Generac QT06024ANSX, QT06024ANAX, QT06024AVAX, QT06024AVSX User Manual

Owner's Manual

Stationary Emergency Generator

NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT

APPLICATIONS. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST FUMES! OUTDOOR INSTALLATION ONLY!

This manual should remain with the unit.

2.4L

60kW Models

EPA Certified

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

Table of Contents

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

Safety Instructions

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this

equipment.

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 incorrectly or carelessly. Observe them carefully. Their definitions are as follows:

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

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 preventing accidents.

Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of information each indicates is as follows:

This symbol points out important safety 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 equipment. The manufacturer strongly recommends that the operator read this Owner's Manual and thoroughly understand all instructions before using this equipment. The manufacturer also strongly recommends instructing other users to properly start and operate the unit. This prepares them if they need to operate the equipment in an emergency.

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 contribute to the need for maintenance service.

Proper maintenance and care of the generator ensure a minimum number of problems and keep operating expenses at a minimum. See 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 factorytrained 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

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, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit are, therefore, not all inclusive. If a procedure, work method or operating technique is used that the manufacturer does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique utilized does not render the generator unsafe.

Despite the safe design of this generator,

operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to install, operate or maintain this equipment.

Potentially lethal voltages are generated by



these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator.

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, standards, laws and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure that the generator is installed, operated and serviced in accordance with the manufacturer’s instructions and recommendations. Following installation, do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes, standards, laws and regulations.

The engine exhaust fumes contain carbon monoxide gas, which •

can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. For that reason, adequate ventilation must be provided. 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 compliance with applicable codes and standards.

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

and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.

Adequate, unobstructed flow of cooling and ventilating air is •

critical in any room or building housing the generator to prevent buildup of explosive gases and to ensure correct generator operation. Do not alter the installation or permit even partial blockage of ventilation provisions, as this can seriously affect safe operation of the generator.

Keep the area around the generator clean and uncluttered. •

Remove any materials that could become hazardous.

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

Never work on the equipment when physically or mentally fatigued.

Inspect the generator regularly, and promptly repair or replace •

all worn, damaged or defective parts using only factoryapproved parts.

Before performing any maintenance on the generator, 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 dangerous 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 dangerous 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.

Safety004 Rev. F 05/10

1-2

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 connected to an approved earth ground. This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator or by static electricity. Never disconnect the ground wire.

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

be adequate to handle the maximum electrical current (ampacity) to which they will be subjected.

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

sure that all power voltage supplies are positively turned off at their source. Failure to do so will result in hazardous and possibly fatal electrical shock.

Connecting this unit to an electrical system normally supplied •

by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distribution system when the generator is operating. Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy.

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 circuit (battery cables, etc.) before working on or around the unit. Then, place a “Do Not Operate” tag on the generator control panel and on the transfer switch.

In case of accident caused by electric shock, immediately •

shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help.

Never wear jewelry when working on this equipment. Jewelry •

can conduct electricity resulting in electric shock, or may get caught in moving components causing injury.

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.

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.

1-3

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.

Safety004 Rev. F 05/10

General Information

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.

Data Label

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 manufacturing details pertaining to your unit. Always supply this number when requesting service, ordering parts or seeking information.

2-1

Identy005 Rev. D 05/10

Equipment Description

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, battery charger, and protective alarms as explained in the following paragraph.

All AC connections, including the power leads from the alternator, 120 volt battery charger input and control connections to the transfer switch are 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 evaluated 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.

Any attempt to crank or start the engine before

it has been properly serviced with the recommended 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 recommended coolant mixture. When adding coolant, always add the recommended 50-50 mixture.

Do not use any chromate base rust inhibitor

with ethylene glycol base anti-freeze or chromium hydroxide (“green slime”) forms and will cause overheating. Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base anti-freeze. Using any high silicate anti-freeze boosters or additives will also cause overheating. The manufacturer also recommends that any soluble oil inhibitor is NOT used for this equipment.

Do not remove the radiator pressure cap while

the engine is hot or serious burns from boiling liquid or steam could result.

Ethylene glycol base antifreeze is poisonous.

Do not use mouth to siphon coolant from the radiator, recovery bottle or any container. Wash hands thoroughly after handling. Never store used antifreeze in an open container because animals are attracted to the smell and taste of antifreeze even though it is poisonous to them.

3-1

Equip001 Rev. G 05/10

Engine Protective Devices

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 information.

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 coolant 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 pressure 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

Fuel System

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 identified 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 distribution line to the standby generator site. The following information applies to natural gas fuel systems.

• Gas pressure in a building is usually regulated by national, state and local codes.

• To reduce gas pressure to a safe level before the gas enters a building, a primary regulator is needed. The natural gas supplier may or may not supply such a regulator.

• It is the responsibility of the gas supplier to make sure sufficient gas pressure is available to operate the primary regulator.

• Gas pressure at the inlet to the fuel shutoff solenoid 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 consumption is high, the vapor withdrawal system may not function efficiently.

• Ambient temperatures around the supply tank must be high enough to sustain adequate vaporization, or the system will not deliver the needed fuel volume.

• In addition to the cooling effects of ambient air, the vaporization process itself provides an additional cooling effect.

5-1

FuelSys001 Rev. F 04/11

Specifications

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 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

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%

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.

GenSpec088 Rev. A 05/10

6-2

L - N

L - L

INTERNAL

CONNECTIONS

00 (NEUTRAL)

S12

S11

S10

L - N

L - L

General Information

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

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 alternator power windings. These windings were connected at the factory to the main circuit breaker with a “Y” configuration as shown in Figures 7.2 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)

7-1

Figure 7.3 — Stator Power Winding

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

ACConn007 Rev. B 05/10

00 (NEUTRAL)

INTERNAL CONNECTIONS

L-L

L-N

L-L

L-N

S10

S12

S11

L - N

L - L

INTERNAL

CONNECTIONS

00 (NEUTRAL)

General Information

Figure 7.4 — Stator Power Winding

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

Figure 7.5 — Stator Power Winding

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

3-PHASE ALTERNATORS ("DELTA" CONFIGURATION)

The Stationary Emergency Generator is designed to supply 3-phase electrical loads. Electric power is produced in the alternator power windings. These windings were connected at the factory to the main circuit breaker with a “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)

INTERNAL

CONNECTIONS

L - L

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

Figure 7.6 — Stator Power Winding

ACConn007 Rev. B 05/10

7-2

E1 E3

L - N

00 (NEUTRAL)

Figure 7.8 — Stator Power Winding

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

S12

S5 S9

L - L

S8 S6

S11

E1 E3

L - N

00 (NEUTRAL)

S10

Control Panel

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 working on or around the generator or transfer switch. Then, place a “DO NOT OPERATE” tag on the generator panel and on the transfer switch.

1. “AUTO” Position – Selecting this switch activates fully automatic system operation. It also allows the unit to automatically 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.

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 maintenance 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.

ACTIVATE THE GENERATOR

When battery power is applied to the generator during the installation 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 disconnect 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.

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".)

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CntrlNexusus001 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.

Language

- English +

Escape Enter

Display Reads: Press ENTER to begin the activation pro-

cess.

Activate me (ENT) or ESC to run in manual

Escape Enter

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

go to www.activategen.com or call

To Activate go to www.activategen.com

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

If you already have your activation code, wait 3-5 seconds for the next display.

Escape Enter

If the wrong language is chosen, it can be changed later using the “edit” menu.

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.

ENTER ACTIVATION CODE (Passcode) TROUBLESHOOTING

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

number of your Activation Code.

Serial 123456789 Passcode XXXXX +/-

Press ENTER to select.

Repeat this step until all digits have been entered.

Escape Enter

Display Reads: Activation is complete when all digits are

“SELECT HOUR (0-23)”

“- +”6

Escape Enter

Use ESCAPE to correct previous digits.

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).

CntrlNexus001 Rev. D 04/11

8-2

Control Panel

INSTALLATION ASSISTANT

Interconnect System Self Test Feature (follow the on-screen

prompts).

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 intervals 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 controller will exit the exercise routine and assume full automatic operation.

USER ADJUSTABLE SETTINGS

Setting

Exercise

time

Exercise

day

Current

Time

Current

Day

Current

Month

Current

Year

Language English French Spanish N/A

Contrast 80% 0% 100% 1%

Factory Default

2 pm 00:00 (12 am)

Wed Sun Sat 1 day

12 am 00:00 (12 am)

Sun Sun Sat 1 day

Jan Jan Dec 1 month

2008 2008 2100 1 year

Minimum

Setting

Maximum

Setting

23:59

(11:59 pm)

23:59

(11:59 pm)

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 automatically 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

Increment

1 min

CntrlNexus001 Rev. D 04/11

Control Panel

SEQUENCE OF AUTOMATIC OPERATION

Initial Conditions: Generator in Auto ready to run, load being supplied 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 initiated. 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 continue 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 utility 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 automatically 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 monitored.

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 microprocessor. 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).

CntrlNexus001 Rev. D 04/11

8-4

Control Panel

Figure 1 – Generator 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.

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 consecutive 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 perform 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.

LOW COOLANT LEVEL ALARM

This is a shutdown alarm. The sensor will be continuously monitored. If an error condition is seen for five (5) consecutive seconds, the alarm will be displayed.

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

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 communicate, 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.

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 potentialfree (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

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.

CntrlNexus001 Rev. D 04/11

SERVICE SCHEDULE ‘B’

Change / Inspect spark plugs alert 2yr/ 250hr

8-6

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

Inspect/clean air inlet &

exhaust alert

Change / Inspect air filter

alert

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

Change / Inspect spark

plugs alert

Inspect Accessory drive

alert

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

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

3mo/30hrs break-in

6mo/50hrs

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

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

3mo/30hrs break-in

1yr /100hrs

3mo/30hrs break-in

1yr/100hrs

3mo/30hrs break-in

6mo/50hrs

3mo/30hrs break-in

1yr /100hrs

3mo/30hrs break-in

1yr/100hrs

3mo/30hrs break-in

6mo/50hrs

3mo/30hrs break-in

1yr /100hrs

3mo/30hrs break-in

1yr/100hrs

3mo/30hrs break-in

6mo/50hrs

3mo/30hrs break-in

1yr /100hrs

8-7

CntrlNexus001 Rev. D 04/11

Control Panel

QT TEST

DEBUG

INPUTS OUTPUTS DISPLAYS

ESC ESC

MAIN MENU

ACTIVATION

ESC

EDIT

ESC

TIME/SPEED

HOURS

RESET

MAINTENANCE

RPM

ENGINE

GENERATOR

FREQUENCY

BATTERY

VO LTAGE

LANGUAGE

TIME/DATE

COMMANDSTAT E VERSIONSDISPLAY

EXERCISE

ESC

ENGINE

MENU SYSTEM

ESC

RUN LOGALARM LOG

Press the “ESCAPE” key

to jump back up through

the menu levels.

Use the “+/-” key

to navigate through

the menu.

Use the “ENTER” key

to select items or

enter data.

HISTORY STATUS

+ / -

ESC

CntrlNexus001 Rev. D 04/11

8-8

ENTER

STATIONARY EMERGENCY

Operation

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 following procedure applies. A manually operated transfer switch is one that will not provide automatic start-up and does not include an intelligence circuit.

ENGINE START-UP AND TRANSFER

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

The Maintenance Disconnect Switch and the

AUTO/OFF/MANUAL switches (if so equipped) must be set properly, or the generator will crank and start as soon as the utility power to the transfer switch is turned off. Refer to applicable control panel and transfer switch manuals for more information.

Do not proceed until certain that utility source

voltage is available to the transfer switch and the transfer switch main contacts are set to UTILITY.

Do not attempt manual operation until all



power supplies to the transfer switch have been 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.•

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

damage the starter motor.

Let engine stabilize and warm up.• Check all applicable instrument and gauge 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

Oil

Dipstick

Oil Fill Cap

Oil Filter

Maintenance

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

Refer to the Service Schedule for engine oil and filter change frequencies.

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 completely 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 filter. 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.

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.

CHANGING ENGINE OIL

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.

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/generator 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 radiator 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.

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

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-generator 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, tightness, leaks, security, damage.

INSPECT ENGINE GOVERNOR

Visually inspect electronic governor.

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 qualified service technicians should adjust the governed 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.

Maint026 Rev. A 05/10

10-2

Air Filter

Maintenance

Figure 10.3 – Engine Air Filter

SPARK PLUGS

Reset the spark plug gap or replace the spark plugs as necessary.

1. Clean the area around the base of the spark plugs to keep dirt and debris out of the engine. Clean by scraping or washing using a wire brush and commercial solvent. Do not blast the spark plugs to clean.

2. Remove the spark plugs and check the condition. Replace the spark plugs if worn or if reuse is questionable. See the “Service Schedule” section for recommended inspection.

3. Check the spark plug gap using a wire feeler gauge. 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 corrosion. Tighten and clean as necessary.

2. Check the battery fluid level of unsealed batteries and, if necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP WATER IN BATTERIES.

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

Storage batteries give off explosive hydrogen



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

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.

Do not use any jumper cables or booster battery to crank and start the generator engine. If

the battery has completely discharged, remove it from the generator for recharging.

Be sure the AUTO/OFF/MANUAL switch is set to the OFF position, before connecting the

battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected.

Be sure the 120VAC power supply to the battery



is turned OFF, or sparking may occur at the battery 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 number 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 generator may require drying.

10-3

Maint026 Rev. A 05/10

SERVICE SCHEDULE

Service Schedule

System / Component

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.

Frequency Procedure

Weekly - W

Monthly - M

Yearly - Y

Inspect Change Clean

11-1

SrvSchd004 Rev. B 05/10

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:

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

REVISION: H-9621-F Page 4 of 8 DATE: 9/26/11

EXPLODED VIEW: CONBOX C2 CPL

DRAWING #: 0H7326 GROUP A

APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION

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

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).

REVISION: H-9621-F Page 5 of 8 DATE: 9/26/11

UL CIRCUIT BREAKER (225AF)

UL CIRCUIT BREAKER (400AF)

EXPLODED VIEW: CONBOX C2 CPL

DRAWING #: 0H7326 GROUP A

APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION

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

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

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

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.

REVISION: H-9621-F Page 6 of 8 DATE: 9/26/11

UL CIRCUIT BREAKER (KG)

UL CIRCUIT BREAKER (FG)

UL CIRCUIT BREAKER (JG)

UL CIRCUIT BREAKER (CC)

EXPLODED VIEW: CONBOX C2 CPL

DRAWING #: 0H7326 GROUP A

APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION

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

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

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

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

UL CIRCUIT BREAKER (QN)

UL CIRCUIT BREAKER (ED)

UL CIRCUIT BREAKER (VL)

UL CIRCUIT BREAKER (FD)

REVISION: H-9621-F Page 7 of 8 DATE: 9/26/11

EXPLODED VIEW: CONBOX C2 CPL

DRAWING #: 0H7326 GROUP A

APPLICABLE TO:

THIS PAGE LEFT INTENTIONALLY BLANK

REVISION: H-9621-F Page 8 of 8 DATE: 9/26/11

1 0G37260ST03 1 WELDMENT FRAME 2.4L C2 60KW

2 05286 0 4 NUT FLANGED HEX M12-1.75

3 05225 1 4 DAMPENER VIBRATION 40 BLUE

4 05225 7 4 SPACER .49 X .62 X 1.87 PWDR/ZNC

5 05225 2 4 DAMPENER VIBRATION

6 05225 9 4 WASHER FLAT M12

7 05289 1 4 SCREW HHC M12-1.75 X 80 G8.8

8 0536210410 1 ASSY WIRE 14.00"

9 04290 9 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 WASHE R SHAKEPROOF INT 1/4 13 022097 1 WASHE R LOCK M6-1/4 14 022473 2 WASHE R FLAT M6-1/4 ZINC 15 049813 1 NUT HEX M 6 -1.0 G8 YEL CHR 16 022261 1 WASHE R SHAKEPROOF INT 3/8 17 0F9597A 1 S UPPORT 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 WASHE R LOCK 7/16 21 022131 5 WASHE R FLAT 3/8-M10 ZINC 22 065852 1 SPRING CLIP HOLDER .37-.62 23 0F9597 1 SUPPORT RH ENGINE 2.4L 24 022129 1 WASHE R LOCK M8-5/16 25 026204 1 WASHE R SHAKEPROOF INT 5/16 26 022145 1 WASHE R FLAT 5/16-M8 ZINC 27 045771 1 NUT HEX M 8-1.25 G8 CLEAR ZINC 29 0F9596A 1 S PACER 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:

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.

REVISION: H-3963 –B PAGE 2 OF 2 DATE: 2/27/09

1 0H30830ST03

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" G 8 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

0H1546 1 HOSE UPPER RADIATOR G2 (USED WITH MANFLD

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

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:

(1) APPLY MEDIUM STRENGTH BLUE THREAD

(2) INCLUDED WITH I/N 26. (3) APPLY LOCTITE #266 TO I/N 75 PRIOR TO

(4) ITEM 70 IS INCLUDED WITH ITEM 1. (5) USE WITH R-200 CONTROL PANEL ONLY.

P/N 0G0707)

P/N 0G8488)

0H1827 ONLY)

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.

LOCKING FLUID TO THREADS.

ASSEMBLY.

EXPLODED VIEW: TURBO 2.4L G2

DRAWING #: 0H3356 GROUP D

APPLICABLE TO:

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

REVISION: -A- PAGE 1 OF DATE: 6/22/09

EXPLODED VIEW: MUFFLER EXH 2.4L G2 TURBO

DRAWING #: 0H3357 GROUP F

APPLICABLE TO:

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

REVISION: H-5192-B PAGE 1 OF DATE: 10/12/09

EXPLODED VIEW: ENGINE COMMON PARTS 2.4L G2 TURBO 60K

DRAWING #:0H7323 GROUP D

APPLICABLE TO:

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

REVISION: H-7244-D Page 3 of 4 DATE: 8/10/10

EXPLODED VIEW: ENGINE COMMON PARTS 2.4L G2 TURBO 60K

DRAWING #:0H7323 GROUP D

APPLICABLE TO:

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

REVISION: H-7244-D Page 4 of 4 DATE: 8/10/10

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.