®

S.O.: 1642775 10
Type: SG80
Engine: G6.8.1

Owner’s Manual
For
Stationary Industrial Generators
Gas or Diesel

DANGER
Asphyxiation. Running engines produce
carbon monoxide, a colorless, odorless,
poisonous gas. Carbon monoxide, if not
avoided, will result in death or serious injury.
(000103)

WARNING
Equipment damage. Only qualified service personnel may
install, operate, and maintain this equipment. Failure to
follow proper installation requirements could result in death,
serious injury, and equipment or property damage.
(000182a)

SAVE THIS MANUAL FOR FUTURE REFERENCE

 WARNING
CANCER AND REPRODUCTIVE HARM
www.P65Warnings.ca.gov.
(000393a)

WARNING
Breathing diesel engine exhaust exposes you
to chemicals known to the State of California
to cause cancer and birth defects or other
reproductive harm.
• Always start and operate the engine in a
well-ventilated area.
• If in an enclosed area, vent the exhaust to
the outside.
• Do not modify or tamper with the exhaust
system.
• Do not idle the engine except as necessary.
For more information go to
www.P65Warnings.ca.gov/diesel. (000394)

ii Owner’s Manual for Stationary Industrial Generators

 Table of Contents
Section 1 Introduction and Safety Bi-fuel Fuel System ...................................... 10
LP Fuel System ............................................ 10
Introduction ................................................ 1
LP Vapor Withdrawal Fuel System ............... 11
Read This Manual Thoroughly ........................1
LP Liquid Withdrawal Fuel System ............... 11
Installation, Operation, and Dual Fuel: NG/LP Fuel System .................... 11
Maintenance ............................................... 1
Specifications ........................................... 11
How to Obtain Service ............................... 1 Generator .....................................................11
Safety Rules ................................................ 2 Engine Oil Recommendations ...................... 11
General Hazards ......................................... 2 Coolant ......................................................... 11
Gearbox Lubrication (If Equipped) ................ 11
Electrical Hazards ...................................... 3
Starting Aids (If Equipped) ...................... 12
Fire and Explosion Hazards ...................... 4
Engine Coolant Heater ................................. 12
Battery Hazards .......................................... 4 Engine Oil Sump Heater ............................... 12
Standards Index ......................................... 5 Battery Warmer ............................................ 12
Glow Plugs / Intake Air Heater ..................... 12
Section 2 General Information
Unit Identification ....................................... 7 Section 3 Operation
Data Label ......................................................7 Generator Control and Operation ........... 13
Model Identification Code ...............................7 Grounding the Generator ............................. 13
Voltage Code ..................................................8 Generator AC Neutral Connections .............. 13
Fuel Type ........................................................8 Initial Startup ................................................ 13
Engine RPM ....................................................8 Control Panel Interface ............................ 14
Controller Type ...............................................8 Emergency Stop Button ............................... 15
Equipment Description .............................. 9 Common Alarm Horn .................................... 15
Standard Generator Features .........................9 Key Switch ....................................................15
Generator and Load Compatibility ..................9 Fuse Block ....................................................15
Single-Phase “A” or “M” Code Units ...............9 Additional Components ........................... 15
Three-Phase Load Imbalance Limits ..............9 Main Line Circuit Breaker (MLCB) ................ 15
Ambient Condition Derate ...............................9 Automatic Transfer Switch ............................ 15
Engine and Generator Protective Automatic Battery Charger ........................... 15
Devices (If Equipped) ................................ 9 Alarm Response Procedures .................. 16
Coolant Temperature Sensor .........................9
Warnings ...................................................... 16
Low Coolant Level Sensor ............................10
Non-Shutdown Alarms .................................. 16
Oil Pressure Sensor ......................................10
Shutdown Alarms ......................................... 16
Oil Temperature Sensor (If Equipped) ..........10
Alarm Display Window .................................. 16
Overspeed Shutdown ...................................10
General Fault Response Procedure ............. 16
Overcrank Shutdown ....................................10
RPM Sensor Loss Shutdown ........................10 Operating the Unit with an Automatic
Transfer Switch ........................................ 16
Low Fuel Pressure Warning .........................10
DC Fuses ................................................... 10
Fuel System .............................................. 10
Diesel Fuel System .......................................10
Natural Gas Fuel System ..............................10

Owner’s Manual for Stationary Industrial Generators iii

 Operating the Unit with a Manual Maintenance and Repair Parts ................24
Transfer Switch ........................................17 Extended Run-Time Maintenance
Manual Engine Startup and Transfer ............17 Checks .......................................................25
Re-Transfer and Shutdown ..........................18
Maintenance Level 1A ..............................26
Shutting Generator Down While Under
Load ..............................................................18 Maintenance Level 1 - Monthly or
Every 24 Hours .........................................27
Section 4 Maintenance Maintenance Level 2 - Semi-Annual
or Every 125 Hours ...................................28
Maintenance ..............................................19
Service Maintenance Intervals .....................19 Maintenance Level 3 - Annual or Every
Maintenance Schedule .................................19 250 Hours ..................................................29
Notes and Maintenance Item Explanations ..20 Maintenance Level 4 - Bi-Annual or
Disabling a Generator for Every 500 Hours .......................................30
Maintenance ..............................................20
To Disable the Generator From Starting ......20 Section 5 Warranty Information
Shutdown and Restart an Operating For Stationary Emergency
Generator .....................................................20 Spark-Ignited Generators ........................31
Maintenance Tasks ...................................21 For Stationary Emergency
Visually Inspect Unit .....................................21 Compression-Ignition Generators ..........33
Check Engine Fluids .....................................21
Check Engine Oil Level .................................. 21
Check Coolant Level ...................................... 22
Check/Change Gearbox Oil (If Equipped) ...... 22
Battery Inspection .........................................23
Battery Installation and Replacement ...........23
Preliminary Instructions .................................. 23
12 VDC System .............................................. 23
24 VDC System .............................................. 24
Final Instructions ............................................ 24
Other Maintenance Checks ..........................24

iv Owner’s Manual for Stationary Industrial Generators

 Introduction and Safety

Section 1 Introduction and Safety

Introduction How to Obtain Service
Thank you for purchasing a Generac Power Systems, NOTE: Use this page to record important information
Inc. product. This unit has been designed to provide high- about the generator set. This label is typically located on
performance, efficient operation, and years of use when the side of the control panel.
maintained properly.
The information in this manual is accurate based on Each generator set has a data label containing important
products produced at the time of publication. The information about the unit.
manufacturer reserves the right to make technical When contacting an IASD about parts or service, always
updates, corrections, and product revisions at any time supply the complete model number and serial number of
without notice. the unit as given on the data label. For quick and easy
reference, copy the information printed on the data label
located on the generator onto the sample label printed
Read This Manual Thoroughly here. See Figure 1-1.
WARNING
Consult Manual. Read and understand manual
completely before using product. Failure to GENERATOR UNIT
completely understand manual and product
could result in death or serious injury. GEN MODEL:
(000100a)
MODEL:
SERIAL:
If any section of the manual is not understood, contact
your nearest Independent Authorized Service Dealer ALTERNATE
(IASD), or contact Generac Customer Service at 1-888- PROD DATE:
GENERAC (1-888-436-3722), or www.generac.com COUNTRY OF ORIGIN:
with any questions or concerns. The owner is responsible
for proper maintenance and safe use of the equipment. GENERATOR DATA
Save these instructions for future reference. This manual
contains important instructions for the generator that
should be followed during installation, operation and KW KVA HZ PF
maintenance of the generator and batteries. Always
supply this manual to any individual that will use this UPSIZE ALT KW KVA
machine.
VOLT / AMP

Installation, Operation, and ENG RPM ALT RPM

Maintenance BREAKER KW AMP
Installation and initial startup of this equipment is not a
“do-it-yourself” project. This generator set must be X’D X”D
installed by an IASD or other competent, qualified
contractor. The initial startup must be performed and
documented by an IASD. An IASD can also provide the
necessary training for authorized operators. It is the
operator’s responsibility to perform all safety checks, to ROTOR STATOR CLASS
make sure that all maintenance for safe operation is WINDINGS @ AMBIENT TEMP
performed promptly, and to have the equipment checked
periodically by an IASD. MANUF.
LOC
Access to the generator shall be through the use of a
special tool, or lock and key, or other means of security
and shall be controlled by the authority responsible for
the location.
Normal maintenance service and replacement of parts
are the responsibility of the owner 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. 003564

Proper maintenance and care of the generator will Figure 1-1. Data Label (Sample)
ensure a minimum number of problems and keep
operating expenses at a minimum. See an IASD for
service aids and accessories.

Owner’s Manual for Stationary Industrial Generators 1

Introduction and Safety

Safety Rules General Hazards

The manufacturer cannot anticipate every possible
circumstance that might involve a hazard. The warnings DANGER
in this manual, and on tags and decals affixed to the unit Asphyxiation. Running engines produce
are, therefore, not all inclusive. If using a procedure, work carbon monoxide, a colorless, odorless,
method or operating technique that the manufacturer poisonous gas. Carbon monoxide, if not
does not specifically recommend, verify that it is safe for avoided, will result in death or serious injury.
others. Also make sure the procedure, work method or (000103)
operating technique utilized does not render the
equipment unsafe.
Throughout this publication, and on tags and decals DANGER
affixed to the unit, DANGER, WARNING, CAUTION and Loss of life. Property damage. Installation must always
NOTE blocks are used to alert personnel to special
instructions about a particular operation that may be comply with applicable codes, standards, laws and
hazardous if performed incorrectly or carelessly. Observe regulations. Failure to do so will result in death
them carefully. Their definitions are as follows: or serious injury.
(000190)
DANGER
WARNING
Indicates a hazardous situation which, if not avoided,
Moving Parts. Keep clothing, hair, and
will result in death or serious injury.
appendages away from moving parts. Failure
(000001) to do so could result in death or serious injury.
(000111)
WARNING
WARNING
Indicates a hazardous situation which, if not avoided,
Moving Parts. Do not wear jewelry when
could result in death or serious injury.
starting or operating this product. Wearing
(000002) jewelry while starting or operating this product
could result in death or serious injury.
(000115)
CAUTION
WARNING
Indicates a hazardous situation which, if not avoided,
Sudden start-up. Always set the safety disconnect
could result in minor or moderate injury.
switch to MANUAL before working on equipment.
(000003) Failure to do so could result in death or serious injury.
(000194)
NOTE: Notes contain additional information important to
a procedure and will be found within the regular text of WARNING
this manual.
Personal injury. Do not insert any object through the
These safety warnings cannot eliminate the hazards that air cooling slots. Generator can start at any time and
they indicate. Common sense and strict compliance with
the special instructions while performing the action or could result in death, serious injury, and unit damage.
service are essential to preventing accidents. (000142a)

WARNING
Vision Loss. Eye goggles are required to be
worn when using this machine. Failure to wear
eye goggles could result in permanent
vision loss. (000101)

WARNING
Loss of life. This product is not intended to
be used in a critical life support application.
Failure to adhere to this warning could result
in death or serious injury.
(000209b)

2 Owner’s Manual for Stationary Industrial Generators

 Introduction and Safety

Electrical Hazards
WARNING DANGER
Hearing Loss. Hearing protection is Electrocution. In the event of electrical accident,
recommended when using this machine. immediately shut power OFF. Use non-conductive
Failure to wear hearing protection could implements to free victim from live conductor. Apply
result in permanant hearing loss. first aid and get medical help. Failure to do so will
(000107)
result in death or serious injury. (000145)

WARNING DANGER
Equipment damage. Only qualified service personnel may
install, operate, and maintain this equipment. Failure to Electrocution. Water contact with a power
follow proper installation requirements could result in death, source, if not avoided, will result in death
serious injury, and equipment or property damage. or serious injury.
(000182a) (000104)

CAUTION DANGER
Equipment or property damage. Do not block air Electrocution. Contact with bare wires,
intake or restrict proper air flow. Doing so could terminals, and connections while generator
result in unsafe operation or damage to unit. is running will result in death or serious injury.
(000229) (000144)

DANGER
Electrocution. Verify electrical system is
properly grounded before applying power.
Failure to do so will result in death or serious
injury. (000152)

DANGER
Electrocution. Turn utility supply OFF before
working on utility connections of the transfer
switch. Failure to do so will result in death or
serious injury. (000123)

DANGER
Electrocution. Never connect this unit to the electrical
system of any building unless a licensed electrician
has installed an approved transfer switch. Failure to
do so will result in death or serious injury.
(000150)

Owner’s Manual for Stationary Industrial Generators 3

Introduction and Safety

Fire and Explosion Hazards Battery Hazards

DANGER DANGER
Explosion and Fire. Fuel and vapors are Electrocution. Do not wear jewelry while
extremely flammable and explosive. Add fuel working on this equipment. Doing so will
in a well ventilated area. Keep fire and spark
away. Failure to do so will result in death result in death or serious injury.
or serious injury. (000105) (000188)

WARNING WARNING
Risk of Fire. Hot surfaces could ignite Explosion. Batteries emit explosive gases while
combustibles, resulting in fire. Fire could charging. Keep fire and spark away. Wear protective
result in death or serious injury. gear when working with batteries. Failure to do so
could result in death or serious injury.
(000110) (000137a)

WARNING WARNING
Risk of Fire. Unit must be positioned in a Explosion. Batteries emit explosive gases.
manner that prevents combustible material Always disconnect negative battery cable
accumulation underneath. Failure to do so first to avoid spark. Failure to do so could
could result in death or serious injury. result in death or serious injury.
(000147) (000238)

WARNING WARNING
Hot Surfaces. When operating machine, do not Explosion. Do not dispose of batteries in a fire.
touch hot surfaces. Keep machine away from Batteries are explosive. Electrolyte solution can cause
combustibles during use. Hot surfaces could burns and blindness. If electrolyte contacts skin or eyes,
result in severe burns or fire. flush with water and seek immediate medical attention.
(000108) (000162)

WARNING
Risk of burn. Do not open or mutilate batteries.
Batteries contain electrolyte solution which can
cause burns and blindness. If electrolyte contacts
skin or eyes, flush with water and seek immediate
medical attention. (000163a)

WARNING
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local
laws and regulations. Failure to do so could result in
environmental damage, death, or serious injury.
(000228)

Always recycle batteries in accordance with local laws

and regulations. Contact your local solid waste collection
site or recycling facility to obtain information on local
recycling processes. For more information on battery
recycling, visit the Battery Council International website
at: http://batterycouncil.org

4 Owner’s Manual for Stationary Industrial Generators

 Introduction and Safety

Standards Index
The generator owner must strictly comply with all
applicable national, state, or local laws, codes, and
regulations pertaining to the installation of engine-
generator power systems. Always use the current
acceptable version or edition of the applicable code or
standard which applies to the local jurisdiction. In the
absence of pertinent local laws and standards, the
following published booklets may be used as a guide:
National Fire Protection Association (NFPA) 70: The
National Electric Code (NEC)*
1. NFPA10: Standard for Portable Fire Extinguishers*
2. NFPA 30: Flammable and Combustible Liquids
Code*
3. NFPA 37: Standard for Stationary Combustion
Engines and Gas Turbines*
4. NFPA 54: National Fuel Gas Code*
5. NFPA 58: Standard for Storage and Handling of
Liquefied Petroleum Gases*
6. NFPA 68: Standard on Explosion Protection by
Deflagration Venting*
7. NFPA 70E: Standard for Electrical Safety in the
Workplace*
8. NFPA 99: Health Care Facilities Code*
9. NFPA 101: Life Safety Code*
10. NFPA 110: Standard for non-emergency and
Standby Power Systems*
11. NFPA 211: Standard for Chimneys, Fireplaces,
Vents, and Solid Fuel Burning Appliances*
12. NFPA 220: Standard on Types of Building Con-
struction*
13. NFPA 5000: Building Code*
14. International Building Code**
15. Agricultural Wiring Handbook***
16. ASAE EP-364.2 Installation and Maintenance of
Farm Standby Electric Power****
This list is not all inclusive. Check with the Authority
Having Local Jurisdiction (AHJ) for any local codes or
standards which may be applicable to the jurisdiction
where the generator is installed. The above listed
standards are available from the following Internet
sources:

* www.nfpa.org

** www.iccsafe.org

*** www.rerc.org Rural Electricity Resource

Council; P.O. Box 309; Wilmington, OH 45177-
0309

**** www.asabe.org American Society of Agricultural

& Biological Engineers; 2950 Niles Road; St.
Joseph, MI 49085

Owner’s Manual for Stationary Industrial Generators 5

Introduction and Safety

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6 Owner’s Manual for Stationary Industrial Generators

 General Information

Section 2 General Information

Unit Identification Model Identification Code
The model identification code gives important information
Data Label about the generator set. For example, if the code is:
Each generator set has a data label containing important SG 0100 A G03 6.8 N 23 H B Y Y 3
information about the generator. The data label lists the
Then the generator would have the attributes shown in
unit serial number, rated voltage, amps, wattage capacity,
bold below:
etc.
NOTE: The figure below is a generic representation only.
For actual information on your particular model, refer to
the data label(s) affixed to your unit.

S Standby
M Modular (MPS)
P Prime
W Prime Modular (MPS)
C Continuous
Z Protector Series
G Gaseous engine SG0100AG036.8N23HBYY3
D Diesel engine
B Bi-Fuel.
0100 kW rating (100kW)
A Voltage code (see Voltage Code)
G03 Engine designation (for internal use)
6.8 Engine size (6.8 = 6.8L, 142 = 14.2L)
N Fuel type (see Fuel Type)
23 Engine RPM (see Engine RPM)
H Control Panel (see Controller Type)
B Brushless excitation
P Permanent magnet (external) excitation
D Direct excitation
Y Standard enclosure (weather protective)
N No enclosure, standard — suitable for indoor installation
S Level 1 sound attenuated
L Level 2 sound attenuated
E Level 3 sound attenuated
C Containerized
Y Exhaust muffler mounted
N Exhaust muffler not provided
L Exhaust muffler shipped loose with unit Sample
3 Emission designation (for internal use)

Owner’s Manual for Stationary Industrial Generators 7

General Information

Voltage Code
Voltages Code Description
A 120/240 VAC, single-phase, three-lead
120/240 VAC, single- or three-phase, 12-lead (Full capacity single- or three-phase; cannot be
D
reconnected for 277/480 VAC)
G 120/208 VAC, three-phase, 12-lead
60 Hz
H 231/400 VAC, three-phase, 12-lead (Adjustable from 380 VAC to 416 VAC)
J 120/240 VAC, three-phase, 12-lead
K 277/480 VAC, three-phase, 12-lead
L 346/600 VAC, three-phase, three-lead
M 110/220 VAC, single-phase, three-lead (Adjustable to 120/240 VAC)
N 115/200 VAC, single-phase, 12-lead
50 Hz P 100/200 VAC, three-phase, 12-lead (Adjustable to 240 VAC)
R 231/400 VAC, three-phase, 12-lead (Adjustable from 380 VAC to 416 VAC)
S 480 VAC, three-phase, three-lead

Fuel Type
Code Description
B Bi-Fuel Diesel and Natural Gas
D Diesel
G Gasoline
N Natural Gas (11-14” WC)
S Natural Gas Low Pressure (7-11” WC)
V Liquid Propane Vapor Withdraw (LPV)
L Liquid Propane Withdraw (LPL)
P Dual Fuel NG (Normal) / LPL Secondary
R Dual Fuel NG (Normal) / LPV Secondary
Q Dual Fuel NG (Low Pressure) / LPL Secondary
T Dual Fuel NG (Low Pressure) / LPV Secondary

Engine RPM
Example Description
15 1500 RPM
18 1800 RPM
23 2300 RPM
30 3000 RPM
36 3600 RPM

NOTE: Engines operating above 1,500 or 1,800 RPM use a gearbox to reduce the engine RPM to the desired
alternator rotor RPM of 1,500 RPM (50 Hz operation) or 1,800 RPM (60 Hz operation).

Controller Type
Code Description
A ComAp
G G-Panel
H H-Panel
P Power Zone Pro Sync
S Power Zone Pro

8 Owner’s Manual for Stationary Industrial Generators

 General Information

Equipment Description Single-Phase “A” or “M” Code Units

This equipment is a revolving field, alternating current The following statement applies to single-phase units
type generator set. The generator is designed to supply with an “A” or “M” code alternator:
electrical power for the operation of compatible electrical The generator is suitable for supplying typical residential
loads when the utility power supply is not available or has loads, such as induction motors (sump pumps,
dropped to an unacceptable level. refrigerators, air conditioners, furnaces, etc.), electronic
The generator’s revolving field is directly connected to components (TV, computer, monitor, etc.), lighting loads,
and driven by an engine by means of flexible discs or a and microwaves.
gearbox. Generators with a four-pole rotor are driven at a
rated speed of 1,800 RPM to supply a frequency of 60
Three-Phase Load Imbalance Limits
Hertz. Four-pole rotors operating at 50 Hertz are driven
at 1,500 RPM. For three-phase units the maximum load imbalance
Refer to the data label affixed to the unit for rated AC between phases can not exceed 25% of rated load
voltage, wattage, amperage, number of phases, etc. See (current).
Model Identification Code for an explanation of how to
identify the unit’s features. Ambient Condition Derate
The maximum ambient temperature for the generator is
Standard Generator Features indicated on the unit data label. Derate values for
The generator incorporates the following features: ambient temperature in excess of that indicated on the
data label, as well as altitude, may apply depending on
• The rotor insulation system is Class “H” rated, and the engine and kW rating of the unit. Contact an IASD for
the stator insulation is Class “H” rated as defined any derate values applicable to this specific generator at
by NEMA MG1-22.4 and NEMA MG1-1.65. its installed location.
• The generator is self-ventilated and drip-proof
constructed. Engine and Generator Protective
• The voltage waveform deviation, total harmonic Devices (If Equipped)
content of the AC waveform and “telephone
influence factor” have been evaluated and are The generator set may be required to operate for long
acceptable according to NEMA MG1-22. periods of time without an operator to monitor conditions
such as coolant temperature, oil pressure, voltage,
• All prototype tested models have passed three- frequency, etc. For this reason, the generator set has
phase symmetrical short circuit test to ensure
numerous sensors to provide the control panel with the
system protection and reliability.
information it needs to protect both the engine and
generator. The control panel is designed to shut down the
Generator and Load Compatibility engine if potentially damaging conditions occur. These
conditions can include low oil pressure, high coolant
The generator must be fully compatible with the rated temperature, low coolant level, engine overspeed, over
voltage, phase, and frequency of the connected electrical or under voltage, over or under frequency, etc. These
loads. The generator, connected electrical devices, or settings are configured at the factory and can be adjusted
both, can be damaged if voltage, phase, and frequency by an IASD if required.
are not compatible.
NOTE: Engine and generator protective devices are only
NOTE: This manual assumes that the generator set has mentioned here for the owner’s general information. For
been properly selected, installed and interconnected by a details, consult the applicable control panel technical
competent, qualified electrician or installation contractor. manual. The list below is not all inclusive.
Once the installation is complete, do nothing that may
result in non-compatibility between the generator and
connected electrical loads. Coolant Temperature Sensor
The control panel automatically shuts down the engine if
the engine coolant temperature rises above a safe level.

Owner’s Manual for Stationary Industrial Generators 9

General Information

Low Coolant Level Sensor DC Fuses

Should the engine coolant level drop below the level of Located inside the front panel, the fuses protect the
the low coolant temperature sensor, it is possible for the control panel wiring and components from damaging
engine to overheat without automatic shutdown. To overload. For fuse location and identification, see
prevent such overheating, the engine has a low coolant the corresponding control panel manual.
level sensor. If the level of engine coolant drops below
the level of the low coolant level sensor, the control panel
will shut the engine down.
Fuel System
This generator set is equipped with one of the following
fuel systems:
Oil Pressure Sensor
• Diesel fuel system
This sensor monitors engine oil pressure. If oil pressure
drops below a safe level, the control system • Natural Gas (NG) fuel system
automatically shuts down the engine. • Bi-Fuel Diesel and Natural Gas
• LP gas vapor withdrawal fuel system (LPV)
Oil Temperature Sensor (If Equipped) • LP liquid withdrawal fuel system (LPL)
The control panel automatically shuts down the engine if • Dual fuel system: Natural Gas (primary fuel
the oil temperature rises above a safe level. source), LP gas vapor (secondary fuel source)
• Dual fuel system: Natural Gas (primary fuel source,
Overspeed Shutdown LP liquid (secondary fuel source)

A speed circuit controls engine cranking, startup,

operation, and shutdown. Engine speed signals are Diesel Fuel System
delivered to the control panel whenever the unit is The manufacturer recommends the use of No. 2 diesel
running. Should the engine overspeed above a safe, fuel when temperatures are above freezing, and No. 1
preset value, the control panel initiates an automatic diesel fuel when temperatures drop below freezing.
engine shutdown. Diesel fuel must meet the following requirements:
Beginning October 1, 2010, owners and operators that
Overcrank Shutdown use diesel fuel must use diesel fuel that meets:
After a pre-specified duration of cranking, this function • Sulfur content of 15 parts per million (ppm)
ends the cranking if the engine has failed to start. The maximum.
default settings are: • Cetane index or aromatic content as follows: A
• The unit will attempt to start (crank) three times. minimum cetane index of 40, or a maximum
• Each crank cycle lasts either 10 or 15 seconds, aromatic content of 35 volume percent.
followed by a five second rest (to cool the starter).
• After three starting attempts the unit will shutdown. Natural Gas Fuel System
Natural gas is supplied by a local utility in its vapor state
RPM Sensor Loss Shutdown through in ground piping.

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

shutdown will occur. Bi-fuel Fuel System
Combines diesel fuel and natural gas fuel systems.
Low Fuel Pressure Warning
• Some gaseous units are equipped with a low fuel LP Fuel System
pressure warning switch which will trigger a LP is supplied as a liquid in pressurized tanks. It is
Warning alarm if the fuel pressure drops below a usually made up of propane, butane, or a mixture of both
minimum setting. gases.
• Diesel units with fuel tanks are equipped with High
and Low fuel level warning alarms, as well as a low
fuel level shutdown alarm.

10 Owner’s Manual for Stationary Industrial Generators

 General Information

LP Vapor Withdrawal Fuel System IASD for oil recommendations. Synthetic oils meeting the
same service category and viscosity requirements for the
Utilizes the vapors formed above the liquid fuel in the
application may be used.
supply tank. Approximately 10 to 20 percent of the tank
capacity is needed for fuel expansion from the liquid to • Recommended API Service Category for gaseous
the vapor state. engines: SJ, SL, SM, or SN.
• Recommended API Service Category for diesel
LP Liquid Withdrawal Fuel System engines: CH-4, CI-4, or CJ-4

LP in a liquid withdrawal system must be converted to its

gaseous state before it is introduced into the engine Coolant
carburetor. A vaporizer converter is used to accomplish
this. In such a converter, heated engine coolant is ported
DANGER
through the converter to provide the necessary heat for Risk of poisoning. Do not use mouth to siphon
conversion of the fuel from a liquid to a gaseous state. coolant. Doing so will result in death or serious
NOTE: Units with LP gas liquid withdrawal systems injury.
incorporate a block heater as standard equipment. The (000149)
heater is powered by the utility power source during non-
operating periods to provide heated coolant to aid in the WARNING
fuel vaporization process.
Risk of burns. Do not open coolant system
until engine has completely cooled. Doing so
Dual Fuel: NG/LP Fuel System could result in serious injury.
Some applications consist of a dual-fuel system. This (000154)
type of fuel system allows the generator to run on either
natural gas (primary) or LP vapor or liquid (secondary). In CAUTION
the event that the primary source (utility supplied)
Risk of overheating. Do not use any chromate base
becomes unavailable, the unit automatically switches to
rust inhibitor with propylene glycol base antifreeze,
the secondary source. It can do so while in operation or boosters, or additives. Doing so will cause overheating
while not operating. and possible equipment damage. (000165a)
NOTE: Engines using propane as an alternative fuel are
limited to a maximum of 100 hours per year solely during Use only deionized or distilled water and Ethylene glycol
emergency operations and must keep records of such antifreeze (Propylene glycol can also be used but do not
use. Further operation requires a performance test to mix with Ethylene glycol). When adding coolant, always
confirm compliance with the emissions standards of add the recommended 50-50 mixture.
§60.4233.

Gearbox Lubrication (If Equipped)

Specifications
Use only SAE 90 gear oil with the correct proportion of
Lucas Heavy Duty Oil Stabilizer. See the Maintenance
Generator section for more information.
Refer to the data plate on the generator for rated watts,
amperes, frequency, voltage, phase, and other important
information.

Engine Oil Recommendations

The engine has been filled with factory engine oil of a
grade recommended by the engine supplier. See the
applicable engine service manual for engine oil
recommendations.
The manufacturer recommends an initial oil and filter
change after the first 50 hours (or first three months) of
service operation. Use a high quality detergent oil with an
appropriate classification and viscosity for the engine
type and ambient temperature conditions. Contact your

Owner’s Manual for Stationary Industrial Generators 11

General Information

Starting Aids (If Equipped)

One or more of the following starting aids may be
provided to ensure quicker, easier starts under varying
climactic conditions.
• Engine coolant heater
• Engine oil heater
• Battery warmer
• Glow Plugs
These aids are powered by a normal (utility) power
source during non-operating periods.

Engine Coolant Heater

Heats the engine coolant when the unit is not operating.
This action keeps the engine warm even in cold weather,
helping to ensure quicker starts. Powered by a circuit
normally fed by the utility power supply.

Engine Oil Sump Heater

Keeps the oil in the sump heated to allow easier starting
and faster engine warm-up. Powered by a circuit
normally fed by the utility power supply.

Battery Warmer
Keeps the battery warm so it can provide full cranking
current when starting in cold conditions. Powered by a
circuit normally fed by the utility power supply.

Glow Plugs / Intake Air Heater

Internally heat the cylinders of a diesel engine. This
assists in achieving a chamber temperature high enough
for combustion. Powered by a circuit normally fed by
battery power.

12 Owner’s Manual for Stationary Industrial Generators

 Operation

Section 3 Operation
Generator Control and Operation Generator AC Neutral Connections
Grounding is recommended only at one point in the
WARNING system. Consult local building codes for proper neutral
Equipment damage. Only qualified service personnel may grounding requirements.
install, operate, and maintain this equipment. Failure to
follow proper installation requirements could result in death,
serious injury, and equipment or property damage. Initial Startup
(000182a)
The initial startup of the generator set must be performed
The operation of this generator set should only be and documented by an IASD.
performed by an Authorized Operator, that is, someone
who has been properly trained by an IASD. Contact your
local IASD for assistance in training Authorized
Operators.
The following instructions assume that the generator has
been properly installed, serviced, tested, adjusted, and
otherwise prepared for use by a competent, qualified
installation contractor and IASD. Carefully read the
Safety Rules and any other safety information before
attempting to operate this (and related) equipment.

Grounding the Generator

Ground the generator set in accordance with all codes
and regulatory requirements.

DANGER
Explosion and Fire. Do not connect ground wire
to any pipe that carries a flammable or explosive
substance. Doing so will result in death or
serious injury. (000211)

A
B

001064

Figure 3-1. Grounding Electrode Terminal (Typical)

A Grounding Electrode Terminal

B Base Frame

Owner’s Manual for Stationary Industrial Generators 13

Operation

Control Panel Interface

The Control Panel Interface mounted on the generator
allows the operator to monitor, and if necessary,
manually start the generator.

G
D
C
D
F
G
E
009612
C
Figure 3-2. H-Panel A

B
H

A
009615
B
Figure 3-5. Power Zone Pro Sync

G
A Emergency Stop Button
D C
B Common Alarm
F
C Key Switch
009613

Figure 3-3. G-Panel D Display Window

E Arrow Key Pad

F Communication Port

G Panel Access

H Battery Charger

D NOTE: Refer to the accompanying control panel manual

for more information.

A B C 009614

Figure 3-4. Power Zone® Pro

14 Owner’s Manual for Stationary Industrial Generators

 Operation

Emergency Stop Button

Pressing the Emergency Stop button while the unit is
running will immediately shut the generator down. To
restart the unit, the Emergency Stop Button must be
manually reset, the alarm acknowledged, the Key Switch
turned to the OFF position, and then turned to either the
AUTO or MAN position, depending on the desired mode
of operation.

CAUTION
Equipment Damage. The emergency stop switch is 001066
not to be used to power down the unit under normal Figure 3-6. Panel Fuse Block (Reference Only)
operating circumstances. Doing so could result in
equipment damage. (000246b) NOTE: Some units will NOT have a fuse in the F4 slot.

Additional Components
Common Alarm Horn
The Common Alarm and corresponding output are
activated whenever a fault condition is set for Alarm and
Main Line Circuit Breaker (MLCB)
if the fault is Active. The Common Alarm will not activate A MLCB is located in the High Voltage Customer
on Warnings or DTC fault conditions. Pressing the Connections panel, typically located to the right of the
ENTER button on the key pad will acknowledge the Control Panel. The MLCB serves as protection for the AC
alarm and silence the horn. The manufacturer wiring and alternator, while also providing a means of
recommends that the local IASD be notified of any alarm disconnecting the generator.
condition in order for qualified service personnel to
assess and correct the situation.
Automatic Transfer Switch
Key Switch DANGER
Electrocution, equipment and property damage.
The Key Switch positions are: Handle transfer switches carefully when installing.
• AUTO: The generator will automatically start when Never install a damaged transfer switch. Doing so
could result in death or serious injury, equipment
a properly connected automatic transfer switch
and property damage. (000195)
senses a loss or reduction of available utility power.
• OFF: Immediately shuts down the generator and A typical automatic transfer switch monitors utility voltage
prevents it from starting automatically. and when that voltage falls outside of specific
• MAN: Immediately starts the generator. parameters, it will initiate the generator start command.
As long as the generator control is in the AUTO position,
it responds to the automatic transfer switch start
Fuse Block command.
The fuse block is located inside the control panel at the For information about any connected automatic transfer
back lower left corner, and provides electrical protection switch, consult the applicable transfer switch owner’s
for the DC power, wiring and other electrical components. manual.

Automatic Battery Charger

One of the following types of battery chargers may be
provided:
• 2.5-amp
• 10-amp
• 20-amp

Owner’s Manual for Stationary Industrial Generators 15

Operation

The 2.5-amp charger is 12 VDC only. The 10-amp Alarm Display Window
charger is available either as a 12 VDC or 24 VDC. The
For information regarding alarm codes and
20-amp charger operates as both 12 VDC or 24 VDC.
troubleshooting procedures, see the applicable manual
The appropriate battery charger is installed per the
for your control panel.
engine’s battery system.
All chargers are fully automatic float types and are fully
fuse protected (input and output). They have automatic General Fault Response Procedure
current limiting to reduce risk of overcharging, and have
automatic maintenance of charge voltage. Therefore, NOTE: See corresponding control panel manual for
they can be connected to the batteries continuously. detailed alarm descriptions and specific procedures.
The chargers require the connection of a charged battery 1. Use the keypad or touch screen to navigate to the
in order to turn on. The battery provides boost voltage for Alarm Display.
the charger, so a completely dead battery will not allow 2. Carefully read each line of the Alarm Warning
the charger to operate. The boost required is Page to determine what fault condition is present. If
approximately 9 to 11 volts for a 12 VDC system, and 18 there is more than one fault, the most recent is
to 22 volts for a 24 VDC system. Replace the battery if it listed first.
is below the boost voltage. 3. Depending on the fault condition, toggle to the
corresponding area.
Alarm Response Procedures 4. Observe the information displayed for the affected
The generator is protected by factory set alarms and area.
warnings. The alarms and warnings alert the owner of a 5. Determine corrective action necessary.
fault condition that requires attention and action to keep 6. When the fault condition is cleared, the Alarm Dis-
the generator operating in an efficient and safe running play will turn off.
order.
When any alarm is triggered, the Common Alarm Horn
sounds and the corresponding fault will be displaed.
Operating the Unit with an Automatic
Transfer Switch
NOTE: Not all faults can be corrected and cleared by the
owner/operator. Some Warnings, and most Alarm If the generator has been installed along with an
conditions, must be safely cleared by a qualified dealer or automatic transfer switch, the engine may be started and
trained technician. stopped automatically or manually.
NOTE: Refer to the applicable manual for any transfer
switch being used and note the dangers during
Warnings operation.
Warnings are the lowest level alarm, and are generated
Normal operation is the generator in AUTOMATIC
to alert the operator that an operating condition has
working with an automatic transfer switch. When the
changed and may require action or inspection. Warnings
transfer switch senses a utility failure or loss it will
clear once they are no longer active.
provide a start command to the generator, the generator
will automatically start and the transfer switch will transfer
Non-Shutdown Alarms power to the load from utility to generator (emergency). It
is important that both the generator and any connected
Non-shutdown alarms are more urgent than warnings, automatic transfer switch(es) be properly connected and
and indicate a system parameter which is approaching or in AUTOMATIC mode for normal operation.
has exceeded a safe operating limit. Non-shutdown
alarms require some form of action, such as inspection,
close monitoring, etc. These types of alarms clear when
they are no longer active and have been acknowledged.

Shutdown Alarms
Shutdown Alarms protect the generator from damage
and indicate a system fault that, if continued without
immediate inspection or correction, would result in
damage to the unit. Shutdown Alarms are cleared only
after the key switch has been placed in the OFF position
and they are no longer active.

16 Owner’s Manual for Stationary Industrial Generators

 Operation

Operating the Unit with a Manual

Transfer Switch
If the generator was installed in conjunction with a
transfer switch capable of manual operation only, or
when an automatic transfer switch has failed and can
only be transferred manually, the following procedure
applies. A manually operated transfer switch is one that
will not provide automatic startup.

DANGER
Electrocution. Do not manually transfer under load.
Disconnect transfer switch from all power sources
prior to manual transfer. Failure to do so will result in
death or serious injury, and equipment damage.
(000132)

DANGER
Electrocution. Only authorized personnel should
access transfer switch interior. Transfer switch
doors should be kept closed and locked. Failure to
do so will result in death or serious injury. (000213)

Manual Engine Startup and Transfer

Refer to the applicable documentation for the control
panel. For additional and specific information about any
transfer switch connected to the generator, refer to the
applicable transfer switch manual as well.
In order to manually transfer load from the utility source
to the generator (emergency source):
1. With the generator OFF, and the generator MLCB
in the OFF (OPEN) position, turn OFF or
disconnect the utility power circuit to the transfer
switch, using the means provided (such as the
utility source MLCB or other means of disconnect).
2. Manually set the automatic transfer switch (ATS) to
its EMERGENCY (STANDBY/GENERATOR)
position with load circuits connected to the
emergency (generator) power supply.
3. Set the generator’s MLCB to its OFF (OPEN)
position.
4. Start the generator.
5. Allow the engine to stabilize and warm up.
6. Check all applicable instrument and gauge
readings. When certain that all readings are
correct, set the emergency generator’s MLCB to its
ON (CLOSED) position.
7. Load circuits are now powered by the stationary
emergency generator.

Owner’s Manual for Stationary Industrial Generators 17

Operation

Re-Transfer and Shutdown

To manually transfer the load back to the utility power
source and shut down the generator:
1. Set the stationary emergency generator’s MLCB to
the OFF (OPEN) position.
2. Verify utility power to the transfer switch is OFF
(open the utility disconnect).
3. Manually move the ATS to the UTILITY (NORMAL)
position, i.e., load circuits connected to the utility.
4. Turn ON the utility power supply to the transfer
switch using the means provided (such as the
utility power source MLCB).
5. Allow the generator to run at no-load for five to ten
minutes to stabilize internal temperatures.
6. Shut down the generator.

Shutting Generator Down While Under Load

IMPORTANT NOTE: To turn the generator OFF
during utility outages to perform maintenance, or
conserve fuel, follow these steps:
To turn the generator OFF (while running in AUTO
and ONLINE):
1. Turn the main utility disconnect OFF.
2. Turn the MLCB on the generator to OFF (OPEN).
3. Allow the generator to run for five minutes to cool
down.
4. Turn the generator OFF.
To turn the generator back ON:
1. Put the generator back into AUTO and allow to
start and warm-up for a few minutes.
2. Set the MLCB on the generator to ON.
The system will now be operating in AUTOMATIC mode.
The main utility disconnect can be turned ON (CLOSED).
To shut the unit OFF, this complete process must be
repeated.

18 Owner’s Manual for Stationary Industrial Generators

 Maintenance

Section 4 Maintenance
Maintenance the first three months or first 50 hours of operation
after installation and startup of the unit.
Regular maintenance will improve performance and
extend engine/equipment life. Generac Power Systems, The various service maintenance intervals are
Inc. recommends that all maintenance work be per- designated by interval numbers:
formed by an Independent Authorized Service Dealer 1. A frequent, periodic inspection of the generator set
(IASD). Regular maintenance, replacement, or repair of to ensure it is ready to operate when required and
the emissions control devices and systems may be per- to identify any potential problem areas. Performed
formed by any repair shop or person of the owner’s monthly, or every 24 hours (interrupted) of
choosing. To obtain emissions control warranty service operation of the unit.
free of charge, the work must be performed by an IASD.
2. An operational service inspection of the generator
See the emissions warranty.
set to ensure it is ready to operate and carry the
Periodic inspection, service, and maintenance of this unit load when required, and to identify any potential
is critical in ensuring its reliable operation. The following problem areas. Performed semi-annually (6
is the manufacturer’s recommended maintenance months) or every 125 hours of operation of the unit.
schedule. The established intervals are the maximum
3. A mid-level service inspection of the generator set
required when the unit is used in typical standby service
to ensure it is ready to operate and carry the load
applications (approximately 250 hours per year). The
when required, and to identify any potential
maintenance items will need to be performed more
problem areas. Performed annually or every 250
frequently if the unit is used in severe applications (such
hours of operation of the unit.
as long duration outages, very high or very low ambient
conditions, or extremely dirty or dusty environments). 4. A comprehensive service inspection of the
Use calendar time or hours of operation, whichever generator set to ensure it is properly serviced and
occurs first, from the previous maintenance interval to ready to operate and carry the load when required,
determine the next required maintenance interval. Note and to identify any potential problem areas.
that some checks are based only on hours of operation. Performed biannually (every 24 months or 500
hours).
There may be times when the generator must operate
continuously for long periods of time (for example, NOTE: Maintenance levels 2, 3, and 4 require the use of
extended utility outages). During such extended the applicable engine service manual and must be
operational periods some items will require more performed by a qualified service technician.
frequent checking (based on hours). Use the “Extended
Run-Time Maintenance Checks” recommendation for
such periods of operation.
Maintenance Schedule
Be sure to follow all applicable safety and caution The following pages contain the maintenance schedule
statements found in the unit operating manual or engine describing the checks/tasks which need to be
service/maintenance manual before performing any accomplished at each designated maintenance interval.
maintenance checks or service. Some maintenance level tasks are combined. For
example, if the six month tasks are due, both the monthly
and the six month task should be completed at the same
Service Maintenance Intervals time. Similarly, when the annual tasks are due, the
Extended Run-Time Maintenance Checks: Daily monthly and semi-annual tasks should also be
checks which must be performed when the unit is completed. There is space on the sheets for recording
operated continuously for extended periods of time. the date and signature of the person completing the task,
These checks and routine monthly checks can be as well as recording the engine hours and other pertinent
performed by an Authorized Operator. information. At the bottom of each sheet, space is also
provided to record any fluids added, parts replaced or
NOTE: For units equipped with a gearbox, the gearbox corrective action taken. All of this recorded information
oil should be checked monthly or every 100 hours of provides a detailed maintenance history of the unit. This
operation. maintenance history may be required for warranty
1A. A one-time post installation, initial operation, validation purposes, and is a good idea to maintain
service inspection of the generator set to ensure it throughout the lifetime of the unit.
is ready to operate, transfer to, and carry the load It is recommended by the manufacturer that service
when required, and to identify any potential procedures beyond the normal monthly checks be
problem areas. Performed ONLY ONCE following performed by an IASD.

Generator Installation and Operating Manual 19

Maintenance

Notes and Maintenance Item Explanations

Maintenance Item Description

Change oil and filter shortly after start up or commissioning of the unit. The recommendation
is that this be done after the first 50 hours of operation or after the first three months of
Oil and Oil Filter service. Perform oil and filter changes every 250 hours (or yearly) thereafter. If an oil analysis
program is used (annually), the acceptable oil change interval can be extended to 500 hours
or every two years, based on the results of the analysis.

Change gearbox oil every two years or 600 hours of operation. Check gearbox oil level
Gearbox Oil (If Equipped)
monthly or every 100 hours of operation.

Check coolant annually for proper thermal protection levels. Drain, flush, and refill the cooling
Coolant Quality
system with fresh coolant every two years regardless of operating hours.

Change coolant, fuel (gaseous supply hoses from regulator to mixer), oil, charge air cooling,
Flexible Hoses
and block heater hoses, flexible joints, etc.) every two years regardless of operating hours.

Replace accessory drive belts every two years regardless of operating hours. If necessary,
Accessory drive belts
check and replace automatic tensioner (if used).
Magnetic Pickup(s) mounted on Remove, clean, inspect, and reset magnetic pickups to the correct operational output voltage
flywheel housing every two years.

Crank and/or Cam Pickup for

Visually inspect (outside) for cleanliness and tightness.
ignition system

NOTE: Certain applications may require more frequent maintenance checks and more frequent operation under load.
NOTE: This schedule does not reflect all of the possible requirements of an individual engine manufacturer service
schedule, particularly if the unit is used in other than a standby power application.
NOTE: For more information about service schedules and support for your application, please contact your local IASD.

Disabling a Generator for 1. Set the control panel AUTO/OFF/MANUAL switch

to the OFF position.
Maintenance
2. Remove the control panel fuse (see wiring
There are two conditions when maintenance checks diagram).
may have to be performed on the unit: 3. Turn OFF power to the battery charger (remove
1. When the unit is in standby mode (automatic) and battery charger ATC style fuse or open the battery
NOT running. To disable the unit from starting in charger circuit breaker located in the load control
this condition, in order to perform maintenance panel).
checks or service, follow the steps in To Disable 4. Disconnect the negative battery cable.
the Generator From Starting.
NOTE: The battery charger must be turned OFF
2. When the unit is running and providing power to
BEFORE disconnecting the battery cable to prevent an
the load. To shut down the unit safely, without over-current condition from burning out sensitive control
damaging loads or the generator, follow the steps panel components and circuits.
for shutting down a unit while in operation. See
Shutdown and Restart an Operating Generator. NOTE: Following any maintenance, reverse these steps
Before shutting down an operating unit for so the unit is returned to standby setup for normal
maintenance, always warn personnel that power operation.
will be shut down temporarily, so equipment that
might be damaged can be properly turned OFF or
Shutdown and Restart an Operating Generator
placed in standby.
If the unit is operating and required checks must be
performed:
To Disable the Generator From Starting
1. Verify power to the load can be interrupted (warn
To prevent injury, BEFORE performing any maintenance, any equipment users that there will be a temporary
disable the generator set from starting and/or connecting power disruption). There may be other procedures
to the load:

20 Generator Installation and Operating Manual

 Maintenance

that must be done before shutting a unit down, Check Engine Oil Level
depending on application. An Authorized Operator should check the levels of
2. Open the utility MLCB. engine oil and engine coolant monthly (or every 24 hours
3. Open the generator MLCB. of operation). The oil level should be maintained between
the FULL and ADD marks on the engine dipstick.
4. Allow the unit to cool down (running at no-load) for Recommended fluids are listed in Engine Oil
approximately five minutes to prevent damage to Recommendations.
critical engine components.
To check the engine oil:
5. Set the control panel AUTO/OFF/MANUAL switch
1. Locate the engine oil dipstick.
to the OFF position. There may be safety tag-outs
or lockouts required at this point, depending on 2. The most accurate oil level readings are measured
application. when the engine is cold. If the engine was running,
6. Perform the necessary maintenance checks or wait at least ten minutes before proceeding.
tasks (based on the hourly requirements). 3. Remove the dipstick and wipe it dry with a clean,

7. When all checks have been completed and any lint free cloth.
discrepancies corrected, set the control panel 4. Slowly insert the clean dipstick into the tube.
AUTO/OFF/MANUAL switch to the AUTO position. Visually confirm that the dipstick is fully seated in
8. When the generator is running, and all engine/ the dipstick tube. A visual inspection is required
generator parameters (voltage, frequency, coolant because some dipsticks will require more effort
temp, oil pressure, etc.) have been verified as than others to fully seat.
correct, close the generator MLCB. The unit will 5. After ten seconds remove the dipstick.
accept and carry the load. 6. Look at the oil level on both sides of the dipstick.
9. Make a last visual inspection of the generator set The lower of the two readings will be the correct oil
to make sure it is operating properly. level measurement.
10. Close the utility MLCB. 7. Add oil (if necessary) to adjust the level. After
adding or changing the oil, the engine should run
for one minute before checking the oil level.
Maintenance Tasks Remember to wait ten minutes to allow the engine
to cool and oil to fully drain into the oil pan.
Visually Inspect Unit
Typical causes of inaccurate oil level readings:
Perform a visual inspection of the unit periodically. If • Reading the high level of the dipstick.
problems are found contact your local IASD. Look for the
following: • Reading the dipstick before the oil fully drains into
the oil pan.
• Any debris, trash, grass or weed growth, which
would obstruct the flow of cooling air into and out of • Inserting and removing the dipstick too quickly.
the unit ventilation louvers. • The dipstick is not fully seated in the dipstick tube.
• Visually inspect hoses and hose connections for
signs of leakage. This includes all coolant hoses,
fuel hoses, exhaust system connections, intake
system connections, etc. Also look at the engine
block and gearbox (if equipped) for signs of fluid
leakage.
• Visually inspect the engine accessory drive belts
for evidence of obvious wear, fraying or
deterioration, and obvious looseness. A
“squealing” sound heard during starting and
running could indicate a loose belt.

Check Engine Fluids

The following checks can be performed by a trained
Authorized Operator. Observe all safety precautions
outlined in Introduction and Safety.

Generator Installation and Operating Manual 21

Maintenance

Check Coolant Level NOTE: Do NOT overfill the gearbox. If too much fluid is
added let the excess drain from the level check plug hole
DANGER and collect it in a suitable container or with rags.
Risk of poisoning. Do not use mouth to siphon
coolant. Doing so will result in death or serious
injury. A
(000149)
B
WARNING
C
Risk of burns. Do not open coolant system
until engine has completely cooled. Doing so
could result in serious injury.
(000154) 001063

CAUTION Figure 4-1. Gearbox Oil Servicing Points

Risk of overheating. Do not use any chromate base

rust inhibitor with propylene glycol base antifreeze, A Oil Filler/Vent Cap
boosters, or additives. Doing so will cause overheating
B Oil Level Check Plug
and possible equipment damage. (000165a)
C Oil Drain Plug
Visually check the coolant expansion tank and verify the
coolant level is between the “Cold” and “Hot” level To change the gearbox oil:
markings. To add coolant to the system add it to the
1. Disable the generator from starting.
expansion tank when the engine is cool (not at operating
temperature, not running). Add only a 50/50 mixture of 2. Remove the oil drain plug and drain the oil into an
the correct antifreeze and distilled or deionized water to appropriate container. Properly dispose of or
the coolant system. recycle the oil.
3. Reinstall the oil drain plug.
Check/Change Gearbox Oil (If Equipped)
4. To add oil to the gearbox, remove the oil level
Check monthly, or every 100 hours of operation. check plug and oil filler/vent cap.
Biannually (or every 600 hours), an authorized service 5. Add the recommended oil/stabilizer mix until it just
technician should completely drain and refill the gearbox. starts to flow from the oil level check plug opening.
Gear oil used is 80W-90. Lucas Heavy Duty Oil Stabilizer 6. Install and tighten the oil filler/vent cap and oil level
should be added as follows by Fluid volume: check plug.
• 390 Gearbox - Approximately 32 oz. total. 26 oz.
gear oil and 6 oz. Lucas Heavy Duty Oil Stabilizer. Return the generator to operating condition. Start the unit
and check for leaks.
• 520 Gearbox - Approximately 55 oz. total. 44 oz.
gear oil and 11 oz. Lucas Heavy Duty Oil Stabilizer.

To check gearbox oil level:

1. Disable the generator from starting.
2. Remove the oil level check plug. See Figure 4-1.
3. The oil level should be at the bottom edge of the oil
level check plug hole.
4. To add oil, remove the oil filler/vent cap, and fill
through the vent line.
5. Replace the vent cap and oil level check plug and
tighten.

22 Generator Installation and Operating Manual

 Maintenance

Battery Inspection An Authorized Operator should inspect the engine bat-

tery system monthly. At this time, the battery fluid level
DANGER should be checked and distilled water added if needed.
Electrocution. Do not wear jewelry while Battery cables and connections also should be inspected
working on this equipment. Doing so will for cleanliness and corrosion.
result in death or serious injury. Once every six months, an Authorized Service
(000188) Technician should inspect the battery system. At this time
the battery condition and state of charge should be
checked using a battery hydrometer. The battery should
WARNING be recharged or replaced as required.
Sudden start-up. Always set the safety disconnect
switch to MANUAL before working on equipment. NOTE: A negative ground system is used. Battery
Failure to do so could result in death or serious injury. connections are shown on the wiring diagrams. Verify the
(000194) battery is correctly connected and terminals are tight.
Observe battery polarity when connecting the battery to
the generator set.
WARNING
Explosion. Batteries emit explosive gases while
Battery Installation and Replacement
charging. Keep fire and spark away. Wear protective
gear when working with batteries. Failure to do so When required, the battery must be replaced with one of
could result in death or serious injury. equivalent size, voltage, and CCA (cold crank amp
(000137a) capacity). Consult the Unit Specification Sheet or contact
the local IASD for proper battery sizing.
WARNING A new battery must be filled with the proper electrolyte
Explosion. Batteries emit explosive gases. and be fully charged before installing.
Always disconnect negative battery cable
first to avoid spark. Failure to do so could Preliminary Instructions
result in death or serious injury. (000238) 1. Set the AUTO/OFF/MANUAL switch on the
generator control panel to OFF.
2. Turn off utility power supply to the battery charger
WARNING
circuit.
Explosion. Do not dispose of batteries in a fire.
Batteries are explosive. Electrolyte solution can cause 3. Remove the 10A fuse from the generator control
burns and blindness. If electrolyte contacts skin or eyes, panel.
flush with water and seek immediate medical attention.
4. Remove the ATC style fuse from the battery
(000162)
charger.

WARNING Battery cables are connected to the generator connection

points at the factory. Connect the cables to the battery
Risk of burn. Do not open or mutilate batteries.
Batteries contain electrolyte solution which can posts as shown in Figure 4-2 and Figure 4-3.
cause burns and blindness. If electrolyte contacts
skin or eyes, flush with water and seek immediate 12 VDC System
medical attention. (000163a) 1. Connect the red battery cable from the starter
contactor to the positive (POS or +) battery post.

WARNING
Vision Loss. Eye protection is required to avoid
spray from spark plug hole when cranking engine.
Failure to do so could result in vision loss.
(000181)

WARNING
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local
laws and regulations. Failure to do so could result in
environmental damage, death, or serious injury.
(000228)

Generator Installation and Operating Manual 23

Maintenance

2. Connect the black battery cable to the frame 2. Install the 10A fuse in the generator control panel.
ground to the negative (NEG or -) battery post. 3. Turn on the utility power supply to the battery
charger circuit.
E 4. If the unit was previously operational, turn the
AUTO/OFF/MANUAL switch on the generator
A F control panel to AUTO.

B
WARNING
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local
laws and regulations. Failure to do so could result in
environmental damage, death, or serious injury.
(000228)
Always recycle batteries in accordance with local laws
001061
and regulations. Contact your local solid waste collection
Figure 4-2. 12 VDC System site or recycling facility to obtain information on local
C E
recycling processes. For more information on battery
A recycling, visit the Battery Council International website
at: http://batterycouncil.org
D F

B
CAUTION
Equipment damage. Do not make battery
connections in reverse. Doing so will result
in equipment damage.
(000167a)

001062
Other Maintenance Checks
Figure 4-3. 24 VDC System The following inspections should be performed by an
IASD, or an Authorized Operator. These maintenance
items require a high level of experience and skill to
A Black Lead to Frame
evaluate and correct.
B Black (-)
• Inspect engine accessory drive belts
C Red or Black Jumper • Inspect hoses and connections
D Wire 13 (if used) • Inspect fuel supply system
E Red Lead from Starter Contactor • Inspect exhaust system

F Red (+)
Maintenance and Repair Parts
24 VDC System All non-emissions related service maintenance or repairs
should be completed by an authorized service technician
1. Connect the red battery cable from the starter
to maintain the warranty status of a unit. Emissions
contactor to the positive (POS or +) post of battery related maintenance and repairs may be performed by a
A. person or repair shop of the owner’s choosing.
2. Connect the black battery cable to the frame
ground to the negative (NEG or -) post of battery B.
NOTE: On 24V gaseous units, center tap wire number
13 between the batteries as shown in Figure 4-3.
3. Connect either a black or red jumper cable from
the negative (NEG or -) post of battery A to the
positive (POS or +) post of battery B.

Final Instructions
1. Install the ATC style fuse in the battery charger.

24 Generator Installation and Operating Manual

 Maintenance

Extended Run-Time Maintenance Checks

These maintenance tasks can be performed by an IASD or an Authorized Operator. Comply with all safety notices
contained in the owner’s manual.

IASD/Authorized Operator Maintenance Tasks. Task Completed

Perform steps 1 through 8 and 11 every 24 continuous operating hours. Date/Initials

1. Before shutting the unit down, perform a thorough visual inspection for leaks, loose
components or connections, excessive apparent wear or damage. Any discrepancies noted
should be further inspected and corrected while the unit is shut down.

2. Shut the unit down per the procedure in the owner’s manual.
3. Check the engine oil level. The level should be between the low and full markings on the
dipstick. Adjust as necessary.

4. Check the engine coolant level. Make sure the level in the coolant catch tank is between the
cold and hot level markings. Adjust as necessary. Use only a 50/50 mixture of appropriate
coolant.
5. Visually inspect the engine accessory drive belts and fan coupling device (if equipped) for
correct tension and any signs of abrasion, wear, deterioration or damage. Correct as
necessary.

6. Visually inspect all hoses and connections (exhaust, intake, coolant, block heater, fuel lines and
filters, oil filters, etc) for leaks, tightness, signs of deterioration, wear, or damage. Correct as
necessary.

7. Check the air inlets and outlets (enclosure or building vents) for debris or blockage. Correct as
necessary.

8. Visually inspect the fuel supply system for signs of leaks or damage. Correct as necessary.

9. Gearbox Equipped Only: Check the gearbox oil level every 100 operating hours. Adjust as
necessary.

10. Weekly When Operating: Check the battery electrolyte level (if accessible). Adjust as
necessary (add only distilled or deionized water to replenish battery cells).

11. Return the unit to operational condition and restart. Check unit voltage and frequency. Visually
inspect the unit for leaks, loose connections or components. Place the unit back in service.

Date inspection Completed: Unit Hour-Meter Reading:

IASD/Authorized Operator signature signifying inspection complete:

Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

Generator Installation and Operating Manual 25

Maintenance

Maintenance Level 1A
One Time at 50 Hours / 3 Months. These maintenance tasks must be performed by an IASD. Comply with all safety
notices contained in the owner’s manual. Some of these tasks require the use of the applicable engine service manual.

IASD Tasks. Task Completed

Perform these tasks in addition to the regularly scheduled Monthly maintenance tasks Date/Initials

1. Disable the unit from operating per the procedure found in the owner’s manual.

2. Check engine valve clearance (valve lash) as specified in the engine service manual.
NOTE: This is NOT required for engines with hydraulic lifters. Check the engine service
manual.
3. Change the engine oil.

4. Change the oil filter(s).

5. Check the engine accessory drive belts and fan coupling device (if equipped) for correct
tension, wear or abrasion, deterioration, or damage. Correct as necessary.
6. Check all hoses, piping, and connections (intake, exhaust, coolant, block heater, fuel and
filters, oil lines and filters) for tightness, leaks, deterioration or damage. Correct as necessary.

7. Check wiring connections (at MLCB, customer connections, control terminal strips, battery,
etc) for loose connections, corrosion or damage. Correct as necessary.

8. Return the unit to operational condition and test. Place the unit in automatic and open the
service disconnect to force the unit to start and transfer to the load. Exercise the unit against
the load for 15 minutes, visually inspecting for leaks, loose connections or components, and
any abnormal operating conditions. Record the unit voltage, frequency, kW and kVA while
running. Restore utility power and monitor transfer to utility, cool-down and shutdown. Correct
any discrepancies.
Voltage: Frequency: kW: kVA:

9. If the control has alarm and/or event or run logs, record the alarm and event logs to a history
file for the unit.

10. Return the unit to operational condition.

Date inspection Completed: Unit hour Meter Reading:

IASD signature signifying inspection complete:

Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

26 Generator Installation and Operating Manual

 Maintenance

Maintenance Level 1 - Monthly or Every 24 Hours

These maintenance tasks can be performed by an IASD or an Authorized Operator. Comply with all safety notices
contained in the owner’s manual.

IASD/Authorized Operator Maintenance Tasks Task Completed

Date/Initials

1. Disable the unit from operating per the instructions in the owner’s manual.

2. Check the engine oil level. The level should be between the low and full markings on the
dipstick. Adjust as necessary.

3. Gearbox Equipped Only: Check the gearbox oil level. Adjust as necessary.
4. Check the engine coolant level. Verify the level in the coolant catch tank is between the cold
and hot level markings. Adjust as necessary. Use only a 50/50 mixture of appropriate
coolant.

5. Check the battery electrolyte level (if accessible). Adjust as necessary (add only distilled or
deionized water to replenish battery cells).
6. Check the battery terminal posts, connections, cables and charger connections, and battery
hold-downs for signs of corrosion, looseness, etc. Remove, clean and tighten connections as
necessary.

7. Check operation and condition of the battery charger. Check operation and condition of
optional block heater, oil sump heater, and battery warmer (if equipped). Correct discrepancies
as necessary.

8. Check the air inlets and outlets (enclosure or building vents) for debris or blockage. Correct as
necessary.

9. Visually inspect the fuel supply system for signs of leaks or damage. Correct as necessary.

10. Perform a 5 minute, no-load operational test of the unit. Check unit voltage and frequency.
Visually inspect the unit for leaks, wear, damage, loose connections or components, and
corrosion. Correct as necessary.
Voltage: Frequency:

11. If the control has alarm and/or event or run logs, record the alarm and event logs to a history
file for the unit.
12. Return the unit to operational condition.

Date inspection Completed: Unit hour Meter Reading:

IASD/Authorized Operator signature signifying inspection complete:

Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

Generator Installation and Operating Manual 27

Maintenance

Maintenance Level 2 - Semi-Annual or Every 125 Hours

These maintenance tasks must be performed by an IASD. Perform these tasks every six months or every 125 hours of
operation. Perform these tasks in addition to the regularly scheduled Monthly maintenance tasks. Comply with all
safety notices contained in the owner’s manual. Some of the tasks will require the use of the applicable engine service
manual.

IASD Tasks Task Completed

Date/Initials

1. Disable the unit from operating per the procedure found in the owner’s manual.

2. Check the engine accessory drive belts and fan coupling device (if equipped) for correct
tension, wear, abrasion, deterioration, or damage. Correct as necessary.

3. Check all hoses, piping, and connections (intake, exhaust, coolant, block heater, fuel and filters,
oil lines and filters) for tightness, leaks, deterioration or damage. Correct as necessary.

4. Load test the battery or test electrolyte levels (specific gravity) with a hydrometer.

5. Return the unit to operational condition and test. Place the unit in automatic and open the
service disconnect to force the unit to start and transfer to the load. Exercise the unit against
the load for 15 minutes, visually inspecting for leaks, loose connections or components, and
any abnormal operating conditions. Record the unit voltage and frequency while running.
Restore utility power and monitor transfer to utility, cool-down and shutdown. Correct any
discrepancies.
Voltage: Frequency: kW: kVA:

6. If the control has alarm and/or event or run logs, record the alarm and event logs to a history file
for the unit.

7. Return the unit to operational condition.

Date inspection Completed: Unit hour Meter Reading:

IASD signature signifying inspection complete:

Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

28 Generator Installation and Operating Manual

 Maintenance

Maintenance Level 3 - Annual or Every 250 Hours

These maintenance tasks must be performed by an IASD. Perform these tasks every 12 months or every 250 hours of
operation. Perform these tasks in addition to the regularly scheduled Monthly and Semi-Annual maintenance tasks.
Comply with all safety notices contained in the owner’s manual. Some of the tasks will require the use of the applicable
engine service manual.

IASD Tasks Task Completed

Date/Initials

1. Disable the unit from operating per the procedure found in the owner’s manual. Some of the
following tasks will require the use of the applicable engine service manual.
2. Change the engine oil.
3. Change the engine oil filter(s).
4. Inspect the air filter. Replace as necessary.
5. Gaseous Units Only: Inspect, clean, and gap the spark plugs. Replace as necessary.
6. Gaseous Units Only: Inspect ignition wires for damage, deterioration and tightness. Replace
as necessary.
7. Diesel Units Only: Test the fuel quality. If required, strip any water/sediment from the tank.
Filter or polish the fuel and add any additional additives required to maintain fuel quality.
8. Diesel Units Only: Change the primary and secondary fuel filters (if equipped). Clean any
water separator or mechanical strainer (if equipped). Prime and bleed the fuel system per the
engine service manual procedures.
9. Check the engine accessory drive belts and fan coupling device (if equipped) for correct
tension, wear or abrasion, deterioration, or damage. Correct as necessary.
10. Check all hoses, piping, and connections (intake, exhaust, coolant, block heater, fuel and
filters, oil lines and filters) for tightness, leaks, deterioration or damage. Correct as necessary.
11. Visually inspect the radiator and charge air core (if equipped) for any build up of dirt, debris,
or oil contamination (external). Clean, correct as necessary.
12. Check the coolant thermal protection level. Correct as necessary.
13. Check all wiring connections in the high voltage and low voltage connection panels. Check
for loose connections, corrosion, arcing or damage. Check torque on all main load lugs at
generator connections (MLCB) and transfer switch connections (refer to applicable transfer
switch manual). Correct as necessary.
14. Return unit to operational condition and test. Place unit in automatic and open the service
disconnect to force the unit to start and transfer to the load. Exercise unit against the load for 1
hour (60 minutes). Visually inspect for leaks, loose connections or components, and any
abnormal operating conditions. Record unit voltage, frequency and kW while running. Restore
utility power and monitor transfer to utility, cool-down and shutdown. Correct any
discrepancies.
Voltage: Frequency: kW: kVA:

15. If control has alarm and/or event or run logs, record the alarm and event logs to a history file.
16. Return the unit to operational condition and place back in automatic operation.
Date inspection Completed: Unit hour Meter Reading:

IASD signature signifying inspection complete:

Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

Generator Installation and Operating Manual 29

Maintenance

Maintenance Level 4 - Bi-Annual or Every 500 Hours

These maintenance tasks must be performed by an IASD. Perform these tasks every 24 months or every 500 hours of
operation. Perform these tasks in addition to the regularly scheduled Monthly, Semi-Annual and Annual maintenance
tasks. Comply with all safety notices contained in the owner’s manual. Some of the tasks will require the use of the
applicable engine service manual.

IASD Tasks Task Completed

Date/Initials

1. Disable the unit from operating per the procedure found in the owner’s manual. Some of the
following tasks will require the use of the applicable engine service manual.

2. Check engine valve clearance (valve lash) as specified in the engine service manual.
NOTE: This is NOT required for engines with hydraulic lifters. Check the engine service manual.

3. Gearbox Equipped Only: Change the gearbox oil. Can be extended to 600 hours.

4. Replace the engine air filter(s).

5. Gaseous Units Only: Replace the spark plugs. Gap per the engine specifications.
6. Replace the engine accessory drive belts. Inspect and lubricate (if required) the belt tensioning
device (if equipped) and replace if necessary.

7. Drain and flush the cooling system. Refill with fresh coolant of appropriate type (50/50 mixture).

8. Replace all flexible hoses: Coolant hoses including the block heater hoses and vaporizer
hoses (if equipped); charge air system connection hoses/joints/couplings, and any flexible fuel
or oil lines.

9. Replace fuel filter. Verify the fuel system is bled and primed before running unit (diesel only).

10. Remove, clean, inspect, reinstall and reset to correct voltage level the flywheel magnetic
pickup(s) (if equipped).

11. Return the unit to operational condition and test. Place the unit in automatic and open the
service disconnect to force the unit to start and transfer to the load. Use an appropriate load
bank to supplement load to full rated load (100% kW at rated kVA) if possible. Exercise the unit
against the load for 2 hours (120 minutes). Visually inspect for leaks, loose connections or
components, and any abnormal operating conditions. Record the unit voltage, frequency, kW
and kVA while running. Remove the load bank load, restore utility power and monitor transfer
to utility, cool-down and shutdown. Correct any discrepancies.
Voltage: Frequency: kW: kVA:

12. If control has alarm and/or event or run logs, record the alarm and event logs to a history file.

13. Return the unit to operational condition and place back in automatic operation.

Date inspection Completed: Unit hour Meter Reading:

IASD signature signifying inspection complete:

Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

30 Generator Installation and Operating Manual

 Warranty Information

Section 5 Warranty Information

For Stationary Emergency Spark-Ignited Generators

United States Environmental Protection Agency Warranty Statement

(Stationary Emergency Spark-Ignited Generators)
Warranty Rights, Obligations and Coverage
The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission
Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system or
component on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diagnosis,
replacement parts and labor provided it be done by a Generac Authorized Warranty Service Facility. Your emission control system may
include parts such as the fuel metering, ignition, and exhaust systems and other related emission related components listed below. Generac
will warrant the emissions control systems on your 2009 and later model year engines provided there has been no abuse, neglect,
unapproved modification, or improper maintenance of your engine. For engines less than 130 HP the warranty period is two years from the
date of sale to the ultimate purchaser. For engines greater than or equal to 130 HP the warranty period is three years or 2500 hours of
operation, whichever comes first, from the date of the engine being placed into service. For high-cost warranted components, the Emission
Control System warranty is valid for 5 years or 3500 hours of operation, whichever comes first.

Purchaser's/Owner's Warranty Responsibilities

As the engine purchaser/owner you are responsible for the following: 1) The engine must be installed and configured in accordance to
Generac's installation specifications. 2) The completion of all maintenance requirements listed in your Owner's Manual. 3) Any engine setting
adjustment must be done in accordance and consistent with the instructions in the Owner's Manual. 4) Any emission control system or
component must be maintained and operated appropriately in order to ensure proper operation of the engine and control system to minimize
emissions at all times.
Generac may deny any and/or all Emission Control System Warranty coverage or responsibility of the engine, or an emission control system
or component on your engine thereof, if it has failed due to abuse, neglect, unapproved modification or improper maintenance, or the use of
counterfeit and/or “gray market” parts not made, supplied or approved by Generac. Warranty service can be arranged by contacting either
your selling dealer or a Generac Authorized Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. The purchaser/owner shall
be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the inspection or
repair facilities. The purchaser/owner shall be responsible for any and/or all damages or losses incurred while the engine is being
transported/shipped for inspection or warranty repairs. Contact Generac Power Systems Inc. for additional Emission Control System
Warranty related information, Generac Power Systems, Inc., PO. Box 8, Waukesha, WI 53187, or call 1-800-333-1322, email
[email protected], or visit www.generac.com.

Important Note
This warranty statement explains your rights and obligations under the Emission Control System Warranty, which is provided to you by
Generac pursuant to federal law. Note that this warranty shall not apply to 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). This warranty is in place of all other
warranties, expressed or implied. Specifically, Generac makes no other warranties as to the merchantability or fitness for a particular
purpose. Any implied warranties which are allowed by law, shall be limited in duration to the terms of the express warranty provided herein.
Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

Emission Related Parts Include the Following (if so equipped)

1) Fuel Metering System 3) Ignition System Including A) Spark Plug, B) Ignition Module,
1.1) Gasoline Carburetor Assembly and Internal Components C) Ignition Coil, D) Spark Plug Wires
A) Fuel Filter, B) Carburetor, C) Fuel Pump 4) Exhaust System
1.2) Carburetion Assembly and Its Components A) Catalyst Assembly*, B) Exhaust Manifold, C) Muffler,
A) Fuel Controller, B) Carburetor and Its Gaskets, D) Exhaust Pipe, E) Muffler Gasket
C) Mixer and Its Gaskets, D) Primary Gas Regulator, 5) Crankcase Breather Assembly Including
E) Liquid Vaporizer A) Breather Connection Tube, B) PCV Valve
1.3) Fuel Regulator 6) Oxygen Sensor
2) Air Induction System Including A) Intake Pipe/Manifold, 7) Diagnostic Emission-Control System
B) Air Cleaner

*High-Cost Warranted Component

Part No. 10000012792 Revision F (3/17)

Generator Installation and Operating Manual 31

Warranty Information

United States Environmental Protection Agency Compliance Requirements

(Stationary Emergency Spark-Ignited Generators)
Purchaser's/Owner's Record Keeping Responsibilities
The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain your record
keeping requirements for compliance with Subpart JJJJ- Standards of Performance for Stationary Spark Ignition Internal Combustion
Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60. As the engine purchaser/owner who operates and maintains
their certified emergency stationary engine and emission control system according to applicable emission related guidelines as specified in
this Owner's Manual, you are required to meet the following notification and record keeping requirements to demonstrate compliance: 1)
Maintain documentation that the engine is certified to meet emission standards. 2) Record keeping of maintenance conducted. 3) Record
keeping of the provision allowing natural gas engines to operate using propane for a maximum of 100 hours per year as an alternate fuel
solely during emergency operations provided the engine is not certified to operate on propane. 4) Meet all compliance notifications submitted
to the purchaser/owner and maintain all supporting documentation. 5) Record keeping of hours of operation, including what classified the
operation as emergency and how many hours are spent for non-emergency operation. For emergency engines greater than or equal to 130
HP, record keeping of hours of operation begins January 1, 2011. For emergency engines less than 130 HP, record keeping of hours of
operation begins January 1, 2009; engines are equipped with non-resettable hour meters to facilitate record keeping.
Specific Air Quality Management or Air Pollution Control Districts may have different and additional record keeping/reporting requirements.
Your permit to construct and/or operate the engine may be contingent upon compliance with those requirements. Check with your local Air
Quality Management or Air Pollution Control District for specific requirements.
Emergency stationary internal combustion engines (ICE) may be operated for the purpose of maintenance checks and readiness testing,
provided that the tests are recommended by Federal, State or local government, Generac, or the insurance company associated with the
engine. Maintenance checks and readiness testing of such units is limited to 100 hours per year. There is no time limit on the use of
emergency stationary ICE in emergency situations. The purchaser/owner may petition the Administrator for approval of additional hours to
be used for maintenance checks and readiness testing, but a petition is not required if the owner maintains records indicating that Federal,
State, or local standards require maintenance and testing of emergency ICE beyond 100 hours per year. Emergency stationary ICE may
operate up to 50 hours per year in non emergency situations, but those 50 hours are counted towards the 100 hours per year provided for
maintenance and testing.
The 50 hours per year for non-emergency situations cannot be used for peak shaving or to generate income for a facility to supply power to
an electric grid or otherwise supply power as part of a financial arrangement with another entity. For purchaser/owner of emergency engines,
any operation other than emergency operation, maintenance and testing, and operation in non-emergency situations for 50 hours per year,
as permitted in this section is prohibited.
If you operate and maintain your certified emergency stationary SI internal combustion engine and emissions control systems in accordance
to the specifications and guidelines in this Owner’s Manual, EPA will not require engine performance testing. If not, your engine will be
considered non-certified and you must demonstrate compliance according to Subpart JJJJ - Standards of Performance for Stationary Spark
Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60.

Emission-Related Installation Instructions

Your certified emergency stationary engine has pre-set emission control systems or components that require no adjustment. Inspection and
replacement of an emissions related component is required to be done so in accordance with the requirements cited in the United States
Environmental Protection Agency Warranty Statement or can be arranged by contacting either your selling dealer or a Generac Authorized
Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. Failing to follow these instructions when installing a certified engine in a
piece of non-road equipment violates federal law 40 CFR 1068.105 (b), subject to fines or penalties as described in the Clean Air Act.

Part No. 10000012792 Revision F (3/17)

32 Generator Installation and Operating Manual

 Warranty Information

For Stationary Emergency Compression-Ignition Generators

To receive information about how to make an emissions-
related warranty claim and how to make arrangements
for authorized repairs, call 1-800-333-1322 or go to
www.generac.com.

Generator Installation and Operating Manual 33

Warranty Information

This page intentionally left blank.

34 Generator Installation and Operating Manual

Part No. 0J5019 Rev. W 05/20/2019
Generac Power Systems, Inc.
©2019 Generac Power Systems, Inc.
S45 W29290 Hwy. 59
All rights reserved
Waukesha, WI 53189
Specifications are subject to change without notice.
1-888-GENERAC (1-888-436-3722)
No reproduction allowed in any form without prior written
www.generac.com
consent from Generac Power Systems, Inc.
Notes
 United States Environmental Protection Agency Warranty Statement
(Stationary Emergency Spark-Ignited Generators)
Warranty Rights, Obligations and Coverage
The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission
Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system or compo-
nent on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diagnosis, replace-
ment parts and labor provided it be done by a Generac Authorized Warranty Service Facility. Your emission control system may include parts
such as the fuel metering, ignition, and exhaust systems and other related emission related components listed below. Generac will warrant
the emissions control systems on your 2009 and later model year engines provided there has been no abuse, neglect, unapproved modifica-
tion, or improper maintenance of your engine. For engines less than 130 HP the warranty period is two years from the date of sale to the ulti-
mate purchaser. For engines greater than or equal to 130 HP the warranty period is three years or 2500 hours of operation, whichever
comes first, from the date of the engine being placed into service. For high-cost warranted components, the Emission Control System war-
ranty is valid for 5 years or 3500 hours of operation, whichever comes first.

Purchaser's/Owner's Warranty Responsibilities

As the engine purchaser/owner you are responsible for the following: 1) The engine must be installed and configured in accordance to Gen-
erac's installation specifications. 2) The completion of all maintenance requirements listed in your Owner's Manual. 3) Any engine setting
adjustment must be done in accordance and consistent with the instructions in the Owner's Manual. 4) Any emission control system or com-
ponent must be maintained and operated appropriately in order to ensure proper operation of the engine and control system to minimize
emissions at all times.
Generac may deny any/or all Emission Control System Warranty coverage or responsibility of the engine, or an emission control system or
component on your engine thereof, if it has failed due to abuse, neglect, unapproved modification or improper maintenance, or the use of
counterfeit and/or “gray market” parts not made, supplied or approved by Generac. Warranty service can be arranged by contacting either
your selling dealer or a Generac Authorized Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. The purchaser/owner shall
be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the inspection or
repair facilities. The purchaser/owner shall be responsible for any and/or all damages or losses incurred while the engine is being trans-
ported/shipped for inspection or warranty repairs. Contact Generac Power Systems Inc. for additional Emission Control System Warranty
related information, Generac Power Systems, Inc., PO. Box 8, Waukesha, WI 53187, or call 1-800-333-1322 or www.generac.com.

Important Note
This warranty statement explains your rights and obligations under the Emission Control System Warranty, which is provided to you by Gen-
erac pursuant to federal law. Note that this warranty shall not apply to 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). This warranty is in place of all other warranties,
expressed or implied. Specifically, Generac makes no other warranties as to the merchantability or fitness for a particular purpose. Any
implied warranties which are allowed by law, shall be limited in duration to the terms of the express warranty provided herein. Some states
do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

Emission Related Parts Include the Following (if so equipped)

1) Fuel Metering System 3) Ignition System Including A) Spark Plug, B) Ignition Module,
1.1) Gasoline Carburetor Assembly and Internal Components C) Ignition Coil, D) Spark Plug Wires
A) Fuel Filter, B) Carburetor, C) Fuel Pump 4) Exhaust System
1.2) Carburetion Assembly and Its Components A) Catalyst Assembly*, B) Exhaust Manifold, C) Muffler,
A) Fuel Controller, B) Carburetor and Its Gaskets, D) Exhaust Pipe, E) Muffler Gasket
C) Mixer and Its Gaskets, D) Primary Gas Regulator, 5) Crankcase Breather Assembly Including
E) Liquid Vaporizer A) Breather Connection Tube, B) PCV Valve
1.3) Fuel Regulator 6) Oxygen Sensor
2) Air Induction System Including A) Intake Pipe/Manifold, 7) Diagnostic Emission-Control System
B) Air Cleaner

*High-Cost Warranted Component

EmsnWrnty001 Revision F (04/15)

 United States Environmental Protection Agency Compliance Requirements
(Stationary Emergency Spark-Ignited Generators)
Purchaser's/Owner's Record Keeping Responsibilities
The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain your record
keeping requirements for compliance with Subpart JJJJ- Standards of Performance for Stationary Spark Ignition Internal Combustion
Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60. As the engine purchaser/owner who operates and maintains
their certified emergency stationary engine and emission control system according to applicable emission related guidelines as specified in
this Owner's Manual, you are required to meet the following notification and record keeping requirements to demonstrate compliance: 1)
Maintain documentation that the engine is certified to meet emission standards. 2) Record keeping of maintenance conducted. 3) Record
keeping of the provision allowing natural gas engines to operate using propane for a maximum of 100 hours per year as an alternate fuel
solely during emergency operations provided the engine is not certified to operate on propane. 4) Meet all compliance notifications submitted
to the purchaser/owner and maintain all supporting documentation. 5) Record keeping of hours of operation, including what classified the
operation as emergency and how many hours are spent for non-emergency operation. For emergency engines greater than or equal to 130
HP, record keeping of hours of operation begins January 1, 2011. For emergency engines less than 130 HP, record keeping of hours of oper-
ation begins January 1, 2009; engines are equipped with non-resettable hour meters to facilitate record keeping.
Specific Air Quality Management or Air Pollution Control Districts may have different and additional record keeping/reporting requirements.
Your permit to construct and/or operate the engine may be contingent upon compliance with those requirements. Check with your local Air
Quality Management or Air Pollution Control District for specific requirements.
Emergency stationary internal combustion engines (ICE) may be operated for the purpose of maintenance checks and readiness testing,
provided that the tests are recommended by Federal, State or local government, Generac, or the insurance company associated with the
engine. Maintenance checks and readiness testing of such units is limited to 100 hours per year. There is no time limit on the use of emer-
gency stationary ICE in emergency situations. The purchaser/owner may petition the Administrator for approval of additional hours to be
used for maintenance checks and readiness testing, but a petition is not required if the owner maintains records indicating that Federal,
State, or local standards require maintenance and testing of emergency ICE beyond 100 hours per year. Emergency stationary ICE may
operate up to 50 hours per year in non emergency situations, but those 50 hours are counted towards the 100 hours per year provided for
maintenance and testing.
The 50 hours per year for non-emergency situations cannot be used for peak shaving or to generate income for a facility to supply power to
an electric grid or otherwise supply power as part of a financial arrangement with another entity. For purchaser/owner of emergency engines,
any operation other than emergency operation, maintenance and testing, and operation in non-emergency situations for 50 hours per year,
as permitted in this section is prohibited.
If you operate and maintain your certified emergency stationary SI internal combustion engine and emissions control systems in accordance
to the specifications and guidelines in this Owner’s Manual, EPA will not require engine performance testing. If not, your engine will be con-
sidered non-certified and you must demonstrate compliance according to Subpart JJJJ - Standards of Performance for Stationary Spark Igni-
tion Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60.

Emission-Related Installation Instructions

Your certified emergency stationary engine has pre-set emission control systems or components that require no adjustment. Inspection and
replacement of an emissions related component is required to be done so in accordance with the requirements cited in the United States
Environmental Protection Agency Warranty Statement or can be arranged by contacting either your selling dealer or a Generac Authorized
Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. Failing to follow these instructions when installing a certified engine in a
piece of non-road equipment violates federal law 40 CFR 1068.105 (b), subject to fines or penalties as described in the Clean Air Act.

EmsnWrnty001 Revision F (04/15)

EXPLODED VIEW: EV ASSY SCROLL 390 SAE
DRAWING #: 0L2973 GROUP H

ITEM PART# QTY. DESCRIPTION

1 0A2110 14 SCREW HWHS 1/4-20 X 1/2 ZYC
2 0A2491 2 SHROUD ALT SHEET METAL
3 0A2496 2 BRKT TENSIONER SAE SCROLL
4 0A2497 2 SCREEN SHROUD SA
5 022097 6 WASHER LOCK M6-1/4
6 022473 6 WASHER FLAT 1/4-M6 ZINC
7 045757 2 SCREW HHC M6-1.0 X 25 C8.8
8 047411 4 SCREW HHC M6-1.0 X 16 C8.8
9 056326 8 TRIM VINYL BLACK 1/8GP

REVISION: -A- Page 2 of 2

DATE: 3/16/15
EXPLODED VIEW: EV CONBOX 390 MODULE
DRAWING #: 0J1339 GROUP A
APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION

SINGLE MODULE
(1)1 0H95790ST0R 1 MD1 / MD2 CB MODULE 390 ALT
(1)(4) 0H9579DST0R 1 MD1, MAIN MODULE 390 ALT G5.4L
(1)2 0J17560ST0R 1 WIRE TUNNEL, MD1-2 390 ALT
3 0A4456 2 WASHER LOCK SPECIAL 3/8
4 061383 1 LUG SLDLSS 3/0-#4 X 13/32 CU
5 0E1534A 2 PLUG PLASTIC 1.50"
6 056326 2 TRIM VINYL BLACK 1/8GP (7.1”LG)
7 045772 2 NUT HEX M10-1.5 G8 YEL CHR
8 067210B 1 DECAL GROUND
10 0A9457A 1 DECAL NEUTRAL
11 0C2454 4 SCREW HWHT M6-1 X 16 N WA Z/JS
12 024526 4 SCREW HHTT 5/16-18 X 3/4 CZ
13 022129 4 WASHER LOCK M8-5/16
14 022145 4 WASHER FLAT 5/16-M8 ZINC
15 0441140781 1 WIRE ASM, GND 2/0 WIRE 3/8 LUG
16 022131 4 WASHER FLAT 3/8-M10 ZINC
17 049541 2 SCREW HHC M10-1.5 X 35 C8.8
(3)(2)18 0J0455 REF BLOCK, TERM 14 POS X 8 X 1600V
(3)(2)19 0J9078 REF DECAL TB4 HV CUSTOMER CONN
(3)(2)21 0J5462 REF SCREW THTT M4-0.7 X 16 ZP
22 023827 REF BLOCK TERM JUMPER FOR S142/542

NOTES (UNLESS OTHERWISE SPECIFIED):

(1) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
• MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
• CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR
CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
(2) WILL BE INSTALLED ON PRIMARY CB MODULES ONLY. NOT REQUIRED WITH LOAD CENTER.
(3) NOT REQUIRED IF EQUIPPED WITH 0J1594, KIT BATTERY CHARGER POWER CORD.
(4) G5.4L Y01 UNITS ONLY.

DUAL MODULE
(1)1 0H95790ST0R 2 MD1 / MD2 CB MODULE 390 ALT
(1)(4) 0H9579DST0R 2 MD1, MAIN MODULE 390 ALT G5.4L
(1)2 0J17560ST0R 2 WIRE TUNNEL, MD1-2 390 ALT
3 0A4456 4 WASHER LOCK SPECIAL 3/8
4 061383 2 LUG SLDLSS 3/0-#4 X 13/32 CU
5 0E1534A 4 PLUG PLASTIC 1.50"
6 056326 4 TRIM VINYL BLACK 1/8GP (7.1”LG)
7 045772 4 NUT HEX M10-1.5 G8 YEL CHR
8 067210A 2 DECAL GROUND LUG
9 0H8006 2 DECAL CAUTION ELEC SHOCK SM
10 0A9457 2 DECAL NEUTRAL
11 0C2454 8 SCREW HWHT M6-1 X 16 N WA Z/JS
12 024526 8 SCREW HHTT 5/16-18 X 3/4 CZ
13 022129 8 WASHER LOCK M8-5/16
14 022145 8 WASHER FLAT 5/16-M8 ZINC
15 0441140781 2 WIRE ASM, GND 2/0 WIRE 3/8 LUG
16 022131 8 WASHER FLAT 3/8-M10 ZINC
17 049541 4 SCREW HHC M10-1.5 X 35 C8.8
(3)(2)18 0J0455 REF BLOCK, TERM 14 POS X 8 X 1600V
(3)(2)19 0J9078 REF DECAL, TB4 HV CUSTOMER CONN
(3)(2)21 0J5462 REF SCREW THTT M4-0.7 X 16 ZP
22 023827 REF BLOCK TERM JUMPER FOR S142/542

NOTES (UNLESS OTHERWISE SPECIFIED):

(1) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
• MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
• CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR
CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
(2) WILL BE INSTALLED ON PRIMARY CB MODULES ONLY. NOT REQUIRED WITH LOAD CENTER.
(3) NOT REQUIRED IF EQUIPPED WITH 0J1594, KIT BATTERY CHARGER POWER CORD.
(4) G5.4L Y01 UNITS ONLY.

REVISION: CN-0032497-N Page 3 of 4

DATE: 12/10/2019
EXPLODED VIEW: EV CONBOX 390 MODULE
DRAWING #: 0J1339 GROUP A
APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION

This page left blank intentionally

REVISION: CN-0032497-N Page 4 of 4

DATE: 12/10/2019
EXPLODED VIEW: 390, BOARD SOLID LEAD TERM BRL
DRAWING #: 0J1479 GROUP A
APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION

1 G051769 3 WASHER LOCK M12
3 VARIES REF FLEX PLATE
4 G055173 6 SCREW HHC M8-1.25 X 20 G10.9
5 G022129 8 WASHER LOCK M8-5/16
6 G022145 8 WASHER FLAT 5/16-M8 ZINC
7 0G0724 1 FAN MACHINED 390 SAE ALTERATOR
(3)8 0A2601 1 SCREW HHC M16-2.0 X 45 G8.8
(3)9 0A2602 1 WASHER FLAT .688ID X 3.25OD
(3)10 0A1138 1 KEY SQ 3/8 X 2-1/2 STEEL
(3)11 G021941 1 COUPLER 390 SAE
12 VARIES REF ROTOR PER ORDER (SEE BOM)
13 (1)G052891 2 SCREW HHC M12-1.75 X 80 C8.8 (1.25” STACK)
(2)G052623 2 SCREW HHC M12-1.75 X 100 PC8.8 (2.00” STACK)
14 0A5580 4 SCREW HHC M14-2.0 X 140 G8.8
15 0A1633 4 WASHER,390 SAE ALT.
16 VARIES REF STATOR PER ORDER (SEE BOM)
20 G068113 1 CARRIER REAR BRG 15"
21 0H8394A 1 390, BOARD SOLID LEAD TERM BRL
22 G043123 4 WASHER LOCK M14
23 G051779 4 NUT HEX M14-2.0 G8 YEL CHR
24 G049808 2 WASHER FLAT M12
25 (1)G053559 1 SCREW HHC M12-1.75 X 45 C8.8 (1.25” STACK)
(2)G098780 1 SCREW HHC M12-1.75 X 65 PC8.8 (2.00” STACK)
26 (1)G070274 1 KEY SQ 3/8 X 2-3/4 STEEL (1.25” STACK)
(2)G072878 1 KEY SQ 3/8 X 3-1/4 STEEL (2.00” STACK)
27 (1)G087271 1 ASSY EXCITER 1.25"STK
(2)G087272 1 ASSY EXCITER 2.00" STK
28 (1)G068404 1 EXCITER FIELD 1.25 STK
(2)068405C 1 EXITER FIELD 2 LG SPD CONN
29 G092950 1 COLLAR SLIP FIT 390 MM
30 G020151 1 CLAMP VINYL .312 X .203 Z
31 G090063 1 BRIDGE SUPPORT DIODE 15"
32 G090152 1 ASSY BRIDGE RECTIFIER
33 G023365 3 WASHER SHAKEPROOF INT #8
34 G033143 2 SCREW HHM #8-32 X 7/8
35 G090064 1 CAP END ROTOR 390MM
36 G033133 1 SCREW HHM #8-32 X 3/8
38 028739A 2 TIE WRAP 3.9" X .10" BLK UL
39 085662D 1 TIE WRAP UL 17.7 X .35 BLK HT
40 G037554 1 SLEEVING UL #2 .268ID
41 G042914 2 SCREW HHC M8-1.25 X 90 C8.8 (1.25” STACK)
G073941 2 SCREW HHC M8-1.25 X 115 C8.8 (2.00” STACK)
42 0H9157 2 HOLLOW DOWEL PIN, 1/2 X 1-1/4
45 0A1786 .5CC ADH LOCTITE #8931 AA W/S

NOTES (UNLESS OTHERWISE SPECIFIED):

(1) FOR 25KW / 35KW UNITS
(2) FOR 40KW AND LARGER UNITS
(3) CONTAINED IN ROTOR ASSEMBLY I/N 12.

REVISION: CN-0010075-F Page 2 of 2

DATE: 12/21/17
EXPLODED VIEW: EV HUIO H-PNL COMM/PWR
DRAWING #: 0G4076D GROUP B
APPLICABLE TO:CO 1330102
ITEM PART# QTY. DESCRIPTION
1 020911 2 SCREW PPHM M5-0.8 X 30 ZINC
2 049226 2 WASHER LOCK M5
3 051713 2 WASHER FLAT M5
4 051716 2 NUT HEX M5-0.8 G8 CLEAR ZINC
5 0G3226 1 H-PNL I/O EXPANSION MOD PROG
6 0E8599A 1 TERMINAL BLK PLUG 2 POS
7 0E8599B 1 TERMINAL BLK PLUG 3 POS
8 0E8599G 2 TERMINAL BLK PLUG 8 POS
9 0G5354 REF MANUAL H-PANEL I/O MODULE (NOT SHOWN)
10 032578 3(FT) CABLE 2COND 18AWG SHIELDED (NOT SHOWN)
11 055199E 4(FT) WIRE 600V 18AWG BLK (NOT SHOWN)
12 061446 5 LUG SNPSPD INS 22-18 X.27 X.87 (NOT SHOWN
13 077043H 3(FT) CONDUIT FLEX .25"ID (NOT SHOWN)
14 0G4076E REF WD HUIO H-PNL COMM/PWR

REVISION: K-2182-D PAGE 2 OF 2

DATE: 3/11/15
EXPLODED VIEW: EV H-PNL 10A BC NO E-GOV DSL24
DRAWING #: 0J0288 GROUP B
APPLICABLE TO:
ITEM PART# QTY. DESCRIPTION
(1)1 0H84230ST0R 1 BRACKET H-PNL MOUNTIN CCI IND
2 0H4733E 1 ASSY H-PANEL 2.5A BATC 12V
0G4140E 1 ASSY H-PANEL 10A BATC 12V
0G4141E 1 ASSY H-PANEL NO BATC NO E-GOV
0G4144E 1 ASSY H-PANEL 10A BATC 24V
3 0E9764 1 RAIL SNAPTRACK PCB HOLDER BULK
(2)4 055911 REF BLOCK TERM 20A 12 X 6 X 1100V
(2)5 057701 REF BLOCK TERM 20A 8 X 6 X 1100V
(1)6 0J01360ST0R 1 PLATE, WIRE HARN BLOCKOFF
(1)7 0H96870ST0R 1 COVER, COSTOMER CONN H-PNL
8 0J5462 6 SCREW THTT M4-0.7 X 16 ZP
9 0J5464 3 SCREW THTT M5-0.8 X 16 ZP
10 051713 3 WASHER FLAT M5
11 049226 3 WASHER LOCK M5
12 0C2454 2 SCREW HWHT M6-1 X 16 N WA Z/JS
13 022097 4 WASHER LOCK M6-1/4
14 047411 4 SCREW HHC M6-1.0 X 16 C8.8
15 022145 4 WASHER FLAT 5/16-M8 ZINC
16 022129 4 WASHER LOCK M8-5/16
17 026850 1 WASHER LOCK EXT 1/4 STL
18 039253 4 SCREW HHC M8-1.25 X 20 C8.8
19 0G6962A 1 ASSY PCB RELAY 24VDC
0G6962B 1 ASSY PCB RELAY 12VDC
20 0J0392 1 DECAL, TB1 LV CUSTOMER CONN
21 0J0398 1 DECAL, CONTACT RAT 30VAC/30VDC
22 0J0393 1 DECAL, TB2 LV CUSTOMER CONN
23 0J0545 1 DECAL, LV CUSTOMER CONN INSIDE
24 0J0575 1 DECAL, CUSTOMER WIRE #14
25 0C3168 1 WASHER LOCK SPECIAL 5/16
(5)26 0J8896 1 BUSHING, STRAIN RND(.290-.385)
(6)(3)27 0H9845 REF HARN 390/520 CONBOX H-PANEL
(4)28 0C8065 1 DIODE ASSEMBLY
29 0J5349 REF HARN 390/520 CONBOX 12V GAS H (NOT SHOWN)

NOTES (UNLESS OTHERWISE SPECIFIED):

(1) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
• MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO XA BOM.
• CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM
FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
(2) PART OF CONNECTION BOX HARNESS
(3) HARNESS GETS WIRED TO LOAD CENTER IF EQUIPPED.
(4) REFERENCE WIRE DIAGRAM FOR PROPER LOCATION.
(5) NOT REQUIRED IF EQUIPPED WITH 0J1594, KIT BATTERY CHARGER POWER CORD.
(6) HARNESS GETS TIED BACK AND BUNDLED WITH OTHER HARNESS AND LEFT UNCONNECTED IF EQUIPPED WITH 0J1594,
KIT BATTERY CHARGER POWER CORD.

REVISION: J-8548-H PAGE 2 OF 2

DATE: 5/1/14
EXPLODED VIEW: EV 390 ALTERNATOR TOWER ASM
DRAWING #: 0J7594 GROUP A
APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION

(1)1 0J75960ST0R 1 MAIN, ALT TOWER 390 W/ SHROUD
(1)2 0H94310ST0R 1 TOP, ALT TOWER 390 SINGLE CB
0H9431BST0R 1 TOP ALT TOWER 390 SNGL CB RH
(1)2A 0H9431AST0R 1 TOP, ALT TOWER 390 DUAL CB
(1)3 0H94320ST0R 1 COVER, ALT TOWER 390
(3)4 0J0481 2/3 XFMR CURRENT 50A W/BRKT UL RCG
0J0481A 2/3 XFMR CURRENT 100A W/BRKT UL G
0J0481B 2/3 XFMR CURRENT 150A W/BRKT UL
0J0481C 2/3 XFMR CURRENT 200A W/BRKT UL
0J0481D 2/3 XFMR CURRENT 300A W/BRKT UL
0J0481E 2/3 XFMR CURRENT 400A W/BRKT UL
0J0481F 2/3 XFMR CURRENT 500A W/BRKT UL
0J0481G 2/3 XFMR CURRENT 600A W/BRKT UL
5 056326 3 TRIM VINYL BLACK 1/8GP (8”LG)
(1)6 0J01360ST0R 1 PLATE, WIRE HARN BLOCKOFF
7 0J5464 2 SCREW THTT M5-0.8 X 16 ZP
8 052250 1 TAPE FOAM 1X1 (52” LG)
9 022473 4 WASHER FLAT 1/4-M6 ZINC
(2)10 056326 2/4 TRIM VINYL BLACK 1/8GP (6”LG)
11 0C2454 12 SCREW HWHT M6-1 X 16 N WA Z/JS
(3)12 022145 4/8 WASHER FLAT 5/16-M8 ZINC
(3)13 022129 2/3 WASHER LOCK M8-5/16
14 042907 2/3 SCREW HHC M8-1.25 X 16 C8.8
15 045771 2/3 NUT HEX M8-1.25 G8 CLEAR ZINC
16 024983 4 SCREW HHTT 1/4-20 X 3/4 CZ
(3)17 0J1857 2/3 CT BRKT 1.1" WINDOW FRAME
0J1857A 2/3 CT BRKT 2.25" WINDOW FRAME
18 0C1229 1 DECAL WARNING ELECTRICAL SHOCK
19 0H9845 1 HARN 390/520 CONBOX H-PANEL (NOT SHOWN)

NOTES (UNLESS OTHERWISE SPECIFIED):

(1) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
• MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO XA BOM.
• CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM
FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
(3) QTY. REQUIRED FOR 1 PHASE / QTY. REQUIRED FOR 3 PHASE.

REVISION: K-1917-D PAGE 2 OF 2

DATE: 2/19/15
EXPLODED VIEW: EV GLAND PLATE
DRAWING #: 0J4768 GROUP C
APPLICABLE TO:
ITEM PART# QTY. DESCRIPTION
(1)(2)1 --- 1/2 GLAND PLATE
(1)2 0C2454 4/8 SCREW HWHT M6-1 X 16 N WA Z/JS

(1) QTY. REQUIRED FOR SINGLE CIRCUIT BREAKER / QTY. REQUIRED FOR DUAL CIRCUIT BREAKER.
(2) SEE BILL OF MATERIALS FOR PART NUMBER.

REVISION: H-9623-C Page 2 of 2

DATE: 9/13/11
EXPLODED VIEW: EV RADIATOR BLOCKOFF 6.8L
DRAWING #: 0J1133 GROUP C
APPLICABLE TO:
ITEM PART# QTY. DESCRIPTION
(1)1 0J11370ST0R 1 RADIATOR BLOCKOFF 6.8L TOP
(1)2 0J11350ST0R 1 RADIATOR BLOCKOFF 6.8L LEFT
(1)3 0J11360ST0R 1 RADIATOR BLOCKOFF 6.8L RIGHT
(1)4 0J11340ST0R 1 RADIATOR BLOCKOFF 6.8L BOTTOM
5 N/A
6 0C2454 18 SCREW HWHT M6-1 X 16 N WA Z/JS
7 052250 2 TAPE FOAM 1X1 (29”LG)
8 052250 2 TAPE FOAM 1X1 (34”LG)

NOTES (UNLESS OTHERWISE SPECIFIED):

(1) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
• MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
• CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE
SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).

REVISION: CN-0003924-D PAGE 2 OF 2

DATE: 10/24/16
EXPLODED VIEW: MTG BASE G6.8.1L C-GRP W/PAN Y02
DRAWING #: A0000253782 GROUP C
ITEM PART# QTY. DESCRIPTION
(1)1 0J0340AST0R 1 MTG BASE G6.8L 390GB CCI W/PAN
0J5310AST0R 1 MTG BASE G6.8L 390GB 3CB W/PAN
2 G024310 1 PLUG STD PIPE 1/2 STEEL SQ HD
3 G052252 4 DAMPENER VIBRATION
4 G052257 4 SPACER .49 X .62 X 1.87 PWDR/ZINC
5 G052259 4 WASHER FLAT M12
6 G055597 4 SCREW HHC M12-1.75 X 85 G8.8
7 052251A 4 DAMPENER VIBRATION 50 WHITE
8 G052860 4 NUT LOCKING M12-1.75
(1)9 0L07030ST0R 1 ENGINE SUPPORT 6.8L RH
(1)10 0L02440ST0R 1 ENGINE MOUNT 6.8L LH
11 0D4239 1 KIT VARMIT GUARD (FOR N/G, L/P VAPOR OR DUAL FUEL
N/G-L/P LIQUID UNITS)
0D4239A 1 KIT VARMIT GUARD (FOR L/P LIQUID UNITS)
0D4239B 1 KIT VARMIT GUARD (FOR DUAL FUEL N/G-L/P VAPOR UNITS)
12 G049814 1 SCREW HHC M10-1.5 X 25 C8.8

15 G025507 2 WASHER LOCK EXT 7/16 STL

16 038805J 1 CABLE BATT BLK #1 X 30.00 NEG

21 096500V 1 ASSY FUEL LEAK DET ALARM W/CON

22 G049813 1 NUT HEX M6-1.0 G8 CLEAR ZINC
23 0C3168 1 5/16 SPECIAL L/WASH
24 G022097 1 WASHER LOCK M6-1/4
25 G052243 4 SCREW HHC M10-1.5 X 60 G8.8
(1)26 0L01390ST0R 1 5.4L RH ENGINE MOUNT SPACER
27 G022131 9 WASHER FLAT 3/8-M10 ZINC
28 G046526 9 WASHER LOCK M10
29 G030985 1 NIPPLE CLOSE 1/2 X 1.125
30 G078944 1 VALVE BALL
31 G044118 1 BARBED STR 1/2 NPT X 5/8
32 G057823 2 CLAMP HOSE #10 .56 - 1.06
33 G065386 1 HOSE 5/8 ID SAE100R6 (11”LG)
34 G044117 1 BARBED STR 3/8 NPT X 5/8
35 G057765 1 ADP OIL DRN M14-1.50
36 G057772 1 WASHER NYLON .565
37 G0536210360 1 WIRE ASSEM #4GA GRD
38 G042568 1 SCREW HHC M6-1.0 X 20 C8.8
39 G022473 1 WASHER FLAT 1/4-M6 ZINC
40 G050331 1 BATT POST COVER BLK -
41 050331A 1 BATT POST COVER RED +
42 03880400AA 1 CABLE BATT RED #1 X 44.00 (G/B)
038804J 1 CABLE BATT RED #1 X 40.50
43 G075763 1 BOOT BATTERY CABLE
44 050277A 1 DECAL OIL DRAIN TRI
45 G051735 4 SCREW HHC M10-1.5 X 70 C8.8

NOTES (UNLESS OTHERWISE SPECIFIED):

(1) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
• MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
• CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE
SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).

REVISION: - A - Page 2 of 2
DATE: 5/13/19
EXPLODED VIEW: EV BAT GRP 31 12V W/BOX INSTAL
DRAWING #: 0F5518B GROUP C
APPLICABLE TO:
ITEM PART# QTY. DESCRIPTION
1 0E2471 1 BATTERY BOX GROUP 27-31 W/COV
2 061119 1 BATTERY BCI GRP 31 925 CCA

REVISION:-A- PAGE 2 OF 2
DATE: 9/13/11
EXPLODED VIEW: EV ENGINE COMM PARTS 6.8L R/H
DRAWING #: 0J2563A GROUP D
APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION

(3)1 029333A 2 TIE WRAP UL 7.4"X .19" BLK (NOT SHOWN)
2 0D5418 1 STARTER MOTOR FORD V-10 ENGINE
(1)3 G052625 5/11 SCREW SHC M10-1.5 X 35 G12.9
4 G065386 1 HOSE COOL 5/8 ID 100R6 (14”LG)
5 G087599 1 PLUG PLASTIC 3/8 NPT
6 G042568 1 SCREW HHC M6-1.0 X 20 G8.8
7 0F2776A 2 BRACKET, SIGNAL CONDITIONER
(1)8 G070264 8/6 WASHER FLAT M10
9 G034339 1 BARBED EL 90 3/8NPT X 5/8
10 0J4574 8 SCREW SHC M10-1.5 X 25 C8.8
11 0D9913 18 SCREW SHC M8-1.25 X 35 SS
(1)12 G046526 33 / 31 WASHER LOCK M10
13 055934M 1 CLAMP VINYL .75 X .343 Z
14 G070008 10 WASHER FLAT M8 SS
15 0G0015 2 CLAMP HOSE 7/8" OD DOUBLE WIRE
16 G049821 3 SCREW SHC M8-1.25 X 30 G12.9
17 G022129 3 WASHER LOCK M8-5/16
18 G022097 3 WASHER LOCK M6-1/4
19 G052647 8 SCREW SHC M10-1.5 X 25 G12.9
20 0D2244M 1 ASSEMBLY MAGPICKUP (3/8-24 MALE)
21 G070006 30 WASHER LOCK M8 SSTL
22 G022473 3 WASHER FLAT 1/4 ZINC
23 0D2608 10 SCREW HHC 5/16-18 X 1/2 SSTL
24 0D5623 2 HEAT SHIELD EXHAUST
25 0D5417 REF SCREW HHC M10-1.0 X 25 G10.9
(2)26 0D3808 2 EXH MANIFOLD MACH 6.8L V-10
27 0D4255 2 GASKET EXHAUST MANIFOLD
28 G070010 2 SCREW HHC M8-1.25 X 35 SS G8.8
29 0D6344 1 ASSEMBLY 6.8L FLYWHEEL (D/D UNITS)
0D6686 1 ASSY 6.8L G-BOX FLYWHEEL (G/B UNITS)
30 0D3803 1 FLYWHEEL HOUSING MACH 6.8L V10
31 0D3805 1 COVER FLYWHEEL MACH 6.8L V-10
32 0A8240 3 FLEX PLATE SAE10 2.2
G021113 1 PLATE, DAMPNER RETNR
33 0E0992A 10 PLUG EXPANSION 14 OD
34 G078637 A/R ADHESIVE LOCTITE 620
35 G047411 1 SCREW HHC M6-1.0 X 16 G8.8
36 G062303 1 ADAPTOR 1/4" NPT TO 3/8" NPT
(1)37 G048191 0/2 DOWEL PIN M10 X 24
38 G049721 1 SCREW HHC M6-1.0 X 35 C8.8 CLR
39 G022131 12 WASHER FLAT 3/8-M10 ZINC
40 G057642 12 SCREW HHC M10-1.5 X 40 C8.8
41 G049808 6 WASHER FLAT M12
42 G051769 6 WASHER LOCK M12
43 G063837 6 SCREW HHC M12-1.75 X 30 C10.9

(1) QTY. REQUIRED FOR DIRECT DRIVE / QTY. REQUIRED FOR GEAR BOX
(2) MANIFOLD IS FLIPPED FOR 150KW UNITS OR NON-ENCLOSED.
(3) 029333A IS FOR HOLDING SENSOR TO I/N 7.
(4) TORQUE VALUES:
I/N 3 TO 46ft-lbs. ADD LOCTITE ON BOLTS.
I/N 10 TO 28ft-lbs. ADD LOCTITE ON BOLTS.
I/N 19 TO 46ft-lbs.
I/N 25 TO 35ft-lbs. ADD LOCTITE ON BOLTS.
I/N 43 TO 83 ft/lbs.

REVISION: CN-0014472-J Page 2 of 2

DATE: 4/10/18
EXPLODED VIEW: EV ENGINE COMM PARTS 6.8L GB L/H
DRAWING #: 0K6753 GROUP D
APPLICABLE TO: G6.8 FAN BELT DRIVE

ITEM PART# QTY. DESCRIPTION

1 0F3017 1 BRACKET, D.C. ALTERNATOR LOWER
2 G039253 3 SCREW HHC M8-1.25 X 20 G8.8
3 G022129 5 WASHER LOCK M8-5/16
4 G022145 5 WASHER FLAT 5/16-M8 ZINC
(2)5 0D5419 REF OIL FILTER, FORD V-10 ENGINE
(2)6 0D7055 REF DIPSTICK TUBE, FORD 6.8L
7 0D3488J 1 SERPENTINE, BELT (65.30" LG) (2300 RPM)
0D3488 1 BELT SERPENTINE (67.16" LG) (3000 RPM)
0D3488K 1 BELT SERPENTINE (68.33" LG) (3600 RPM)
8 057795B 1 BARBED EL 90 5/8 PLASTIC
9 G065386 1 HOSE COOL 5/8 ID 100R6 (16.75”LG)
10 0F3287 1 BRACKET DC ALTERNATOR UPPER
(3)11 0H3074 1 HARN ENG G6.8L H-100 CPL EMSN (USE WITH PROBE P/N 0H1827)
0J7330 1 HARN ENG G6.8L G3 PM-PC CCI (USE WITH PROBE P/N 0H1827)
12 0E9868A 1 ALTERNATOR DC W/OUT PULLEY
13 --- -- ----------
14 0F3216A 1 PULLEY 102 OD DC ALTERNATOR (2300 RPM)
0F3216C 1 PULLEY 132 OD DC ALTERNATOR (3000 RPM)
0F3216D 1 PULLEY 160 OD DC ALTERNATOR (3600 RPM)
15 G035579 1 BSHG RDCR HEX 1/4 TO 1/8
16 0F4612 1 SENDER OIL PRESSURE 1/8"NPT
(2)17 0D6658 REF DIPSTICK 6.8L FORD
(3)(1)18 029333A 2 TIE WRAP UL 7.4" X .19" BLK
19 G022097 2 WASHER LOCK M6-1/4
20 G022473 2 WASHER FLAT 1/4 ZINC
21 G042568 2 SCREW HHC M6-1.0 X 20 G8.8
(2)22 G049897 4 SCREW SHC M8-1.25 X 20 G8.8
23 0D8025 1 BOLT GROOVED IDLER PULLEY
24 0D8026 3 BOLT BELT TENSIONER
25 0D8030 1 TENSIONER ENG. AUTOMATIC BELT
26 0D8029 1 PULLEY ENGINE WATER PUMP
27 0D8028 1 PULLEY GROOVED ENGINE IDLER
28 G045771 2 NUT HEX M8-1.25 G8 YEL CHR
29 0H0923 REF ENGINE G6.8L G3 V-10 (2009/10)
30 G022131 2 WASHER FLAT 3/8-M10 ZINC
31 G046526 1 WASHER LOCK M10
32 G064416 1 SCREW HHC M10-1.5 X 45 G8.8 FT
33 G045772 1 NUT HEX M10-1.5 G8 YEL CHR
34 0F3217 1 SPACER DC ALTERNATOR PULLEY
35 0F2776A 1 BRACKET SIGNAL CONDITIONER
36 0F6151 1 CAP RUBBER (100KW & 130KW)
37 0F4308 1 BRACKET DC ALT STABILIZER
(4)38 0F3158 1 OIL COOLER FORD (150KW 3600RPM)
39 0G0015 3 CLAMP HOSE 7/8" OD DOUBLE WIRE
40 0E0502 1 TEMPERATURE SENDER, DELPHI
(4)41 0G0866 1 HOSE OIL COOLER PREFORMED 3/4 (150KW 3600RPM)
(4)42 0F4301 1 HOSE OIL COOLER (150KW 3600RPM)
(3)43 0F5512 1 REFLEX WRAP 13MM 13 X 460
(4)44 G047527 1 BARBED STR 1/2NPT X 3/4
45 0F5114 1 DECAL, REFER TO OWNERS MANUAL
(4)46 0F4355 1 ADAPTER 1/2"NPT X 3/8"NPT
47 0F3113 1 ASSY PCB HSB CTRL IGN MODULE
48 0F6317 1 MOUNT IGN MODULE
49 G077996 1 CAP ANTIFREEZE 5/8"ID X 1.2"LG (100/130KW)
50 G032712 2 SCREW HHTT #10-32 X 1.75 CZ
51 G023897 2 WASHER FLAT #10 ZINC
52 G022152 2 WASHER LOCK #10
53 G022158 2 NUT HEX #10-32 STEEL

REVISION: CN-0022095-E Page 2 of 4

DATE: 11/29/2018
EXPLODED VIEW: EV ENGINE COMM PARTS 6.8L GB L/H
DRAWING #: 0K6753 GROUP D
APPLICABLE TO: G6.8 FAN BELT DRIVE

ITEM PART# QTY. DESCRIPTION

54 0G9378 1 DECAL SORE EPA CERTIFICATION
0H0777 1 DECAL LSI EPA CERTIFICATION
55 0K6456 1 PLATE, G6.8 WPP, FAN PULLEY
56 0K3440 3 CLAMP HOSE 1.062" OD DOUBLE WIRE
57 0A2110 2 SCREW HWHS 1/4-20 X 1/2 ZYC

(1) NOTE: I/N 18 IS FOR HOLDING SENSOR TO I/N 35.

(2) NOTE: COMES WITH ENGINE
(3) NOTE: NOT SHOWN
(4) 150KW UNITS ONLY
(5) APPLY BLUE LOCTITE 242 TO HARDWARE BEFORE INSTALLATION.

REVISION: CN-0022095-E Page 3 of 4

DATE: 11/29/2018
EXPLODED VIEW: EV ENGINE COMM PARTS 6.8L GB L/H
DRAWING #: 0K6753 GROUP D
APPLICABLE TO: G6.8 FAN BELT DRIVE

ITEM PART# QTY. DESCRIPTION

THIS PAGE LEFT BLANK INTENTIONALLY

REVISION: CN-0022095-E Page 4 of 4

DATE: 11/29/2018
EXPLODED VIEW: EV FAN GAURD 6.8L G/B
DRAWING #: A0000080562 GROUP C
APPLICABLE TO: G6.8 FAN BELT DRIVE
ITEM PART# QTY. DESCRIPTION
1 A0000080561 1 ST03 FAN GUARD, RH SIDE, 6.8L G/B
2 A0000080551 1 ST03 FAN GAURD, LH SIDE, 6.8L G/B
3 A0000080567 1 ST03 FAN GUARD, BOTTOM, 6.8L G/B
4 0C2454 16 SCREW HWHT M6-1 X 16 N WA Z/JS

REVISION: -A- Page 2 of 2

DATE: 1/10/2019
EXPLODED VIEW: EV COOLING SYSTEM 6.8L C-GROUP
DRAWING #: 0K6750 GROUP D
APPLICABLE TO: G6.8 FAN BELT DRIVE

ITEM PART# QTY. DESCRIPTION

(1)1 0J06070ST0R 1 RADIATOR SUPPORT LH 6.8L
(1)2 0J06060ST0R 1 RADIATOR SUPPORT RH 6.8L
3 0G1286A 1 RADIATOR, R/H-IN L/H-OUT
4 046627 1 CAP RADIATOR 14PSI
5 0D3520 1 HOSE, LOWER RADIATOR
6 0D3521 1 HOSE, UPPER RADIATOR
7 042561 2 CLAMP HOSE #36 1.88 - 2.75
(1)8 0J06270ST0R 1 ASSY VENTURI 6.8L B/C-GRP
9 042907 8 SCREW HHC M8-1.25 X 16 C8.8
10 051768 6 SCREW HHC M12-1.75 X 25 C8.8
11 049808 6 WASHER FLAT M12
12 052860 6 NUT TOP LOCK FL M12-1.75
13 052250 2 TAPE FOAM 1 X 1 (27"LG)
14 035685 2 CLAMP HOSE #28 1.32-2.25
15 0K6401 1 PULLEY ASSY G6.8 FAN DRIVE
16 0D7975 1 WATER BOTTLE BRACKET
17 076749 1 TANK COOLANT RECOVERY
18 048031C 3 CLAMP HOSE BAND 1/4
19 029032 1 HOSE 9/32 ID (31"LG)
20 0A5703 1 FAN, KYSOR 22” LH
21 046526 10 WASHER LOCK M10
22 022131 7 WASHER FLAT 3/8-M10 ZINC
23 045771 8 NUT HEX M8-1.25 G8 CLEAR ZINC
24 022129 16 WASHER LOCK M8-5/16
25 0C2454 2 SCREW HWHT M6-1 X 16 N WA Z/JS
26 0F2776A 1 BRACKET, SIGNAL CONDITIONER
27 0H1827 1 PROBE COOLANT LEVEL 3/8-18NPTF
28 022145 17 WASHER FLAT 5/16-M8 ZINC
29 049814 11 SCREW HHC M10-1.5 X 25 C8.8
30 0G7895B 1 HARN RADIATOR GND 46"
31 077043H 1 CONDUIT FLEX .25"ID (46”LG)
32 0A4456 1 WASHER LOCK SPECIAL 3/8
33 0H3852 1 HOSE HOLDER PLASTIC (.4-.5 ID)
34 050276 1 DECAL RADIATOR DRAIN
35 0K5969 1 COUPLER, G6.8 FAN PULLEY
36 0D3488W 1 BELT SERPENTINE 32.64”
37 0K5966A 1 PULLEY, HARM BLNCR G6.8 130KW
38 0K5965 1 COUPLER, HARMONIC BALANCER G6.8
39 0D8028 1 PULLEY GROOVED ENGINE IDLER
40 0K5971 1 IDLER PULLEY SHAFT, G6.8
(1)41 0K59720ST0R 1 IDLER PULLEY MNTG BRKT, G6.8
42 0K5973 1 IDLER PULLEY TENSIONING BLOCK
(2)43 0K6455 4 SCREW SHC M8-1.25 X 12 G8.8
44 039253 9 SCREW HHC M8-1.25 X 20 C8.8
45 050190 1 WASHER FLAT .344ID X 1.0OD
46 052858 1 NUT TOP LOCK FL M8-1.25
47 052859 2 NUT TOP LOCK FL M10-1.50
48 0C2375 1 SCREW HHC M8-1.25 X 90 C8.8
49 042907 1 SCREW HHC M8-1.25 X 16 C8.8
50 029032 1 HOSE 9/32 ID (42” LG)
51 085662 3 TIE WRAP UL 14.6 X .14 BLK (NOT SHOWN)
52 057593 3 CABLE TIE MOUNT (NOT SHOWN)

NOTES (UNLESS OTHERWISE SPECIFIED):

(1) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
• MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
• CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY)
IN THE SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
(2) APPLY BLUE LOCTITE 242 TO HARDWARE BEFORE INSTALLATION.
(3) FASTEN HOSE TO VENTURI USING TIE WRAP I/N 51 AND CABLE TIE MOUNTS I/N 52. DIRECT HOSE TOWARDS THE
BOTTOM OF UNIT AND AWAY FROM EXHAUST COMPONENTS.

REVISION: J-9516-C Page 3 of 4

DATE: 9/9/14
EXPLODED VIEW: EV COOLING SYSTEM 6.8L C-GROUP
DRAWING #: 0K6750 GROUP D
APPLICABLE TO: G6.8 FAN BELT DRIVE

ITEM PART# QTY. DESCRIPTION

This page left blank intentionally

REVISION: J-9516-C Page 4 of 4

DATE: 9/9/14
EXPLODED VIEW: EV PULLEY ASSY, G6.8 FAN DRIVE
DRAWING #: 0K6536 GROUP D
APPLICABLE TO: G6.8 FAN BELT DRIVE
ITEM PART# QTY. DESCRIPTION
1 0K5967 1 PULLEY, FAN G6.8 IDLER
2 0K5968 1 ADAPTER, G6.8 WPP - FAN PULLEY
3 0K5975 2 BEARING,BALL 25X47X12
4 0K5970 1 SPACER, BEARING 25ID
5 0D8025 1 BOLT HEX FL HD M8-1.25 X 28

REVISION: - A - Page 2 of 2
DATE: 11/08/13
 1 0D2513E 1 PLATE AIR CLEANER W/COUPLER
2 0F5419 1 ELEMENT AIR FILTER
3 0F4268 1 TOP PLATE VENTURI
4 0F4270A 1 HOLD DOWN AIR CLEANER PLATED
5 0F6977 1 PLATE AIR CLEAN TOP 5.4L/6.8L
6 037561 1 NUT WING 1/4-20 NYLK
7 047411 4 SCREW HHC M6-1.0 X 16 G8.8
8 022097 4 WASHER LOCK M6-1/4
9 049811 4 WASHER FLAT M6
10 0F4269 1 GASKET MIXER BODY
11 022473 1 WASHER FLAT 1/4-M6 ZINC
12 0A4256 1 INDICATOR FILTER MINDER
EXPLODEDVIEW: EV GEARBOX ASSY 390 ALT
DRAWING#: 0F1792 GROUP D
APPLICABLETO:

ITEM PART# QTY. DESCRIPTION

1 0F2123 1 GEAR CASE ENG. MACHINED
2 0F2122 1 GEAR CASE ALT. MACHINED
3 095613 1 SEAL OIL
4 051756 2 SCREW HHC M10-1.5 X 20 G8.8
5 046526 42 WASHER LOCK M10
6 049814 4 SCREW HHC M10-1.5 X 25 G8.8
7 051735 8 SCREW HHC M10-1.5 X 70 G8.8
8 0F2097 1 GASKET 390 GEARBOX
9 072879 1 SPACER .69 X 2.75 X .37 ST/ZNC
10 097557B 1 KEY 10 X 16 X 46
11 0H3114 1 GEAR OUTPUT 1.65:1
095970 1 GEAR OUT 390-50H 37T
095968 1 GEAR OUT 390-60H 35T
0E6866 1 GEAR OUTPUT 2:1 50HZ 390
12 070263 2 SCREW HHC M16-2.0 X 35 G10.9
13 057019 2 BALL BRG 65 X 120 X 23
14 026847 1 BREATHER
15 0H3113 1 GEAR INPUT 1.65: 1
095969 1 GEAR INPT 390-50 25T
095967 1 GEAR INPT 390-60 27T
0E6865 1 GEAR INPUT 2:1 50HZ 390
16 095966 1 SHAFT 390 INPUT GEAR
17 095976 1 COLLAR HARDENED
18 095971 1 SEAL OIL
19 096777 1 SNAP RING INT 120MM
20 057019S 1 BEARING #6213 SEALED
22 096379 1 PLATE INTRNL BRG RET
23 048189 2 PIN DOWEL M8 X 24
24 095979 1 PLATE BEARING THRST
25 021159 1 SPACER STRESSPROOF
26 097557A 1 KEY 10 X 16 X 40
27 057163 1 PLUG PIPE 3/8" MAGNETIC
28 0F6518 4 SCREW HHFC M10-1.5 X 25 G10.9
29 0F3201 1 COVER GEARBOX GUARD
30 020443 1 COUPLING INNER DRAWN
31 094666A 1 COUPLING OUTER MACHN
32 099828 8 DAMPER GB CPLR VIBRA
33 099828A 8 DAMPER GB CPLR VIBRA
34 026925 2 PLUG STD PIPE 3/8 STEEL SQ HD
35 097557C 1 KEY 10 X 16 X 50
36 038591 1 NIPPLE PIPE 3/8 NPT X 3-1/2
37 025066 1 COUPLING FULL 3/8-18
38 031578 6 SCREW HHC 3/8-16 X 1-1/2 G8
052625 REF. SCREW SHC M10-1.5 X 35 G12.9 (FORD ENGINES)
39 049814 10 SCREW HHC M10-1.5 X 25 G8.8
40 0A1786 2.5cc RETAINING COMPOUND
41 027175 .200 GAL LUBE GREASE SAE #90 80W90 (NOT SHOWN)
44 045772 10 NUT HEX M10-1.5 G8 YEL CHR
45 052243 10 SCREW HHC M10-1.5 X 60 G8.8
46 057642 2 SCREW HHC M10-1.5 X 40 G10.9
47 0F6487 4 WASHER FLAT M10 SEALING COPPER
48 0F6355 1 GASKET SEAL PLATE 390 GB
49 0F6477 .050 GAL ENHANCER GEAR OIL (NOT SHOWN)
50 0F6557 0.4cc THREADLOCK AND SEALANT
51 026924 1 ELBOW 90D STREET 3/8

REVISION: CN-0021689-G Page 2 of 2

DATE: 11/14/2018
EXPLODED VIEW: EV FUEL 6.8L 100KW LPV EMSN
DRAWING #: 0J4388 GROUP E
APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION

1 049721 4 SCREW HHC M6-1.0 X 35 C8.8 BLK

2 0F8313 1 ASSY RGLTR INLET NPT FITTINGS

A 065908 1 SUPPORT NAT GAS SOLENOID
B 039130 1 NIPPLE CLOSE 1.25 NPT X 1.625
C 030131 1 ELBOW 90D 1-1/4 NPT
D 031015 1 NIPPLE PIPE 1-1/4 NPT X 3
E 0K2771 1 CROSS 1-1/4" NPT
F 0A8064 2 BSHG RDCR HEX 1-1/4-3/4
G 026915 2 NIPPLE CLOSE 3/4 X 1.375
H 0E7162 1 BSHG RDCR HEX 1-1/4 X 1/4FNPT
J 0K2340 1 PLUG, PRESSURE GAUGE, 1/4" NPT

2 0F8313A 1 ASSY RGLTR INLET NPT FITTINGS

A 065908 1 SUPPORT NAT GAS SOLENOID
B 039130 1 NIPPLE CLOSE 1.25 NPT X 1.625
C 030131 1 ELBOW 90D 1-1/4 NPT
D 088963 1 NIPPLE PIPE 1.25NPTX5.5 BL IRN
E 0K2771 1 CROSS 1-1/4" NPT
F 0A8064 2 BSHG RDCR HEX 1-1/4-3/4
G 026915 2 NIPPLE CLOSE 3/4 X 1.375
H 0E7162 1 BSHG RDCR HEX 1-1/4 X 1/4FNPT
J 0K2340 1 PLUG, PRESSURE GAUGE, 1/4" NPT

2 0J4590 1 ASSY RGLTR INLET NPT FITTINGS

A 065908 1 SUPPORT NAT GAS SOLENOID
B 039130 3 NIPPLE CLOSE 1.25 NPT X 1.625
C 030131 2 ELBOW 90D 1-1/4 NPT
D 088963 1 NIPPLE PIPE 1.25NPTX5.5 BL IRN
E 0K2771 1 CROSS 1-1/4" NPT
F 0A8064 2 BSHG RDCR HEX 1-1/4-3/4
G 026915 1 NIPPLE CLOSE 3/4 X 1.375
H 0J3858E 1 BALL VALVE, 1-1/4" NPT
J 035589 2 NIPPLE PIPE 3/4 NPT X 3-1/2
K 0E7162 1 BSHG RDCR HEX 1-1/4 X 1/4FNPT
L 0K2340 1 PLUG, PRESSURE GAUGE, 1/4" NPT

3 0G9781 1 REG 6.8L 100KW LP CPL&CONF EMS

0G9781A 1 REG 6.8L 130KW LP CPL&CONF EMS
0G9781B 1 REG 6.8L 150KW LP CPL&CONF EMS
0H6135D 1 REG 6.8L 80KW LPV CONF EMSN
4 052645 2 SCREW HHC M12-1.75 X 30 C8.8
5 022304 4 WASHER FLAT 1/2 ZINC
6 077879 1 HOSE VACUUM 5/32 (10.5”LG)
7 045773 2 NUT HEX M12-1.75 G8 YEL CHR
8 077879 2 HOSE VACUUM 5/32 (12”LG)
9 039450 2 BARBED EL 90 3/16 X 1/8
10 0G4588 1 PIPE TEE W/ BRACKET WELDED
11 0C2454 2 SCREW HWHT M6-1 X 16 N WA Z/JS
12 049811 2 WASHER FLAT M6
13 057823 4 CLAMP HOSE #10 .56-1.06
14 059057 2 HOSE 3/4 ID SAE-30R2 (46” LG)
15 0D2698 1 GASKET ADAPTER THROT BODY
18 0J7476 1 ADAPTOR THROTTLE BODY
19 0E4390 1 GASKET GOVERNOR ACTUATOR
20 0E4392 1 ACTUATOR BOSCH 60 GOVERNOR
21 0F0960 1 REDUCER 3.0" TO 2.75" TURBO
22 0F3885 1 MIXER 40/60MM ACTUATOR ASSY
23 0G3167 2 O-RING 2-3/4 X 3/32 X 2-15/16
24 0F3691E 1 VENTURI, THROTTLE 42MM (6.8L 100KW)
0F3691F 1 VENTURI THROTTLE 44MM (6.8L 130KW)
0F3691J 1 VENTURI, THROTTLE 50MM (6.8L 150KW)
25 022195 2 WASHER LOCK 1/2
26 0G5989 1 HARNESS FUEL JUMPER DUAL REG
27 026073A 1 PLUG STD PIPE 1/4 STEEL SQ HD
28 0D2157 4 SCREW SHC M6-1.0 X 50 C8.8
29 039294 1 CLAMP HOSE #44 2.31-3.25
30 022097 10 WASHER LOCK M6-1/4
33 0F1866A 1 BARBED EL W/VENT (.052")

REVISION: K-3102-G Page 2 of 4

DATE: 10/6/15
EXPLODED VIEW: EV FUEL 6.8L 100KW LPV EMSN
DRAWING #: 0J4388 GROUP E
APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION

34 066212 1 CLAMP HOSE #52 2.81-3.75
35 0G46350ST03 1 BRACKET, HOSE RISER
36 042568 2 SCREW HHC M6-1.0 X 20 G8.8
37 050280A 1 DECAL FUEL INLT LPG 1 1/4" NPT
38 0L5885 1 PLUG PLASTIC 1.25" TAPERED CAP

REVISION: K-3102-G Page 3 of 4

DATE: 10/6/15
EXPLODED VIEW: EV FUEL 6.8L 100KW LPV EMSN
DRAWING #: 0J4388 GROUP E
APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION

This page left blank intentionally

REVISION: K-3102-G Page 4 of 4

DATE: 10/6/15
EXPLODED VIEW: EV EXHAUST 6.8L C-GRP
DRAWING #: 0J4245 GROUP F
APPLICABLE TO:
ITEM PART# QTY. DESCRIPTION
(1)1 0J42720ST0R 2 ASSY, 6.8L C-GRP EXHAUST BRACE
(1)2 0C57370ST0R 2 BRACKET, HEAT SHIELD
3 0D6929 4 MTG BAND CATALYST-MUFFLER
4 0D3197 1 MUFFLER 6.8L G3 C-GRP
(2)0D5027A 1 CATALYST MUFFLER 6.8L C-GRP
5 0J3460 1 PIPE, 6.8L RH MUFFLER
(2)0J3460A 1 PIPE, 6.8L RH MUFFLER (W/O2)
6 0J3458 1 PIPE, 6.8L LH MUFFLER
7 0A5215B 2 FLEX PIPE 2.5"
8 0J3459 1 PIPE, 6.8L RH EXHAUST MANIFOLD
9 0J3457 1 PIPE, 6.8L LH EXHAUST MANIFOLD
10 0D3159 2 FLANGE, EXHAUST
11 0A6765 2 RING GASKET 2.5DIA
12 0C3433A 4 CLAMP BAND 2.5"
13 G058623 2 BOLT U 3/8-16 X 2.75
(2)14 0F9071 1 SENSOR OXYGEN
15 G051756 8 SCREW HHC M10-1.5 X 20 C8.8
16 G046526 8 WASHER LOCK M10
17 G022131 8 WASHER FLAT 3/8-M10 ZINC
18 0F2773A 2 EXHAUST BLANKET 1130MM LONG
19 G090388 2 SCREW HHTT M6-1.0 X 12 ZINC
20 0J4403 1 HEAT SHIELD C-GRP
(3)21 G083218 1 RAIN CAP 4.00/4.19
22 0G6401 6 SCREW HHC M10-1.5 X 45 SS FTH
23 0F4710 6 WASHER LOCK M10 SS
24 G088775 6 WASHER FLAT 3/8 SS
25 G039287 4 SCREW HHC M8-1.25 X 45 C8.8
26 G022145 8 WASHER FLAT 5/16-M8 ZINC
27 G067989 4 NUT HEX FL WHIZ M8-1.25
(2)28 0H4954 1 HARN OXYGEN SENSOR EXTEN 50" (NOTSHOWN)
(2)29 G072252 1 GROMMET 1.37 X .06 X 1.00
(4)30 G032321 1 SCREW HHC 1/4-20 X 2 G5

NOTES (UNLESS OTHERWISE SPECIFIED):

(1) SHEET METAL PARTS LISTED IN THE BOM TABLE, PRIOR TO 1/1/16, ARE REPRESENTING GENERIC
PARTS (NO COLOR) :
• MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO SAP BOM.
• CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY)
IN THE SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
(2) USED IN EMISSIONS APPLICATIONS ONLY.
(3) IN EMISSIONS APPLICATIONS USE BOLT SUPPLIED WITH RAIN CAP.
(4) TO BE USED FOR NON-EMISSIONS APPLICATIONS ONLY.

REVISION: CN-0026529-F PAGE 2 OF 2

DATE: 5/24/2019
EXPLODED VIEW: EV ENCL L2A C-GRP
DRAWING #: 0J0436 GROUP F

ITEM PART# QTY. DESCRIPTION

(1)1 0H98330ST0R 1 CENTER PANEL C-GRP REAR
(1)2 0J19690AL0R 1 ASSY, ROOF C-GRP
(1)3 0J60200ST0R 2 OVRHD MOD SIDE OUTER L2A C-GRP
(1)4 0J35670ST0R 1 INTAKE OVERHEAD REAR BAFFLE
(1)5 0F44240ST0R 1 DUCT FRONT PANEL L2A
6 0J0992 4 T-HANDLE, 2-POINT DBL DOOR
7 G022097 17 WASHER LOCK M6-1/4
(1)8 0J16010ST0R 8 BRACKET, ROD GUIDE
(1)9 0J38000ST0R 1 INTAKE OVRHD MOD FRONT
10 0E3257 14 SCREW HWHTF M6-1.0 X 16
(1)11 0J43760ST0R 1 CORNER POST LH FRONT C-GRP
12 0C3393 2 SCREW SHOULDER M8-1.25 X 20
(1)13 0J43770ST0R 1 CORNER POST RH FRONT C-GRP
(1)14 0F19450ST0R 1 BLKOFF FRONT OVHD MOD LVL2 RAW
15 0C6748 16 NUT HEX LOCK M4-0.7 SS NYL INS
(1)16 0H98290ST0R 1 CORNER POST LH REAR
(1)17 0H98340ST0R 4 SIDE BRACE TOP&BTM C-GRP
18 G049813 16 NUT HEX M6-1.0 G8 CLEAR ZINC
19 0C2634A 1 ASSY ACCESS COVER
(1)20 0J31430ST0R 1 BRACE FRONT TOP
(1)21 0G24100AL0R 1 DUCT TOP EXH 6.8L C-GRP AL RAW
22 G022473 17 WASHER FLAT 1/4-M6 ZINC
(1)23 0F04770ST0R 1 BARRIER DUCT INSIDE FRT RAW
24 G022769 4 WASHER LOCK INT #10
25 0C3397 4 SCREW RATCHET BLK NYLON
26 G066760 1 STRIP SEALANT 1/8 X 1
27 G022145 4 WASHER FLAT 5/16-M8 ZINC
28 0C6749 16 SCREW PPHM M4-0.7 X 12 SS
(1)29 0F19430ST0R 2 ANGLE WATER DFLCT L2A C-GRP
30 0A9881 1 TRIM VINYL SEAL
(1)31 0G24110ST0R 1 DUCT FRONT LH 6.8L C-GRP RAW
(1)32 0H98300ST0R 1 CORNER POST RH REAR
33 0A5991 70 SCREW BHSC M8-1.25 X 16 SS
(1)34 0J37190ST0R 1 INTAKE OVRHD MOD REAR
35 0C2454 192 SCREW HWHT M6-1 X 16 N WA Z/JS
(1)36 0J00800ST0R 4 DOOR LH SOLID
37 G022129 4 WASHER LOCK M8-5/16
38 G042907 4 SCREW HHC M8-1.25 X 16 C8.8
39 0C3595A 4 ASSY M8 HINGE RH TOP
40 0C3595 4 ASSY M8 HINGE LH TOP
(1)41 0F01530ST0R 7 SPLITTER RAW
(1)42 0F30630ST0R 2 CAP END OVRHD MOD L2A RAW
(1)43 0H97910ST0R 2 CENTER DOOR SUPPORT
44 0J0993 8 ROLLER ROD, T-HANDLE
(1)45 0J00810ST0R 4 DOOR RH SOLID
46 G080490 16 WASHER FLAT #8 SS
(1)47 0G16120ST0R 1 DUCT, FRONT BOTTOM
(1)48 0G24120ST0R 1 DUCT FRONT RH 6.8L C-GRP ST
49 G022127 1 NUT HEX 1/4-20 STEEL
50 0E7222 2 RAIN SHIELD,DOOR JAMB
(2)51 G027529 REF NUT HEX LOCK 1/4-20 NY INS
52 0A3359 6 SCREW BHSC M6-1.0 X 16 SS
53 G027958 6 WASHER NYLON .260
(1)54 0J60210ST0R 2 OVRHD MOD SIDE INNER L2A C-GRP
55 078115B 12 WASHER SELF LOCKING BLK #4-40
56 0C3595B 4 ASSY, M8 HINGE LH BOTTOM
57 0C3595C 4 ASSY, M8 HINGE RH BOTTOM
(2)58 G022473 REF WASHER FLAT 1/4-M6 ZINC

REVISION: CN-0029904-J Page 3 of 4

DATE: 9/10/19
EXPLODED VIEW: EV ENCL L2A C-GRP
DRAWING #: 0J0436 GROUP F

ITEM PART# QTY. DESCRIPTION

59 0K3108 INSUL IND COMMON CGRP SLV
A 0J0553BI 8 INSUL SIDE SUPPORT RAIL
B 0J0553BX 1 INSUL OVRHD MDL BOTTOM
C 0J0553BY 1 INSUL FRONT DUCT BAFFLE
D 0J0553BZ 1 INSUL FRONT DUCT
E 0J0553CA 2 INSUL FRONT DUCT
F 0J0553CB 1 INSUL FRONT DUCT LH
G 0J0553CC 1 INSUL FRONT DUCT RH
H 0J0553CD 1 INSUL FRONT DUCT BOTTOM

60 0K3111 INSUL FRONT NO HI TEMP CGRP

J 0J0553BJ 2 INSUL REAR CORNER POST
K 0J0553EK 1 INSUL FRONT CENTER SUPPORT
L 10000009566 2 INSUL REAR CORNER POST CGRP
61 0K3113 INSUL DOORS BOTH SIDE CGRP
M 0J0553BK 1 INSUL REAR CENTER PANEL
N 0J0553E 2 INSUL CTR DOOR SUPPORT
P 0J0553K 4 INSUL RH SOLID DOOR
Q 0J0553L 4 INSUL LH SOLID DOOR

62 0K3115 INSUL IND INTAKE CGRP L2A BLK

R 0K0328AQ 2 INSULATION OVRHD MDL SPLITTER
S 0K0328AR 14 INSULATION OVRHD MDL SPLITTER
T 0K0328AU 1 INSUL ROOF REAR
U 0K0328AV 1 INSUL ROOF MIDDLE
V 0K0328AW 1 INSUL ROOF FRONT
W 0K0328AX 1 INSUL OVRHD MDL FRONT
X 0K0328AY 4 INSUL OVRHD MDL SIDE
Y 0K0328AZ 1 INSUL OVRHD MDL REAR
Z 0K0328BA 2 INSUL OVRHD MDL SIDE
AA 0K0328BB 4 INSUL OVRHD MDL SIDE
AB 0K0328BC 4 INSUL OVRHD MDL BOTTOM

NOTES (UNLESS OTHERWISE SPECIFIED):

(1) SHEET METAL PARTS LISTED IN THE BOM TABLE, PRIOR TO 1/1/16, ARE REPRESENTING GENERIC
PARTS (NO COLOR) :
• MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO SAP BOM.
• CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY)
IN THE SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
(2) HARDWARE INCLUDED WITH I/N 6, P/N 0J0992.

REVISION: CN-0029904-J Page 4 of 4

DATE: 9/10/19
EXPLODED VIEW: EV 390 ALT SHROUD KIT CCI
DRAWING #: 0J7592 GROUP H

ITEM PART# QTY. DESCRIPTION

(1)1 0J7590AST0R 2 SHROUD 390 ALT X 76MM
0J75900ST0R 2 SHROUD 390 ALT X 50MM
0J75910ST0R 2 SHROUD 390 ALT X 150MM
(2)2 0C2454 8/10 SCREW HWHT M6-1 X 16 N WA Z/JS
3 0E1534A 4 PLUG PLASTIC 1.50"

(1)NOTE:
0J7590AST0R INCLUDED IN KIT #0J7593A
0J75900ST0R INCLUDED IN KIT #0J7593
0J75910ST0R INCLUDED IN KIT #0J7593B

(2) QTY DETERMINED BY SHROUD MOUNTING REQUIREMENTS.

REVISION: -A- Page 2 of 2

DATE: 11/21/11
EXPLODED VIEW: EV ANN MTG FOR ENCL UNIT Y02
DRAWING #: 0J7226 GROUP H

ITEM PART# QTY. DESCRIPTION

1 0G6770B REF ANN 57.6 BAUD SURF Y02 CCI
A 0G5719 REF ASSY 57.6K BAUD ANN (RRP&RAP)
B 0G6131 REF SCREW HHC M6-1.00 X 30 C8.8 FT
C 022473 REF WASHER FLAT 1/4-M6 ZINC
D 0B2236 REF NUT HEX LOCK M6-1 NY INS
E 022097 REF WASHER LOCK M6-1/4
F 049813 REF NUT HEX M6-1.0 G8 CLEAR ZINC

(1)2 0J58140ST0R 1 MOUNT ANN 57.6 BAUD 390 CCI

NOTES (UNLESS OTHERWISE SPECIFIED):

(1) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
• MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
• CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR
CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).

REVISION: J-9863-D Page 2 of 2

DATE: 9/30/14
EXPLODED VIEW: EV BLOCK HTR 1500W 60/80F 6.8L G3 W/VALVES
DRAWING #: 0J6715 GROUP C

ITEM PART# QTY. DESCRIPTION

1 042568 4 SCREW HHC M6-1.0 X 20 C8.8
2 022097 2 WASHER LOCK M6-1/4
3 022473 6 WASHER FLAT 1/4-M6 ZINC
4 084918Q 1 HEATER BLOCK 1500W 120V 60/80F
5 0G0015 2 CLAMP HOSE 7/8" OD DOUBLE WIRE
6 077043E 1 CONDUIT FLEX 1.0"ID (30” LG)
7 084427 1 BRACKET HEATER W/WELDNUTS
8 035467 1 NIPPLE CLOSE 3/8NPT X 1 VIBRA
9 052857 2 NUT TOP LOCK FL M6-1.0
10 050967 1 HOSE COOL 5/8 ID 20R3 (31”LG)
11 0G5212B 1 VALVE 3/8"
12 0C4905 1 BARBED EL 45 3/8NPT X 5/8OD
(1) 13 0A6283 1 HOSE PREFORMED BLOCK HEATER
(1) 14 0G5212B 1 VALVE 3/8"
(1) 15 0G0015 2 CLAMP HOSE 7/8" OD DOUBLE WIRE
(1) 16 044117 1 BARBED STR 3/8NPT X 5/8
(1)17 035467 1 NIPPLE CLOSE 3/8NPT X 1 VIBRA
(1)18 077043E 1 CONDUIT FLEX 1.0"ID (12” LG)

(1) ITEMS NOT USED ON L.P. LIQUID UNITS.

REVISION: -A- Page 2 of 2

DATE: 8/16/11
EXPLODED VIEW: EV KIT 12/24V RUN RELAY
DRAWING #: 0J1171 GROUP H
APPLICABLE TO:
ITEM PART# QTY. DESCRIPTION
1 0C3211E 1 RELAY PNL 12VDC DPDT 8PIN
0C3211F 1 RELAY 24VDC DPDT 8 PIN
(1)2 0J0400 1/2 DECAL, HV CONNECTION RUN RELAY
3 0C3211H 2 SPRING RELAY RETAINING
(1)4 0J5462 2/4 SCREW THTT M4-0.7 X 16 ZP
5 0J0836 1 HARN RUN RELAY H-PANEL
(1)6 0F5828 2/4 SCREW PHTT M4-0.7 X 25 ZP
7 0J8896 1 BUSHING, STRAIN RND(.290-.385)

(1) QTY. MAY CHANGE BASED ON OPTION OFFERED.

REVISION: J-8095-D PAGE 2 OF 2

DATE: 3/17/14
EXPLODED VIEW: EV, NEUTRAL BLOCK 0-250A
DRAWING #: 0J1047 GROUP H
APPLICABLE TO:
ITEM PART# QTY. DESCRIPTION
NEUTRAL BLOCK (250A)
1 057073 2 JUNCTION BLOCK 3/8-16
2 0H9690 1 NEUTRAL, BRACKET (60-100A)
3 0F8451 1 LUG SLDLSS 300 MCM-6 AL/CU
4 0J5464 4 SCREW HDPHT M5-0.8 X 16 ZP
5 022131 2 WASHER FLAT 3/8-M10 ZINC
6 022237 2 WASHER LOCK 3/8
7 022241 2 NUT HEX 3/8-16 STEEL
8 067989 1 NUT HEX FL WHIZ M8-1.25
9 043107 1 SCREW HHC M8-1.25 X 25 C8.8

NEUTRAL BLOCK (300A - 600A)

1 057073 2 JUNCTION BLOCK 3/8-16
2 0H9689A 1 BUS BAR, NTRL BLK 520 0-600A
3 0A7822 2 LUG SLDLSS 600/250-1/0X1/4-28
4 0J5464 4 SCREW HDPHT M5-0.8 X 16 ZP
5 022511 2 SCREW HHC 3/8-16 X 1-1/4 G5
6 022237 4 WASHER LOCK 3/8
7 022241 4 NUT HEX 3/8-16 STEEL
8 022131 6 WASHER FLAT 3/8-M10 ZINC
9 045335 4 SCREW HHC 1/4-28 X 3/4 G5
10 022097 4 WASHER LOCK M6-1/4

NEUTRAL BLOCK (700A – 1200A)

1 057073 2 JUNCTION BLOCK 3/8-16
2 0H9689 1 BUS BAR, NTRL BLK 520 600-1600
3 0A7822 4 LUG SLDLSS 600/250-1/0X1/4-28
4 0J5464 4 SCREW HDPHT M5-0.8 X 16 ZP
5 022511 5 SCREW HHC 3/8-16 X 1-1/4 G5
6 022237 7 WASHER LOCK 3/8
7 022241 7 NUT HEX 3/8-16 STEEL
8 022131 12 WASHER FLAT 3/8-M10 ZINC
9 045335 8 SCREW HHC 1/4-28 X 3/4 G5
10 022097 8 WASHER LOCK M6-1/4

NEUTRAL BLOCK (1400A – 2500A)

1 0C6937M 2 INSULATOR, STANDOFF 600V3/8-16
2 0J4583 2 BUS BAR, 1/4"X6"X10"
3 031578 3 SCREW HHC 3/8-16 X 1-1/2 G8
4 022131 10 WASHER FLAT 3/8-M10 ZINC
5 022237 7 WASHER LOCK 3/8
6 022241 3 NUT HEX 3/8-16 STEEL
7 023152 2 SCREW HHC 3/8-16 X 3/4 G5
8 029745 2 SCREW HHC 3/8-16 X 1 G5

REVISION: CN-0021325-E PAGE 2 OF 2

DATE: 10/31/2018
EXPLODED VIEW: EV, CB MOUNTING KIT MD1 390
DRAWING #: 0J1027 GROUP H
APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION

NO CIRCUIT BREAKERS
(1)1 0H93780ST0R 1 MD1,MODULE COVER 390 G-FRAME
2 0C2454 9 SCREW HWHT M6-1 X 16 N WA Z/JS
3 0J0679 1 DECAL, CANADIAN SAFETY CODE
4 0J0546 REF DECAL, HV CUSTOMER CONN INSIDE
10000011043 REF DECAL, HV CUSTOMER CONN INSIDE
5 0D3719C REF DECAL CUSTOMER CONN E1 E2 E3
0D3719D REF DECAL CUSTOMER CONN E1 E3
(1)6 0J34710ST0R 1 MD1-MD3 NO CB MNT BRACKET
7 0J3958 REF CU BUSS BAR 1/4"X2.5" 625A
8 G022145 4 WASHER FLAT 5/16-M8 ZINC
9 G022129 4 WASHER LOCK M8-5/16
10 G042907 4 SCREW HHC M8-1.25 X 16 C8.8
11 0C6937M 6 INSULATOR, STANDOFF 600V3/8-16
12 G022241 6 NUT HEX 3/8-16 STEEL
13 G022237 12 WASHER LOCK 3/8
14 G022131 12 WASHER FLAT 3/8-M10 ZINC
15 G032414 8 SCREW HHC 3/8-16 X 5/8 G5
16 G090865 6 STUD 3/8-16 X 1.75 G5 STEEL
17 G022511 REF SCREW HHC 3/8-16 X 1-1/4 G5
18 G022237 REF WASHER LOCK 3/8
19 G022241 REF NUT HEX 3/8-16 STEEL
20 G022131 REF WASHER FLAT 3/8-M10 ZINC
UL CIRCUIT BREAKER (225AF)
(1)1 0H9378EST0R 1 MD1,MODULE COVER 390 GEN-225
0H9378KST0R 1 MD1,CB COVER 390 GEN-225 1PH
2 0C2454 7 SCREW HWHT M6-1 X 16 N WA Z/JS
3 REF 1 CIRCUIT BREAKER
(1)4 0J14770ST0R 1 MD1, C/B MOUNTING BRACKET 225
5 G022145 4 WASHER FLAT 5/16-M8 ZINC
6 G022129 4 WASHER LOCK M8-5/16
7 G042907 4 SCREW HHC M8-1.25 X 16 C8.8
8 0J0679 1 DECAL, CANADIAN SAFETY CODE
9 0J0546 REF DECAL, HV CUSTOMER CONN INSIDE
10000011043 REF DECAL, HV CUSTOMER CONN INSIDE
(2)11 G053640 2/4 SCREW RHM #8-32 X 3-1/4
(2)12 G038150 2/4 WASHER FLAT #8 ZINC
(2)13 G022264 2/4 WASHER LOCK #8-M4
(2)14 G022471 2/4 NUT HEX #8-32 STEEL
20 0F8432 1 INSUL CB 225AF (3 PHASE)
0F8432A 1 INSULATOR CB 2P 225AF (1 PHASE)
21 0D3719C REF DECAL CUSTOMER CONN E1 E2 E3
0D3719D REF DECAL CUSTOMER CONN E1 E3
UL CIRCUIT BREAKER (400AF)
(1)1 0H9378JST0R 1 MD1,MODULE COVER 390 GEN-400
2 0C2454 7 SCREW HWHT M6-1 X 16 N WA Z/JS
3 REF 1 CIRCUIT BREAKER
(1)4 0J00680ST0R 1 MD2, C/B BACK MOUNTING BRACKET
5 G022145 4 WASHER FLAT 5/16-M8 ZINC
6 G022129 4 WASHER LOCK M8-5/16
7 G042907 4 SCREW HHC M8-1.25 X 16 C8.8
8 0J0679 1 DECAL, CANADIAN SAFETY CODE
9 0J0546 REF DECAL, HV CUSTOMER CONN INSIDE
10000011043 REF DECAL, HV CUSTOMER CONN INSIDE
11 G069232 4 SCREW RHM #10-32 X 3-3/4
12 G023897 4 WASHER FLAT #10 ZINC
13 G022152 4 WASHER LOCK #10
14 G022158 4 NUT HEX #10-32 STEEL
15 0D3719C REF DECAL CUSTOMER CONN E1 E2 E3
0D3719D REF DECAL CUSTOMER CONN E1 E3
UL CIRCUIT BREAKER (G-FRAME)
(1)1 0H9378AST0R 1 MD1,MODULE COVER 390 G-FRAME
2 0C2454 7 SCREW HWHT M6-1 X 16 N WA Z/JS
3 REF 1 CIRCUIT BREAKER
(1)4 0J14880ST0R 1 MD1, C/B MOUNTING BRACKET G

REVISION: CN-0011118-H Page 4 of 6

DATE: 11/21/17
EXPLODED VIEW: EV, CB MOUNTING KIT MD1 390
DRAWING #: 0J1027 GROUP H
APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION

5 G022145 4 WASHER FLAT 5/16-M8 ZINC
6 G022129 4 WASHER LOCK M8-5/16
7 G042907 4 SCREW HHC M8-1.25 X 16 C8.8
8 0J0679 1 DECAL, CANADIAN SAFETY CODE
9 0J0546 REF DECAL, HV CUSTOMER CONN INSIDE
10000011043 REF DECAL, HV CUSTOMER CONN INSIDE
10 0D3719C REF DECAL CUSTOMER CONN E1 E2 E3
0D3719D REF DECAL CUSTOMER CONN E1 E3
11 0J4465 4 SCREW SHC M4-0.7 X 80 C12.9
12 G043180 4 WASHER FLAT M4
13 G022264 4 WASHER LOCK #8-M4
14 G051715 4 NUT HEX M4-0.7 G8 YEL CH
UL CIRCUIT BREAKER (F -FRAME)
(1)1 0H9378BST0R 1 MD1,MODULE COVER 390 F-FRAME
2 0C2454 7 SCREW HWHT M6-1 X 16 N WA Z/JS
3 REF 1 CIRCUIT BREAKER
(1)4 0J14860ST0R 1 MD1, C/B MOUNTING BRACKET F
5 G022145 4 WASHER FLAT 5/16-M8 ZINC
6 G022129 4 WASHER LOCK M8-5/16
7 G042907 4 SCREW HHC M8-1.25 X 16 C8.8
8 0J0679 1 DECAL, CANADIAN SAFETY CODE
9 0J0546 REF DECAL, HV CUSTOMER CONN INSIDE
10000011043 REF DECAL, HV CUSTOMER CONN INSIDE
10 0D3719C REF DECAL CUSTOMER CONN E1 E2 E3
0D3719D REF DECAL CUSTOMER CONN E1 E3
11 0J4899 4 SCREW SHC M4-0.7 X 45 C12.9
12 G043180 4 WASHER FLAT M4
13 G022264 4 WASHER LOCK #8-M4
14 G051715 4 NUT HEX M4-0.7 G8 YEL CHR
UL CIRCUIT BREAKER (JG -FRAME)
(1)1 0H9378DST0R 1 MD1,MODULE COVER 390 JG-FRAME
2 0C2454 7 SCREW HWHT M6-1 X 16 N WA Z/JS
3 REF 1 CIRCUIT BREAKER
(1)4 0J14860ST0R 1 MD1, C/B MOUNTING BRACKET F
5 G022145 4 WASHER FLAT 5/16-M8 ZINC
6 G022129 4 WASHER LOCK M8-5/16
7 G042907 4 SCREW HHC M8-1.25 X 16 C8.8
8 0J0679 1 DECAL, CANADIAN SAFETY CODE
9 0J0546 REF DECAL, HV CUSTOMER CONN INSIDE
10000011043 REF DECAL, HV CUSTOMER CONN INSIDE
10 0D3719C REF DECAL CUSTOMER CONN E1 E2 E3
0D3719D REF DECAL CUSTOMER CONN E1 E3
11 0J4466 4 SCREW SHC M4-0.7 X 100 C12.9
12 G043180 4 WASHER FLAT M4
13 G022264 4 WASHER LOCK #8-M4
14 G051715 4 NUT HEX M4-0.7 G8 YEL CHR
UL CIRCUIT BREAKER (J -FRAME)
(1)1 0H9378CST0R 1 MD1,MODULE COVER 390 J-FRAME
2 0C2454 7 SCREW HWHT M6-1 X 16 N WA Z/JS
3 REF 1 CIRCUIT BREAKER
(1)4 0J00680ST0R 1 MD2, C/B BACK MOUNTING BRACKET
5 G022145 4 WASHER FLAT 5/16-M8 ZINC
6 G022129 4 WASHER LOCK M8-5/16
7 G042907 4 SCREW HHC M8-1.25 X 16 C8.8
8 0J0679 1 DECAL, CANADIAN SAFETY CODE
9 0J0546 REF DECAL, HV CUSTOMER CONN INSIDE
10000011043 REF DECAL, HV CUSTOMER CONN INSIDE
10 0D3719C REF DECAL CUSTOMER CONN E1 E2 E3
0D3719D REF DECAL CUSTOMER CONN E1 E3
11 G049967 4 SCREW SHC M6-1.0 X 70 C12.9
12 G022473 4 WASHER FLAT 1/4-M6 ZINC
13 G022097 4 WASHER LOCK M6-1/4
14 G049813 4 NUT HEX M6-1.0 G8 CLEAR ZINC

REVISION: CN-0011118-H Page 5 of 6

DATE: 11/21/17
EXPLODED VIEW: EV, CB MOUNTING KIT MD1 390
DRAWING #: 0J1027 GROUP H
APPLICABLE TO:

ITEM PART# QTY. DESCRIPTION

UL CIRCUIT BREAKER (K -FRAME)
(1)1 0H9378FST0R 1 MD1,MODULE COVER 390 K-FRAME
2 0C2454 7 SCREW HWHT M6-1 X 16 N WA Z/JS
3 REF 1 CIRCUIT BREAKER
(1)4 0J00680ST0R 1 MD2, C/B BACK MOUNTING BRACKET
5 G022145 4 WASHER FLAT 5/16-M8 ZINC
6 G022129 4 WASHER LOCK M8-5/16
7 G042907 4 SCREW HHC M8-1.25 X 16 C8.8
8 0J0679 1 DECAL, CANADIAN SAFETY CODE
9 0J0546 REF DECAL, HV CUSTOMER CONN INSIDE
10000011043 REF DECAL, HV CUSTOMER CONN INSIDE
10 0D3719C REF DECAL CUSTOMER CONN E1 E2 E3
0D3719D REF DECAL CUSTOMER CONN E1 E3
11 G046580 4 SCREW SHC M6-1.0 X 45 C12.9
12 G022473 4 WASHER FLAT 1/4-M6 ZINC
13 G022097 4 WASHER LOCK M6-1/4
14 G049813 4 NUT HEX M6-1.0 G8 CLEAR ZINC
UL CIRCUIT BREAKER (L -FRAME)
(1)1 0H9378GST0R 1 MD1,MODULE COVER 390 L-FRAME
2 0C2454 7 SCREW HWHT M6-1 X 16 N WA Z/JS
3 REF 1 CIRCUIT BREAKER
(1)4 0J00680ST0R 1 MD2, C/B BACK MOUNTING BRACKET
5 G022145 4 WASHER FLAT 5/16-M8 ZINC
6 G022129 4 WASHER LOCK M8-5/16
7 G042907 4 SCREW HHC M8-1.25 X 16 C8.8
8 0J0679 1 DECAL, CANADIAN SAFETY CODE
9 0J0546 REF DECAL, HV CUSTOMER CONN INSIDE
10000011043 REF DECAL, HV CUSTOMER CONN INSIDE
10 0D3719C REF DECAL CUSTOMER CONN E1 E2 E3
0D3719D REF DECAL CUSTOMER CONN E1 E3
11 G046580 4 SCREW SHC M6-1.0 X 45 C12.9
12 G022473 4 WASHER FLAT 1/4-M6 ZINC
13 G022097 4 WASHER LOCK M6-1/4
14 G049813 4 NUT HEX M6-1.0 G8 CLEAR ZINC
UL CIRCUIT BREAKER (LG-FRAME)
(1)1 0H9378HST0R 1 MD1,MODULE COVER 390 LG-FRAME
2 0C2454 7 SCREW HWHT M6-1 X 16 N WA Z/JS
3 REF 1 CIRCUIT BREAKER
(1)4 0J00680ST0R 1 MD2, C/B BACK MOUNTING BRACKET
5 G022145 4 WASHER FLAT 5/16-M8 ZINC
6 G022129 4 WASHER LOCK M8-5/16
7 G042907 4 SCREW HHC M8-1.25 X 16 C8.8
8 0J0679 1 DECAL, CANADIAN SAFETY CODE
9 0J0546 REF DECAL, HV CUSTOMER CONN INSIDE
10000011043 REF DECAL, HV CUSTOMER CONN INSIDE
10 0D3719C REF DECAL CUSTOMER CONN E1 E2 E3
0D3719D REF DECAL CUSTOMER CONN E1 E3
11 0J4467 REF SCREW SHC M5-0.8 X 100 C12.9
12 G051713 4 WASHER FLAT M5
13 G049226 4 WASHER LOCK M5
14 G051716 4 NUT HEX M5-0.8 G8 CLEAR ZINC

NOTES (UNLESS OTHERWISE SPECIFIED):

(1) SHEET METAL PARTS LISTED IN THE BOM TABLE, PRIOR TO 1/1/16, ARE REPRESENTING GENERIC PARTS
(NO COLOR) :
• MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO SAP BOM.
• CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY)
IN THE SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
(2) QTY. REQUIRED FOR 1Ø BREAKER / QTY. REQUIRED FOR 3Ø BREAKER.

REVISION: CN-0011118-H Page 6 of 6

DATE: 11/21/17
1 047290 (1) 1 HOSE 3/8 ID SINGLE BRAID (24”LG)
047290 (2) 1 HOSE 3/8 ID SINGLE BRAID (42”LG)
2 0C7649 2 CLAMP HOSE .38-.87
3 036865 1 DRAINCOCK 41.8LG BRASS
4 065852 1 SPRING CLIP HOLDER .37-.62
5 086292 1 SCREW DRILLTITE #10-16 X 3/4

(1) USED IN RADIATOR DRAIN HOSE KIT P/N 0G9064

(2) USED IN RADIATOR DRAIN HOSE KIT P/N 0G9064A
GENERAC® POWER SYSTEMS, INC.
211 MURPHY DR. • P.O. BOX 310
EAGLE, WI 53119