen shows this

display.

Follow the controller prompts to continue

setting the time function. Refer to your

Owner’s Manual with questions.

What happens if “Wrong Passcode Try

Again” appears?

Re-enter the activation code. If a second

attempt is unsuccessful, check the number

against the code given on activategen.com.

If it is correct and the generator will not

accept it, contact 1-888-9ACTIVATE (922-

8482).

“SELECT HOUR (0-23)”

“- +”6

Escape Enter

Serial 123456789

Passcode XXXXX +/-

Escape Enter

To Activate go to

www.activategen.com

Escape Enter

Activate me (ENT) or

ESC to run in manual

Escape Enter

Language

- English +

Escape Enter

INSTALLATION ASSISTANT

Interconnect System Self Test Feature (follow the on-screen

prompts).

Upon power up, this controller will go through a system self test

which will check for the presence of utility voltage on the DC

circuits. This is done to prevent damage if the installer mistakenly

connects AC utility power sense wires into the DC terminal block.

If utility voltage is detected, the controller will display a warning

message and lock out the generator, preventing damage to the

controller. Power to the controller must be removed to clear this

warning.

Utility voltage must be turned on and present at the N1 and N2

terminals inside the generator control panel for this test to be

performed and pass.

NOTE:

DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT

WIRES IS NOT WARRANTABLE!

This test will be performed each time the controller is powered

up.

Upon first power up of the generator, the display interface will

begin an installation assistant. The assistant will prompt the user

to set the minimum settings to operate. These settings are simply:

Current Date/Time and Exercise Day/Time. The maintenance inter-

vals will be initialized when the exercise time is entered.

The exercise settings can be changed at any time via the "EDIT"

menu (see Appendix, "Menu System").

If the 12 volt battery is disconnected or the fuse removed, the

Installation Assistant will operate upon power restoration. The

only difference is the display will only prompt the customer for the

current Time and Date.

IF THE INSTALLER TESTS THE GENERATOR PRIOR TO

INSTALLATION, PRESS THE “ENTER” KEY TO AVOID SETTING

UP THE EXERCISE TIME. THIS WILL ENSURE THAT WHEN

THE CUSTOMER POWERS UP THE UNIT, HE WILL STILL BE

PROMPTED TO ENTER AN EXERCISE TIME.

SETTING THE EXERCISE TIMER

This generator is equipped with an exercise timer. Once it is set,

the generator will start and exercise every seven days, on the day

of the week and at the time of day specified. During this exercise

period, the unit runs for approximately 12 minutes and then shuts

down. Transfer of loads to the generator output does not occur

during the exercise cycle unless utility power is lost.

LOW SPEED EXERCISE

The standard start sequence will be initiated.

• All 1800 rpm units will exercise at 1400 RPM

• All 3600 rpm units will exercise at 1800 RPM

If utility is lost during exercise the controller will do the following:

• Wait for the “line interrupt period” for utility to return. If utility

returns within the “line interrupt period”, continue to exercise

at low RPM.

• If utility is still lost after the “line interrupt period”, run the engine

up to normal RPM and transfer the load. At this time the con-

troller will exit the exercise routine and assume full automatic

operation.

USER ADJUSTABLE SETTINGS

Setting Factory

Default

Minimum

Setting

Maximum

Setting Increment

Exercise

time 2 pm 00:00 (12 am) 23:59

(11:59 pm) 1 min

Exercise

day Wed Sun Sat 1 day

Current

Time 12 am 00:00 (12 am) 23:59

(11:59 pm) 1 min

Current

Day Sun Sun Sat 1 day

Current

Month Jan Jan Dec 1 month

Current

Year 2008 2008 2100 1 year

Language English French Spanish N/A

Contrast 80% 0% 100% 1%

FUEL CONVERSION

For fuel conversion steps, refer to the GenSpec section,

RECONFIGURING THE FUEL SYSTEM.

OPERATION

This system is intended to supply standby power in the event of a

utility failure. The control system will monitor the utility voltage to

determine if stand-by power is required. Should the utility voltage

fail, the generator will start and run normally, detaching from the

utility and supplying the customer load from the generator. When

utility power returns, the controller will re-transfer the customer

load back to utility and shut down the generator.

AUTOMATIC TRANSFER OPERATION

To select automatic operation, do the following:

1. Make sure the transfer switch main contacts are set to their

UTILITY position, i.e., loads connected to the utility power

source.

2. Be sure that normal UTILITY power source voltage is avail-

able to transfer switch terminal lugs N1 and N2 (Refer to the

Electrical Data section).

3. Set the generator’s AUTO/OFF/MANUAL switch to AUTO.

4. Set the generator’s main circuit breaker to its ON (or CLOSED)

position.

With the preceding steps complete, the generator will start auto-

matically when utility source voltage drops below a preset level.

After the unit starts, loads are transferred to the standby power

source. Refer to the Sequence of Automatic Operation section.

8-3

CntrlNexus001 Rev. D 04/11

Control Panel

SEQUENCE OF AUTOMATIC OPERATION

Initial Conditions: Generator in Auto ready to run, load being sup-

plied by the Utility Source through the transfer switch.

1. When the utility voltage fails (falls below 60% of nominal), a

10-30 second (programmable) “line interrupt” delay timer is

started. The factory set time delay is 10 seconds. If at the

end of the line interrupt time the utility voltage is above 60%

the engine will not crank. If the utility voltage is still below

the 60% of nominal at the end of the line interrupt time, the

unit will crank and start. If the unit cranks for more than 10

seconds and the utility voltage rises above 80% of nominal

(programmed pickup voltage) and the unit has not started, the

crank cycle will abort.

2. As soon as the unit starts a 5 second “warm-up” timer is initi-

ated. When the warm-up timer expires the control will transfer

the load to the generator (through the RTS switch) if the utility

voltage is less than 80% of nominal. If the utility voltage is

greater than the 80% of nominal at the end of the warm-up

time the load will not be transferred to the generator and a one

minute low-speed cool down period will start. At the end of

the one minute cool down period the generator will stop.

3. Once the unit is running and the switch has transferred the

load to the generator the unit will monitor utility voltage.

When utility voltage returns (above the programmable pickup

voltage, normally 80% of nominal), a 15 second “Return to

Utility” timer will start. At the end of the return to utility time,

if the utility voltage is still above the pickup voltage, the unit

will transfer the load back to the utility source and run the unit

through a one minute cool down period. When the cool down

period is over the unit will shut down and be ready for the next

outage.

4. If during the cool down period utility voltage should fall below

60% of nominal the 5 second warm-up timer is initiated and

the unit will transfer the load back to the generator and con-

tinue to monitor the utility.

CRANK CYCLES AND OVERCRANK SHUTDOWN

If the unit fails to start during a cranking period it will display the

Overcrank Shutdown Alarm. The system will control the cranking

cycles as follows:

The first crank cycle is a 16 second crank time followed by a 7

second rest. The next 5 cycles will be 7 seconds of cranking time

each followed by a 7 second rest time.

If the unit fails to start by the end of the 6 crank/rest cycles

the Overcrank Shutdown Alarm will display and the unit will not

attempt to crank until the alarm is reset.

AUTO START

This unit is designed to automatically start in the event of a util-

ity failure or brown out condition. Brown out is defined as utility

voltage less than 60% nominal, while utility is considered good

when it is restored to at least the pickup value, 80% of nominal.

These levels are fixed. The “Line Interrupt period” is an adjustable

parameter by the dealer. If 2-wire start mode is activated, the unit

will start when 2-wire start is active.

MANUAL START

Allows the user to start and run the generator manually.

Transfer of the load to the generator will occur if utility is lost while

the unit is running in the manual mode (only if activated).

ALARM AND WARNING MESSAGES

Alarms are defined as “Latching” which means they must be

cleared before the alarm message on the screen will clear. They

can be of type “Shutdown” or not and are logged in the alarm log.

Alarms are all annunciated on the display).

Warnings are “Non Latching” meaning the message automati-

cally clears when the warning condition goes away. Warnings can

not be of type “Shutdown” but they are logged in the alarm log.

Warnings are all annunciated on the display.

LOW OIL PRESSURE SHUTDOWN ALARM

There is a 10 second delay before oil pressure is monitored.

HIGH COOLANT TEMPERATURE SHUTDOWN ALARM

There is a 10 second delay before engine temperature is moni-

tored.

Once running there is a 1/4 second delay before shut down. The

limit is set at 125° C or 257° F.

OVERCRANK SHUTDOWN ALARM

Occurs if the engine has not started within the specified crank

cycle.

OVERSPEED SHUTDOWN ALARM

Warning indicator is measured and calculated by the microproces-

sor. Overspeed is defined as +20% of nominal engine speed for 3

seconds, or +25% immediate.

Nominal engine speed = 60.0 Hz

RPM SENSOR FAILURE SHUTDOWN ALARM

During cranking: If the board does not see a valid RPM signal

within four (4) seconds of cranking it will shut down and lock out

on RPM sensor loss.

During running: If the RPM signal is lost for one full second the

board will shut the engine down, wait 15 seconds, then re-crank

the engine if in AUTO, it will not re-crank in MANUAL.

If no RPM signal is detected within the first four (4) seconds of

cranking, the control board will shut the engine down and latch out

on RPM sensor loss.

If the RPM signal is detected the engine will start and run normally.

If the RPM signal is subsequently lost the control board will try

two more re-cranks before latching out and flashing the RPM

Sensor Failure message (if it is in AUTO).

8-4

CntrlNexus001 Rev. D 04/11

Control Panel

CHECK ENGINE MESSAGE

The control system has detected an emissions related fault. This

fault cannot be cleared using the control panel interface. The unit

will continue to operate in automatic mode. Contact your local

servicing dealer.

UNDER-FREQUENCY SHUTDOWN ALARM

After starting, if the generator stays under frequency for more than

30 seconds, it will shutdown.

LOW BATTERY ALARM

While running, if the average battery voltage falls below 11.9 volts

for one (1) minute, the low battery alarm will be displayed.

LOW BATTERY WARNING

The microprocessor will continually monitor the battery voltage

and display the Low Battery Voltage message if the battery voltage

falls below 12.2 Volts for one (1) minute.

No other action is taken on a low battery warning condition. The

warning will automatically clear if the battery voltage rises above

12.2 volts.

NOTE:

The battery sentinel is a separate feature that monitors battery

condition.

LOW COOLANT LEVEL ALARM

This is a shutdown alarm. The sensor will be continuously moni-

tored. If an error condition is seen for five (5) consecutive sec-

onds, the alarm will be displayed.

MISSING CAM PULSE ALARM

This is a shutdown alarm. The alarm will activate after five (5)

seconds of continuously missing cam pulses.

MISSING CRANK PULSE ALARM

This is a shutdown alarm. The alarm will activate after 12 con-

secutive revs where crank pulses are missing.

LOW FUEL PRESSURE WARNING

Fuel pressure is monitored by a digital sensor with a fixed setpoint

of below five (5) inches water column.

GOVERNOR SENSOR FAULT ALARM

The governor position is monitored by an analog feedback signal. If

the throttle position is seen outside of the normal operating range,

a shutdown alarm is displayed. If the throttle is commanded to

move, and no movement is seen, a shutdown alarm is displayed.

WIRING ERROR ALARM

When power is first apllied to the contoller, the software will per-

form a check on the wiring of the transfer output, and ensure it

does not have high voltage on the wire. If this is the case, it will

signal a miswire alarm and will not run. The test can be skipped

by use of the escape key.

UNDERVOLTAGE ALARM

If the generator voltage falls below 60% for >5 seconds, an alarm

will be issued.

8-5

CntrlNexus001 Rev. D 04/11

Control Panel

Figure 1 – Generator Control Panel

OVERVOLTAGE ALARM

If the generator voltage rises above 110% for >3 seconds, an

alarm will be issued.

If the generator voltage rises above 130% for >0.2 seconds, an

alarm will be issued.

INTERNAL FAILURE SHUTDOWN ALARM

Any internal failure that can be detected such as corrupted

firmware will cause this shutdown alarm. This alarm cannot be

cleared.

CANBUS ALARM

Where applicable, if the Canbus communications link fails to com-

municate, a “Canbus Alarm” will be generated. This only applies

to systems with external ignition modules. The alarm may be

generated if:

1. The physical link is broken.

2. The Ignition Module fails or resets.

3. The Nexus Controller fails or resets.

4. Having the Battery Chargers 120 VAC connected without a

battery installed.

5. A blown 10 amp Ignition Module fuse (approximately 12

inches away from the starter).

6. A blown 25 amp system fuse (located approximately 12

inches away from the DC alternator).

NOTE:

The “Canbus Alarm” will not clear on its own. To clear the

alarm, press the “enter” key to acknowledge the alarm. The

alarm will clear and if the fault is still present, the alarm will

reoccur.

IGNITION ALARM

When an ignition alarm occurs, a generic message “Ignition Fault”

will be displayed as the fault code.

MAINTENANCE WARNING

When a maintenance period expires, a warning message will be

posted. The warning can be reset by hitting the Enter key. Resetting

will clear the warning and reset the maintenance counters for the

condition annunciated. The history log will reflect the maintenance

warning.

ALARM CANCEL

When the generator is shut down due to a latching alarm, the Auto

/Off/ Manual switch must be set to the off position and the ENTER

key pressed to unlatch any active fault and clear the corresponding

fault alarm message.

COMMON ALARM RELAY

The common alarm relay will be activated if there is a shutdown

alarm. It will not activate on warnings or indicate that the Auto/Off/

Manual switch is in the OFF position. The OFF position will clear

the alarms and the relay. The relay will not be used to indicate a

generator is not activated.

The common alarm connections are wired to a set of potential-

free (dry) contacts on the Nexus controller board. These Normally

Open (N.O.) contacts close when an alarm condition occurs and

are used to activate a remote signaling device. The circuit is rated

for a maximum of 130mA at 24 VDC. The connections are a short

set of free hanging wires that exit the engine harness loom directly

behind the Nexus Control Panel and are labeled numbers 209 and

210.

MAINTENANCE ALERTS

Maintenance alerts will be provided for these conditions (see the

Maintenance Alert Chart).

SERVICE SCHEDULE ‘A’

Inspect Accessory drive alert 1yr /100hrs

Coolant change & flush 1yr /100hrs

Inspect spark plugs alert 1yr /100hrs

Change oil & filter alert 1yr /100hrs

Inspect battery alert 1yr /100hrs

Change / Inspect air filter alert 1yr /100hrs

SERVICE SCHEDULE ‘B’

Change / Inspect spark plugs alert 2yr/ 250hr

8-6

CntrlNexus001 Rev. D 04/11

Control Panel

MAINTENANCE ALERT CHART

CONDITION 1.6 CHERY 2.4/1800 MITSU 2.4/3600 MITSU 4.2 FORD

Change oil & filter alert 3mo/30hrs break-in

1yr/100hrs

3mo/30hrs break-in

1yr/100hrs

3mo/30hrs break-in

1yr/100hrs

3mo/30hrs break-in

1yr/100hrs

Inspect/clean air inlet &

exhaust alert

3mo/30hrs break-in

6mo/50hrs

3mo/30hrs break-in

6mo/50hrs

3mo/30hrs break-in

6mo/50hrs

3mo/30hrs break-in

6mo/50hrs

Change / Inspect air filter

alert

1yr/100hr 1yr/100hr 1yr/100hr 1yr/100hr

Inspect spark plugs alert 1yr /100hrs 1yr /100hrs 1yr /100hrs 1yr /100hrs 1yr /100hrs

Change / Inspect spark

plugs alert

2yr/ 250hr 2yr/ 250hr 2yr/ 250hr 2yr/ 250hr

Inspect Accessory drive

alert

3mo/30hrs break-in

1yr /100hrs

3mo/30hrs break-in

1yr /100hrs

3mo/30hrs break-in

1yr /100hrs

3mo/30hrs break-in

1yr /100hrs

Coolant change & flush 1yr /100hrs 1yr /100hrs 1yr /100hrs 1yr /100hrs

Inspect battery alert 1yr /100hrs 1yr /100hrs 1yr /100hrs 1yr /100hrs

8-7

CntrlNexus001 Rev. D 04/11

Control Panel

8-8

CntrlNexus001 Rev. D 04/11

Control Panel

ACTIVATION

RUN LOGALARM LOG

HISTORY STATUS

COMMANDSTATE VERSIONSDISPLAY

GENERATOR

FREQUENCY

ENGINE

HOURS

ENGINE

RPM

BATTERY

VO LTAGE

DEBUG

INPUTS OUTPUTS DISPLAYS

EDIT

LANGUAGE

TIME/DATE

EXERCISE

TIME/SPEED

ESC Press the “ESCAPE” key

to jump back up through

the menu levels.

+ / - Use the “+/-” key

to navigate through

the menu.

ENTER Use the “ENTER” key

to select items or

enter data.

ESC

ESC

ESC

ESC

ESC ESC

RESET

MAINTENANCE

QT TEST

MAIN MENU

MENU SYSTEM

STATIONARY EMERGENCY

GENERATOR CONTROL AND

OPERATION

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

unit.

OPERATING UNIT WITH MANUAL

TRANSFER SWITCH

If the Stationary Emergency Generator was installed in conjunction

with a transfer switch capable of manual operation only, the fol-

lowing procedure applies. A manually operated transfer switch is

one that will not provide automatic start-up and does not include

an intelligence circuit.

ENGINE START-UP AND TRANSFER

For additional information, refer to the applicable control panel

manual for this unit, as well as any literature pertaining to the

specific transfer switch.

n

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 appli-

cable control panel and transfer switch manuals

for more information.

n

Do not proceed until certain that utility source

voltage is available to the transfer switch and

the transfer switch main contacts are set to

UTILITY.



Do not attempt manual operation until all

power supplies to the transfer switch have been

positively turned off, or extremely dangerous -

possibly lethal - electrical shock will result.



Transfer switch enclosure doors should be kept

closed and locked. Only authorized personnel

should be allowed access to the transfer switch

interior. Extremely high and dangerous voltages

are present in the transfer switch.

In order to transfer load from the utility source to the generator,

follow these directions:

Turn OFF or disconnect the utility power circuit to the transfer •

switch, using the means provided (such as the utility source

main line circuit breaker).

Set the transfer handle to its UTILITY (NORMAL) position with •

load circuits connected to the utility power supply.

Set the generator’s main line circuit breaker to its OFF (or OPEN) •

position.

Start the generator.•

n Do not crank the engine continuously for lon-

ger than 30 seconds, or the heat may

damage the starter motor.

Let engine stabilize and warm up.•

Check all applicable instrument and gauge readings. When •

certain that all readings are correct, move the transfer switch

manual handle to the STANDBY (or EMERGENCY STANDBY)

position, i.e., load circuits supplied by the generator.

Set the generator’s main line circuit breaker to its ON (or •

CLOSED) position.

Load circuits are now powered by the generator.•

RETRANSFER AND SHUTDOWN

For additional information, refer to the applicable control panel

manual for this unit, as well as any literature pertaining to the

specific transfer switch.

To transfer the load back to the utility power source and shut down

the generator, follow these directions:

Set the generator’s main line circuit breaker to its OFF (or OPEN) •

position.

Manually move the transfer switch handle to its UTILITY •

(NORMAL) position, i.e., load circuits connected to the utility.

Turn ON the utility power supply to the transfer switch, using •

the means provided (such as the utility power source main line

circuit breaker).

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

internal temperatures.

Shut down the generator.•

OPERATING UNIT WITH AUTOMATIC

TRANSFER SWITCH

If the Stationary Emergency Generator has been installed with an

automatic transfer switch, the engine may be started and stopped

automatically or manually.

NOTE:

Refer to the applicable manual for your transfer switch and to

“Transfer Switch Start Signal Connections”. In addition, please

note the dangers under “Engine Start-up and Transfer.”

9-1

Oper001 Rev. D 05/10

Operation

GENERAL MAINTENANCE

 Before working on the Stationary Emergency

Generator, ensure the following:

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

The control panel fuse has been removed from the control •

box.

The 120VAC supply to the battery charger is switched OFF.•

The negative battery cable has been removed.•

CHECK ENGINE OIL

Check engine crankcase oil level (Figure 10.1) according to the

Service Schedule and SIB10-10-L24G.

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

Install oil dipstick, then remove again.•

Oil should be between FULL and ADD marks.•

If oil level is below the dipstick ADD mark, remove oil fill cap-. •

Add the recommended oil to bring oil level up to the FULL

mark. DO NOT FILL ABOVE THE “FULL” MARK. See “Engine Oil

Recommendations” for recommended oils.

Figure 10.1 - Oil Dipstick and Oil Fill Cap

Oil

Dipstick

Oil Fill Cap

Oil Filter

CHANGING ENGINE OIL

n Hot oil may cause burns. Allow engine to cool

before draining oil. Avoid prolonged or repeat-

ed skin exposure with used oil. Thoroughly

wash exposed areas with soap.

Refer to the Service Schedule for engine oil and filter change fre-

quencies.

Drain the oil while the engine is still warm from running. This

means warm up the engine, shut it down and drain immediately

as follows:

1. Remove the drain hose from its retaining clip or cut the zip-tie

securing the oil drain hose.

2. Loosen and remove OIL DRAIN HOSE CAP. Drain oil com-

pletely into suitable container.

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

CAP and secure drain hose with a new zip-tie, or place the

hose in its retaining clip.

4. Turn OIL FILTER (Figure 10.1) counterclockwise and remove.

Properly dispose of old filter.

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

ter. Install FILTER and tighten by hand only. DO NOT OVER

TIGHTEN.

6. Remove OIL FILL CAP and add recommended oil. Crankcase

oil capacity is listed in the "Specifications" section.

n After refilling the crankcase with oil, always

check oil level on dipstick. NEVER OPERATE

ENGINE WITH OIL BELOW THE DIPSTICK “ADD”

MARK.

7. Start engine and check for oil leaks.

8. Shut OFF engine and wait 10 minutes for the oil to settle down

into the oil pan. Recheck oil level on dipstick. DO NOT fill

above the dipstick "FULL" mark.

9. Dispose of used oil at a proper collection center.

COOLING INTAKE/OUTLET

Air intake and outlet openings in the generator compartment must

be open and unobstructed for continued proper operation. This

includes such obstructions as high grass, weeds, brush, leaves

and snow.

Without sufficient cooling and ventilating air flow, the engine/gen-

erator quickly overheats, which causes it to shut down. (See the

installation diagram.)

 The exhaust system parts from this product get

extremely hot and remains hot after shutdown.

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

remain clear of the exhaust. Such materials may

ignite and burn from the heat of the exhaust

system.

INSPECT COOLING SYSTEM

Inspect engine cooling system. See the Service Schedule.•

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

discrepancies found.

Check hose clamps for tightness.•

10-1

Maint026 Rev. A 05/10

Maintenance

ENGINE COOLANT

Check coolant level in coolant recovery bottle. See the Specifications

and Service Schedule sections.

Add recommended coolant mixture as necessary.•

Periodically remove radiator pressure cap (only when engine •

has cooled down) to make sure the coolant recovery system

is functioning properly. Coolant should be at bottom of radia-

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

pressure cap. Replace cap, if necessary. To have pressure cap

tested, contact a Service Facility. Inspect cooling system and

coolant recovery system for leaks.

COOLANT CHANGE

Every year, have a service facility drain, flush and refill the cooling

system. See the Specifications and Service Schedule for cooling

system recommendations.

OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL

SYSTEM

Engine cranking, start up and running are controlled by a solid

state Engine Controller circuit board. Battery voltage is delivered

to that circuit board via the control panel fuse. This overcurrent

protection device will open if the circuit is overloaded.

n If a circuit breaker opens or a fuse element

melts, find the cause of the overload before

resetting the circuit breaker or replacing the

fuse.

EXERCISE SYSTEM

Starts the Stationary Emergency Generator engine once every

seven days and lets it run for 12 minutes.

PERFORM VISUAL INSPECTION

Complete a thorough visual inspection of the entire engine-genera-

tor monthly. Look for obvious damage, loose, missing or corroded

nuts, bolts and other fasteners. Look for fuel, oil or coolant leaks.

INSPECT EXHAUST SYSTEM

Inspect the exhaust system at least once every year. Check all

exhaust system pipes, mufflers, clamps, etc. for condition, tight-

ness, leaks, security, damage.

CHECK FAN BELT

Inspect fan belts every year. Replace any damaged, deterio-•

rated, worn or otherwise defective belt.

Check fan belt tension. Thumb pressure, exerted midway •

between pulleys, should deflect about 3/8 to 5/8 of an inch.

Adjust belt tension as required.

Check fan belt alignment (see Figure 10.2).•

Figure 10.2 – Fan Belt

INSPECT ENGINE GOVERNOR

Visually inspect electronic governor.

n Do not attempt to adjust the governor. Only

qualified service facilities should adjust the

governor. Excessively high operating speeds

are dangerous and increase the risk of personal

injury. Low speeds impose a heavy load on the

engine when adequate engine power is not

available and may shorten engine life. Correct

rated frequency and voltage are supplied only

at the proper governed speed. Some connected

electrical load devices may be damaged by

incorrect frequency and/or voltage. Only quali-

fied service technicians should adjust the gov-

erned speed.

CHANGING THE ENGINE AIR FILTER

To replace the engine air filter, remove the air filter cover and

replace the air filter making sure it is positioned properly before

reattaching the cover (Figure 10.3).

See the Service Schedule for air filter maintenance.

10-2

Maint026 Rev. A 05/10

Maintenance

Figure 10.3 – Engine Air Filter

Air Filter

SPARK PLUGS

Reset the spark plug gap or replace the spark plugs as neces-

sary.

1. Clean the area around the base of the spark plugs to keep dirt

and debris out of the engine. Clean by scraping or washing

using a wire brush and commercial solvent. Do not blast the

spark plugs to clean.

2. Remove the spark plugs and check the condition. Replace

the spark plugs if worn or if reuse is questionable. See the

“Service Schedule” section for recommended inspection.

3. Check the spark plug gap using a wire feeler gauge. See the

Specifications section for the required spark plug gap.

BATTERY MAINTENANCE

The battery should be inspected per the Service Schedule section.

The following procedure should be followed for inspection:

1. Inspect the battery posts and cables for tightness and corro-

sion. Tighten and clean as necessary.

2. Check the battery fluid level of unsealed batteries and, if

necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP

WATER IN BATTERIES.

3. Have the state of charge and condition checked. This should

be done with an automotive-type battery hydrometer.

 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 smok-

ing, open flame, sparks or any spark producing

tools or equipment near the battery.

n Battery electrolyte fluid is an extremely corro-

sive 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.

n Do not use any jumper cables or booster bat-

tery to crank and start the generator engine. If

the battery has completely discharged, remove

it from the generator for recharging.

n Be sure the AUTO/OFF/MANUAL switch is set

to the OFF position, before connecting the

battery cables. If the switch is set to AUTO or

MANUAL, the generator can crank and start as

soon as the battery cables are connected.

Be sure the 120VAC power supply to the battery

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

tery posts as the cables are attached and cause

an explosion.

BATTERY REPLACEMENT

NOTE:

Unit DOES NOT include battery.

When supplying or replacing the battery, the recommended num-

ber and type of battery is listed in the Specifications Section.

NOTE:

The BCI number should be located directly on the battery.

BATTERY FLUID

Check battery electrolyte fluid based on the Service Schedule.

Fluid should cover separators in all battery cells. If fluid level is

low, add distilled water to cover tops of separators. DO NOT USE

TAP WATER IN BATTERY.

CLEANING THE STATIONARY EMERGENCY GENERATOR

Keep the generator as clean and as dry as possible. Dirt and

moisture that accumulates on internal generator windings have an

adverse effect on insulation resistance.

Periodically clean generator exterior surfaces. A soft brush may be

used to loosen caked on dirt. Use a vacuum system or dry, low

pressure air to remove any accumulations of dirt. The generator is

housed inside an all-weather enclosure, clean the enclosure with a

soft, damp cloth or sponge and water.

Once each year have the generator cleaned and inspected by a

Service Dealer. That dealer will use dry, low pressure air to clean

internal windings.

Finally, have the insulation resistance of stator and rotor windings

checked. If insulation resistances are excessively low, the genera-

tor may require drying.

10-3

Maint026 Rev. A 05/10

Maintenance

SERVICE SCHEDULE

System / Component Frequency Procedure

Weekly - W

Monthly - M

Yearly - Y

Inspect Change Clean

Fuel

Fuel Lines & Connections M X

Lubrication

Oil Level M X*

Oil Y X**

Oil Filter Y X**

Cooling

Engine Coolant Lines & Connections M X

Engine Coolant Level M X

Engine Coolant Y X

Enclosure Louvers W X X

Engine

Air Cleaner Y X X***

Spark Plugs Y X X***

Battery

Remove Corrosion, Ensure Dryness M X X

Clean & Tighten Battery Terminals M X X

Check Charge State M X X***

Check Electrolyte Level M X X***

General Condition

Vibration, Noise, Leakage, Temperature M X

Generator System

Complete Tune-up and System Inspection Y To be completed by an Authorized Service Dealer.

Footnotes

* Inspect the oil level monthly or every 12 hours during continuous operation.

** Change oil and oil filter after the first 30 hours of operation and then every 100 hours or annually thereafter, whichever occurs first.

Change sooner when operating under heavy load or in a dusty or dirty environment or in high ambient temperatures.

*** Replace as necessary.

11-1

SrvSchd004 Rev. B 05/10

Service Schedule

Troubleshooting

TROUBLESHOOTING GUIDE

PROBLEM CAUSE CORRECTION

Engine won’t crank. 1. Control panel 7.5 amp fuse blown. 1. Replace fuse.*

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

battery cables. battery cables as necessary.*

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

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

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

Engine cranks but won't start. 1. Out of fuel. 1. Replenish fuel/turn on fuel valve.

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

3. Spark plugs defective. 3. Clean, regap or replace plugs.

Engine starts hard, runs rough. 1. Air cleaner plugged or damaged. 1. Clean or replace as needed.

2. Defective spark plugs. 2. Clean, regap or replace plugs.

3. Fuel pressure incorrect. 3. Confirm fuel pressure to regulator is as

recommended in SPECIFICATIONS.*

4. Insufficient fuel supply. 4. Confirm fuel pressure to regualtor is as

recommended in SPECIFICATIONS.*

5. Fuel system set to wrong fuel type. 5. Reconfigure the fuel system. (See

RECONFIGURING THE FUEL SYSTEM in

manual.*

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

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

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

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

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

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

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

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

engine continues to run. 2. Defective Control Module circuit board 2. Replace board.*

No AC output from generator. 1. Main line circuit breaker is tripped/open. 1. Reset to ON/CLOSED.

2. Generator internal failure. 2. *

3. Thermal circuit breaker open. 3. Auto-reset - Wait 5 min. and attempt restart.

*Contact the nearest Dealer for assistance.

12-1

Trblsht003 Rev. B 05/10

1 0F9677 1 ROTOR-2390-45KD1 CPL

0G0056 1 ROTOR-2390-35KD1 CPL

0G0959 1 ROTOR-2390-45KD1 CPL (G2)

0G1155 1 ROTOR-2390-35KD1 CPL (G2)

0G1931 1 ROTOR 25KW 3PH DIRECT 390 1800

0G2101 1 ROTOR 25KW 1PH DIRECT 390 1800

0G3734 1 RTR-2390-60KD2 CPL

0G6562 1 RTR 390 35AD1 CPL

0G6564 1 RTR 390 35KD1 CPL

2 0F9664 1 STATOR-390 45K 2P 1PH DIRECT

0G0057 1 STATOR-2390-35AD1 CPL

0G0058 1 STATOR-2390-35KD1 CPL

0G0059 1 STATOR-2390-35GD1 CPL

0G0183 1 STATOR-2309-45KW 2P 3PH 208V

0G0184 1 STATOR-2309-45-KD1 CPL

0G1932 1 ASSY STR 390 25GD3 CPL

0G2098 1 ASSY STR 390 25AD1 CPL

0G2099 1 ASSY STR 390 25KD3 CPL

0G2100 1 ASSY STR 390 25JD3 CPL

0G3736 1 ASSY STR 2390 60AD2 CPL

0G3737 1 ASSY STR 390 60KW 2P 3PH 208V

0G3738 1 ASSY STR 390 60KW 2P 3PH 480V

0G6104 1 STR-2390--45JD1 CPL

0G6563 1 STR 390 35AD1 CPL

0G6565 1 STR 390 35GD1 CPL

0G6566 1 STR 390 35KD1 CPL

0G6567 1 STR 390 35JD1 CPL

0H0201 1 STR-2390--60JD2 CPL

0H1299 1 ASSY STR 390 36AD1 CPL

0H1300 1 ASSY STR 390 36JD1 CPL

0H1301 1 ASSY STR 390 36 GD1 CPL

3 0C9708 REF INSTR HYPOT TEST (NOT SHOWN)

4 SEE ENGINE EV REF ENGINE ADAPTER

5 SEE ENGINE EV REF FLEXPLATE

6 0F5767B 1 ASSY FLYWHEEL CPL W/40MM FAN B

7 0E5706 1 REAR BEARING CARRIER 390/DRCT

8 0F7874 1 ASSY BRUSH HOLDER 390/HSB

0F7874A 1 ASSY BRUSH HOLDER 390/HSB

9 0G0587 1 GUARD REAR BEARING CARRIER

10 038150 4 WASHER FLAT #8 ZINC

11 023454 1 KEY WOODRUFF #E

12 077043E 1 CONDUIT FLEX 1.0" ID (35” LG)

13 04576100BU 4 STUD M14-2.0 570 G5 ZINC

14 052646 4 WASHER FLAT M14

15 043123 4 WASHER LOCK M14

16 051779 4 NUT HEX M14-2.0 G8 YEL CHR

17 0A2601 1 SCREW HHC M16-2.0 X 45 G8.8

18 072879 1 SPACER .69 X 2.75 X .37 ST/ZNC

19 0F8408 4 SCREW HHC M10-1.50 X 16 G10.9

20 046526 4 WASHER LOCK M10

21 0C3992 4 SCREW HHTT M4-0.7 X 16 BP

22 022264 4 WASHER LOCK #8-M4

23 * 047248 1 BALL BEARING-45 MM

24 * 070892 1 SLIP RING MACHINED

25 0G0588 1 GUARD REAR BEARING CARRIER

26 077043A 1 CONDUIT FLEX .38" ID (60”)

27 056326 1 TRIM VINYL BLACK 1/8GP (16.5”LG)

* ROTOR REPLACEMENT PARTS

EXPLODED VIEW: CONBOX C2 CPL

DRAWING #: 0H7326 GROUP A

APPLICABLE TO:

REVISION: H-9621-F Page 4 of 8

DATE: 9/26/11

ITEM PART# QTY. DESCRIPTION

1 0H6266 1 BACK PANEL CONBOX SUPPORT C2

2 0H6265 1 TOP PANEL CONBOX SUPPORT C2

3 0H6160 1 COVER WIRE ENTRY CONBOX

4 057073 2 JUNCTION BLOCK 3/8-16

5 056739 1 RELAY SOLENOID 12VDC PNL MNT

(6)6 0H67330ST0R 1 BRACKET GIMBAL CONTROL PNL RAW

7 0H7668B 1 ASSY CTRL PROGRAMMED

8 0A2115 2 WASHER FLAT NYLON 0.257 X 0.625

9 022097 3 WASHER LOCK M6-1/4

10 022473 8 WASHER FLAT 1/4-M6 ZINC

11 0H7115 2 KNOB M6-1.0 CONTROL PANEL

12 0C2454 13 SCREW HWHT M6-1 X 16 N WA Z/JS

13 0F5458 12 SCREW HHSP #10 X 3/8 HI-LOW

14 042568 2 SCREW HHC M6-1.0 X 20 C8.8

(6)15 0H88390ST0R 1 SHIELD HIGH/LOW C2 RAW

16 0C2265 4 SCREW PHTT M4-0.7 X 12 ZP

(3)17 0H6169B 1 ASSY PROG 2010 IGN MOD 6 CYL

(3)18 023897 4 WASHER FLAT #10 ZINC

(3)19 036943 2 SCREW PPHM #10-32 X 2

(3)20 022152 2 WASHER LOCK #10

(3)21 022158 2 NUT HEX #10-32 STEEL

(3)22 055934D 1 CLAMP STL/VNL 1.06 X .406 Z

(2)23 0D5464B 1 NEUTRAL BLOCK 390/200-400A

24 022237 2 WASHER LOCK 3/8

25 022241 2 NUT HEX 3/8-16 STEEL

26 0D3700 6 NUT FLANGE M6-1.0 NYLOK

27 0H6267 1 COVER VOLTAGE SHIELD

28 0F5752F 1 RES WW 15R 5% 25W QK CONN

29 052777 3 WASHER FLAT M3

30 043182 3 WASHER LOCK M3

31 051714 3 NUT HEX M3-0.5 G8 CLEAR ZINC

32 0D7177V 2 DIODE BRIDGE 1P 35A 1000V

33 051713 2 WASHER FLAT M5

34 049226 2 WASHER LOCK M5

35 051716 2 NUT HEX M5-0.8 G8 CLEAR ZINC

36 056326 1 TRIM VINYL BLACK 1/8GP (3”LG)

37 0J0489 1 DECAL CUSTOMER POWER CONNECT

38 0H7292 1 DECAL CUSTOMER CONTROL CONNECT

39 0H7293 1 DECAL CONBOX TB1 CONNECTIONS

40 026850 1 WASHER LOCK EXT 1/4 STL

41 055414 1 LUG SLDLSS #2-#8 X 17/64 CU

(4)42 SEE CHART 1 CIRCUIT BREAKER

(6)43 0H81040AS0R 1 COVER DPE BREAKER NEXUS RAW

44 0A9457 1 DECAL NEUTRAL

45 022264 4 WASHER LOCK #8-M4

46 045764 2 SCREW HHTT M4-0.7 X 8 ZP

47 067210A 1 DECAL GROUND LUG

(1)48 0D7393T REF TERM BLOCK 3P UL 12-20AWG

(1)49 0D7393U REF TERM BLOCK 4P UL 12-20AWG

(1)50 0F5376S0AR REF MX150L SLRRMNT 22-18 8P W/O GA

(1)51 0F5396S0AR REF MX150L SLRRMNT 22-18 12P W/OGA

(2)52 0A7822 REF LUG SLDLSS 600/250-1/0X1/4-28

(2)53 083896 REF WASHER LOCK 1/4-M6 SS

(2)54 045335 REF SCREW HHC 1/4-28 X 3/4 G5

55 029289 1 TAPE ELEC 1/2 FOAM (69“LG)

56 0F6146 1 HANG TAG 2 WIRE START (NOT SHOWN)

57 0H6692 1 HARN CONBOX NEXUS (NOT SHOWN)

58 0D6029 5 SCREW HHTT M6-1.0 X 16 ZYC

59 0D7178T REF FUSE ATO TYPE 7.5AMP (BROWN)

60 0J3060 1 GASKET WIRE ENTRY COVER

61 0H8006 1 DECAL CAUTION ELEC SHOCK SM

EXPLODED VIEW: CONBOX C2 CPL

DRAWING #: 0H7326 GROUP A

APPLICABLE TO:

REVISION: H-9621-F Page 5 of 8

DATE: 9/26/11

ITEM PART# QTY. DESCRIPTION

UL CIRCUIT BREAKER (225AF)

A 0G5250 1 CB 175A 2 POLE 240V 225AF

B 0H7356 1 COVER CB C2 CPL

C 0F4186AGS0R 1 COVER CB DISH 2P G 225AF

D 0F8432A 1 INSULATOR CB 2P 225AF

E 0H7311 1 STANDOFF CB BOX CONBOX

F 045771 2 NUT HEX M8-1.25 G8 CLEAR ZINC

G 036261 4 RIVET POP .125 X .275 SS

H 0C2454 12 SCREW HWHT M6-1 X 16 N WA Z/JS

J 053640 2 SCREW RHM #8-32 X 3-1/4

K 038150 2 WASHER FLAT #8 ZINC

L 022264 2 WASHER LOCK #8-M4

M 022471 2 NUT HEX #8-32 STEEL

N 049897 4 SCREW SHC M8-1.25 X 20 G8

P 022129 6 WASHER LOCK M8-5/16

R 022145 4 WASHER FLAT 5/16-M8 ZINC

S 058306 2 SCREW SHC M8-1.25 X 25 C12.9

T 0F8843 2 BUS BAR 200A LUG ADAPTOR

U 0F8451 2 LUG SLDLSS 300 MCM-6 AL/CU

V 0G3259 1 DECAL TERMINAL SHOCK HZD BI

UL CIRCUIT BREAKER (400AF)

A 0F4153 1 CB 0250A 3P 480V G 400AF

B 0H6735 1 COVER CB 400AF C2 CONBOX

C 0A7822 3 LUG SLDLSS 600/250-1/0X1/4-28

D 0H6734 1 STANDOFF CB MOUNT CONBOX

E 042419 4 SCREW RHM 10-32 X 4

F 022097 6 WASHER LOCK M6-1/4

G 052647 6 SCREW SHC M10-1.5 X 25 C12.9

H 0C2454 12 SCREW HWHT M6-1 X 16 N WA Z/JS

J 046526 6 WASHER LOCK M10

K 023897 4 WASHER FLAT #10 ZINC

L 022152 4 WASHER LOCK #10

M 022158 4 NUT HEX #10-32 STEEL

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

P 022473 6 WASHER FLAT 1/4-M6 ZINC

Q 0G3259 1 DECAL TERMINAL SHOCK HZD BI

(1) ITEMS INCLUDED WITH HARNESS P/N 0H6692.

(2) ITEMS INCLUDED WITH NEUTRAL BLOCK P/N 0D5464B.

(3) ITEMS INCLUDED WITH 4.2L MODELS ONLY.

(4) SEE “C2 DPE BREAKER SELECTION” TABLE.

(5) QTY. REQ. FOR 2 POLE BREAKER / QTY. REQ. FOR 3 POLE BREAKER.

(6) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)

• MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.

• CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE

SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).

EXPLODED VIEW: CONBOX C2 CPL

DRAWING #: 0H7326 GROUP A

APPLICABLE TO:

REVISION: H-9621-F Page 6 of 8

DATE: 9/26/11

ITEM PART# QTY. DESCRIPTION

UL CIRCUIT BREAKER (KG)

A 0H5582 1 CB 0300 3P 600V E KG LL

B 0H6740 1 COVER CB E KG C2 CONBOX

C 0D3700 4 NUT FLANGE M6-1.0 NYLOK

D 0H5581A 1 INSULATOR CB E 3P KG

E 0H6734 1 STANDOFF CB MOUNT CONBOX

G 022129 3 WASHER LOCK M8-5/16

H 0C2454 12 SCREW HWHT M6-1 X 16 N WA Z/JS

J 0D2157 4 SCREW SHC M6-1.0 X 50 C8.8

K 049897 3 SCREW SHC M8-1.25 X 20 G8

L 022145 3 WASHER FLAT 5/16-M8 ZINC

UL CIRCUIT BREAKER (FG)

A 0H5486 1 CB 0060 3P 480V E FG LL

B 0H7356 1 COVER CB C2 CPL

C 0H7434 1 COVER CB DISH 3P E FG

D 0H4698A 1 INSULATOR CB 3P E TYPE CC/FG

E 0H7311 1 STANDOFF CB BOX CONBOX

F 022471 4 NUT HEX #8-32 STEEL

G 036261 4 RIVET POP .125 X .275 SS

H 0C2454 12 SCREW HWHT M6-1 X 16 N WA Z/JS

J 0H5721 4 SCREW PPHM #8-32 X 1-3/4 ZINC

K 022264 4 WASHER LOCK #8-M4

L 038150 4 WASHER FLAT #8 ZINC

M 052619 3 SCREW HHC M5-0.8 X 20 G8.8

N 023897 3 WASHER FLAT #10 ZINC

P 049226 3 WASHER LOCK M5

UL CIRCUIT BREAKER (JG)

A 0H5580 1 CB 0250 3P 600V E JG LL

B 0H6739 1 COVER CB E JG C2 CONBOX

D 0H5576A 1 INSULATOR CB E 3P JG

E 0H6734 1 STANDOFF CB MOUNT CONBOX

F 022127 4 NUT HEX 1/4-20 STEEL

G 022097 4 WASHER LOCK M6-1/4

H 0C2454 12 SCREW HWHT M6-1 X 16 N WA Z/JS

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

K 022473 4 WASHER FLAT 1/4-M6 ZINC

L 049897 3 SCREW SHC M8-1.25 X 20 G8

M 022145 3 WASHER FLAT 5/16-M8 ZINC

N 022129 3 WASHER LOCK M8-5/16

UL CIRCUIT BREAKER (CC)

A 0H4748 1 CB 0175A 2P 240V E CC LL

0H4915 1 CB 0150 3P 240V E CC LL

B 0H7356 1 COVER CB C2 CPL

C 0H7432 1 COVER CB DISH 2P E CC

0H7433 1 COVER CB DISH 3P E CC

(5)D 051716 2/3 NUT HEX M5-0.8 G8 CLEAR ZINC

E 0H7311 1 STANDOFF CB BOX CONBOX

(5)F 022471 2/4 NUT HEX #8-32 STEEL

G 036261 4 RIVET POP .125 X .275 SS

H 0C2454 12 SCREW HWHT M6-1 X 16 N WA Z/JS

(5)J 053640 2/4 SCREW RHM #8-32 X 3-1/4

(5)K 022264 2/4 WASHER LOCK #8-M4

(5)L 038150 2/4 WASHER FLAT #8 ZINC

(5)M 052619 2/3 SCREW HHC M5-0.8 X 20 G8.8

(5)N 023897 4/6 WASHER FLAT #10 ZINC

(5)P 049226 2/3 WASHER LOCK M5

(5) QTY. REQ. FOR 2 POLE BREAKER / QTY. REQ. FOR 3 POLE BREAKER.

EXPLODED VIEW: CONBOX C2 CPL

DRAWING #: 0H7326 GROUP A

APPLICABLE TO:

REVISION: H-9621-F Page 7 of 8

DATE: 9/26/11

ITEM PART# QTY. DESCRIPTION

UL CIRCUIT BREAKER (QN)

A 0E7284 1 CB 0175A 2P 240V S QN2 LL

B 0H7356 1 COVER CB C2 CPL

C 0H7429 1 COVER CB DISH 2P S QN

D 0E3664 1 BASE, QN CIRCUIT BREAKER

E 0H7311 1 STANDOFF CB BOX CONBOX

F 074908 2 SCREW HHTT M5-0.8 X 10 BP

G 036261 4 RIVET POP .125 X .275 SS

H 0C2454 12 SCREW HWHT M6-1 X 16 N WA Z/JS

UL CIRCUIT BREAKER (ED)

A 0D9693 1 CB 0125A 3P 480V S ED4 LL

B 0H6736 1 COVER CB S ED C2 CONBOX

C 022158 4 NUT HEX #10-32 STEEL

D 0F0492 1 INSULATOR CB S(ED-3P)

E 0H6734 1 STANDOFF CB MOUNT CONBOX

F 022152 4 WASHER LOCK #10

G 023897 4 WASHER FLAT #10 ZINC

H 0C2454 12 SCREW HWHT M6-1 X 16 N WA Z/JS

J 048927 4 SCREW RHM #10-32 X 4-1/2

UL CIRCUIT BREAKER (VL)

A 0H7519 1 CB 0300A 3P 600V S JG-VL LL

B 0H6738 1 COVER CB S JG VL C2 CONBOX

C 040976 3 SCREW SHC M8-1.25 X 20 C12.9

D 022129 3 WASHER LOCK M8-5/16

E 0H6734 1 STANDOFF CB MOUNT CONBOX

F 022145 3 WASHER FLAT 5/16-M8 ZINC

G 023897 4 WASHER FLAT #10 ZINC

H 0C2454 12 SCREW HWHT M6-1 X 16 N WA Z/JS

J 042419 4 SCREW RHM 10-32 X 4

K 022152 4 WASHER LOCK #10

L 022158 4 NUT HEX #10-32 STEEL

UL CIRCUIT BREAKER (FD)

A 0D5572 1 CB 0150A 3P 600V S FD6 LL

B 0H6737 1 COVER CB S FD6 C2 CONBOX

C 081320 4 SCREW SHC 1/4-20 X 4.5 G8.8 NZ

D 0F0199 1 INSULATOR CB FD FRAME 30MIL

E 0H6734 1 STANDOFF CB MOUNT CONBOX

F 022473 4 WASHER FLAT 1/4-M6 ZINC

G 022097 4 WASHER LOCK M6-1/4

H 0C2454 12 SCREW HWHT M6-1 X 16 N WA Z/JS

J 022127 4 NUT HEX 1/4-20 STEEL

EXPLODED VIEW: CONBOX C2 CPL

DRAWING #: 0H7326 GROUP A

APPLICABLE TO:

REVISION: H-9621-F Page 8 of 8

DATE: 9/26/11

THIS PAGE LEFT INTENTIONALLY BLANK

1 0G37260ST03 1 WELDMENT FRAME 2.4L C2 60KW

2 052860 4 NUT FLANGED HEX M12-1.75

3 052251 4 DAMPENER VIBRATION 40 BLUE

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

5 052252 4 DAMPENER VIBRATION

6 052259 4 WASHER FLAT M12

7 052891 4 SCREW HHC M12-1.75 X 80 G8.8

8 0536210410 1 ASSY WIRE 14.00"

9 042909 1 SCREW HHC M8-1.25 X 30 G8.8

10 047411 1 SCREW HHC M6-1.0 X 16 G8.8

11 055414 1 LUG SLDLSS #2-#8 X 17/64 CU

12 022447 1 WASHER SHAKEPROOF INT 1/4

13 022097 1 WASHER LOCK M6-1/4

14 022473 2 WASHER FLAT M6-1/4 ZINC

15 049813 1 NUT HEX M6 -1.0 G8 YEL CHR

16 022261 1 WASHER SHAKEPROOF INT 3/8

17 0F9597A 1 SUPPORT LH ENGINE 2.4L

18 045764 1 SCREW HHTT M4-0.7 X 8 BP

19 062963 4 SCREW HHC M10-1.25 X 30 G8.8

20 022302 5 WASHER LOCK 7/16

21 022131 5 WASHER FLAT 3/8-M10 ZINC

22 065852 1 SPRING CLIP HOLDER .37-.62

23 0F9597 1 SUPPORT RH ENGINE 2.4L

24 022129 1 WASHER LOCK M8-5/16

25 026204 1 WASHER SHAKEPROOF INT 5/16

26 022145 1 WASHER FLAT 5/16-M8 ZINC

27 045771 1 NUT HEX M8-1.25 G8 CLEAR ZINC

29 0F9596A 1 SPACER LH ENGINE MOUNT

30 052212 1 SCREW HHC M10-1.25 X 25 C8.8

1 0F3408C 1 BATTERY TRAY, C1 & C2

2 0F3411 1 STRAP BATTERY RETAINMENT

3 025507 REF WASHER SHAKEPROOF EXT 7/16 STL

4 052212 REF SCREW HHC M10-1.25 X 25 G8.8

5 046526 REF WASHER LOCK M10

6 022131 REF WASHER FLAT 3/8-M10 ZINC

7 050331A REF BATTERY POST COVER RED +

8 050331 REF BATTERY POST COVER BLACK -

9 038805Y 1 CABLE BATTERY BLACK #1 X 18.00

10 03880400AE 1 CABLE BATT RED #1 X 18.00

11 045771 REF NUT HEX M8-1.25 G8 YEL CHR

12 022129 REF WASHER LOCK M8-5/16

13 077483 REF BATTERY 12VDC 75-AH 26

14 0F3976 1 BOOT CONTACTOR CABLES

15 042568 4 SCREW HHC M6-1.0 X 20 C8.8

16 022145 REF WASHER FLAT 5/16-M8 ZINC

17 0D3700 4 NUT FLANGE M6-1.0 NYLOK

18 049811 4 WASHER FLAT M6

EXPLODED VIEW: AIR CLEANER 2.4L G2 TURBO

DRAWING #: 0H1954 GROUP D

APPLICABLE TO:

REVISION: H-3963 –B PAGE 2 OF 2

DATE: 2/27/09

ITEM PART# QTY. DESCRIPTION

1 0F4269 2 GASKET MIXER BODY

2 0H0030 1 ADAPTOR-MIXER

3 0G39340ST03 1 BRACKET AIR INTAKE

4 035480 1 BOLT U 5/16-18 X 2.06

5 0H0028 1 ADAPTOR-AIR CLEANER

6 0F4271 1 BASE PLATE, AIR CLEANER

7 0H0219 1 PLUG PLASTIC 2.5" BLACK

8 0F5418 1 ELEMENT AIR FILTER

9 0F4270 1 HOLD DOWN AIR CLEANER PLATED

10 0F6323 1 PLATE, AIR CLEANER TOP

11 0H0035 1 HOSE AIR INTAKE

12 0G0153 1 BARBED EL 90 1/2NPT X 3/4 HOSE

13 0D3700 4 NUT FLANGE M6-1.0 NYLOK

14 049811 8 WASHER, FLAT, M6

15 045757 4 SCREW HHC M6-1.0 X 25 G8.8

16 022097 4 WASHER LOCK M6-1/4

17 047411 4 SCREW HHC M6-1.0 X 16 C8.8

18 022145 2 WASHER FLAT 5/16-M8 ZINC

19 022129 2 WASHER LOCK M8-5/16

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

21 037561 1 NUT WING 1/4-20 W/NY INS ST ZN

22 0D3700 4 NUT FLANGE M6-1.0 NYLOK

23 049811 8 WASHER, FLAT, M6

24 045757 4 SCREW HHC M6-1.0 X 25 G8.8

25 022097 4 WASHER LOCK M6-1/4

26 047411 4 SCREW HHC M6-1.0 X 16 C8.8

27 086133C 2 CLAMP HI TORQUE 1.75 - 2.625

28 039253 2 SCREW HHC M8-1.25 X 20 G8.8

29 022129 4 WASHER LOCK M8-5/16

30 022145 4 WASHER FLAT 5/16-M8 ZINC

31 022259 2 NUT HEX 5/16-18 STEEL

32 0H1712 1 BARBED EL-90 POLY 1/2NPT X ¾

33 057822 2 CLAMP HOSE #8 .53-1.00

34 059057 1 HOSE 3/4 ID SAE-30R2 (7.62”LG”)

35 0H0027 1 FITTING VENT VALVE COVER 2.4L

047527(3)(4) 1 BARBED STR 1/2NPT X 3/4

0H1644(4) 1 FTG VNT VALVE COVER

0G10080103(4) 1(REF) GASKET, PCV VALVE

36(1)(2) 0H1787A 1 PIPE INSULATION ELBO

37(2) 0H1787 1 PIPE INSULATION (4.5”LG)

38(2) 0H1801 1 PIPE INSULATION TAPE (7”LG)

(1)TRIM PIPE INSULATION ELBOW TO FIT.

(2)INSULATION SHALL COMPLETELY COVER I/N’S 32, 34 & 35.

(3)APPLY PIPE SEALANT COMPOUND TO THREADS.

(4) ALTERNATE CONFIGURATION REQUIRES ALL NOTED PARTS.

NOTE: APPLY LOCTITE 620 BEARING RETAINMENT COMPOUND TO OUTSIDE

SURFACE OF FITTING (I/N 35) THAT PRESSES INTO VALVE COVER.

1

0H30830ST03

1

WELDMENT RADIATOR SUPPORT C2

2 0F2608 1 RADIATOR 598 X 568 X 49 CPL RH

3 0F5263 1 V-BELT 31/64" X 57-3/8"

4 046526 5 WASHER LOCK M10

(1) 5 059981 4 SCREW HHC M10-1.5 X 30 G10.9

6 0D3700 4 NUT FLANGE M6-1.0 NYLOK

7 0F5050A 1 SHIELD RADIATOR C4

8 0G9332C 1 OIL LINE REMOTE FILTER/ENGINE

9 0F2573 1 PULLEY FAN V-GROOVE 9"

10 0F4011 1 FAN COOL 22" DIA 10 BLADE LH

11 0H20620ST03 1 ARM BELT TENSIONER

(1) 12 0H2051 1 SHOULDER BOLT 1/2 X 2-1/4"

13 0F2862 1 SPRING TENSION CPL

14 0F2560 1 PULLEY V-BELT 4" FLANGED

15 022131 4 WASHER FLAT 3/8-M10 ZINC

16 0E2507 1 PROBE COOLANT LEVEL 3/8 NPTF

0H1827 1 PROBE COOLANT LEVEL 3/8-18NPTF

17 035685 2 CLAMP HOSE #28 1.32-2.25

18 0F2561 1 HUB FLEX PLATE

19 0C8145 8 WASHER FLEX (THIN)

20 052250 2 TAPE FOAM 1 X 1 (26.75” LG)

21 0C7043 12 DISK FLEX

22 0G9332B 1 OIL LINE REMOTE COOLER/FILTER

23 022473 8 WASHER FLAT 1/4-M6 ZINC

(1) 24 0C8146 4 SCREW HHC 5/16-24 X 1.124

25 022097 16 WASHER LOCK M6-1/4

26 076749 1 TANK COOLANT RECOVERY

(2) 27 048031C 2(REF) CLAMP HOSE BAND 1/4

28 031971 1 BEARING #6205 2NSE C3 E SRI2 S

29 0H0271 1 PULLEY 5.125" DIA MACHINED

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

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

32 022304 1 WASHER FLAT 1/2 ZINC

33 022195 1 WASHER LOCK 1/2

34 022196 1 NUT HEX 1/2-13 STEEL

35 0F8651 8 SCREW HHFC M8-1.25 X 20 W/M6

36 052677 1 WASHER NYLON .50 X .87 X .06

37 0F9867 1 SHAFT FAN DRIVE

38 0F2461 1 RETAINER BEARING

39 022145 16 WASHER FLAT 5/16-M8 ZINC

40 022129 9 WASHER LOCK M8-5/16

(1) 41 039287 1 SCREW HHC M8-1.25 X 45 C8.8

42 082774 1 KEY WOODRUFF 4 X 19D

43 0G0795 1 HOSE LOWER RADIATOR G2

44 0G0816 1 HOSE UPPER RADIATOR G2 (USED WITH MANFLD

P/N 0G0707)

0H1546 1 HOSE UPPER RADIATOR G2 (USED WITH MANFLD

P/N 0G8488)

45 049813 8 NUT HEX M6 X 1.0 G8 YEL CHR

46 052644 1 SPACER .5 X 1.5 X .25 STL/ZINC

47 0C8566 20 SCREW HHFC M6-1.0 X 20 G8.8

48 0C2454 9 SCREW THF M6-1 X 16 N WA Z/JS

49 090283 1 CAP RADIATOR 13 PSI

50 080713 1 BRACKET COOLANT TANK

51 055934M 1 CLAMP STL/VNL .75 X .343 Z

52 0A5259A 2 HOSE 2"ID X 3.0"LG

53 039253 2 SCREW HHC M8-1.25 X 20 C8.8

54 0G9595 1 BRACKET RESERVOIR MOUNTING

55 049820 5 NUT HEX LOCK M8-1.25 NY INS

56 0H30880ST03 1 BRACKET TENSIONER SPRING

57 099502 2 CLAMP HOSE #24 B1.06-2.00

58 0C8165 2 NUT HEX LOCK 5/16-24 NY INS

59 029032 1 HOSE 9/32 ID (36”LG)

60 0G3762 1 CAC 504W X 152H X 50D 2.4L G2

61 0G1285C 8 CLAMP CNST TENSION 1.75-2.625

62 071296A 2 HOSE 2"ID X 3.0"LG

63 0G3985 1 TUBE CAC IN G2 TURBO

64 0G3989 1 TUBE CAC OUT G2 TURBO

65 0C2454B 4 SCREW THF M6-1 X 30 N WA DELTA

66 0G9332A 1 OIL LINE REMOTE ENG/COOLER

67 0C4975 1 ADAPTOR 1/2 NPT X 37JIC 3/4-16

68 0G3990 1 COOLER OIL 2.4L G2 TURBO

69 0C4973D 2 ADAPTER 90D JIC37 1/2NPT X 3/4

(4) 70 0H2844 2 (REF) BEARING SLEEVE 1/2/ X 3/4 X 1

71 0G53150AL0R 1 SPACER CPL COOLING FAN 1/8"

72 0G3986 2 MOUNT OIL COOLER 2.4L G2

73 0G9910 1 ADAPTER 45D JIC37 1/2NPT X 3/4

74 0G9331 1 MOUNT REMOTE OIL FILTER 2.4 G2

(3) 75 0G9333 1 NIPPLE-OIL FILTER

76 0A45310244 1 FILTER 1.5L/2.4L G2 OIL

77 043107 3 SCREW HHC M8-1.25 X 25 C8.8

(5) 78 0H1851 1 ASSY PCB LCL SENSOR (USE WITH I/N 16, P/N

0H1827 ONLY)

79 029333A 9 TIE WRAP UL 7.4” X .19” BLK (NOT SHOWN)

80 0D3700 8 NUT FLANGE M6-1.0 NYLOK

BEARING PRESS NOTE:

APPLY LOCTITE 620 BEARING RETAINMENT

COMPOUND TO BEARING SURFACE ON ITEM 37

PRIOR TO PRESSING ITEM 28 ONTO ITEM 37.

ALSO APPLY LOCTITE 620 BEARING RETAINMENT

COMPOUND TO THE OUTSIDE OF 28 PRIOR TO

INSTALLING ITEM 28 INTO ITEM 38.

(1) APPLY MEDIUM STRENGTH BLUE THREAD

LOCKING FLUID TO THREADS.

(2) INCLUDED WITH I/N 26.

(3) APPLY LOCTITE #266 TO I/N 75 PRIOR TO

ASSEMBLY.

(4) ITEM 70 IS INCLUDED WITH ITEM 1.

(5) USE WITH R-200 CONTROL PANEL ONLY.

EXPLODED VIEW: TURBO 2.4L G2

DRAWING #: 0H3356 GROUP D

APPLICABLE TO:

REVISION: -A- PAGE 1 OF

DATE: 6/22/09

ITEM PART# QTY. DESCRIPTION

1 042574 1 ADAPTER 1/8NPTF TO 1/8 BSPT

2 064094 1 MALE ELBOW 45 #49X3

3 064096B 1 OIL SUPPLY 3LHA(38")

4 0G8690 1 GASKET 2.4L G2

5 0G8692 1 GASKET 2.4L G2

6 0H2811 1 TURBOCHARGER G2 2.4L

7 0A4707B 1 ADAPTER 1/4NPT X M12-1.5

8 0A4707F 1 ADAPTER 1/2NPT X M16-1.5

9 0C4975 1 ADAPTER 1/2 NPT X 37JIC 3/4-16

10 0C4973C 1 ADAPTER 90D JIC37 1/4NPT X 1/2

11 0E5343 4 NUT HEX FL WHIZ M10-1.50

12 0H0457 4 STUD M10-1.5 X 40 G10.9

EXPLODED VIEW: MUFFLER EXH 2.4L G2 TURBO

DRAWING #: 0H3357 GROUP F

APPLICABLE TO:

REVISION: H-5192-B PAGE 1 OF

DATE: 10/12/09

ITEM PART# QTY. DESCRIPTION

1 0G86870ST03 1 BRACKET MUFFLER

2 0G8686 1 BRACKET STIFFENER

3 0G6150 1 MUFFLER 60kW

4 0G0113 1 EXHAUST ELBOW

5 0F2808D 1 EXHAUST PIPE

6 0G0007 1 DIFFUSER EXHAUST WELDMENT

7 0H3371 1 PIPE EXHAUST 2.4L 60kW

8 0H3372 1 UPPER EXHAUST PIPE ASM

9 0G8685 1 STRAP MUFFLER

10 0C2454 4 SCREW THF M6-1 X 16 N WA Z/JS

11 022473 2 WASHER FLAT 1/4-M6 ZINC

12 022097 2 WASHER LOCK M6-1/4

13 049721 2 SCREW HHC M6-1.0 X 35 G8.8 BLK

14 080762 3 BOLT U 3/8-16 X 2.62

15 022241 6 NUT HEX 3/8-16 STEEL

16 036797 1 BOLT U 5/16-18 X 2.25

17 070006 6 WASHER LOCK M8 SS

18 022259 2 NUT HEX 5/16-18 STEEL

19 0A6928 4 SCREW HHC M8-1.25 X 20 SS

20 022237 6 WASHER LOCK 3/8

21 0H1310 1 BOLT U 3/8-16 X 2.30 W/SADDLE

22 0F3794 1 EXHAUST BLANKET 600MM LONG

23 0G3770 1 EXHAUST BLANKET 737MM

EXPLODED VIEW: ENGINE COMMON PARTS 2.4L G2 TURBO 60K

DRAWING #:0H7323 GROUP D

APPLICABLE TO:

REVISION: H-7244-D Page 3 of 4

DATE: 8/10/10

ITEM PART# QTY. DESCRIPTION

1 0H1619 1 ENGINE 2.4L G2 CERTIFIED

2 035472 1 CLAMP HOSE #6 .43-.78

3 0G1738 1 CAP ANTIFREEZE RUBBER 9.5DIA

4 0G0950 1(REF) GASKET INTAKE MANIFOLD G2

5 0G8488 1 MANIFOLD INTAKE (MACHINED)

6 022129 30 WASHER LOCK M8-5/16

7 058306 7 SCREW SHC M8-1.25 X 25

8 0E0502 1 TEMPERATURE SENDER, DELPHI

9 026073A 3 PLUG STD PIPE 1/4 STEEL SQ HD

10 045771 3 NUT HEX M8-1.25 G8 CLEAR ZINC

11 057772 1 WASHER NYLON .565

12 069860E 1 HOSE DRAIN ASSY 28"

13 0C7649 1 CLAMP HOSE .38-.87

14 043790A 1 BARBED EL 90 3/8NPT X 3/8 VS

15 057765 1 ADAPTER M14-1.50 X 3/8 NPT

16 049821 3 SCREW SHC M8-1.25 X 30 C12.9

17 0D2244M 1 MAGNETIC PICKUP

18 0G7461 1 MOTOR STARTER

19 0F9583 1 SPACER 2.4L G2 FLEX PLATE

20 0F9420 1 ADAPTER ENGINE

21 0F9965E 1 FLEX PLATE 2 POLE 2.4L G2

22 063076 7 WASHER FLAT .531 ID X 1.062 OD

23 0G1394 7 SCREW HHC M12-1.25 X 20 C10.9

24 052830 2 SCREW HHC M10-1.25 X 45 G8.8

25 025507 5 WASHER SHAKEPROOF EXT 7/16 STL

26 062963 3 SCREW HHC M10-1.25 X 30 G8.8

27 077043H 2 CONDUIT FLEX .25"ID

28 0G3995 1 SHIELD INNER HEAT 2.4L TURBO

29 090388 7 SCREW HHTT M6-1.0 X 12 ZINC

30 0D3701 1 PLATE "HOT"

31 0F0710 2 RIVET POP .125 X 0.337 STEEL

32 0H6859H 1 ASSY DIPSTICK W/TEXT GTH-530

33 0G8427A 1 ASSY DIPSTICK TUBE 2.4 G2

34 052213 3 SCREW HHC M10-1.25 X 20 C8.8

35 046526 6 WASHER LOCK M10

36 022131 5 WASHER FLAT 3/8-M10 ZINC

37 0G3823 2 O-RING SIZE 9.0MM X 2.0MM NITR

38 0G7902 1 TUBE TURBO OIL RETURN G2 2.4L

39 0H2574 1 CONDUIT THERMAL FLEX 13MM ID

40 047411 1 SCREW HHC M6-1.0 X 16 C8.8

41 022097 1 WASHER LOCK M6-1/4

42 022473 1 WASHER FLAT 1/4-M6 ZINC

43 0G39910ST03 1 BRACKET EXH MANIFOLD 2.4 TURBO

44 0G4000 1 HEAT SHIELD TURBO 2.4L

45 0G39970ST03 1 BRACKET HEAT SHIELD 2.4L

46 042907 4 SCREW HHC M8-1.25 X 16 C8.8

47(1) 0G0951 1(REF) GASKET EXHAUST MANIFOLD

48 0E4507 1 SCREW HHC M10-1.5 X 120 C8.8

49(2) 0E9868A 1 ALTERNATOR DC W/OUT PULLEY

50 0G0788 1 PULLEY DC ALTERNATOR

51 0F3217 1 SPACER DC ALTERNATOR PULLEY

52 0A8258 9 SCREW HHC M8-1.25 X 25 G10.9

53 022145 7 WASHER FLAT 5/16-M8 ZINC

54 039414 4 SCREW HHC M8-1.25 X 35 G8.8

55 0G0149 1 SCREW SHC M14-1.5 X 35 G10.9

56 0F9501 1 ADAPTER 2.4L CRANKSHAFT MACH

57(1) 0G0952 1(REF) POLY V-BELT G2

58 0G1472A 1 CAM SENSOR PIN ASSY

59 0G1477 1(REF) COVER CAM GEAR G2 REWORKED

60 0G8852 1 BRACKET ASM-2.4L COIL G2

61(1) 052265 1(REF) SCREW HHC M8-1.25 X 65 C8.8

62(1) 052203 1(REF) SCREW HHC M8-1.25 X 70 G8.8

63 046525 2 NUT HEX M10-1.25 G8 YEL CHR

64 0G3921A 1 VR SENSOR ASSY 3/8-24 LOW SENS

65 029333A 3 TIE WRAP UL 7.4"X .19" BLK

EXPLODED VIEW: ENGINE COMMON PARTS 2.4L G2 TURBO 60K

DRAWING #:0H7323 GROUP D

APPLICABLE TO:

REVISION: H-7244-D Page 4 of 4

DATE: 8/10/10

ITEM PART# QTY. DESCRIPTION

66 0G8853 4 COIL-2.4L G2 IGNITION

67 023897 8 WASHER FLAT #10 ZINC

68 022152 8 WASHER LOCK #10

69 034413 8 SCREW HHM #10-32 X 1-1/4

70 0G9350 1 O-RING 2.5"X 2.75"X 1/8" VITON

71 0G9329 1 ADAPTOR OIL FILTER 2.4L G2

72 0H7435 1 HARN LOW OIL PRESS SWITCH ASSY

73 0G9910 2 ADAPTOR 45D JIC37 1/2NPT X ¾

74 0G9349 1 O-RING 1" X 1.25" X 1/8" VITON

75 0G9330 1 NUT OIL FILTER ADAPTOR 2.4L G2

76 084750 4 PLUG SPARK

77 0G4003 1 SHIELD HEAT IGNITION COIL 2.4L

78 0G8854 1 SPARK PLUG WIRE SET 2.4L G2 IG

79 0H1432B 1 MANIFOLD EXH 60K G2 TURBO (MA)

80 (1) 0A45310244 1(REF) FILTER 1.5L/2.4L G2 OIL (NOT SHOWN)

81 0H6689 1 HARN ENG G2.4L G2 NEXUS (NOT SHOWN)

82 045772 1 NUT HEX M10-1.5 G8 YEL CHR

(1) SUPPLIED WITH ENGINE

(2) APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THE THREADS

1 057147 1 HOSE 3/4 ID LPG & NG (43”LG)

2 065908 1 FLANGE FUEL INLET

3 039130 1 NIPPLE CLOSE 1.25 NPT X 1.625

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

5 088963 1 NIPPLE PIPE 1.25 NPT X 5.5 BL IRN

6 026915 2 NIPPLE CLOSE 3/4 X 1.375

7 0A8064 2 BSHG RDCR HEX 1-1/4-3/4

8 064346 1 PIPE TEE 1-1/4 NPT

9 0G9239C 1 REG ASSY 2.4L 60KW NG CPL

10 046580 4 SCREW SHC M6-1.0 X 45 C12.9

11 043107 2 SCREW HHC M8-1.25 X 25 C8.8

12 022131 4 WASHER FLAT 3/8-M10 ZINC

13 022129 2 WASHER LOCK M8-5/16

14 045771 2 NUT HEX M8-1.25 G8 CLEAR ZINC

15 050279 1 DECAL FUEL INLET NG

16 0D1509 1 DECAL INLET PRESSURE

17 057147 1 HOSE 3/4 ID LPG & NG (43” LG)

18 0H7438 1 HARN FUEL JUMPER DUAL REG

19 057823 4 CLAMP HOSE #10 .56-1.06

20 0E4394 1 ACTUATOR BOSCH 40 GOVERNOR

21 0E6586 1 GASKET BOSCH 32

22 086133C 1 CLAMP HI TORQUE 1.75 - 2.625

23 0F3857 1 REDUCER RUBBER 3.0"-2.00"

24 086133E 1 CLAMP HI TORQUE 2.75 - 3.625

25 0F3885 1 MIXER 40/60MM ACTUATOR ASSY

26 0G3167 2 O-RING 2-3/4 X 3/32 X 2-15/16

27 0F3691 1 VENTURI THROTTLE 32MM

28 022097 4 WASHER LOCK M6-1/4

1 057147 1 HOSE 3/4 ID LPG & NG (45”LG)

2 075580 1 FLANGE, FUEL INLET

3 026915 1 NIPPLE CLOSE 3/4 X 1.375

4 026812 2 ELBOW 90D 3/4NPT

5 0F8379 1 NIPPLE PIPE 3/4 NPT X 7

6 026915 2 NIPPLE CLOSE 3/4 X 1.375

7 022097 4 WASHER LOCK M6-1/4

8 0F3691 1 VENTURI THROTTLE 32MM

9 0G9189C 1 REG ASSY 2.4L 60KW LPV CPL

10 046580 4 SCREW SHC M6-1.0 X 45 C12.9

11 043107 2 SCREW HHC M8-1.25 X 25 C8.8

12 022131 4 WASHER FLAT 3/8-M10 ZINC

13 022129 2 WASHER LOCK M8-5/16

14 045771 2 NUT HEX M8-1.25 G8 CLEAR ZINC

15 050280 1 DECAL FUEL INLET LPG

16 0D1509 1 DECAL INLET PRESSURE

17 057147 1 HOSE 3/4 ID LPG & NG (41” LG)

18 0H7436 1 HARN FUEL JUMPER SINGLE REG

19 057823 4 CLAMP HOSE #10 .56-1.06

20 0E4394 1 ACTUATOR BOSCH 40 GOVERNOR

21 0E6586 1 GASKET BOSCH 32

22 086133C 1 CLAMP HI TORQUE 1.75 - 2.625

23 0F3857 1 REDUCER RUBBER 3.0"-2.00"

24 086133E 1 CLAMP HI TORQUE 2.75 - 3.625

25 0F3885 1 MIXER 40/60MM ACTUATOR ASSY

26 0G3167 2 O-RING 2-3/4 X 3/32 X 2-15/16

(2) 1 0G80180AL0R 1 REAR WRAP C2 G2 60KW

2 0C2454 58 SCREW THF M6-1 X 16 N WA Z/JS

(2) 3 0F58490AL0R 2 DOOR C2

4 087233 2 RIVET POP .1875 X .450 SS

5 0E3257 4 SCREW TH-FRM M6 W/CAP SHKPRF W

(2) 6 0F58520AL0R 2 DUCT DSCHRG LH&RH

(2) 7 0F98330AL0R 2 FRONT CORNERS C2

(2) 8 0F58510AL0R 1 DUCT DISCHARGE C2

9 049813 2 NUT HEX M6 X 1.0 G8 YEL CHR

(1) 10 077992 21 NUT HEX LOCK M6-1.0 SS NY INS

(2) 11 0F98350AL0R 1 ROOF C2

12 0F2786 2 SLITTER C4

13 0F2785 1 SPLITTER LOWER C4

14 0F3364 1 SPLITTER STINGER C2

15 0F4880 2 SUPPORT SPLITTER LH C2

16 0F5049 2 TAB PULL

17 0F4487A 1 ASSEMBLY COVER ACCESS

18 022473 3 WASHER FLAT 1/4-M6 ZINC

19 022097 1 WASHER LOCK M6-1/4

20 022127 1 NUT HEX 1/4-20 STEEL

21 0F3072 10 INSULATION RETAINMENT HANGER

22 078115 26 WASHER SELF LOCKING DOME #4-40

23 0G5892 2 INSULATION DOOR C2

24 0G5892A 1 INSULATION ROOF TOP

25 0F5048D 2 VISE-ACTION LATCH SLOTTED CIR

26 0E5968 1 GASKET EXTRUDED TRIM (328” LG)

27 0G5892D 2 INSULATION SPLITTER

28 0G5892C 2 INSULATION SPLITTER

29 0F4051C 2 INSULATION DUCT

30 0F3890B 4 RETAINER INSULATION (820)

31 0F4051B 2 INSULATION DUCT SIDES

32 0F3890 4 RETAINER INSULATION (450)

33 078115A 6 WASHER SELF LOCKING DOME #8-32

34 0G5892E 1 INSULATION LOWER SPLITTER

35 042568 2 SCREW HHC M6-1.0 X 20 G8.8

36 0912970094 2 ASSY WIRE 14 AWG 34.8" GRN/YEL

37 022447 2 WASHER SHAKEPROOF INT 1/4

38 0G9473 1 DEFLECTOR INTAKE 2.4L G2 TURBO

39 0F8869D 1 KEY VISE-ACTION LATCH SLOT CIR

40 052250 1 TAPE FOAM 1X1 (17.25”LG)

41 066760 1 STRIP SEALANT 1/8 X 1 (44.52”LG)

42 0E5298L 1 FOAM 300 X 300 THERMAL ACO

43 0H1208A 1 RF COVER PLATE-PLASTIC-BISQUE

0H1208B 1 RF COVER PLATE-PLASTIC-GREY

(1) ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE

SECURED USING ITEM 2 & 5 THREAD FORMING FASTENER AND I/N 10 LOCK NUT. LOCK NUT IS TO BE INSTALLED

AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS. ALL

ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER.

(2) 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-0H7169” INCLUDED IN THE MANUAL OR

AVAILABLE ON THE GENERAC WEBSITE.

BackPg001 Rev. A 04/07