Generac Power Systems 005220-0 User Manual

Serial Number

STANDBY GENERATOR

OWNER'S MANUAL

QT

3.0L

30kW

Model: 005220-0

A new standard of reliability

—CAUTION—

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!

This manual should remain with the unit.

Cover025 Rev. 0 09/05 Part No. 0F7911

Standby Generator Sets

Table of Contents

SECTION PAGE

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

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

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

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

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

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

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

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

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

Engine Oil Requirements .............................................3-1

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

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

High Coolant Temperature Switch ............................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 Fuse ....................................................................4-1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Initial Inspection for QT Genset Start-up .....................8-1

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

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

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

Maintenance Performed by Authorized

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

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

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

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

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

Engine Coolant .......................................................10-1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

30 kW - 150 kW Standby Gas Engine

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

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

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

NOTES

EXPLODED VIEWS & PARTS LISTS

WIRING DIAGRAMS & SCHEMATICS

WARRANTY

Content001 Rev. 0 08/05

Standby Generator Sets

Important 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.





The engine exhaust from this product

contains chemicals known to the state



This product contains or emits chemicals
known to the state of California to cause

cancer, birth defects or other reproductive harm.

Study these SAFETY RULES carefully before install­ing, operating or servicing this equipment. Become
familiar with this Owner’s Manual and with the unit.
The generator can operate safely, efficiently and reli­ably only if it is properly installed, operated and
maintained. Many accidents are caused by failing to
follow simple and fundamental rules or precautions.

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

WARNING:

of California to cause cancer, birth

defects or other reproductive harm.

WARNING:





DANGER

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 an Authorized Service Dealer or other
competent, qualified electrician or installation tech­nician who is familiar with applicable codes, stan­dards and regulations. The operator also must
comply with all such codes, standards and regula­tions.

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

• The engine exhaust fumes contain carbon monox­ide gas, which can be DEADLY. This dangerous gas,
if breathed in sufficient concentrations, can cause
unconsciousness or even death. For that reason,
adequate ventilation must be provided. Exhaust
gases must be piped safely away from any building
or enclosure that houses the generator to an area
where people, animals, etc., will not be harmed.
This exhaust system must be installed properly, in
strict compliance with applicable codes and stan­dards.

• Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit
is operating.

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

• Keep the area around the generator clean and
uncluttered. Remove any materials that could
become hazardous.

• When working on this equipment, remain alert
at all times. Never work on the equipment when
physically or mentally fatigued.

• Inspect the generator regularly, and promptly
repair or replace all worn, damaged or defective
parts using only factory-approved parts.

1-1



Safety 001 Rev. 0 08/05

Standby Generator Sets

Important Safety Instructions

• Before performing any maintenance on the gen­erator, disconnect its battery cables to prevent
accidental start-up. Disconnect the cable from the
battery post indicated by a NEGATIVE, NEG or (–)
first. Reconnect that cable last.

• Never use the generator or any of its parts as a
step. Stepping on the unit can stress and break
parts, and may result in dangerous operating con­ditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.

ELECTRICAL HAZARDS

• All generators covered by this manual produce



dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely
high and dangerous voltages to the transfer switch
as well as the standby generator. Avoid contact
with bare wires, terminals, connections, etc., on
the generator as well as the transfer switch, if
applicable. Ensure all appropriate covers, guards
and barriers are in place before operating the gen­erator. If work must be done around an operating
unit, stand on an insulated, dry surface to reduce
shock hazard.

• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.

• If personnel must stand on metal or concrete while
installing, operating, servicing, adjusting or repair­ing this equipment, place insulative mats over a
dry wooden platform. Work on the equipment only
while standing on such insulative mats.

• The National Electrical Code (NEC) requires the
frame and external electrically conductive parts
of the generator to be connected to an approved
earth ground. This grounding will help prevent
dangerous electrical shock that might be caused
by a ground fault condition in the generator set or
by static electricity. Never disconnect the ground
wire.

• Wire gauge sizes of electrical wiring, cables and
cord sets must be adequate to handle the maxi­mum electrical current (ampacity) to which they
will be subjected.

• Before installing or servicing this (and related)
equipment, make sure that all power voltage
supplies are positively turned off at their source.
Failure to do so will result in hazardous and pos­sibly fatal electrical shock.

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

Safety 001 Rev. 0 08/05



• 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 generator sets may operate using one of
several types of fuels. All fuel types are potentially
FLAMMABLE and/or EXPLOSIVE and should be
handled with care. Comply with all laws regulat­ing the storage and handling of fuels. Inspect the
unit’s fuel system frequently and correct any leaks
immediately. Fuel supply lines must be prop­erly installed, purged and leak tested according to
applicable fuel-gas codes before placing this equip­ment into service.

• Diesel fuels are highly FLAMMABLE. Gaseous
fluids such as natural gas and liquid propane
(LP) gas are extremely EXPLOSIVE. Natural gas
is lighter than air, and LP gas is heavier than air;
install leak detectors accordingly.

1-2





Standby Generator Sets

Important Safety Instructions

INTRODUCTION

Thank you for purchasing this model of the standby
generator set product line.

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

READ THIS MANUAL THOROUGHLY



If any portion of this manual is not understood, con­tact the nearest Authorized Service Dealer for start­ing, operating and servicing procedures.

Throughout this publication, and on tags and
decals affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert person­nel to special instructions about a particular service
or operation that may be hazardous if performed
incorrectly or carelessly. Observe them carefully.
Their definitions are as follows:

DANGER

After this heading, read instructions that, if not

strictly complied with, will result in personal injury
or property damage.

After this heading, read instructions that, if not

strictly complied with, may result in personal
injury or property damage.

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.

OPERATION AND MAINTENANCE



It is the operator's responsibility to perform all safety
checks, to make sure that all maintenance for safe
operation is performed promptly, and to have the
equipment checked periodically by an Authorized
Service Dealer. Normal maintenance service and
replacement of parts are the responsibility of the
owner/operator and, as such, are not considered
defects in materials or workmanship within the terms
of the warranty. Individual operating habits and usage
contribute to the need for maintenance service.

Proper maintenance and care of the generator ensure
a minimum number of problems and keep operating
expenses at a minimum. See an Authorized Service
Dealer for service aids and accessories.

Operating instructions presented in this manual
assume that the standby electric system has been
installed by an Authorized Service Dealer or other
competent, qualified contractor. Installation of this
equipment is not a “do-it-yourself” project.

After this heading, read instructions that, if not

strictly complied with, could result in damage to
equipment and/or property.

NOTE:

After this heading, read explanatory statements

that require special emphasis.

These safety warnings cannot eliminate the hazards
that they indicate. Common sense and strict 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 infor-



mation that, if not followed, could endanger
personal safety and/or property of others.

This symbol points out potential explosion



hazard.

HOW TO OBTAIN SERVICE



When the generator requires servicing or repairs,
simply contact an Authorized Service Dealer for
assistance. Service technicians are factory-trained
and are capable of handling all service needs.

When contacting an Authorized Service Dealer or the
factory about parts and service, always supply the
complete model number of the unit as given on the
front cover of this manual or on the DATA LABEL
affixed to the unit.

AUTHORIZED SERVICE DEALER LOCATION

To locate the nearest AUTHORIZED

SERVICE DEALER, please call this number:

1-800-333-1322

or locate us on the web at:

www.generac.com

1-3

Safety 001 Rev. 0 08/05

Standby Generator Sets

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, etc.

Data Label

GENERATOR SET DATA

MODEL

RATED KW

RATED VOLTAGE

RATED KVA

NOTE:

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

Generator Model and Serial Number



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

MADE IN USA

SERIAL

PHASE

RATED AMPS

POWER FACTOR

ENGINE RPM

HERTZ

PRODUCTION DATE

ALTERNATOR SUBTRANSIENT REACTANCE

ALTERNATOR TRANSIENT REACTANCE

CLASS

ROTOR STATOR WINDING INSULATION AT 25°C AMBIENT

GENERAC POWER SYSTEMS, INC.

WAUKESHA, WI

ALT RPM

2-1

Identy 002 Rev. A 12/05

Standby Generator Sets

Equipment Description

EQUIPMENT DESCRIPTION

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

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 generator incorporates the following generator
features:

• Rotor and Stator insulation is Class H rated as
defined by NEMA MG1-32.6, NEMA MG1-1.66.
The generator is self ventilated and drip-proof con­structed.

• The voltage waveform deviation, total harmonic
content of the AC waveform and telephone influ­ence factor have been evaluated and are acceptable
according to NEMA MG1-32.

ENGINE OIL RECOMMENDATIONS

The unit has been filled with 15W-40 engine oil at
the factory. Use a high-quality detergent oil classified
“For Service CC, SD, SE, SF.” Detergent oils keep the
engine cleaner and reduce carbon deposits. Use oil
having the following SAE viscosity rating, based on
the ambient temperature range anticipated before the
next oil change:

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.

DANGER

Do not remove the radiator pressure cap while



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

Ethylene glycol base antifreeze is poisonous.



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

Temperature Oil Grade (Recommended)
Above 80° F (27° C) SAE 30W or 15W-40
32° to 80° F (0° to 27° C) SAE 20W-20 or 15W-40
Below 32° F (0° C) See Note

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:

For temperatures below 32° F, it is strongly recom­mended to use the optional Cold Weather Start Kit
(part number listed in the Specification Section).
The oil grade for temperatures below 32° F is 5W­30 synthetic oil.

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Equip001 Rev. 0 08/05

Standby Generator Sets

Engine Protective Devices

ENGINE PROTECTIVE DEVICES

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

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 SWITCH



This switches contacts close if the temperature should
exceed approximately 140° C (284° F), initiating an
engine shutdown. The generator will automatically
restart and the LED will reset once the temperature
has returned to a safe operating level.



LOW COOLANT LEVEL SENSOR

Should the engine coolant level drop below the level
of the high coolant temperature switch, it is possible
for the engine to overheat without automatic shut­down. To prevent such overheating, the engine has 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 LED 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 FUSE

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

4-1

EngProt001 Rev. 0 08/05

Standby Generator Sets

Fuel Systems

FUEL SYSTEM

FUEL REQUIREMENTS



The standby generator may be equipped with one of
the following fuel systems:

• Natural gas fuel system

• Propane vapor (PV) fuel system

The Manual Drawing Listing that is affixed to the
unit includes the “Identification Code,” which may be
used to identify the type of fuel system installed on
the unit.

Recommended fuels should have a Btu content of at
least 1,000 Btus per cubic foot for natural gas; or at
least 2,520 Btus per cubic foot for LP gas. Ask the
fuel supplier for the Btu content of the fuel.

Required fuel pressure for natural gas is 5 inches

to 14 inches water column (0.18 to 0.5 psi); and
for liquid propane, 5 inches to 14 inches of water
column (0.18 to 0.5 psi).

NOTE:

Any piping used to connect the generator to the
fuel supply should be of adequate size to ensure
the fuel pressure NEVER drops below five inches
water column for natural gas or 5 inches water
column for propane vapor for all load ranges.

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

PROPANE VAPOR WITHDRAWAL FUEL SYSTEM



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

• The natural gas and LP gas systems are similar.
However, the natural gas system delivers gas at a
pressure of approximately five inches water col­umn to the carburetor.

• When ambient temperatures are low and engine
fuel consumption is high, the vapor withdrawal
system may not function efficiently.

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

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

LP FUEL SYSTEM



LP is supplied as a liquid in pressure tanks. It is
usually made up of propane, butane, or a mixture of
the two gases. Propane tends to vaporize readily even
at temperatures as low as -20° F (-29° C). However,
butane reverts to its liquid state when temperatures
drop below 32° F (0° C).

LP in a liquid withdrawal system must be converted
to its gaseous state before it is introduced into the
engine carburetor. A vaporizer-converter is generally
used to accomplish this. In such a converter, heated
engine coolant is ported through the converter to
provide the necessary heat for conversion of the fuel
from a liquid to a gaseous state.

5-1

FuelSys001 Rev. 0 08/05

Standby Generator Sets

Specifications

SPECIFICATIONS

GENERATOR



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

Rotor Insulation ............................................................Class F or H

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

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

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

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

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

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

Load Capacity (Standby Rating) ............................................30kW*

* 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 30 125 150
120/208V, 3-phase, 0.8 pf 30 104 125
277/480V, 3-phase, 0.8 pf 30 45 50
Generator Locked Rotor KVA Available @ Voltage Dip of 35%

Single-phase or 208 3-phase ............................................. 60 KVA

480V, 3-phase .................................................................... 70 KVA



ENGINE

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

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

Cylinders and Arrangement ............................................................ 6

Displacement ....................................................................... 3.0 Liter

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

Stroke ..................................................................................... 3.1 in.

Compression Ratio ............................................................... 9.3-to-1

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

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

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

Engine Lubrication System

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

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

Crankcase Oil Capacity ....................................................4 U.S. qts.

COOLING SYSTEM



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

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

Fan Speed ................................................................................ 2150

Fan Diameter .....................................................................18 inches

Fan Mode ..............................................................................Pusher

Air Flow (inlet air including alternator and

combustion air) .......................................................... 2460 ft3/min.

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

Heat Rejection to Coolant ..........................................115,000 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

70/28.3 111/45 214/86.1 298/120 412/166

ELECTRICAL SYSTEM



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

Static Battery Charger ............................................................2 Amp

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

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

Engine Parameters

Rated Synchronous RPM ..............................................60 Hz, 1800

HP at rated kW ..................................................................60 Hz, 48

Exhaust System

Exhaust Flow at Rated Output 60 Hz .................................. 200 cfm

Exhaust Temperature at Rated Output .................................. 890° F

Combustion Air Requirements (Natural Gas)

Flow at rated power, 60 Hz ................................................... 92 cfm

Governor

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

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

Steady State Regulation ........................................................± 1/2%

Adjustments:

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

Voltage Regulator

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

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

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

Features ................................................. V/F Adjustable, Adjustable

Voltage and Gain LED Indicators

Power Adjustment for Ambient Conditions

Temperature Deration

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

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

Altitude Deration

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

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

Controller .................................................R-100

6-1

GenSpec002 Rev. C 11/05

Standby Generator Sets

Specifications

Figure 1 — Interconnections

COLD WEATHER KIT



For cold climates, optional cold weather kit (part
number 0F6148) is recommended. The kit includes:

• Battery Warmer

• 4” Junction Box with hardware

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



RECONFIGURING THE FUEL SYSTEM

NOTE:

All models are configured for natural gas or LP
vapor from the factory.

To reconfigure the fuel system from NG to LP, follow
these steps:

1. Turn the main gas supply off.

2. Remove the carburetor fuel hose from the outlet
port (Port 1) of the demand regulator (Figure

6.2).

3. Remove the brass hose fitting from the outlet port
(Port 1) of the demand regulator.

4. Remove pipe plug from Port 2.

5. Install brass hose fitting into Port 2.

6. Install pipe plug into Port 1.

7. Connect carburetor gas hose to brass fitting.

8. Tighten all clamps and plugs.

9. Make sure fuel supply is of the proper pressure
and type for configuration.

GenSpec002 Rev. C 11/05

10. Reverse the procedure to convert back to natural
gas.

11. The Dip switch inside the control panel must be
in the LP or NG position when switching to differ­ent fuels.

Figure 6.2 — Reconfigure the Fuel System

Por t 1

PLUG

NG FUEL SYSTEM

FUEL HOSE

BRASS HOSE
FITTING

PORT 1

HOUSING
PORTS

OUT

FUEL HOSE

BRASS HOSE
FITTING

OUT
PORT 2

HOUSING
PORTS

NOTE:

Port 1 is for NG only and Port 2 is for LP vapor
only. No provision for dual fuel has been made.

NOTE:

For LP vapor application substitue LPG fuel inlet
decal P/N 050280 for NG fuel inlet decal P/N

050279.

6-2

Por t 2

LP FUEL SYSTEM

PLUG

S6

3

S3

CO

S

N

S4

S2

S5

S1

L

3

)

S1

S1

S4

S4

6

S6

S3

S3

S5

S5

S2

S2

Standby Generator Sets

General Information

GENERATOR AC LEAD CONNECTIONS

See “Voltage Codes”. This generator may be rated
at any one of three voltages, either single-phase or
three-phase. The electrical wires in the unit’s AC con­nection (lower) panel should be installed according to
the number of leads and the voltage/phase required
for the application. If there are any questions regard­ing lead connection, refer to the wiring diagrams at
the back of this manual.

Voltage codes apply to the type of stator assembly
installed on a particular generator.

FOUR-LEAD, SINGLE-PHASE STATOR



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

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



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

The rated voltage between circuit breaker terminals
E1-E2, E1-E3 and E2-E3 is either 480V or 208V
depending on the model.

The rated voltage between each circuit breaker termi­nal and the neutral point 00 is either 277V or 120V
depending on the model.

Figure 7.2 — Stator Power Winding

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

NNECTION

-

NEUTRA

E

L-

Figure 7.3 — Stator Power Winding

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

-

S

E

00 (NEUTRAL

-

7-1

ACConn001 Rev. 0 08/05

Standby Generator Sets

Installation

INSTALLATION

Refer to the separate “Installation Guide QT Product
Line” supplied with the unit.

PREPARATION BEFORE START-UP

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

Before starting the generator for the first time, the
installer must complete the following procedures. For
follow-up maintenance information and/or service
intervals, please refer to the “Maintenance” section
and the “Service Schedule”.

TRANSFER SWITCH



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



FUEL SYSTEM

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

GENERATOR SET LUBRICATION



Check the engine crankcase oil level before operating
and add oil to the proper level – the dipstick “FULL”
mark. Never operate the engine with the oil level
below the dipstick “ADD” mark. See “Specifications”
and “Engine Oil Recommendations”.

NOTE:

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

Check the oil level in the generator gearbox (if so
equipped) prior to initial use and at the intervals
indicated by the “Service Schedule.” The recom­mended oil is SAE 90 gear lubricant.

Also, if the engine is equipped with a mechanical gov­ernor, make sure the governor is properly lubricated
with clean engine oil.

PRIOR TO INITIAL START-UP



Prior to initially starting the generator, it must



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



ENGINE COOLANT

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



BELT TENSION

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



ELECTRICAL SYSTEM

Make sure the generator is properly connected to an
approved earth ground.

Make sure the generator battery is fully charged,
properly installed and interconnected, and ready for
use.

Check to ensure that there are no loose electrical con­nections. Restrain any loose wires to keep them clear
of any moving generator set components.

INITIAL INSPECTION FOR QT GENSET
STARTUP

Inspect for the following.

• Freight Damage.

• Manuals present.

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

• Correct fuel piping.

• Correct muffler installation for QT50, QT70,

QT100 - QT150.

• Adequate air flow, clearances and ventilation per

installation drawings and applicable codes.

• Correct AC and DC wire size, connections and

grounding. Control and communication wiring to/
from the transfer switch must be run in a separate
conduit from the AC power leads.

• Battery charger connection to 120 VAC.

• Communication wires connected between transfer

switch and generator (HTS only).

• Unit secured to pad.

8-1

Install001 Rev. A 11/05

Standby Generator Sets

Installation

START-UP CHECKLIST

Before working on the generator, ensure the fol-



lowing:

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

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

PREPARATION FOR START-UP



• Ensure that the 120VAC circuit breaker to the bat­tery charger is open.

• Remove the fuse from the the control panel. For
the H-100 and R-100: Open the front door of the
control box and remove the 15 Amp ATO fuse in
the lower left-hand corner of the control box.

• Connect the battery cables to the battery. Attach
negative battery cable last.

• Close the 120VAC circuit breaker to the battery
charger.

• Measure the voltage at the battery before and after
the charger is turned on.

• Verify all AC electrical connections are tight at the
circuit breaker and transfer switch.

• Visually inspect entire area looking for loose paper,
plastic wrappings, leaves, etc.

• Check all hoses clamps fittings for leaks or dam­age.

• Check all electrical plugs throughout the genera­tor. Ensure each plug is seated correctly and fully
inserted into its receptacle.

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

• Open the valve to the engine fuel line.

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

• Open the generator main line circuit breaker.

• Connect a manometer to the gas line and record
the static pressure. It must be as listed in the
Specifications.

• Insert the fuse into the control panel.

• Move the AUTO/OFF/MANUAL switch to the MAN­UAL position. The engine should now crank and
start.

• Check voltage at the generator terminals.

• For 3-phase units, check phase rotation at the
transfer switch terminals. The generator phase
rotation must match the utility phase rotation.

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

• Close the generators main line circuit breaker.

• Turn the generator set off.

• Connect the UTILITY supply to the transfer
switch.

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

• Disconnect utility power before the transfer
switch.

Engine should start, transfer to load.
Run at least 15 minutes on generator power.

Make certain all 3-phase loads are functioning
correctly (correct phase rotation).

• Reconnect Utility power

Transfer switch will transfer back to Utility and

engine will shut down within the given time
parameters set up for the specific transfer switch
and controller.

• Install all covers, access plates and door panels.

• Put the Owners Manual in a safe and accessible
place.

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

START-UP INSPECTION



When a start-up is performed by an Authorized
Service Dealer, a standard three-part form titled
“Start-up Inspection for Standby Power Systems”
(part no. 067377), should be completed by the instal­lation technician or engineer. See page 1-3 for infor­mation on locating the nearest Authorized Service
Dealer. The installer should complete the form and
disseminate copies as follows:

• White copy: Mail to Generac Warranty Department,
P.O. Box 340, 211 Murphy Dr., Eagle, WI 53119-

2062.

• Pink Copy: For service file of installing dealer.

• Yellow Copy: For the customer’s records.

Install001 Rev. A 11/05

8-2

GENERATOR CONTROL AND

Standby Generator Sets

Operation

OPERATION

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

OPERATING UNIT WITH MANUAL
TRANSFER SWITCH

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

ENGINE START-UP AND TRANSFER



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

DANGER

The Maintenance Disconnect Switch and the



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

Do not proceed until certain that utility source



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

Do not attempt manual operation until all power



supplies to the transfer switch have been 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 standby 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 its
STANDBY (GENERATOR) position, i.e., load cir­cuits supplied by the generator.

• Set the standby generator’s main line circuit break­er to its ON (or CLOSED) position.

• Load circuits are now powered by the standby
generator.

RETRANSFER AND SHUTDOWN



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

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

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

• Manually move the transfer switch handle to its
UTILITY (NORMAL) position, i.e., load circuits
connected to the utility.

• Turn ON the utility power supply to the transfer
switch, using the means provided (such as the util­ity power source main line circuit breaker).

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

• Shut down the generator.

OPERATING UNIT WITH AUTOMATIC
TRANSFER SWITCH

If the generator has been installed with an automatic
transfer switch, such as an RTS, HTS, or GTS-type
transfer switch, the engine may be started and
stopped automatically or manually.

NOTE:

Refer to the applicable manual for your trans­fer switch and to “Transfer Switch Start Signal
Connections”. In addition, please note the dangers
under “Engine Start-up and Transfer.”

9-1

Oper001 Rev. 0 08/05

MAINTENANCE PERFORMED BY

Standby Generator Sets

Maintenance

AUTHORIZED SERVICE FACILITIES

Before working on the generator, ensure the fol-



lowing:

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

• The 15A fuse has been removed from the con­trol box.

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

EVERY THREE MONTHS



1. Check battery state of charge and condition.

2. Inspect and test fuel system.

3. Check transfer switch.

4. Inspect exhaust system.

5. Check engine ignition system.

6. Check fan belts.

ONCE EVERY SIX MONTHS



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

coolant level, high coolant temperature).



ONCE ANNUALLY

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

2. Clean, inspect generator.

3. Flush cooling system.

The exhaust system parts from this product get



extremely hot and remain hot after shutdown.
High grass, weeds, brush, leaves, etc. must
remain clear of the exhaust. Such materials may
ignite and burn from the heat of the exhaust
system.

CHECKING FLUID LEVELS

CHECK ENGINE OIL



Check engine crankcase oil level (Figure 10.1) at least
every 20 hours of operation, or prior to use.

• Remove oil dipstick and wipe dry with a clean, lint­free cloth.

• Install oil dipstick, then remove again.

• Oil should be between FULL and ADD marks.

• If oil level is below the dipstick ADD mark,
remove oil fill cap. Add the recommended oil to
bring oil level up to the FULL mark. DO NOT
FILL ABOVE THE “FULL” MARK. See “Engine Oil
Recommendations” for recommended oils.

Figure 10.1 - Oil Dipstick and Oil Fill Cap

Oil Dipstick

Oil Fill



FIRST 100 OPERATING HOURS

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

EVERY 500 OPERATING HOURS



1. Service air cleaner.

2. Check starter.

3. Check engine DC alternator.

COOLING SYSTEM

Air intake and outlet openings in the generator 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.

10-1

Oil Filter



BATTERY FLUID

Check battery electrolyte fluid at least once weekly.
Fluid should cover separators in all battery cells. If
fluid level is low, add distilled water to cover tops of
separators. DO NOT USE TAP WATER IN BATTERY.

Maint001 Rev. 0 08/05

Standby Generator Sets

Maintenance

ENGINE COOLANT



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

• Add recommended coolant mixture as necessary.

• Periodically remove radiator pressure cap to make

sure the coolant recovery system is functioning
properly. Coolant should be at bottom of radiator
filler neck. If coolant level is low, inspect gasket in
radiator pressure cap. Replace cap, if necessary.
To have pressure cap tested, contact an Authorized
Service Dealer. Inspect cooling system and coolant
recovery system for leaks.

MAINTENANCE OWNER/
OPERATOR CAN PERFORM

CHECK ENGINE OIL LEVEL



Refer to the “Checking Fluid Levels” section.

CHECK BATTERY



• Check battery fluid level each week as outlined

under “Check Fluid Levels”.

• Check battery cables for condition, tightness, cor-

rosion or damage. Clean, tighten or replace as
necessary.

EXERCISE SYSTEM



Start the generator engine at least once every seven
days and let it run at least 20 minutes. See the
“Weekly Exercise Cycle” section.

INSPECT COOLING SYSTEM



• Inspect engine cooling system at least once each

month.

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

Correct any discrepancies found.

• Check hose clamps for tightness.

CHECK ENGINE COOLANT LEVEL



See the “Checking Fluid Levels” section.

PERFORM VISUAL INSPECTION



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

CHECK FAN BELT



• Inspect fan belts every three months. Replace any
damaged, deteriorated, worn or otherwise defec­tive belt.

• Check fan belt tension. Thumb pressure, exerted
midway between pulleys, should deflect about 3/8
to 5/8 inch. Adjust belt tension as required.

INSPECT ENGINE GOVERNOR



Visually inspect electronic governor.

DANGER

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 ENGINE OIL



Refer to maintenance performed by authorized service
facilities 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 OIL DRAIN HOSE from its retaining

clip.

2. Loosen and remove OIL DRAIN HOSE CAP. Drain

oil completely into suitable container.

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

DRAIN HOSE CAP, and re-install into its retaining
clip.

4. Turn OIL FILTER (Figure 10.2) counterclockwise

and remove. Dispose of old filter.

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

oil filter.-Install FILTER and tighten by hand only.
DO NOT OVERTIGHTEN.

6. Remove OIL FILL CAP. Add recommended oil (see

SPECIFICATIONS). DO NOT FILL ABOVE THE
DIPSTICK “FULL” MARK. Crankcase oil capacity
is 4.0 U.S. quarts (3.8 liters).

INSPECT EXHAUST SYSTEM



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

Maint001 Rev. 0 08/05

10-2

After refilling the crankcase with oil, always



check oil level on dipstick. NEVER OPERATE
ENGINE WITH OIL BELOW THE DIPSTICK “ADD”
MARK.

Standby Generator Sets

Maintenance

7. Start engine and check for oil leaks.

Figure 10.2 - Oil Filter

Oil Filter

CHANGING THE ENGINE AIR CLEANER



To replace the engine air cleaner, (part number
0A4637), remove the air cleaner cover and replace
the air filter making sure it is positioned properly
before reattaching the cover.

See the “Service Schedule” section for air cleaner
maintenance.

SPARK PLUGS



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

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

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

3. Check the spark plug gap using a wire feeler
gauge. Adjust the gap to 1.01 mm (0.040 inch)
by carefully bending the ground electrode (Figure

10.3).

Figure 10.3 – Setting the Spark Plug Gap

SET PLUG GAP AT 1.01 mm

(0.040 inch)

10-3

COOLANT CHANGE



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

MISCELLANEOUS MAINTENANCE

CLEANING THE GENERATOR



Keep the generator as clean and as dry as possible.
Dirt and moisture that accumulates on internal gen­erator windings have an adverse effect on insulation
resistance.

Periodically clean generator exterior surfaces. A soft
brush may be used to loosen caked on dirt. Use a
vacuum system or dry, low pressure air to remove
any accumulations of dirt. The generator is housed
inside an all-weather enclosure, clean the enclosure
with a soft, damp cloth or sponge and water.

Once each year, have the generator cleaned and
inspected by an Authorized Service Dealer. That
dealer will use dry, low pressure air to clean internal
windings. Parts inside the control console should be
cleaned and inspected at this time as well.

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

BATTERY



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

• DO NOT use jumper cables and a booster battery
to crank or start the generator engine.

• DO NOT recharge a weak battery while it is
installed in the generator. Remove battery from
generator and recharge in a well-ventilated area,
away from fuel vapors, sparks, heat or flames.

• Battery electrolyte fluid is an extremely caustic
sulfuric solution that can cause severe burns. DO
NOT permit fluid to contact eyes, skin, clothing,
painted surfaces, wiring insulation, etc. If any bat­tery fluid is spilled, flush the affected area with
clear water immediately.

• Always wear safety glasses, rubber apron and
gloves when handling a battery.

• Batteries give off explosive hydrogen gas while
charging. The gas can form an explosive mixture
around the battery for several hours after charging.
Any spark, heat or flames can ignite the gas and
cause an explosion which can shatter the battery,
causing blindness or other serious injury.

Maint001 Rev. 0 08/05

Standby Generator Sets

Maintenance

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.

DANGER

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 caus-



tic sulfuric acid solution that can cause severe
burns. Do not permit fluid to contact eyes, skin,
clothing, painted surfaces, etc. Wear protective
goggles, protective clothing and gloves when
handling a battery. If the fluid is spilled, flush
the affected area immediately with clear water.

Do not use any jumper cables or booster battery



to crank and start the generator engine. If the
battery has completely discharged, remove it
from the generator for recharging.

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



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

Be sure the 120VAC power supply to the battery



is turned OFF, or sparking may occur at the bat­tery posts as the cables are attached and cause
an explosion.

BATTERY REPLACEMENT



When replacing batteries, use the same number and
the type of battery that follows:

BCI Group No. CCA

24F-6 525 @ 0 deg. F

NOTE:

The BCI number should be located directly
on the battery.

REPAIR PARTS

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

Periodic Replacement Parts

Part Name Part Number

Oil Filter # 0E7415

Radiator Cap # 046627

Air Cleaner # 0A4637

Spark Plug Champion # RC12LC4

Maint001 Rev. 0 08/05

10-4

Standby Generator Sets

Service Schedule

SERVICE SCHEDULE

30 KW - 150 KW STANDBY GAS ENGINE DRIVEN GENERATOR SETS

The following is a recommended maintenance schedule for standby gas engine driven generator sets from 30kW to
150 kW in size. The established intervals in the schedule are the maximum recommended when the unit is used
in an average service application. They will need to be decreased (performed more frequently) if the unit is used
in a severe application. Use calendar time, from the previous maintenance interval to determine the next required
maintenance interval.

Service Maintenance Interval Information:

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

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

tial problem areas.

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

the engine from starting automatically without warning:

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

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

Manual switch to the “OFF” position.

• Remove the 15 amp control panel fuse.

• Turn off the battery charger.

• Remove the negative battery cable.

The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition
from burning out sensitive control panel components and circuits.

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

operation when required.

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

required, and to identify any potential problem areas.

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

the unit.

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

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

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

and to identify any potential problem areas.

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

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

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

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

and to identify any potential problem areas.

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

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

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

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

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

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

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

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

11-1

SrvSchd001 Rev. A 09/05

Standby Generator Sets

Service Schedule

Maintenance Level 1 Level 2 Level 3 Level 4 Level5
Tasks Recom- Task Required Task Required Task Task Required Task

mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.
to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Date­ monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) annually/ Initials)
10 hrs. 30 hrs. 50 hrs. 100 hrs. 250 hrs.

1. Disable the unit

from operating
per the first page
warning.

2. Check the engine

oil level. Adjust
as necessary.

3. Check the engine

coolant level.
Adjust as
necessary.

4. Check the engine

coolant thermal
protection level.
Correct as
necessary.

5. Check the natural

gas delivery
system for leaks
and correct
pressure on gas
engine driven
units. Tighten
connections as
necessary.

6. Check the air

inlets and outlets
for debris. Clean
as necessary.

7. Check the battery

electrolyte level
and specific
gravity if
accessible. Adjust
as necessary.

8. Check the battery

posts, cables,
and charger for
loose
connections,
corrosion, and
proper operation.
Correct as
necessary.

9. Check the unit

wiring for loose
connections,
corrosion, and
damage. Correct
as necessary.

SrvSchd001 Rev. A 09/05

11-2

Standby Generator Sets

Service Schedule

Maintenance Level 1 Level 2 Level 3 Level 4 Level5
Tasks Recom- Task Required Task Required Task Task Required Task

mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.
to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Date­ monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) annually/ Initials)
10 hrs. 30 hrs. 50 hrs. 100 hrs. 250 hrs.

10. Check the engine

accessory drive
belts and fan
coupling device
if equipped for
correct tension,
wear, weather
cracking, and
damage. Replace
as necessary.

11. Check the engine

valve clearance.
Adjust as
necessary.

12. Visually inspect

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

13. Test the engine

and transfer
switch safety
devices. Correct
and/or adjust as
necessary.

14. Initiate an

automatic start
and transfer of
the unit to site
load and exercise
it for at least 1
hour looking for
leaks, loose
connections or
components, and
abnormal
operating
conditions.
Correct as
necessary.

15. Replace the

engine
accessory
drive belts.

16. Check gearbox

oil level (if
equipped).

17. Change gearbox

oil (if equipped).

11-3

SrvSchd001 Rev. A 09/05

Standby Generator Sets

Service Schedule

Maintenance Level 1 Level 2 Level 3 Level 4 Level5
Tasks Recom- Task Required Task Required Task Task Required Task

mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.
to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Date­ monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) annually/ Initials)
10 hrs. 30 hrs. 50 hrs. 100 hrs. 250 hrs.

18. Start and

exercise the unit
at full rated load
(use a load bank
if the site load is
not enough) for
at least 2 hours
looking for leaks,
loose
connections or
components, and
abnormal
operating
conditions.
Correct as
necessary.

19. Perform an

engine oil
analysis (send a
sample to a lab
for results).
Change the
engine oil and
filters if the
analysis results
indicate this is
required.

20. Change the

engine oil.

21. Replace the

engine oil filter(s).

22. Replace engine

spark plugs.
Clean and re-gap
or replace as
necessary.

23. Replace the

engine air
filter(s).

24. Perform a 5

minute no-load
operational run
of the unit
looking for any
post service
problems.

25. Return the unit

to standby setup
for operation
when required.

SrvSchd001 Rev. A 09/05

11-4

Standby Generator Sets

Troubleshooting

TROUBLESHOOTING GUIDE

PROBLEM CAUSE CORRECTION

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

2. Loose or corroded or defective 2. Tighten, clean or replace
battery cables. battery cables as necessary.

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

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

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

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

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

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

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

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

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

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

damaged.

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

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

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

recommended in SPECIFICATIONS.

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

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

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

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

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

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

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

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

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

AUTO/OFF/MANUAL switch and Control
Module circuit board.

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

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

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

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

4. Generator internal failure. 4. *

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

attempt restart.

*Contact the nearest Authorized Dealer for assistance.

12-1

Trblsht001 Rev. 0 08/05

Standby Generator Sets

Notes

1 0F3137 1 PAN CB CONN BOX
2 0F3188 1 STAND RH CONTROL
3 0F3189 1 STAND LH CONTROL
4 023484N 1 BUSHING SNAP SB-2.5-31

5 *** 0F6366B 1 / 2 XFMR DUAL 120V/16V (FOR 120/240V & 277/480V UNI TS)
6 *** 043180 2 / 4 WASHER FLAT M4

7 *** 022264 2 / 4 WASHER LOCK #8-M4
8 *** 0C3990 2 / 4 SCREW PHTT M4-0.7 X 10 ZYC

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

10 022155 4 WASHER LOCK #6
11 0C2428 4 SCREW PHTT #6-3 2 X 1 / 2 ZYC
12 0F3824 1 DECAL UTIL SENSE/CUST CONN
13 0A9457 1 DECAL NEUTRAL

14 0570 73 2 JUNCTION BLOCK 3/8-16
15 ** 0D5466 REF BUS BAR NEUTRAL BLOCK 390
16 ** 0A7822 REF LUG SLDLSS 600/250-1/0 X 1/4-28

17 022237 2 WASHER LOCK 3/8

18 022241 2 NUT HEX 3/8-16 STEEL

19 049226 7 WASHER LOCK M5

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

21 0C2454 8 SCREW THF M6-1 X 16 N WA Z/JS

23 022473 8 WASHER FLAT 1/4-M6 ZINC

24 022097 4 WASHER LOCK M6-1/4

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

27 0F4464 1 DECAL CUST CONN 120V UTILITY

28 0254 3 3 1 L UG SLDLSS #6-14 X 13 /6 4 C U

29 0244 6 9 1 SCREW HHTT #10-32 X 3/8 CZ

30 067210A 1 DECAL GROUND LUG

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

32 081008 1 GROMMET 1.25 X .25 X .75

33 077043J 1 CONDUIT FLEX 2.0" ID (36” LG)

34 051713 2 WASHER FLAT M5

35 0F6156 1 PLATE WIRE SNGL GALV

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

37 047411 4 SCREW HHC M6-1.0 X 16 G8.8

38 **** 064153B 2 WIRE JUMPER TRANSFORMER (NOT SHOWN)

1) UL CIRCUIT BREAKER (ED)

2) UL CIRCUIT BREAKER (FD)

3) UL CIRCUIT BREAKER (JD+LD)

0F6366A 1 XFMR DUAL 104V/16V (FOR 120/208V UNITS)

A 0F3328 1 COVER ED CB SHORT STND
B 065469 1 DECAL DANGER HIGH VOLTAGE
C 0D5552 1 CB 0050A 3P 480V S ED4 LL

D 0F0492 1 INSULATOR CB S (ED-3P)
E 048927 4 SCREW RHM #10-32 X 4-1/2
F 023897 4 WASHER FLAT #10 ZINC
G 022152 4 WASHER LOCK #10
H 022158 4 NUT HEX #10-32 STEEL
J 0C245 4 7 SCREW THF M6-1 X 16 N WA Z/JS
K 029289 1 TAPE ELEC 1/2 FOAM (AS REQ’D)
L 0F1733 1 DECAL CUSTOME R CONNECT INSIDE

A 0F3138 1 COVER CB CONN BOX
B 065469 1 DECAL DANGER HIGH VOLTAGE
C 0D5572 1 CB 0150A 3P 600V S FD6 LL

D 0F0199 1 INSULATOR CB FD FRAME 30MIL
E 081320 4 SCREW SHC 1/4-20 X 4.5 G8.8 NZ
F 022473 4 WASHER FLAT 1/4-M6 ZINC
G0220974WASHER LOCK M6-1/4
H 022127 4 NUT HEX 1/4-20 STEEL
J 0C245 4 7 SCREW THF M6-1 X 16 N WA Z/JS
K 029289 1 TAPE ELEC 1/2 FOAM (AS REQ’D)
L 0F1733 1 DECAL CUSTOME R CONNECT INSIDE

0D5554 - CB 0070A 3P 480V S ED4 LL
0D5556 - CB 0090A 3P 480V S ED4 LL
0D9693 - CB 0125A 3P 480V S ED4 LL

0D5573 - CB 0175A 3P 600V S FD6 LL
0D5574 - CB 0200A 3P 600V S FD6 LL
0D5575 - CB 0225A 3P 600V S FD6 LL
0D5576 - CB 0250A 3P 600V S FD6 LL

A 0F3329 1 COVER JD/LD CB SHRT STAND

B 06546 9 1 DECAL DANGER HIG H VOLTAGE
C 0D5577 1 CB 0300A 3P 600V S JD6 LL
D 0F2353 2 INSULATOR CIRCUIT BR. JD /LD
E 022770 4 SCREW RHM 1/4-20 X 3
F 022473 4 WASHER FLAT 1/4-M6 ZINC
G 022097 4 WASHER LOCK M6-1/4
H 022127 4 NUT HEX 1/4-20 STEEL
J 0C2454 7 SCREW THF M6-1 X 16 N WA Z/JS
K 029289 1 TAPE ELEC 1/2 FOAM (AS REQ’D)
L 0F1733 1 DECAL CUSTOME R CON NECT INS IDE

4) UL CIRCUIT BREAKER (QN)
A 0F8135 1 COVER QN FRM CB
B 065469 1 DECAL, DANGER HIGH VOLTAGE
C 0E7283 - CB 0 150A 2P 240V S QN2 LL

D 0E3664 1 BASE, QN CIRCUIT BREAKER
E 074908 2 SCREW HHTT M5-0.8 X 10 BP
F 0F8140 1 COVER QN CB DISH
G 036261 4 RIVET POP .125 X .275 SS
H 0C2454 7 SCREW THF M6-1X16 N WA Z/JS
J 029289 1 TAPE ELEC 1/2 FOAM (AS REQ’D)
K 0F1733 1 DECAL CUSTOMER CONNECT INS IDE

5) UL CIRCUIT BREAKER (QJ-2P)
A 0F8137 1 COVER QJ 2P FRM CB
B 065469 1 DECAL, DANGER HIGH VOLTAGE
C 0E7994 - CB 0225A 240V 2P S QJ22
D 0F8136 1 COVER QJ 2P CB DISH
E 036261 4 RIVET POP .125 X .275 SS
F 022473 2 WASHER FLAT 1/4-M6 ZINC
G 022097 2 WASHER LOCK M6-1/4
H 022127 2 NUT HEX 1/4-20 STEEL
J0F81391INSUL CB 2P QJ
K 0C2454 7 SCREW THF M6-1X16 N WA Z/JS
L 022237 2 WASHER LOCK 3/8
M 048527 2 SCREW SHC 3/8-16 X 3/4 G8.8 NZ
N 029289 1 TAPE ELEC 1/2 FOAM (AS REQ’D)
P 022770 2 SCREW RHM 1/4-20 X 3
Q 0F1733 1 DECAL CUSTOMER CONNECT INSIDE

6) NEUTRAL BLOCK 390 / 200-400A
A 0D5466 2 BUS BAR NEUTRAL BLOCK 390
B 039287 1 SCREW HHC M8-1.25 X 45 G8.8 FT
C 022145 1 WASHER FLAT 5/16-M8 ZINC
D 022129 1 WASHER LOCK M8-5/16
E 045771 1 NUT HEX M8-1.25 G8 YEL CHR
F 022473 2 WASHER FLAT 1/4-M6 ZINC
G 022097 2 WASHER LOCK M6-1/4
H 04 5 3 3 5 2 SCREW HHC 1/4-28 X 3/4 G5
J 0A7822 1 LUG SLDLSS 600/250-1/0 X 1/4-28

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

* ITEM INCLUDED WITH HARNESS
** ITEM INCLUDED WITH 0D5464B
*** ITEM QTY DOUBLES FOR 277/480V
**** ITEM USED WITH 277/480V UNIT S ONL Y

1 0F3438 1 RTR 390 30AD1 CPL

2 0F3439 1 STR 390 30AD1 CPL

3 0C9708 1 INSTR HYPOT TEST
4 SEE ENGINE EV REF ENGINE ADAPTER
5 SEE ENGINE EV REF FLEXPLATE
6 0F5536 1 ASSY FLYWHEEL C2 CPL
7 0E5706 1 REAR BEARING CARRIER 390/DRCT
8 0F7874 1 ASSY BRUSH HOLDER 390/HSB
9 0F61 24 1 G UA RD RE AR BEARING CARRIER CPL 3.0L 30KW

10 0E6076 1 REVCOR FAN 12.63 X 2 W/PRESSDISK
11 023454 1 KEY WOODRUFF #E
12 077043F 1 CONDUIT FLEX 1-1/4" (30” LG)
13 04576100BU 4 STUD M14-2.0 570 G5 ZINC (30KW)

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 0A2602 1 WASHER FLAT .688 ID X 3.25 OD
19 0F3398 8 SCREW SHC M10-1.5 X 16 G10.9
20 046526 8 WASHER LOCK M10
21 0C3993 4 SCREW HHTT M4-0.7 X 25 BP
22 022264 4 WASHER LOCK #8-M4

23 038150 4 WASHER FLAT #8 ZINC
24 * 047248 1 BALL BEARING-45 MM
25 * 070892 1 SLIP RING MACHINED

0F3440 1 RTR 390 40AD2 CPL HI-EF
0F6188 1 ASSY RTR 39 0 30 KD 1 CP L
0F6190 1 ASSY RTR 39 0 40 KD 2 CP L

0F3441 1 STR 390 40AD 2 CP L
0F6189 1 STR 390 30G D 1 CPL
0F6199 1 STR 390 40G D 2 CPL
0F6655 1 ASSY STR 390 30KD1 CPL
0F6656 1 ASSY STR 390 40KD2 CPL

0F6123 1 GUARD RE AR BEARING CARRIER CPL 3.9L 40KW

04576100AQ 4 STUD M14-2.0 X 615 G5 ZINC

* ROTOR REPLACEMENT PARTS

1 0F1823A 1 ENCL HSB CO NT ROL PANE L

COMPONENTS INCLUDED IN 01827E

2 0F3078 1 COVER CONTR OL PANEL
3 0F2606 1 HINGE CONTINUOUS H-PA NE L
4 036261 6 RIVET POP .125 X .275 SS
5 043181 4 SCREW PHM M3-0.5 X 10MM
6 052777 7 W AS HER FLAT M3
7 0F4245E 1 ASS Y PCB CPL CT RL R 1800 RPM
8 0F1262 4 HOLDER FUSE WICKMANN 178.6150

9 0F1263 1 ADPTR RH SIDE WICKMA N 178.6191
10 0F1264 1 ADPTR LH SIDE WICKMAN 178.6192
11 0F1725C 1 ASSY PCB 2AM P 12V UL BA TT C H GR
12 067680 1 ASSY VOLTAGE REGULATOR 60HZ
13 0E6875A 2 RELAY 12VDC C FORM W/DIODE
14 0559 11 1 BLOCK TE RM 20 A 12 X 6 X 1100V
15 0E3161 1 ASSY PCB BOSCH GOV DRIVER
16 0F5459 1 DECAL CPL CONTRO L PANEL FUSES
17 0F5462 1 DECAL CPL 3.9L TB1
18 0A5062J 4 SPAC ER 9.5H 3.2 ID
19 0296 73 1 DIO BRIDGE 25A 600V
20 0484 67 1 CIRCT BRK 7 X 1 ET A 46- 5 00-P
21 0F1958 1 PLATE,HARNESS CLAMP
22 0825 7 3 1 SWITCH R KR DPST 1 25V SPD
23 0E4494 1 SWITCH R K R DPDT ON-OFF-ON
24 0F3215 1 DECAL CONTROL HSB
25 0F5886 3 SCREW HHPM M5-0.8 X 12
26 0517 13 12 WASHER FLAT M5
27 0492 26 12 WASHER LOCK M5
28 0F5752F 1 RES WW 15 R 5% 25W QK CONN
29 0F5884 2 SCREW PHTT M 3.5-0.6 X 10
30 0F5896 2 SCREW PHTT M 3.5-0.6 X 16
31 0C2265 4 SCREW PH TT M4-0.7 X 12 ZYC
32 0C3990 2 SCREW PH TT M4-0.7 X 10 ZYC
33 0915 2 6 4 SCREW P PHM M5-0.8 X 12 ZNC
34 051716 9 NUT HEX M5-0.8 G8 CLEAR ZINC
35 0792 2 4 2 SCREW P PHM M5-0.8 X 30 SS
36 043182 7 WASHER LOCK M3
37 0517 14 7 NUT HEX M3-0.5 G8 YEL CH R
38 0F3192 1 SUPPORT ANGLE PCB
39 0E7403C 1 FUSE ATO TYPE 15 AMP (BLUE)
40 0F4416 1 HARN 1800RPM R-100 CONTRO L PNL (NO T SH O W N)
41 0F6305 2 SEAL COVER 3.18 X 12.7 X 382
42 0F6305A 1 SEAL COVER 3.18 X 12.7 X 283

A 056739 1 RELAY SOLENO ID 12VDC PNL MNT

COMP ONENT S I N CLUDED IN 0F7376D

B 047411 2 SCREW HHC M6-1.0 X 16 G8.8
C 022473 4 WASHER FLAT 1/4-M6 ZINC
D 022097 2 WASHER LO CK M6-1/4

E 049813 2 NUT HEX M6 X 1.0 G8 YEL CHR

F 0F6145 A/R SEAL WEATHER .45"DIA
G 0F26 27A 1 COV ER CONTROL PANEL SIDE
H 049815 4 SCREW HHC M5-0.8 X 16 G8.8

J 049226 4 W AS HER LOCK M5
K 023897 4 WASHER FLAT #10 ZINC

1 0F3270A 1 MTG BASE 3.0L 30KW C2

2 052860 4 NUT FLANGED HEX M12-1.75

3 052251 4 DAMPENER VIBRATION 40 BLUE

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

5 052252 4 DAMPENER VIBRATION

6 052259 4 WASHER FLAT M12

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

8 0536210410 1 ASSY WIRE 14.00"

9 04 29 0 9 1 SCREW HHC M8-1.2 5 X 30 G8. 8
10 047411 1 SCREW HHC M6-1.0 X 16 G8.8
11 055414 1 LUG SLDLSS #2-#8 X 17/64 CU
12 022447 1 WASHER SHAKEPROOF INT 1/4
13 022097 1 WASHER LOCK M6-1/4
14 022473 2 WASHER FLAT M6-1/4 ZINC
15 049813 1 NUT HEX M6 -1.0 G8 YEL CHR
16 022261 1 WASHER SHAKEPROOF INT 3/8
17 0E8824 2 STAMPING ENG FOOT 3.0L FORD
18 045764 1 SCREW HHTT M4-0.7 X 8 BP
19 04981 4 4 SCREW HHC M10- 1. 5 X 25 G8. 8
20 022302 5 WASHER LOCK 7/16
21 022131 4 WASHER FLAT 3/8-M10 ZINC
22 065852 1 SPRING CLIP HOLDER .37-.62
23 0F5898 2 P LAT E ALT VARMINT
24 022129 1 WASHER LOCK M8-5/16
25 026204 1 WASHER SHAKEPROOF INT 5/16
26 022145 1 WASHER FLAT 5/16-M8 ZINC
27 045771 1 NUT HEX M8-1.25 G8 CLEAR ZINC
28 05175 5 1 SCREW HHC M10- 1. 5 X 16 G8. 8

1 0F3408 1 TRAY BATTERY
2 0F3411 1 STRAP BATTERY RETAINMENT
3 05820 8 REF BATT 12VD C 24 F 625
4 03683 3 1 S CRE W HH C 3/8-16 X 1 G8
5 022237 1 WASHER LOCK 3/8
6 022131 1 WASHER FLAT 3/8-M10 ZINC
7 050331A 1 BATT POST COVER RED +
8 050331 1 BATT POST COVER BLK -

9 038805H 1 CABLE BATT BLK #1 X 23.00
10 038804Y 1 CABLE BATT RED #1 X 35.00
11 045771 1 NUT HEX M8-1.25 G8 YEL CHR
12 022129 1 WASHER LOCK M8-5/16
13 027482 2 WASHER SHAKEPROOF EXT 5/16 STL
14 075763 1 BOOT BATTERY CABLE
15 0C2454 6 SCREW THF M6-1 X 16 N WA Z/JS

1 0E5193 1 PLATE AIR CLE ANER ADAPTER
2 0E0519A 1 AD APTER CAR BU RETOR W/PVC CONN
3 022127 1 NUT HEX 1/4-20 STEEL
4 062974 1 STUD TH 1/4-20 X 4-1/2 G2 ZNC
5 052619 4 SCREW HHC M5-0.8 X 20 G8.8
6 0C8127 1 ELEMENT AIR CLEANER
7 0A5547 1 COVER - AIR CLEANER
8 037561 1 NUT WING 1/4-20 NYLK
9 0E6586 2 GASKET BOSCH 32 & 40

1 0F6842 1 ENGINE 3.0L FORD (FD) (MAKE) CPL
2 022131 14 WASHER FLAT 3/8-M10 ZINC (1800 RPM ONLY)

022131 * 9 WASHER FLAT 3/8-M10 ZINC (3600 RPM ONLY)

3 0E8963 1 P U L LEY CRANKSHAF T 3.0L FORD (1800 RP M ONLY)
4 0F6912 1 BRACKET R/H SIDE D.C. ALT

5 0F6873 1 BRACKET TENSIONER
6 0E9868A 1 ALTERNATOR DC W/OUT PULLEY
7 0F3216 1 PULLEY 80 OD DC ALTERNATOR (1800 RPM)

8 0E6308 1 PULLEY WATERPUMP 3.0L FORD (RD)
9 0E7080 REF. OIL FILTER 3.0L FORD

10 0D3488F 1 BELT SERPENTINE 38.35” LG (1800 RPM)
11 0E8940 1 SPACER FLEXPLATE HSB (1800 RPM)

0E6309 1 PULLEY CRANKSHAFT 3.0L FORD (3600 RPM ONLY)

0F3216C 1 PULLEY 132 OD DC ALTERNATOR (3600 RPM)

0D3488B * 1 BELT SERPENTINE 40.85" LG (3600 RPM)

0F5753 * 1 SPACER FLEX PLATE 3.0L FORD (3600 RPM)

12 027482 1 WASHER SHAKEPROOF EXT 5/16 STL
13 061012 1 PLUG STD PIPE 1/8 SOCKET HEAD
14 0A6751 1 SWITCH HI-TEMP 245D X 3/8NPT
15 033472 3 RIVET POP .125 X .400 AL
16 0E6729 1 STARTER 12V
17 0E6703 1 COVER FLYWHEEL ACCESS 3.0L HSB
18 0E6667 1 ENGINE ADAPTER 3.0L FORD
19 0F3903 * 1 FLEX PLATE 2 POLE 3.0L FORD (3600 RPM)

20 035579 1 BUSHING REDUCER 1/4 TO 1/8
21 0A8584 1 SWITCH OIL PRESSURE 10 PSI 2 POL
22 0C7649 1 CLAMP HO S E . 3 8 - .87
23 069860E 1 HOSE DRAIN ASSY 28"
24 083896 6 WASHER LOCK 1/4-M6 SS
25 084929 6 WASHER FLAT 1/4 SS
26 0F3844 6 WASHER FLAT .45 X 1.00
27 0F6151 1 CAP RUBB ER
28 0578 2 3 1 CLAMP HOS E #10 .56-1.06
29 043790 1 BARBED EL 90 3/8 NPT X 3/8
30 047411 4 SCREW HHC M6-1.0 X 16 G8.8
31 022097 4 WASHER LOCK M6-1/4
32 022473 4 WASHER FLAT 1/4-M6 ZINC
33 057765 1 ADAPTER M14-1.50 X 3/8 NPT
34 040976 8 SCREW SHC M8-1.25 X 20 G12.9
35 022129 12 WASHER LOCK M8-5/16
36 022145 5 WASHER FLAT 5/16-M8 ZINC
37 057772 1 WASHER NYLON .565
38 057645 3 SCREW HHC M10-1.5 X 50 G8.8
39 0D9913 12 SCREW SHC M8-1.25 X 35 SS
40 059980 4 SCREW HHC M10-1.5 X 25 G10.9 (1800 RPM ONLY)
41 0D5417 REF. SCREW HHC M10-1.0 X 25 G10.9
42 046526 14 WASHER LOCK M10 (1800 RPM ONLY)

44 059982 4 SCREW SHC M12-1.75 X 45 G10.9
45 098780 2 SCREW HHC M12-1.75 X 65 G8.8
46 051769 2 WASHER LOCK M12
47 049808 2 WASHER FLAT M12
48 051430 6 WASHER SHAKEPROOF INT 1/2
49 045773 2 NUT HEX M12-1.75 G8 YEL CHR
50 0852 9 6 6 SCREW HHC 1/4-20 X 1/2 SS
51 0E7202 2 HEAT SHIELD 260 X 80 HOT
52 0E5527 2 MANIFOLD EXHAUST 3.0L FORD
53 0E7163 2 GASKET EXHAU S T 3. 0 L FO RD
54 0F6840 * 1 HARN ENG 3.0L 3600RPM R-100 (NOT SHOWN)

55 0F6809 1 ADAPTER, WATER PUMP
56 039253 1 SCREW HHC M8-1.25 X 20 G8.8
57 0F6833 2 SPACER .44 X .87 X 1.14 AL
59 070008 12 WASHER FLAT M8 SS
60 070006 12 WASHER LOCK M8 SS
61 0F5114 1 DE CA L REFE R TO O WNE RS MA NU AL
62 0F5966 1 REFLECTIVE HEAT SHIELD 3.0L FD
63 022985 3 WASHER FLAT #6 ZINC
64 0578 2 2 1 CLAMP H OS E #8 .53-1.00
65 059057 1 HOSE 3/4 ID SAE-30R2 (14” LG)
66 057795A 1 BARBED EL 90 3/4 PLASTIC
67 057796 1 GROMMET

68 * 0E6313A * 1 SPACER PULLEY 3.0L FORD (FD) (3600 RPM ONLY)

69 049541 2 SCREW HHC M10-1.5 X 35 G8.8
70 026925 1 PLUG STD PIPE 3/8 STEEL SQ HD
71 0F3217 1 SPACER DC ALTERNATOR PULLEY

0E5048 1 FLEXPLATE HSB 3.0L FORD (1800 RPM)

046526 * 9 WASHER LOCK M10 (3600 RPM ONLY)

0F6841 1 HARN ENG 3.0L 1800RPM R-100 (NOT SHOWN)

(3600 RPM)
(1800RPM)

* F0R 3600 RPM UNITS ONLY

1 0F3203A 1 WELDMENT RAD SUPPORT 3.0L C2
2 03 56 8 5 6 CLAMP HOSE #28 1. 32- 2.25
3 0F2608A 1 RADIATOR 598 X 568 X 49,CPL LH
4 0F6761 1 HOSE UPPER RAD CPL C2 3.0L
5 0F32 28 1 HO S E LOW E R RA D CP L C2 3. 0L
6 0F51 43 1 S P ACE R FAN 3.0L C2
7 0F0230A 1 FAN COOLING 16" DI A 8 BLADE
8 045764 1 SCREW HHTT M4-0.7 X 8 BP
9 065852 1 SPRING CLIP HOLDER .37-.62

10 * 069811 REF. CAP HEX 1/4 NPT BRASS

11 0F3312 1 DU C T INNER DISCHARGE TOP C2
12 0C2454 13 SCREW THF M6- 1 X 16 N WA Z/JS
13 039253 4 SCREW HHC M8-1.25 X 20 G8.8
14 022129 12 WASHER LOCK M8-5/16
15 022145 4 WASHER FLAT 5/16-M8 ZINC
17 022097 10 WASHER LOCK M6-1/4
18 0C8566 8 SCREW HHFC M6-1.0 X 20 G8.8
19 0E3257 4 SCREW HWHTF M6-1.0 X 16
20 0F3313 1 DUCT INNER DISCHARGE C 2
21 080712 1 BRKT COOLANT RECOVERY TANK
22 076749 1 TANK COOLAN T RECOVERY
23 04 80 3 1C 1 CLAMP HOSE BAND 1/4
24 0F4051D 3 INSULATION INNER DUCT
25 0F4073C 1 INSUL DUCT SIDE OR INNER DUCT
26 0F3890 3 RETAINER INSULATION (450)
27 0F3890C 2 RETAINER INSULATION (220)
28 0F3072 10 INSULATION RETAINMENT HANGER
29 078115 10 WASHER SELF LOCKING DOME
30 089961 1 FOAM STRIP 3/4" WIDE X 3/16" THK (46” LG)
31 05225 0 2 TAPE FOAM 1 X 1 (22.5” LG )
32 069860E 1 HOSE DRAIN ASSY 28"
33 0F8085 1 GUARD FAN C2 CPL, BOTTOM
34 0C7649 1 CLAMP HOSE .38-. 87
35 055596 1 BARBED STR 3/8 NPT X 3/8
36 089685 1 GROMMET .75 X .12 X .50
37 0E0561 1 ASSY WATER LEVEL SENSOR C/E PL
38 0F8085A 1 GUARD FAN C2 CPL TOP
39 055934V 2 CLAMP VINYL 1.5 X .281 Z
40 092079 2 SCREW HHTT M6-1.0 X 25 BP
42 076340 2 SCREW HHFC M6-1.0 X 16 G8.8
43 0F6657 2 SUPPORT TUBE RADIATOR
44 0F6631 1 HOSE RADIATOR ENGINE
45 0F6746 1 TUBE UP P ER COOLANT C4 3.0L
46 09028 3 1 CAP RADIATOR 13 PSI
47 0F8651 8 SCREW HHFC M8-1.25 X 20 W/M6

* ITEM #10 IS INCLUDED WITH ITEM #32.

1 026915 2 NIPPLE CLOSE 3/4 X 1.375

2 075580 1 FLANGE FUEL INLET

3 0F6390 1 REGULATOR ASSEMBLY DUAL FUEL

4 039253 2 SCREW HHC M8-1.25 X 20 G8.8

5 022145 2 WASHER FLAT 5/16-M8 ZINC

6 022129 4 WASHER LOCK M8-5/16

7 045771 2 NUT HEX M8-1.25 G8 CLEAR ZINC

8 042907 2 SCREW HHC M8-1.25 X 16 G8.8

9 0E9295A 1 ASSY THROTTLE 27MM

10 026812 2 ELBOW 90D 3/4NPT
11 025424 1 NIPPLE PIPE 3/4NPT X 6
12 0F3869 1(REF) SWITCH, PRESSURE GAS 5" RISE (INCLUDED WITH I/N 3)
13 057823 6 CLAMP HOSE #1 0 .56 - 1. 06
14 059194 1 HOSE 5/8 ID LPG & NG (31.5 ” LG )
15 044117 1 BARBED STR 3/8 NPT X 5/8
16 0D1509 1 DECAL INLET PRESSURE

17* 05027 9 1 DECAL FUEL INLET NG (NATURAL GAS APPLICATION)

050280 1 DECAL FUEL INLET LPG (LP VAPOR APPLICATION)
18 0E6123 1 INTAKE ADAPTER 3.0L FORD-BOSCH
19 0E6586 1 GASKET BOSCH 32
20 0E4395 1 ACTUATOR BOSCH 32 GOVERNOR
21 057753B 1 HOSE 1.5 ID X 2 LG 20R4
22 0E6382A 1(REF) VENTURI HOLDER W/32MM ACTUATOR
23 0E7121 1(REF) O-RING 47.625 ID X 2.38 WIDTH
24 0E6376A 1(REF) VENTURI, 27 ID THROTTLE W/CHOKE
25 047487 4 SCREW SHC M6-1.0 X 18 G12.9
26 022097 8 WASHER LOCK M6-1/4
27 051751 4 SCREW HHC M6-1.0 X 50 G8.8
28 035685 2 CLAMP HOSE #2 8 1.32- 2.25
29 0A2038 2 WASHER FLAT 3/8 ZINC
30 047290 1 HOSE 3/8 ID SINGLE BRA ID (305mm [12”] LONG )
31 047290 1 HOSE 3/8 ID SINGLE BRA ID (432mm [17”] LONG )
32 0A4121 1 VALVE PCV
33 0E6 60 9 1 GROMMET ROC KER COVE R 3. 0LFORD
34 049099 1 BARBED EL 90 3/8 X 3/8 PLST

35 ** 055934 M 1 CLAMP VINYL .75 X .343 Z
36 ** 047411 1 SCREW HHC M6-1.0 X 16 G8.8
37 ** 022097 1 WASHER LOCK M6-1/4
38 ** O22473 1 WASHER FLAT 1/4-M6 ZINC

39 0F6155 1 HARNESS, CPL FUEL JUMPER

NOTES:

1. REGULATOR (I/N 3) AS SHOWN IN ILLUSTRATION IS SET UP FOR
NATURAL GAS APPLICATIO N.

2. TO CONFIGURE REGULATOR FOR LP VAPOR, SWITCH HOSE BARB,
HOSE CLAMP (I/N 13) AND HOSE (I/N 14) FROM “OUT-1” TO “OUT-2”.
REPLACE PIPE PLUG FROM “OUT-2” TO “OUT-1”. USE PIPE SEALANT
ON HOSE BARB AND PIPE PLUG. MAKE SURE TO KEEP PORTS FREE
FROM DEBRIS DURING RECONFIGURATION PRO CES S .

3*. FOR LP VAPOR APPLICATION SUBSTITUE LPG FUEL INLET DECAL P/N
050280 FOR NG FUEL INLET DECAL P/N 050279 (ITEM17).
4 . WHEN SWITCHING FUEL TYPES, THE PROPER DIP SWITCH SITTINGS
MUST BE MADE TO THE CONTROL PANEL. SEE OWNERS MANUAL, FUEL
SECTION FOR MORE DETAILS.

** NOT SHOWN-USED TO HOLD #31 IN PLACE

1 0F0738 1 MUFFLER 7" X 9"-(2) 2" IN/2.5" OUT
2 0F2808B 1 PIPE EXHAUST MUFFLER
4 0F2830 1 MUFFLER BRACKET STIFFENER
5 0F2962 1 MUFFLER STRAP
6 080762 1 BOLT U 3/8-16 X 2.62
7 0E0170B 1 EXHAUST BLANKET 800MM (C2)
8 0E0170 1 EXHAUST BLANKET 750MM (C2)

9 0F4343 1 EXHAUST PIPE 3.0L C2 CPL RH
10 0F4 344 1 EXHAUST PIPE 3.0L C2 CPL LH
11 044149 2 GASKET EXHAUST RING
12 085917 4 WASHER LOCK 3/8 SS
13 0D2611 4 SCRE W HHC 3/8-16 X 1-3 / 4 SS
14 0E8816 2 EXHAUST FLANGE 2" PIPE
15 047411 2 SCREW HHC M6-1.0 X 16 G8.8
16 022097 2 WASHER LOCK M6-1/4
17 022473 2 WASHER FLAT 1/4-M6 ZINC
18 036797 4 BOLT U 5/16-18 X 2.25
19 024114 8 NUT HEX 5/16-24 STEEL
20 022129 8 WASHER LOCK M8-5/16
21 088775 4 WASHER FLAT 3/8 SS
22 0F7100 2 PIPE EXHAUST ELBOW 3.0L C2

1 0F5853 (XX) 1 REAR WRAP C2
2 0C2454 68 SCREW THF M6- 1 X 16 N WA Z/JS
3 0F5849 (XX) 2 DOOR C2
4 087233 2 RIVET POP .1875 X .450 SS
5 0E3257 4 SCREW TH-FRM M6 W/CAP SHKPRF W
6 0F5852 (XX) 2 DISCHARGE DUCT,LH & RH SIDE C2
7 0F5850 (XX) 2 FRONT CORNERS C2
8 0F5851 (XX) 1 DISCHARGE CENTER DUCT C2

9 0F33 13 1 (REF.) DUCT INNER DIS C HA RGE C 2
10 0F3312 1 (REF.) DUCT INNER DIS C HA RGE TO P C2
11 0F5848 1 ROOF C2 ALUM
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 0C2634A 1 AS S EM BL Y CO VE R AC CE S S
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 16 INSULATION RETAINMENT HANGER
22 078115 48 WASHER SELF LOCKING DOME
23 0F4051 2 INSULATION DOOR C2
24 0F4051A 1 INSULATION ROOF TOP
25 0F5048 2 LATCH VISE ACTION 5/16HEX SOCK
26 0E5968 1 GASKET EXTRUDED TRIM (440.64” LG)
27 0F3760K 2 INSULATION SPLITTER
28 0F3760E 2 INSULATION SPLITTER
29 0F4051C 2 INSULATION DUCT
30 0F3890B 8 RETAINER INSULATION (820 )
31 0F4051B 2 INSULATION DUCT SIDES
32 0F3890 4 RETAINER INSULATION (450)
33 0F3890A 3 RETAINER INSULATION (740 )
34 0F3760L 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 049813 2 NUT HEX M6 X 1.0 G8 YEL CHR

39 ** 077992 21 NUT HEX LOCK M6-1.0 SS NY INS

40 * 0F6321 1 ROOF RAIN DEFLECTOR

43 *** 0C3397 4 FASTENER RATCHET

OPTIONAL COMPARTMENT MATERI AL S:
ALL P/N’S WITH AN (XX) SUFFIX INDICATE A MULTIPLE MATERIAL AND COLOR OPTION.
USE THE FOLLOWING LEGEND TO IDENTIFY THE CORRECT PART NUMBER:

PART NO. MATERIAL

COLOR
0XXXXXSN STEEL TAN
0XXXXXAN ALUMINUM TAN
0XXXXXSG STEEL GRAY
0XXXXXAG ALUMINUM GRAY

* 3.9L ONLY
** ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO

THE BASE FRAME MUST BE SECURED USING ITEM 2 & 5 THREAD FORMING
FASTENER AND ITEM 39 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.

*** 3.0L ONLY

Standby Generator Sets

Warranty

GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR

HOME STANDBY/LIGHT COMMERCIAL PRODUCT 45kW AND BELOW

For a period of two (2) years from the date of sale, or start-up by Authorized/Certified Generac Power Systems Dealer, or branch thereof, Generac
Power Systems, Inc. will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or
an Authorized/Certified Generac Power Systems Dealer, or branch thereof, is found to be defective under normal use and service, in accordance with
the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Authorized/
Certified Generac Power Systems Dealer, or branch thereof. This warranty applies only to Generac Power Systems Generators used in "Standby"
applications, as Generac Power Systems, Inc. has defined Standby, provided said generator has been properly installed and inspected on-site by
appropriate personnel. Scheduled maintenance, as outlined by the generator owner's manual, is highly recommended. This should be performed by
an Authorized/Certified Generac Power Systems Dealer, or branch thereof. This will verify service has been performed on the unit throughout the
warranty period.

WARRANTY SCHEDULE

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

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

Guidelines:

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

• A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a Non - Generac Power
Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the genset, no warranty coverage shall apply.

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

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

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

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

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

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

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

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

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

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

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

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

normally exist.

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

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

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

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

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

defective part(s).

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

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

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

13. Overtime, holiday, or emergency labor.

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

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

cause of the problem.

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

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC POWER SYSTEMS
MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow
limitations on how long an implied warranty lasts, so the above limitation may not apply to purchaser/owner.

GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT
SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A
DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.

Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/
owner. Purchaser/owner agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gives purchaser/owner
specific legal rights. Purchaser/owner also may have other rights that vary from state to state.

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

Ph: [phone] • Fax: [phone]

Bulletin 0171360SVE / Printed in U.S.A. 7.05

Printed in U.S.A.