13633160200

Model: 13633160200
Type: SG070
Engine: G6.8.1
Owner's Manual
Stationary Emergency Generator
C
LISTED
This manual should remain with the unit.
US
INTRODUCTION
Thank you for purchasing this model of the standby
generator set product line by Generac Power Systems,
Inc..
Every effort was expended to make sure that the
information and instructions in this manual were
both accurate and current at the time the manual was
written. However, the manufacturer reserves the right
to change, alter or otherwise improve this product(s)
at any time without prior notice.
READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, contact the nearest Authorized Service Dealer for starting, operating and servicing procedures.
Throughout this publication, and on tags and decals
affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service
or operation that may be hazardous if performed
incorrectly or carelessly. Observe them carefully.
Their definitions are as follows:
DANGER
The operator is responsible for proper and safe use

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

It is the operator's responsibility to perform all safety
checks, to make sure that all maintenance for safe
operation is performed promptly, and to have the
equipment checked periodically by an Authorized
Service Dealer. Normal maintenance service and
replacement of parts are the responsibility of the
owner/operator and, as such, are not considered
defects in materials or workmanship within the
terms of the warranty. Individual operating habits
and usage contribute to the need for maintenance
service.
Proper maintenance and care of the generator ensure
a minimum number of problems and keep operating
expenses at a minimum. See an Authorized Service
Dealer for service aids and accessories.
After this heading, read instructions that, if not

strictly complied with, will result in personal injury
or property damage.
Operating instructions presented in this manual

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

strictly complied with, may result in personal injury
or property damage.
HOW TO OBTAIN SERVICE

strictly complied with, could result in damage to
equipment and/or property.
NOTE:
After this heading, read explanatory statements
that require special emphasis.
When the generator requires servicing or repairs,

contact an Authorized Service Dealer for assistance.
Service technicians are factory-trained and are capable of handling all service needs.
When contacting an Authorized Service Dealer about
parts and service, always supply the complete model
number of the unit as given on the front cover of this
manual or on the DATA LABEL affixed to the unit.
These safety warnings cannot eliminate the hazards

that they indicate. Common sense and strict compliance with the special instructions while performing
the service are essential to preventing accidents.
Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type
of information each indicates is as follows:
symbol points out important safety infor This
mation that, if not followed, could endanger
personal safety and/or property of others.
symbol points out potential explosion
This
hazard.
This symbol points out potential fire hazard.

symbol points out potential electrical shock
This
hazard.
AUTHORIZED SERVICE
DEALER LOCATION
To locate the nearest AUTHORIZED SERVICE
DEALER, please call this number:
1-800-333-1322
DEALER LOCATION INFORMATION
CAN BE OBTAINED AT THIS NUMBER
or visit the website at
www.generac.com.
Table of Contents
Introduction ...........................Inside Front Cover
Section 2 Installation ......................................9
Read This Manual Thoroughly ...........................................................IFC
STATIONARY EMERGENCY GENERATOR INSTALLATION.......................9

NFPA Standards ...............................................................................9
Other Published Standards ...............................................................9
Operation and Maintenance ...............................................................IFC

How to Obtain Service ......................................................................IFC
Authorized Service Dealer Locator Number .............................................IFC
Safety Rules .......................................................2

Section 1 General Information .......................4
BASIC STATIONARY EMERGENCY GENERATOR

ELECTRIC SYSTEM ............................................................................10
EMERGENCY CIRCUIT ISOLATION METHOD .......................................10
TOTAL CIRCUIT ISOLATION METHOD .................................................10
GROUNDING THE STATIONARY EMERGENCY GENERATOR ................10
IDENTIFICATION RECORD ....................................................................4
STATIONARY EMERGENCY GENERATOR AC

NEUTRAL CONNECTIONS ..................................................................11
Data Label .......................................................................................4
TRANSFER SWITCH START SIGNAL CONNECTIONS ..........................11
XPL Label ........................................................................................4
BATTERY INSTALLATION....................................................................11
Vented Batteries .............................................................................11
EQUIPMENT DESCRIPTION ..................................................................5

Standard Generator Features ............................................................5
ENGINE PROTECTIVE DEVICES ............................................................5
Coolant Temperature Sender ............................................................5
Low Coolant Level Sensor................................................................5
Oil Pressure Sender .........................................................................5
Low Fuel Pressure Switch (Gas Units Only) ......................................5
Overspeed Shutdown .......................................................................5
Overcrank Shutdown ........................................................................5
RPM Sensor Loss Shutdown............................................................5
DC FUSES............................................................................................5
FUEL SYSTEM .....................................................................................5
Fuel Requirements ...........................................................................5
Diesel Fuel System...........................................................................6
LP Fuel System ................................................................................6
Natural Gas Fuel System ..................................................................6
Combination LP/Natural Gas Fuel System .........................................6
Propane Vapor Withdrawal Fuel System............................................6
SPECIFICATIONS ..................................................................................7
Stationary Emergency Generator ......................................................7
Engine .............................................................................................7
Engine Oil Recommendations ...........................................................7
Coolant ............................................................................................8
Fuel System Requirements and Recommendations ...........................8
ALTERNATOR AC LEAD CONNECTIONS................................................8
Four-lead, Single-phase Stator..........................................................8
STATIONARY EMERGENCY GENERATOR AND
LOAD COMPATIBILITY ..........................................................................8
STARTING AIDS ...................................................................................8
PREPARATION BEFORE START-UP .....................................................12

Prior to Initial Start-up ....................................................................12
Start-up Inspection ........................................................................13
Section 3 Operation ......................................13

STATIONARY EMERGENCY GENERATOR CONTROL
AND OPERATION................................................................................13
OPERATING UNIT WITH MANUAL TRANSFER SWITCH .......................13
Engine Start-up and Transfer ..........................................................13
Retransfer and Shutdown ...............................................................14
OPERATING UNIT WITH AUTOMATIC TRANSFER SWITCH ..................14
Section 4 Maintenance..................................14
SERVICE SCHEDULE ..........................................................................14
Authorized Operator Maintenance Functions ...................................14
Authorized Service Technician Maintenance Functions ....................14
PERIODIC MAINTENANCE ..................................................................15
Test Stationary Emergency Generator System
Operation and Components ............................................................15
Inspect Battery...............................................................................15
Battery Replacement ......................................................................15
Check Fluids ..................................................................................16
Inspect Exhaust System .................................................................16
Inspect/Test Fuel Supply System ....................................................16
REPAIR PARTS...................................................................................16
Stationary Emergency Generator XPL Label ....................................16
How to Order Parts ........................................................................16
Section 5 Warranty .................................................17
Engine Coolant Heaters ....................................................................8

Battery Chargers ..............................................................................9
SG 6.8 Liter 04.09
Important Safety Instructions

SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted in
potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians
for this equipment.
SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during installation
and maintenance of the generator and batteries.
WARNING:
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
WARNING:
This product contains or emits chemicals

known to the state of California to cause
cancer, birth defects or other reproductive harm.
Study these SAFETY RULES carefully before installing, operating

or servicing this equipment. Become familiar with this Owners
Manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and
maintained. Many accidents are caused by failing to follow simple
and fundamental rules or precautions.
The manufacturer cannot anticipate every possible circumstance
that might involve a hazard. The warnings in this manual, and on
tags and decals affixed to the unit are, therefore, not all-inclusive.
If using a procedure, work method or operating technique that the
manufacturer does not specifically recommend, ensure that it is
safe for others. Also make sure the procedure, work method or
operating technique utilized does not render the generator unsafe.
DANGER
the safe design of this generator, operat Despite
ing this equipment imprudently, neglecting its
maintenance or being careless can cause possible injury or death. Permit only responsible and
capable persons to install, operate or maintain
this equipment.
lethal voltages are generated by

Potentially
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
of the generator are rotating and/or hot

Parts
during operation. Exercise care near running
generators.
GENERAL HAZARDS
For safety reasons, the manufacturer recommends that this
equipment be installed, serviced and repaired by an Authorized
Service Dealer or other competent, qualified electrician or
installation technician who is familiar with applicable codes,
standards and regulations. The operator also must comply with
all such codes, standards and regulations.
Installation, operation, servicing and repair of this (and related)
equipment must always comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and
national electrical and building codes. Comply with regulations
the Occupational Safety and Health Administration (OSHA) has
established. Also, ensure that the generator is installed, operated and serviced in accordance with the manufacturers instructions and recommendations. Following installation, do nothing
that might render the unit unsafe or in noncompliance with the
aforementioned codes, standards, laws and regulations.
The engine exhaust fumes contain carbon monoxide gas,
which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even
death. For that reason, adequate ventilation must be provided.
Exhaust gases must be piped safely away from any building or
enclosure that houses the generator to an area where people,
animals, etc., will not be harmed. This exhaust system must be
installed properly, in strict compliance with applicable codes
and standards.
Keep hands, feet, clothing, etc., away from drive belts, fans,
and other moving or hot parts. Never remove any drive belt or
fan guard while the unit is operating.
Adequate, unobstructed flow of cooling and ventilating air is
critical in any room or building housing the generator to prevent
buildup of explosive gases and to ensure correct generator
operation. Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seriously affect
safe operation of the generator.
Keep the area around the generator clean and uncluttered.
Remove any materials that could become hazardous.
When working on this equipment, remain alert at all times.
Never work on the equipment when physically or mentally
fatigued.
Inspect the generator regularly, and promptly repair or replace
all worn, damaged or defective parts using only factoryapproved parts.
Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start-up. Disconnect
the cable from the battery post indicated by a NEGATIVE, NEG
or () first. Reconnect that cable last.
Important Safety Instructions

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

on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel
leakage, oil leakage, etc.
ELECTRICAL HAZARDS
All generators covered by this manual produce dangerous
electrical voltages and can cause fatal electrical shock. Utility
power delivers extremely high and dangerous voltages to the
transfer switch as well as the Stationary Emergency Generator.
Avoid contact with bare wires, terminals, connections, etc.,
on the generator as well as the transfer switch, if applicable.
Ensure all appropriate covers, guards and barriers are in place
before operating the generator. If work must be done around
an operating unit, stand on an insulated, dry surface to reduce
shock hazard.
Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
If people must stand on metal or concrete while installing,
operating, servicing, adjusting or repairing this equipment,
place insulative mats over a dry wooden platform. Work on the
equipment only while standing on such insulative mats.
The National Electrical Code (NEC), Article 250 requires the
frame and external electrically conductive parts of the generator
to be connected to an approved earth ground and/or grounding rods. This grounding will help prevent dangerous electrical
shock that might be caused by a ground fault condition in
the generator set or by static electricity. Never disconnect the
ground wire.
Wire gauge sizes of electrical wiring, cables and cord sets must
be adequate to handle the maximum electrical current (ampacity) to which they will be subjected.
Before installing or servicing this (and related) equipment, make
sure that all power voltage supplies are positively turned off at
their source. Failure to do so will result in hazardous and possibly fatal electrical shock.
Connecting this unit to an electrical system normally supplied
by an electric utility shall be by means of a transfer switch so as
to isolate the generator electric system from the electric utility
distribution system when the generator is operating. Failure to
isolate the two electric system power sources from each other
by such means will result in damage to the generator and may
also result in injury or death to utility power workers due to
backfeed of electrical energy.
Generators installed with an automatic transfer switch will
crank and start automatically when NORMAL (UTILITY) source
voltage is removed or is below an acceptable preset level. To
prevent such automatic start-up and possible injury to personnel, disable the generators automatic start circuit (battery
cables, etc.) before working on or around the unit. Then, place
a Do Not Operate tag on the generator control panel and on
the transfer switch.
In case of accident caused by electric shock, immediately

shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID
DIRECT CONTACT WITH THE VICTIM. Use a nonconducting
implement, such as a dry rope or board, to free the victim from
the live conductor. If the victim is unconscious, apply first aid
and get immediate medical help.
Never wear jewelry when working on this equipment. Jewelry
can conduct electricity resulting in electric shock, or may get
caught in moving components causing injury.
FIRE HAZARDS
Keep a fire extinguisher near the generator at all times. Do NOT
use any carbon tetra-chloride type extinguisher. Its fumes are
toxic, and the liquid can deteriorate wiring insulation. Keep the
extinguisher properly charged and be familiar with its use. If
there are any questions pertaining to fire extinguishers, consult
the local fire department.
EXPLOSION HAZARDS
Properly ventilate any room or building housing the generator to
prevent build-up of explosive gas.
Do not smoke around the generator. Wipe up any fuel or oil
spills immediately. Ensure that no combustible materials are left
in the generator compartment, or on or near the generator, as
FIRE or EXPLOSION may result. Keep the area surrounding the
generator clean and free from debris.
These generator sets may operate using one of several types
of fuels. All fuel types are potentially FLAMMABLE and/or
EXPLOSIVE and should be handled with care. Comply with all
laws regulating the storage and handling of fuels. Inspect the
units fuel system frequently and correct any leaks immediately.
Fuel supply lines must be properly installed, purged and leak
tested according to applicable fuel-gas codes before placing
this equipment into service.
Diesel fuels are highly FLAMMABLE. Gaseous fluids such
as natural gas and liquid propane (LP) gas are extremely
EXPLOSIVE. Natural gas is lighter than air, and LP gas is heavier
than air; install leak detectors accordingly.
Section 1 General Information

IDENTIFICATION RECORD
DATA LABEL
Every generator set has a DATA LABEL that contains important
information pertinent to the generator (Figure 1.1). The data label,
which can be found attached to the generators lower connection
box, lists the units serial number and its rated voltage, amps, wattage capacity, phase, frequency, rpm, power factor, etc.
Figure 1.1 Data Label
NOTE:
The above is a generic representation of a data label. For actual
information related to this particular model, please refer to the
construction document located at the end of this manual, or
to the data labels affixed to the unit.
XPL LABEL
A XPL LABEL is also affixed to the lower connection box of each
Stationary Emergency Generator set. Like the data label, this card
also contains valuable information pertaining to the generator.
When requesting information, ordering replacement parts, asking
for service, etc., the information from this card is needed (see
page 17 for example of generator set XPL Label). It provides the
following information:
Generator Model Number

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

This number is the key to numerous engineering and manufacturing details pertaining to the unit. Always supply this number when
requesting service, ordering parts or seeking information.
Identification Code
Use this code to obtain important information about the generator.
For example, if the code is ...
SD 100-- A 1 6 5.0 D 18 HB Y N C
Identify the generator as follows:
SD Standby diesel generator (SG indicates a standby gaseous fuel unit).
100 Rated output is 100,000 watts (100 kW).
A Voltage code (see Voltage Codes on this page).
1 Indicates single-phase unit (3 indicates three-phase
unit).
6 Indicates unit rated 60 Hertz (Hz) (5 indicates 50 Hz).
5.0 Engine is 5.0 liter (304 cubic inches).
D Unit has diesel fuel system (N indicates natural gas;
L indicates LP Liquid Withdrawal; V indicates LP Vapor
Withdrawal).
18 Alternator rpm rating (1,800 rpm); 36 indicates 3,600
rpm.
H Unit has an option H control panel (R, "E" and "G" panels are also available on some units).
B Indicates a brushless unit (D indicates a direct excited unit
with brushes and slip rings; P indicates a permanent magnet
excitation).
Y Unit is equipped with a standard enclosure (N indicates no
enclosure; S indicates unit has an acoustic enclosure).
N Unit does not have an exhaust muffler (Y indicates a muffler has been mounted; L indicates a muffler has been shipped
loose with the unit).
Y Unit has a main line circuit breaker (C indicates unit has
a UL-listed circuit breaker; N indicates no circuit breaker has
been mounted).
Groups and Assembly Numbers

The XPL label lists the groups and corresponding assembly
numbers for each unit. The assembly numbers refer to exploded
view drawing numbers that are applicable to the specific generator model. These drawings are located in the back half of this
manual.
Voltage Codes
The identification code letter following the units kilowatt rating is
the generators voltage code. Any one of the following voltage
codes may be listed.
A 120/240 volts, single-phase, four-lead, 60 Hz
D 120/240 volts, single- and three-phase, 12-lead, 60 Hz
G 120/208 volts, three-phase, 12-lead, 60 Hz Broad Range
J 120/240 volts, three-phase, 12-lead, 60 Hz Broad Range
K 277/480 volts, three-phase, 12-lead, 60 Hz Broad Range
L 346/600 volts, three-phase, six-lead, 60 Hz
M 110/220 volts, single-phase, four-lead, 50 Hz
N 115/200 volts, three-phase, 12-lead, 50 Hz Broad Range
P 100/200 volts, three-phase, 12-lead, 50 Hz Broad Range
R 231/400 volts, three-phase, 12-lead, 50 Hz Broad Range
S 277/480 volts, three-phase, six-lead, 50 Hz

EQUIPMENT DESCRIPTION
OIL PRESSURE SENDER
This equipment is a revolving field, alternating current generator

set. The generator was designed to supply electrical power for the
operation of compatible electrical loads-when the UTILITY power
supply is not available or has dropped to an unacceptable level.
This sender monitors oil pressure in the engine. If oil pressure

drops below a safe level, the control system automatically shuts
down the engine.
The generators revolving field is directly connected to and driven

by an engine by means of flexible discs. Generators with a fourpole rotor are driven at rated speeds of 1,800 rpm to supply a
frequency of 60 Hertz.
LOW FUEL PRESSURE SWITCH (GAS UNITS ONLY)
Refer to the data label on this specific generator or to the data label
affixed to the unit for rated AC voltage, wattage, amperage, number
of phases, etc. See Identification Code for an explanation of the
way to identify the units features.
STANDARD GENERATOR FEATURES

This generator incorporates the following generator features:
This normally closed (N.C.) switch is held open by fuel pressure

during operation. If fuel pressure drops below a safe level, the
switch contacts close, automatically shutting down the engine.
OVERSPEED SHUTDOWN
A speed circuit controls engine cranking, start-up, operation and
shutdown. Engine speed signals are delivered to the circuit board
whenever the unit is running. Should the engine overspeed above
a safe, preset value, the circuit board initiates an automatic engine
shutdown.
The rotor insulation system is Class H rated, and the stator

insulation is Class H rated as defined by NEMA MG1-22.4
and NEMA MG1-1.65.
The generator is self-ventilated and drip-proof constructed.
The voltage waveform deviation, total harmonic content of
the AC waveform and telephone influence factor have been
evaluated and are acceptable according to NEMA MG1-22.
All prototype tested models have passed three-phase symmetrical short circuit test to ensure system protection and
reliability.
OVERCRANK SHUTDOWN
ENGINE PROTECTIVE DEVICES
These fuses are located inside the front panel of the control system. They protect the panel wiring and components from damaging overload.
The Stationary Emergency Generator may be required to operate

for long periods of time without an operator on hand to monitor
such engine conditions as coolant temperature, oil pressure or
rpm.-For that reason, the engine has several devices designed to
protect it against potentially damaging conditions by automatically
shutting down the unit when the oil pressure is too low, the coolant
temperature is too high, the coolant level is too low, or the engine
is running too fast.
NOTE:
Engine protective switches and sensors are mentioned here for
the readers convenience. Also refer to the applicable control
panel manual for additional automatic engine shutdown information.
COOLANT TEMPERATURE SENDER

This sender automatically shuts down the engine if the engine
coolant temperature rises above a safe level.
LOW COOLANT LEVEL SENSOR

Should the engine coolant level drop below the level of the high
coolant temperature switch, it is possible for the engine to overheat
without automatic shutdown. To prevent such overheating, the
engine has a low coolant level sensor. If the level of engine coolant
drops below the level of the low coolant level sensor, the engine
automatically shuts down.
After a pre-specified duration of cranking, this function ends the

cranking if the engine has failed to start.
RPM SENSOR LOSS SHUTDOWN

If the speed signal to the control panel is lost, engine shutdown
will occur.
DC FUSES
FUEL SYSTEM
FUEL REQUIREMENTS
The Stationary Emergency Generator may be equipped with one of
the following fuel systems:
Diesel fuel system
Liquid propane (LP) fuel system
Propane vapor (PV) fuel system
Natural gas fuel system
Combination LP/natural gas fuel system
The data card that is affixed to the unit includes the Identification
Code, which may be used to identify the type of fuel system
installed on the unit.
NOTE:
It is the responsibility of the installer to make sure that only
the correct recommended fuel is supplied to the generator fuel
system. Thereafter, the owner/operator must make certain that
only the proper fuel is supplied.
For further information on the various types of fuel systems,
refer to Engine-Generator Standby Electric Power Systems
Installers Guide and Reference Manual (part #046622).
5

DIESEL FUEL SYSTEM
COMBINATION LP/NATURAL GAS FUEL SYSTEM
Diesel fuel is supplied to the generator set from a base-mounted

fuel tank.
In some areas, the cost of natural gas may be reduced considerably by procuring the gas on interrupted service rates. Such
rates may be obtained by using LP gas as an emergency fuel
when natural gas is not available. Automatic changeover is accomplished by using two regulators, (for example, a line pressure
regulator for natural gas, and a vacuum-operated regulator for LP
gas). The difference in pressure compensates for the greater Btu
value of LP gas.
Diesel fuels are less volatile than gaseous fuels, however, careless
installation can lead to safety hazards and/or serious problems
with engine/generator performance and reliability.
NOTE:
Appropriate care should be taken in applications where
extremely low ambient temperatures are possible to ensure the
temperature of the diesel fuel is not allowed to fall below levels
where gelling could occur.
LP FUEL SYSTEM
During operation on natural gas, a positive pressure exists in the

common line to the carburetor. This pressure closes the LP gas
regulator and stops the flow of LP gas. Loss of natural gas pressure causes a partial vacuum in the line, and the LP gas regulator
then opens to admit LP gas into the system. Adjusting a separate
power mixture in the LP gas line permits precise setting of air-tofuel ratios on each of the fuels. Changeover is automatic with the
engine operating.
LP is supplied as a liquid in pressure tanks. It is usually made up

of propane, butane, or a mixture of the two gases. Propane tends
to vaporize readily even at temperatures as low as -20 F (-29 C).
However, butane reverts to its liquid state when temperatures drop
below 32 F (0 C).
PROPANE VAPOR WITHDRAWAL FUEL SYSTEM
LP in a liquid withdrawal system must be converted to its gaseous

state before it is introduced into the engine carburetor. A vaporizerconverter is generally used to accomplish this. In such a converter,
heated engine coolant is ported through the converter to provide
the necessary heat for conversion of the fuel from a liquid to a
gaseous state.
This type of system utilizes the vapors formed above the liquid
fuel in the supply tank. Approximately 10 to 20 percent of the tank
capacity is needed for fuel expansion from the liquid to the vapor
state. The vapor withdrawal system is generally best suited for
smaller engines that require less fuel. The installer should be aware
of the following:
NOTE:
The natural gas and LP gas systems are similar. However, the
natural gas system delivers gas at a pressure of approximately
five inches water column to the carburetor. The LP gas system
delivers gas at a slightly negative pressure (about negative one
inch) to the engine carburetor.
When ambient temperatures are low and engine fuel consumption is high, the vapor withdrawal system may not function
efficiently.
Ambient temperatures around the supply tank must be high
enough to sustain adequate vaporization, or the system will not
deliver the needed fuel volume.
In addition to the cooling effects of ambient air, the vaporization
process itself provides an additional cooling effect.
On units with LP gas liquid withdrawal fuel systems, a block

heater is included as standard equipment. The heater is
powered by the UTILITY power source during non-operating
periods. Thus, heated coolant is always available to aid the fuel
vaporization process.
NATURAL GAS FUEL SYSTEM

Natural gas is supplied in its vapor state. In most cases, the gas
distribution company provides piping from the main gas distribution line to the standby generator site. The following information
applies to natural gas fuel systems.
Gas pressure in a building is usually regulated by national, state
and local codes.
To reduce gas pressure to a safe level before the gas enters a
building, a primary regulator is needed. The natural gas supplier
may or may not supply such a regulator.
It is the responsibility of the gas supplier to make sure sufficient
gas pressure is available to operate the primary regulator.
Gas pressure at the inlet to the fuel shutoff solenoid should
not exceed approximately 14 inches water column (0.6 psi).
Optimum pressure at the fuel shutoff solenoid is 11 inches
water column (0.4 psi).

SPECIFICATIONS
STATIONARY EMERGENCY GENERATOR
Refer to the data plate on the generator for rated watts, amperes,
frequency, voltage, phase and other pertinent information.
ENGINE
General:
Cylinders and Arrangement .....................................................V-10
Displacement ......................................................... 6.8 L (415 in3)
Bore................................................................. 90.2 mm (3.55 in.)
Stroke ............................................................ 105.8 mm (4.16 in.)
Compression Ratio............................................................... 9-to-1
Number of Main Bearings.............................................................6
Aspiration
SG070/075 ............................................ Naturally Aspirated (NA)
SG080/100/130...................... Naturally Aspirated Gearbox (G/B)
Governed Engine Speed ....................................... See DATA PLATE
Type of Valve Lifters ...............................................Hydraulic Roller
Cylinder Head ................................................................ Aluminum
Pistons ..................................................................Aluminum Alloy
Crankshaft .................................................................. Forged Steel
Number of Flywheel Teeth ........................................................164
Engine Lubrication System:

Type of Oil Pump ....................................................................Gear
Oil Filter ..............................................Spin-on, Full Flow, Cartridge
Crankcase Oil Capacity ......................................6.8 L (6 U.S. qts.)
Fuel System:
Type of Fuel .................................................. Natural Gas/LP Vapor
NOTE: Turbocharged units not for use with LP.
Coolant Flow Per Minute (60 Hz)

SG070/075 ............................................................. 40 U.S. gals.
SG100 .................................................................... 52 U.S. gals.
SG130 .................................................................... 70 U.S. gals.
SG150 .................................................................... 84 U.S. gals.
Heat Rejection to Coolant (50 Hz and 60 Hz)
SG070/075 ...........................................................255,000 Btu/h
SG100 ..................................................................340,000 Btu/h
SG130 ..................................................................496,000 Btu/h
SG150 ..................................................................568,000 Btu/h
Cooling Fan
SG070/075 .......................................................(6-Blade Pusher)
SG100 ................................................................ (7-Blade Puller)
SG130/SG150 .................................................... (7-Blade Puller)
Diameter of Fan
SG070 ........................................................ 558.8 mm (22.0 in.)
SG100 ........................................................... 580 mm (23.0 in.)
SG130 ........................................................... 580 mm (23.0 in.)
SG150 ........................................................... 660 mm (23.0 in.)
Cooling Airflow Required (50 Hz and 60 Hz)
SG070/075 .................................................................5,600 cfm
SG100 ........................................................................5,500 cfm
SG130 ........................................................................6,000 cfm
SG150 ........................................................................7,800 cfm
Recommended Coolant ............................................ See Coolant
Combustion Airflow Required (60 Hz)
SG070/075 .............................................. 213 cfm (6.0 m3/min.)
SG100 ..................................................... 295 cfm (8.3 m3/min.)
SG130 ................................................... 379 cfm (10.7 m3/min.)
SG150 ................................................... 410 cfm (11.6 m3/min.)
Exhaust System:
Type
Rated
Freq.
Fuel
System
25%
Load
50%
Load
75%
Load
100%
Load
SG070
50 Hz
NG
208
399
557
816
Exhaust Flow at Rated Output at 60 Hz

SG070/075 .................................................................679.5 cfm
SG100 ........................................................................938.7 cfm
SG130 ......................................................................1206.2 cfm
SG150 .........................................................................1500 cfm
Exhaust Outlet Size (2) ............................................. 2.5 in. (N.P.T.)
Exhaust Temperature at Rated Output ................. (677 C) 1,250 F
SG075
50 Hz
LP
83
159
222
325
Engine Electrical System:
SG100
50 Hz
NG/LP
297/118
560/223
800/318
1080/430
SG130
50 Hz
NG/LP
386/153
742/295
1034/411
1429/568
SG150
50 Hz
NG/LP
445/176
856/340
1193/474
1650/656
SG070
60 Hz
NG
260
499
696
1020
SG075
60 Hz
LP
103
199
277
406
SG100
60 Hz
NG/LP
371/148
700/278
1000/398
1350/537
SG130
60 Hz
NG/LP
482/192
927/369
1292/514
1786/710
SG150
60 Hz
NG/LP
556/221
1491/593
2061/820
406
Consumption:
Values in Cu. Ft/Hr.
NG = Natural Gas
Cooling System:
LP = Vapor Propane
Type................................................. Pressurized, Closed Recovery

Coolant Capacity
System .................................................... 23.7 L (6.3 U.S. gals.)
Engine ..................................................... 12.3 L (3.3 U.S. gals.)
DC Alternator Output ....................................... 15 amps at 12 volts

Starter Motor ...................................................... 12-volt DC, 3 kW
Recommended Battery .................................... 12-volt, 90 Ah, 27 F
Ground Polarity ........................................................... Negative ()
ENGINE OIL RECOMMENDATIONS

The unit has been filled with 15W-40 engine oil at the factory. Use
a high-quality detergent oil classified For Service CC, SD, SE or
SF. Detergent oils keep the engine cleaner and reduce carbon
deposits. Use oil having the following SAE viscosity rating, based
on the ambient temperature range anticipated before the next oil
change:
Temperature
Oil Grade (Recommended)
Above 80 F (27 C)
SAE 30W or 15W-40
32 to 80 F (-1 to 27 C)
SAE 20W-20 or 15W-40
Below 32 F (0 C)
SAE 10W or 15W-40

7

COOLANT
Figure 1.2 Four-lead, Single-phase Stator
Use a mixture of half Propylene glycol base antifreeze and half

de-ionized water. Use only de-ionized water and Propylene glycol
antifreeze. When adding coolant, always add the recommended
50-50 mixture.
DANGER
not remove the radiator pressure cap while
Do
the engine is hot or serious burns from boiling
liquid or steam could result.
glycol base antifreeze is poisonous.

Propylene
Do not use mouth to siphon coolant from the
radiator, recovery bottle or any container. Wash

hands thoroughly after handling. Never store
used antifreeze in an open container because
animals are attracted to the smell and taste of
antifreeze even though it is poisonous to them.
not use any chromate base rust inhibitor

Do
with propylene glycol base antifreeze. Using any
high silicate antifreeze boosters or additives
also will cause overheating. We also recommend that any soluble oil inhibitor is NOT USED
for this equipment.
FUEL SYSTEM REQUIREMENTS

AND RECOMMENDATIONS
Diesel Fuel System: See Chapter 8 of Engine-Generator Standby
Electric Power Systems Installers Guide and Reference Manual
(part no. 046622).
Gaseous Fuel System: See Chapter 9 of Engine-Generator
Standby Electric Power Systems Installers Guide and Reference
Manual (part no. 046622).
ALTERNATOR AC LEAD
CONNECTIONS
The electrical wires in the units AC connection (lower) panel

should be installed according to the number of leads and the
voltage/phase required for the application. If there is any question
regarding lead connection, refer to the wiring diagrams at the back
of this manual.
FOUR-LEAD, SINGLE-PHASE STATOR

Four-lead generators are dual voltage coils or windings (Figure
1.2). Units may be assigned the following voltage code:
A units are rated 120/240 VAC, single-phase, 60 Hertz.
Each stator winding in this case delivers a 120 VAC output, and
connecting the two windings series results in a 240 VAC output.
The neutral line is formed by a junction of stator leads 22 and
33. Therefore, connection of 120 VAC (60 Hertz) or 110 VAC (50
Hertz) loads across leads 11 and neutral, or across leads 44 and
neutral can be made.
8
STATIONARY EMERGENCY
GENERATOR AND LOAD
COMPATIBILITY
The generator must be fully compatible with the rated voltage,

phase and frequency of the connected electrical loads. The generator, connected electrical devices, or both, can be damaged if
voltage, phase and frequency are not compatible.
NOTE:
This manual assumes that the Stationary Emergency Generator
has been properly selected, installed and interconnected by a
competent, qualified electrician or installation contractor. Once
the installation is complete, do nothing that may result in noncompatibility between the generator and connected electrical
loads.
STARTING AIDS
This Stationary Emergency Generator is equipped with the following starting aids that serve to provide quicker, easier starts under
varying climactic conditions.
This generator has been mounted with an engine coolant heater
and a battery charger. These aids are powered by a NORMAL
(UTILITY) power source during non-operating periods.
ENGINE COOLANT HEATERS

This unit is equipped with an engine coolant (block) heater (Figure
1.3), it is powered by a circuit normally fed by the utility power
supply. The heater acts to heat the engine coolant when the unit
is not operating. This action keeps the engine warm even in cold
weather, thus helping ensure quicker starts. Heated coolant in the
engine rises continuously drawing cold coolant into the heater,
thus making certain of a constant flow of warm coolant through
the engine.
Section 2 Installation
Figure 1.3 Typical Engine Coolant Heater

OUTPUT
the system has been installed, do nothing

After
that might render the installation in noncompliance with such codes, standards and regulations.
NOTE:
For more information about the installation of a standby system, order Engine-Generator Standby Electric Power Systems
Installers Guide and Reference Manual (part #046622) from
an Authorized Service Dealer.
NFPA STANDARDS
BATTERY CHARGERS
All generators may be ordered with either a 2A or 10A battery
charger installed in the control panel.
GENERATOR INSTALLATION
DANGER
this generator to an electrical sys Connecting
tem normally supplied by an electric utility shall
be by means of a transfer switch (such as the
GTS type transfer switch), so as to isolate the
electric system from the utility distribution system when the generator is operating. Failure to
isolate the electric system by these means will
result in damage to the generator and may also
result in injury or death to utility workers due to
backfeed of electrical energy.
open bottom is used, the engine-generator

Ifis an
to be installed over non-combustible materi-
als and should be located such that combustible

materials are not capable of accumulating under
the generator set.
Only qualified, competent installation contractors or electricians
thoroughly familiar with applicable codes, standards and regulations should install this stationary emergency electric power system. The installation must comply strictly with all codes, standards
and regulations pertaining to the installation.
The following published standards booklets pertaining to stationary emergency electric systems are available form the National
Fire Protection Association (NFPA), Batterymarch Park, Quincy,
MA 02269:
NFPA No. 37, STATIONARY COMBUSTION ENGINES AND GAS
TURBINES.
NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS FOR
HEALTH CARE FACILITIES.
NFPA No. 220, STANDARD TYPES OF BUILDING
CONSTRUCTION
NFPA No. 68, GUIDE FOR EXPLOSION VENTING
NFPA No. 70, NATIONAL ELECTRICAL CODE.
NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS
CODE.
NFPA No. 10, INSTALLATION, MAINTENANCE AND USE OF
PORTABLE FIRE EXTINGUISHERS.
OTHER PUBLISHED STANDARDS

In addition to NFPA standards, the following information pertaining to the installation and use of Stationary Emergency Generator
electric systems is available:
Article X, NATIONAL BUILDING CODE, available from the
American Insurance Association, 85 John Street, New York,
N.Y. 10038.
AGRICULTURAL WIRING HANDBOOK, obtainable from the Food
and Energy Council, 909 University Avenue, Columbia, MO,
65201.
ASAE EP-364.2, INSTALLATION AND MAINTENANCE OF FARM
STANDBY ELECTRIC POWER, available from the American
Society of Agricultural Engineers, 2950 Niles Road, St. Joseph,
MI 49085.
A52.1, AMERICAN NATIONAL STANDARD FOR CHIMNEYS,
FIREPLACES AND VENTING SYSTEMS, available from the
American National Standard Institute, 1430 Broadway, New
York, N.Y. 10018.
This genset must be installed on a level surface. The base frame

must be level within two (2) inches all around.
BASIC STATIONARY EMERGENCY

GENERATOR ELECTRIC SYSTEM
Figure 2.1 shows a schematic diagram of a basic Stationary

Emergency Generator electric system. Both the UTILITY power
supply and the GENERATOR output are connected to an approved
transfer switch. The transfer switch is required by electrical code
and serves the following functions:
Permits the LOAD circuits to be connected to only one power
supply at a time.
Prevents electrical backfeed between the generator and the
UTILITY power circuits.
Notice that both the STATIONARY EMERGENCY GENERATOR and
the UTILITY power supplies to the transfer switch are protected
against overload by a main line circuit breaker.
NOTE:
The manufacturer recommends the use of a GTS type transfer
switch in conjunction with this generator.
Figure 2.1 Basic Stationary Emergency Generator

Electric System
TOTAL CIRCUIT ISOLATION METHOD
When a generator capable of powering all electrical loads in the

circuit is to be installed, use the Total Circuit Isolation Method. It
is possible for the generator to be overloaded when this isolation
method is employed. The following apply to the transfer switch in
this type of system.
Ampere rating of the transfer switch must equal the ampere
rating of the normal incoming utility service.
The transfer switch is installed between the utility service
entrance and the building distribution panel.
GROUNDING THE STATIONARY

EMERGENCY GENERATOR
The National Electrical Code requires the frame and external electrically conductive parts of this equipment to be properly connected
to an approved earth ground and/or grounding rods. For that
purpose, a GROUND LUG (Figure 2.2) is provided on the generator mounting base. Consult a qualified electrician for grounding
requirements in the area. Grounding procedures must meet local
regulations.
DANGER
not connect the ground wire to any pipe that
Do
carries a flammable or explosive substance
FIRE or an EXPLOSION may result.

Proper grounding helps protect personnel against electrical shock
in the event of a ground fault condition in the generator or in connected electrical devices. In addition, grounding helps dissipate
static electricity that often builds up in ungrounded devices.
Figure 2.2 Stationary Emergency Generator Grounding

Lug (typical)
EMERGENCY CIRCUIT ISOLATION

METHOD
This prevents overloading the generator by keeping electrical

loads below the wattage/amperage capacity of the generator. If
the generator is powering only critical loads, within the wattage/
amperage capacity, during utility power outages, consider using
the emergency circuit isolation method.
Critical electrical loads are grouped together and wired into a separate Emergency Distribution Panel. Load circuits powered by that
panel are within the wattage/amperage capacity of the generator
set. When this method is used, it is difficult to overload the generator. The transfer switch must meet the following requirements:
It must have an ampere rating equal to the total amperage rating
of the emergency distribution panel circuit.
Have it installed between the buildings main distribution panel
and the emergency distribution panel.
10
GENERATOR AC NEUTRAL
CONNECTIONS
The manufacturer uses an UNGROUNDED AC neutral. Grounding

is recommended only at the main service entrance. If the neutral
wire is grounded and one of the phase loads becomes grounded,
the excessive current opens the load circuit breaker or collapses
the generator field. The actual result depends on the electrical
characteristics of the particular installed generator.
TRANSFER SWITCH START SIGNAL

CONNECTIONS
If the generator is to be installed with a standard automatic transfer

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

injury. Any area that houses a storage battery
must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing
tools or equipment near the battery.
electrolyte fluid is an extremely caus Battery
tic sulfuric acid solution that can cause severe
burns. Do not permit fluid to contact eyes, skin,

clothing, painted surfaces, etc. Wear protective
goggles, protective clothing and gloves when
handling a battery. If fluid is spilled, flush the
affected area immediately with clear water.
not dispose of the battery in a fire. The

Do
battery is capable of exploding.
not open or mutilate the battery. Released
Do
electrolyte can be toxic and harmful to the skin
and eyes.
battery represents a risk of high short

The
circuit current. When working on the battery,
always remove watches, rings or other metal

objects, and only use tools that have insulated
handles.
VENTED BATTERIES
electrolyte is a dilute sulfuric acid that is
The
harmful to the skin and eyes. It is electrically
BATTERY INSTALLATION
DANGER
Emergency Generators installed with

Stationary
automatic transfer switches will crank and start
automatically when NORMAL (UTILITY) source

voltage is removed or is below an acceptable
preset level. To prevent such automatic start-up
and possible injury to personnel, do not connect
battery cables until certain that normal source
voltage at the transfer switch is correct and the
system is ready to be placed into operation.
batteries give off explosive hydrogen

Storage
gas. This gas can form an explosive mixture
around the battery for several hours after charging. The slightest spark can ignite the gas and
cause an explosion. Such an explosion can
conductive and corrosive. The following procedures are to be observed:

Wear full eye protection and protective clothing,
Where electrolyte contacts the skin, wash it off
immediately with water,
Where electrolyte contacts the eyes, flush thoroughly and immediately with water and seek medical attention, and
Spilled electrolyte is to be washed down with an
acid-neutralizing agent. A common practice is to
use a solution of one pound (500 grams) bicarbonate of soda to one gallon (4 liters) of water. The
bicarbonate of soda solution is to be added until
the evidence of reaction (foaming) has ceased.
The resulting liquid is to be flushed with water and
the area dried.
Lead acid batteries present a risk of fire
because they generate hydrogen gas. The following procedure are to be followed:
DO NOT SMOKE when near batteries,
DO NOT cause flame or spark in battery area, and
Discharge static electricity from body before touching batteries by first touching a grounded metal
surface.
11
Servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep
unauthorized personnel away from batteries.
For recommended batteries, see Specifications. All batteries
must be at 100 percent state-of-charge before they are installed
on the generator.
When using maintenance-free batteries, it is not necessary
to check the specific gravity or electrolyte level. Have these
procedures performed at the intervals specified in Section 4,
Maintenance. A negative ground system is used. Battery connections are shown on the wiring diagrams. Make sure all batteries
are correctly connected and terminals are tight. Observe battery
polarity when connecting batteries to the generator set.
NOTE:
Damage will result if the battery connections are made in
reverse.
PREPARATION BEFORE START-UP
The instructions in this section assume that the Stationary

Emergency Generator has been properly installed, serviced, tested,
adjusted and otherwise prepared for use by a competent, qualified
installation contractor. Be sure to read the Safety Rules on Pages
2 and 3, as well as all other safety information in this manual,
before attempting to operate this (and related) equipment.
PRIOR TO INITIAL START-UP
Fuel System
Make sure the fuel supply system to the generator (a) delivers the
correct fuel at the correct pressure and (b) is properly purged and
leak tested according to code. No fuel leakage is permitted. See
Specifications for more information.
If the unit has been idle for a long period of time, or if the fuel lines
or system components have been removed and reinstalled, the fuel
system may require bleeding to remove air from the system. Air in
the fuel system causes hard starting and rough operation. All fuel
system lines must be installed and must be tight. A loose line may
show no sign of leakage, but may draw air into the system.
a suitable container to catch the fuel that

Use
will spill during system bleeding process. Clean
up all spilled fuel after bleeding.
Stationary Emergency Generator Set Lubrication

Check the engine crankcase oil level before operating and add
oil to the proper level the dipstick FULL mark. Never operate
the engine with the oil level below the dipstick ADD mark. See
Specifications and Engine Oil Recommendations.
NOTE:
This engine is shipped from the manufacturer with 15W-40 oil.
This oil should be changed after 30 hours of operation.
The engine is equipped with a mechanical governor. Make sure the
governor is properly lubricated with clean engine oil.
to initially starting the generator, it must

Prior
be properly prepared for use. Any attempt to
crank or start the engine before it has been

properly serviced with the recommended types
and quantities of engine fluids (oil, coolant, fuel,
etc.) may result in an engine failure.
Before starting the generator for the first time, the installer must
complete the following procedures. For follow-up maintenance
information and/or service intervals, please refer to Section 4,
Maintenance, and the Service Schedule.
Transfer Switch
If this generator is used to supply power to any electrical system
normally powered by an electric utility, the National Electrical Code
requires that a transfer switch be installed. The transfer switch prevents electrical backfeed between two different electrical systems.
(For additional information, see the applicable transfer switch
manual for this unit.) The transfer switch, as well as the generator
and other electrical components, must be properly located and
mounted in strict compliance with applicable codes, standards
and regulations.
12
Engine Coolant
Have the engine cooling system properly filled with the recommended coolant mixture. Check the system for leaks and other
problems. See Specifications and Coolant.
Belt Tension
Check-the engine-fan belt tension and condition prior to placing
the unit into service and at recommended intervals. Belt tension is
correct when a force of approximately 22 pounds (10 kg), applied
midway between pulleys, deflects the belt about 3/8- to 5/8-inch
(10 to 16 mm).
Electrical System
Make sure the generator is properly connected to an approved
earth ground.
Make sure the generator battery is fully charged, properly installed
and interconnected, and ready for use.
Check to ensure that there are no loose electrical connections.
Restrain any loose wires to keep them clear of any moving generator set components.
Section 3 Operation
Rodent Protection
ENGINE START-UP AND TRANSFER
Make sure the four, 3-inch diameter cap plugs (part no. 0A8785)
are properly installed in the tie-down holes in the side rails of the
units base frame (Figure 2.3). The cap plugs are shipped in a
plastic bag located in the lower connection box. These plugs are
needed to prevent rodents from accessing the interior of the generator set. On acoustic units, cap plugs also are needed to stay
within noise specification limits.
For additional information, refer to the applicable control panel

manual for this unit, as well as any literature pertaining to the
transfer switch.
DANGER
Maintenance Disconnect Switch and the
The
AUTO/OFF/MANUAL switches (if so equipped)
must be set properly, or the generator will crank

and start as soon as the UTILITY power to the
transfer switch is turned off. Refer to applicable
control panel and transfer switch manuals for
more information.
Figure 2.3 Base Frame Cap Plugs
not proceed until certain that utility source

Do
voltage is available to the transfer switch and
the transfer switch main contacts are set to
UTILITY.
not attempt manual operation until all power

Do
supplies to the transfer switch have been posi-
tively turned off, or extremely dangerous possibly lethal electrical shock will result.
switch enclosure doors should be kept

Transfer
closed and locked. Only authorized personnel
START-UP INSPECTION
A standard three-part form titled Start-up Inspection for Standby
Power Systems (part no. 067377) should be completed by the
installation technician or engineer. As stated on the form, inspections are to be accomplished only by factory-trained personnel.
The installer should complete the form and disseminate copies
as follows:
White copy: Mail to Generac Warranty Department, P.O. Box 8,
Waukesha, WI 53187.
Pink Copy: For service file of installing dealer.
Yellow Copy: For the customers records.
GENERATOR CONTROL AND
OPERATION
should be allowed access to the transfer switch

interior. Extremely high and dangerous voltages
are present in the transfer switch.
In order to transfer load from the utility source to the generator,
follow these directions:
Turn OFF or disconnect the utility power circuit to the transfer
switch, using the means provided (such as the utility source
main line circuit breaker).
Set the transfer handle to its UTILITY (NORMAL) position with
load circuits connected to the utility power supply.
Set the Stationary Emergency Generator's main line circuit
breaker to its OFF (or OPEN) position.
Start the generator.
not crank the engine continuously for longer

Do
than 30 seconds, or the heat may damage the
Refer to the appropriate control panel operators manual for this

unit.
OPERATING UNIT WITH MANUAL

TRANSFER SWITCH
If the generator was installed in conjunction with a transfer switch

capable of manual operation only, the following procedure applies.
A manually operated transfer switch is one that will not provide
automatic start-up and does not include an intelligence circuit.
starter motor.
Let engine stabilize and warm up.
Check all applicable instrument and gauge readings. When
certain that all readings are correct, move the transfer switch
manual handle to its STANDBY position, i.e., load circuits supplied by the generator.
Set the Stationary Emergency Generator's main line circuit
breaker to its ON (or CLOSED) position.
Load circuits are now powered by the standby generator.
13
Section 4 Maintenance
RE-TRANSFER AND SHUTDOWN

For additional information, refer to the applicable control panel
manual for this unit, as well as any literature pertaining to the
transfer switch.
To transfer the load back to the utility power source and shut down
the generator, follow these directions:
Set the Stationary Emergency Generators main line circuit
breaker to its OFF (or OPEN) position.
Manually move the transfer switch handle to its UTILITY (NORMAL) position, i.e., load circuits connected to the utility.
Turn ON the utility power supply to the transfer switch, using
the means provided (such as the utility power source main line
circuit breaker).
Let the generator run at no-load for a few minutes to stabilize
internal temperatures.
Shut down the generator.
OPERATING UNIT WITH AUTOMATIC

TRANSFER SWITCH
If the generator has been installed along with an automatic transfer

switch, such as a GTS-type switch, the engine may be started and
stopped automatically or manually.
NOTE:
Refer to the applicable manual for the transfer switch and to
Transfer Switch Start Signal Connections. In addition, please
note the dangers under Engine Start-up and Transfer.
SERVICE SCHEDULE
AUTHORIZED OPERATOR MAINTENANCE FUNCTIONS
Every Month or 100 Hours (whichever comes first)
Test Stationary Emergency Generator system.

Inspect battery (batteries) and cables.
Check engine oil level.
Check gearbox oil level (if so equipped).
Check engine coolant level.
Check generator ground connections.
Test/inspect starting aids.
Every Three Months or Every 120 Hours

(whichever comes first)
Inspect and test fuel system and connections.

Inspect exhaust system.
Inspect/test fuel supply system.
AUTHORIZED SERVICE TECHNICIAN MAINTENANCE

FUNCTIONS
After First 30 Hours of Operation
Inspect wiring.
Change engine crankcase oil and oil filter.
Inspect engine fan belts.
Inspect battery (batteries) and cables.
Every Six Months or Every 200 Hours

(whichever comes first)
Change engine oil and filter.

Lubricate engine controls.
Service engine air cleaner.
Service engine fuel filter.
Inspect AC generator.
Test engine safety controls.
Inspect fan belts.
Check engine coolant level.
Inspect engine cooling system hoses.
Check optional starting aids.
Check battery (batteries).
Check engine compression.
Check electrical connections.
Check/test annunciator panel.
Perform operational test.
Annually or Every 600 Hours (whichever comes first)
Check engine valve clearance.

Test fuel injection nozzles.
Test injection timing.
Inspect all wiring.
Test engine starter operation.
Drain water from fuel tank.
Retorque fan bolts.
Drain and refill gearbox (If so equipped, contact sales for availability.)
Every Two Years
Replace all rubber hoses.

Replace engine fan belts.
Inspect the Stationary Emergency Generator System.
Drain, flush, refill cooling system.
Every 1,000 Operating Hours
Inspect engine DC alternator.

Inspect engine starter.
Retorque engine mounting brackets.
Remove/test fuel injection pump.
Remove/test cooling system thermostat.
As Required
Bleed engine fuel system.
14
PERIODIC MAINTENANCE
A rigorous program of scheduled periodic maintenance should

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

OPERATION AND COMPONENTS
An authorized operator should test the operation of the Stationary
Emergency Generator system and inspect its components monthly
(or 100 hours). This should include inspecting the transfer switch
for evidence of arcing, and pitted or burned contacts; inspecting wiring and grounding connections (see Grounding the
Generator); and ensuring that starting devices are operational.
During this operational test, all instrument and gauge readings
should be recorded in a Maintenance Log. The transfer system
also should be tested at this time; the engine should be run at least
30 minutes and any discrepancies corrected immediately.
Every six months (or 200 hours), an Authorized Service Technician
should perform a system operational test.
INSPECT BATTERY
DANGER
Emergency Generators installed with
Stationary
automatic transfer switches will crank and start
automatically when NORMAL (UTILITY) source

voltage is removed or is below an acceptable
preset level. To prevent such automatic start-up
and possible injury to personnel, do not connect
battery cables until certain that normal source
voltage at the transfer switch is correct and the
system is ready to be placed into operation.
batteries give off explosive hydrogen

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

tic sulfuric acid solution that can cause severe
burns. Do not permit fluid to contact eyes, skin,

clothing, painted surfaces, etc. Wear protective
goggles, protective clothing and gloves when
handling a battery. If fluid is spilled, flush the
affected area immediately with clear water.
not dispose of the battery in a fire. The

Do
battery is capable of exploding.
not open or mutilate the battery. Released
Do
electrolyte can be toxic and harmful to the skin
and eyes.
battery represents a risk of high short circuit

The
current. When working on the battery, always
remove watches, rings or other metal objects,

and only use tools that have insulated handles.
An authorized operator should inspect the engine battery system
monthly (or 100 hours). At this time, the battery fluid level should
be checked and distilled water added if needed. Battery cables
and connections also should be inspected for cleanliness and
corrosion.
Once every six months (or 200 hours), an Authorized Service
Technician should inspect the battery system. At this time the
battery condition and state of charge should be checked using a
battery hydrometer. The battery should be recharge or replaced as
required.
BATTERY REPLACEMENT
When replacing batteries, use the same number and the following
type batteries.
Part No.
BCI Group No.
CCA
058665
27F
700 @ 0 deg. F
NOTE:
The BCI number should be located directly on the battery. For
more information, see Specifications.
15
CHECK FLUIDS
Figure 4.1 XPL Label
An authorized operator should check the levels of engine oil, and

engine coolant monthly (or 100 hours). The oil level should be
maintained between the FULL and ADD marks on the engine
dipstick. Recommended fluids are listed are in the "Specifications"
section.
INSPECT EXHAUST SYSTEM

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

Every three months (or 120 hours), an authorized operator should
inspect and test the fuel supply system, as well as all fuel system
connections. All connections must be tight and in good condition.
A loose fuel system line may show no signs of leakage, but may
draw air into the system causing rough operation and starting difficulties. Any defective or leaking component should be repaired or
replaced immediately by an Authorized Service Technician.
REPAIR PARTS
The latter portion of this manual consist of exploded views,

parts lists and electrical data pertaining to this generator set. The
parts lists consist of (a) an item number, (b) a part number, (c)
the quantity required, and (d) a description of the part. The item
number corresponds to an identical number on the exploded view
drawing.
STATIONARY EMERGENCY GENERATOR XPL LABEL

Every generator set has a XPL LABEL affixed to the lower connection box (Figure 4.1). Additionally, a printed CONSTRUCTION
DOCUMENT containing identical information can be found at the
end of this manual.
When requesting information, ordering replacement parts, asking
for service, etc., one or more of the following may be needed:
Generator Model Number

Date of Manufacture
Generator Identification Code
Generator Assembly Groups
NOTE:
The above is a generic representation of a data card. For actual

information related to this particular model, please refer to the
construction document located at the end of this manual, or
to the data cards affixed to the unit.
16
HOW TO ORDER PARTS

To order a replacement part, locate the part in the applicable
exploded view. Contact an Authorized Service Dealer (call 800333-1322 to locate one in the area) and provide the following
information:
The generator model number.
The generator identification code, which indicates the specific
generator assembly for each unit.
The part number and corresponding description from the applicable parts list in this manual.
The applicable exploded view Group letter (A-H) and drawing number (five-digit number), which can be found on the
exploded view drawing.
NOTE:
In most cases, repair parts can be obtained by providing the
Authorized Service Dealer with the data label information and
a description of the required part. If unable to locate either
the data label or the construction document, describe the part
needed and provide the units model number. This number can
be found on the DATA LABEL attached to the generators lower
connection box.
Section 5 Warranty
United States Environmental Protection Agency Warranty Statement

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 year from the date of the engine
being placed into service.
Purchasers/Owners Warranty Responsibilities

As the engine purchaser/owner you are responsible for the following. 1.) The engine must be installed and configured in
accordance to the Generacs installation specifications. 2.) The completion of all maintenance requirements listed in your
Owners Manual. 3.) Any engine setting adjustment must be done in accordance and consistent with the instructions in the
Owners 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, 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/scheduled maintenance can be arranged by contacting your selling dealer or a Generac Authorized
Warranty Service dealer, 888-GENERAC (888-436-3722) or www.generac.com 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. P.O. Box 8,
Waukesha, WI 53187, Phone 888-GENERAC (888-436-3722) or www.generac.com
Emission Related Parts Include the Following (if so equipped)

1) Fuel Metering System
1.1) Gasoline Carburetor assembly and internal components
a) Fuel filter, b) Carburetor, c) Fuel Pump
1.2) Carburetion assembly and its components
a) Fuel controller, b) Carburetor and its gaskets,
c) Mixer and it gaskets, d) Primary gas regulator
e) Liquid vaporizer
1.3) Fuel Regulator
2) Air Induction System including
a) Intake pipe/manifold, b) Air cleaner
3) Ignition System including

a) Spark plug, b) Ignition module,
c) ignition coil, d) Spark plug wirers
4) Exhaust system
a) Catalyst assembly, b) Exhaust manifold,
c) Muffler, d) Exhaust pipe, e) Muffler gasket
5) Crankcase Breather Assembly including
a) Breather connection tube, b) PCV valve
6) Oxygen Sensor
7) Diagnostic Emission-Control System
17
Section 5 Warranty
United States Environmental Protection Agency Compliance Requirements

Purchasers/Owners Recordkeeping Responsibilities
The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac), are pleased to
explain your recordkeeping 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 Owners Manual you are required to meet the following notification and recordkeeping requirements to demonstrate compliance. 1.) Maintain documentation that the engine
is certified to meet emission standards. 2.) Recordkeeping of maintenance conducted. 3.) Recordkeeping 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.) Recordkeeping 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, recordkeeping of hours of operation begins January 1, 2011. For emergency engines less than 130 HP, recordkeeping of hours of operation begins January 1, 2009; Engines are equipped with
non-resettable hour meters to facilitate recordkeeping.
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 nonemergency 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 with the specifications and guidelines in the Owners 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 in accordance with the requirements
cited in the United States Environmental Protection Agency Warranty Statement or can be arranged by contacting your selling
dealer or a Generac Authorized Warranty Service dealer, 888-GENERAC (888-436-3722) or www.generac.com for the dealer
nearest you. Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates
federal law 40 CFR 1068.105 (b), subject to fines or penalties as described in the Clean Air Act.
18
Section 5 Warranty
GENERAC POWER SYSTEMS STANDARD TWO-YEAR LIMITED WARRANTY

FOR STATIONARY EMERGENCY POWER SYSTEMS
NOTE: ALL UNITS MUST HAVE A START-UP INSPECTION PERFORMED BY AN AUTHORIZED GENERAC DEALER.
For a period of two (2) years or two thousand (2,000) hours of operation from the date of start-up, which ever occurs first, Generac Power Systems,
Inc. will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or an Authorized/
Certified Generac Power Systems Dealer, or branch thereof, is found to be defective under normal use and service, in accordance with the warranty
schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Authorized/Certified
Generac Power Systems Dealer, or branch thereof. This warranty applies only to Generac Power Systems Generators used in "Stationary Emergency"
applications, as Generac Power Systems, Inc. has defined Stationary Emergency, provided said generator has been initially installed and/or inspected on-site by an Authorized/Certified Generac Power Systems Dealer, or branch thereof. Scheduled maintenance, as outlined by the generator
owner's manual, must be performed by an Authorized/Certified Generac Power Systems Dealer, or branch thereof. This will verify service has been
performed on the unit throughout the warranty period. This warranty is limited to and available only on Liquid-cooled units.
WARRANTY SCHEDULE
YEAR ONE One hundred percent (100%) coverage on mileage, labor, and parts listed.
ALL COMPONENTS ENGINE, ALTERNATOR, AND TRANSFER SWITCH
YEAR TWO One hundred percent (100%) coverage on parts listed.
ALL COMPONENTS ENGINE, ALTERNATOR, AND TRANSFER SWITCH PARTS ONLY
Gearbox Equipped Units - Limited Gearbox Coverage
YEARS ONE THROUGH FIVE Parts and labor coverage on gearbox and components.
YEARS SIX THROUGH TEN Parts only coverage on gearbox and components.
Guidelines:
Warranty only applies to permanently wired and mounted units.

Any and all warranty repairs and/or concerns, must be performed and/or addressed by an Authorized/Certified Generac Power Systems Dealer, or
branch thereof.
A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the generator set. If a Non-Generac Power
Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the generator set, no warranty coverage shall apply.
All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty, Policies, Procedures and Flat Rate
Manual.
Units that have been resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable except with change
of ownership of original structure.
Unit enclosure is only covered during the first year of the warranty provision.
Use of Non-Generac replacement part(s) will void the warranty in its entirety.
Engine coolant heaters (block-heaters), heater controls and circulating pumps are only covered during the first year of the warranty provision.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
Any unit built/manufactured prior to July 1, 2004.

Costs of normal maintenance (i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up).
Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze.
Units sold, rated or used for "Prime Power", "Trailer Mounted" or "Rental Unit" applications as Generac Power Systems has defined Prime Power,
Trailer Mounted or Rental Unit. Contact a Generac Power Systems Distributor for Prime Power, Trailer Mounted or Rental Unit definition.
Failures caused by any external cause or act of God such as, but not limited to, collision, fire, theft, freezing, vandalism, riot or wars, lightning,
earthquake, windstorm, hail, volcanic eruption, water or flood, tornado, hurricane, terrorist acts or nuclear holocaust.
Products that are modified or altered in a manner not authorized by Generac Power Systems in writing.
Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing.
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).
Damage related to rodent and/or insect infestation.
Failure due to misapplication, misrepresentation, or bi-fuel conversion.
Telephone, facsimile, cellular phone, satellite, Internet, or any other communication expenses.
Rental equipment used while warranty repairs are being performed (i.e. rental generators, cranes, etc.).
Overtime, holiday, or emergency labor.
Modes of transportation deemed abnormal (refer to Generac Power Systems Warranty, Policies, Procedures and Flat Rate Manual).
Steel enclosures that are rusting due to improper installation, location in a harsh or saltwater environment or scratched where integrity of paint
applied is compromised.
Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct
cause of the problem.
Starting batteries, fuses, light bulbs, engine fluids, and overnight freight cost for replacement part(s).
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC POWER SYSTEMS MAKES NO
OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how
long an implied warranty lasts, so the above limitation may not apply to purchaser/owner.
GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL
GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT
RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/
owner. Purchaser/owner agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gives purchaser/owner
specific legal rights. Purchaser/owner also may have other rights that vary from state to state.
Generac Power Systems, Inc. P.O. Box 8 Waukesha, WI 53187

Ph: (262) 544-4811 Fax: (262) 544-4851
1-888-GENERAC (1-888-436-3722)
Bulletin 0166290SBY Rev. A / Printed in U.S.A.
10.08
Printed in U.S.A.
Notes
20
Notes
21
EXPLODED VIEW: EV H-PNL 10A BC NO E-GOV DSL24
GROUP B
DRAWING #: 0J0288
APPLICABLE TO:
ITEM
(1)1
2
3
(2)4
(2)5
(1)6
(1)7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
(3)27
(4)28
29
PART#
QTY.
0H84230ST0R
0H4733E
0G4140E
0G4141E
0E9764
055911
057701
0J01360ST0R
0H96870ST0R
0J5462
0J5464
051713
049226
0C2454
022097
047411
022145
022129
026850
039253
0G6962A
0G6962B
0J0392
0J0398
0J0393
0J0545
0J0575
0C3168
022206
0H9845
0C8065
0J5349
1
1
1
1
1
REF
REF
1
1
6
3
1
1
2
4
4
4
4
1
4
1
1
1
1
1
1
1
1
1
REF
1
REF
DESCRIPTION
BRACKET H-PNL MOUNTIN CCI IND
ASSY H-PANEL 2.5A BATC 12V
ASSY H-PANEL 10A BATC 12V
ASSY H-PANEL NO BATC NO E-GOV
RAIL SNAPTRACK PCB HOLDER BULK
BLOCK TERM 20A 12 X 6 X 1100V
BLOCK TERM 20A 8 X 6 X 1100V
PLATE, WIRE HARN BLOCKOFF
COVER, COSTOMER CONN H-PNL
SCREW THTT M4-0.7 X 16 ZP
WASHER FLAT M5
WASHER LOCK M5
SCREW HWHT M6-1 X 16 N WA Z/JS
WASHER LOCK M6-1/4
SCREW HHC M6-1.0 X 16 C8.8
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
WASHER LOCK EXT 1/4 STL
ASSY PCB RELAY 24VDC
ASSY PCB RELAY 12VDC
DECAL, TB1 LV CUSTOMER CONN
DECAL, CONTACT RAT 30VAC/30VDC
DECAL, TB2 LV CUSTOMER CONN
DECAL, LV CUSTOMER CONN INSIDE
DECAL, CUSTOMER WIRE #14
WASHER LOCK SPECIAL 5/16
FITTING CONDUIT STR 3/8
HARN 390/520 CONBOX H-PANEL
DIODE ASSEMBLY
HARN 390/520 CONBOX 12V GAS H (NOT SHOWN)
(1) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR).
MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.
CUSTOMER: FOR CORRECT MATERIAL AND COLOR OF REPLACEMENT PARTS REFER TO REPLACEMENT SHEET
METAL PARTS ORDERING GUIDE-0H7169 INCLUDED IN THE MANUAL OR AVAILABLE ON THE GENERAC WEBSITE.
(2) PART OF CONNECTION BOX HARNESS
(3) HARNESS GETS WIRED TO LOAD CENTER IF EQUIPPED.
(4) REFERENCE WIRE DIAGRAM FOR PROPER LOCATION.
REVISION: H-9805-C
DATE: 10/10/11
PAGE 2 OF 2
EXPLODED VIEW: EV, CB MOUNTING KIT MD1 390
GROUP H
DRAWING #: 0J1027
APPLICABLE TO:
ITEM
(1)1
2
3
4
5
(1)6
7
8
9
10
11
12
13
14
15
16
(1)1
2
3
(1)4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
(1)1
2
3
(1)4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
PART#
QTY.
DESCRIPTION
NO CIRCUIT BREAKERS
0H93780ST0R
1
MD1,MODULE COVER 390 G-FRAME
0C2454
9
0J0679
1
DECAL, CANADIAN SAFETY CODE
0J0546
1
DECAL, HV CUSTOMER CONN INSIDE
0D3719C
REF
0D3719D
REF
DECAL CUSTOMER CONN E1 E3
0J34710ST0R
1
MD1-MD3 NO CB MNT BRACKET
0J3958
REF
CU BUSS BAR 1/4"X2.5" 625A
022145
4
022129
4
WASHER LOCK M8-5/16
042907
4
0C6937M
6
INSULATOR, STANDOFF 600V3/8-16
022241
6
NUT HEX 3/8-16 STEEL
022237
12
WASHER LOCK 3/8
022131
12
032414
8
SCREW HHC 3/8-16 X 5/8 G5
090865
6
STUD 3/8-16 X 1.75 G5 STEEL
UL CIRCUIT BREAKER (225AF)
0H9378EST0R
1
MD1,MODULE COVER 390 GEN-225
0C2454
7
REF
1
CIRCUIT BREAKER
0J14770ST0R
1
MD1, C/B MOUNTING BRACKET 225
022145
13
022129
13
WASHER LOCK M8-5/16
042907
4
0J0679
1
0J0546
1
0D3719C
REF
DECAL CUSTOMER CONN E1 E2 E3
0D3719D
REF
053640
4
SCREW RHM #8-32 X 3-1/4
038150
4
WASHER FLAT #8 ZINC
022264
4
WASHER LOCK #8-M4
022471
4
NUT HEX #8-32 STEEL
049897
6
SCREW SHC M8-1.25 X 20 G8
058306
3
SCREW SHC M8-1.25 X 25 C12.9
0F8451
3
LUG SLDLSS 300 MCM-6 AL/CU
0F8843
3
BUS BAR 200A LUG ADAPTOR
045771
3
NUT HEX M8-1.25 G8 CLEAR ZINC
0F8432
1
INSUL CB 225AF
UL CIRCUIT BREAKER (400AF)
0H9378JST0R
1
MD1,MODULE COVER 390 GEN-400
0C2454
7
REF
1
CIRCUIT BREAKER
0J00680ST0R
1
MD2, C/B BACK MOUNTING BRACKET
022145
4
022129
4
WASHER LOCK M8-5/16
042907
4
0J0679
1
0J0546
1
0D3719C
REF
0D3719D
REF
069232
4
SCREW RHM #10-32 X 3-3/4
023897
4
WASHER FLAT #10 ZINC
022152
4
WASHER LOCK #10
022158
4
NUT HEX #10-32 STEEL
052647
3
SCREW SHC M10-1.5 X 25 C12.9
046526
3
WASHER LOCK M10
0A7822
6
LUG SLDLSS 600/250-1/0X1/4-28
022473
12
022097
12
WASHER LOCK M6-1/4
023334
12
0J7188
3
BUS BAR ADAPTOR
REVISION: H-9731-C
DATE: 9/23/11
Page 4 of 6
GROUP H
DRAWING #: 0J1027
APPLICABLE TO:
ITEM
(1)1
2
3
(1)4
5
6
7
8
9
10
11
12
13
14
(1)1
2
3
(1)4
5
6
7
8
9
10
11
12
13
14
(1)1
2
3
(1)4
5
6
7
8
9
10
11
12
13
14
(1)1
2
3
(1)4
5
6
7
8
9
10
11
12
13
14
PART#
QTY.
DESCRIPTION
UL CIRCUIT BREAKER (G-FRAME)

0H9378AST0R
1
MD1,MODULE COVER 390 G-FRAME
0C2454
7
REF
1
CIRCUIT BREAKER
0J14880ST0R
1
MD1, C/B MOUNTING BRACKET G
022145
4
022129
4
WASHER LOCK M8-5/16
042907
4
0J0679
1
0J0546
1
0D3719C
REF
0D3719D
REF
0J4465
4
SCREW SHC M4-0.7 X 80 C12.9
043180
4
WASHER FLAT M4
022264
4
WASHER LOCK #8-M4
051715
4
NUT HEX M4-0.7 G8 YEL CHR
UL CIRCUIT BREAKER (F -FRAME)
0H9378BST0R
1
MD1,MODULE COVER 390 F-FRAME
0C2454
7
REF
1
CIRCUIT BREAKER
0J14860ST0R
1
MD1, C/B MOUNTING BRACKET F
022145
4
022129
4
WASHER LOCK M8-5/16
042907
4
0J0679
1
0J0546
1
0D3719C
REF
0D3719D
REF
0J4899
4
043180
4
WASHER FLAT M4
022264
4
WASHER LOCK #8-M4
051715
4
UL CIRCUIT BREAKER (JG -FRAME)
0H9378DST0R
1
MD1,MODULE COVER 390 JG-FRAME
0C2454
7
REF
1
CIRCUIT BREAKER
0J14860ST0R
1
MD1, C/B MOUNTING BRACKET F
022145
4
022129
4
WASHER LOCK M8-5/16
042907
4
0J0679
1
0J0546
1
0D3719C
REF
0D3719D
REF
0J4466
4
SCREW SHC M4-0.7 X 100 C12.9
043180
4
WASHER FLAT M4
022264
4
WASHER LOCK #8-M4
051715
4
UL CIRCUIT BREAKER (J -FRAME)
0H9378CST0R
1
MD1,MODULE COVER 390 J-FRAME
0C2454
7
REF
1
CIRCUIT BREAKER
0J00680ST0R
1
022145
4
022129
4
WASHER LOCK M8-5/16
042907
4
0J0679
1
0J0546
1
0D3719C
REF
0D3719D
REF
049967
4
022473
4
022097
4
WASHER LOCK M6-1/4
049813
4
REVISION: H-9731-C
DATE: 9/23/11
Page 5 of 6
GROUP H
DRAWING #: 0J1027
APPLICABLE TO:
ITEM
(1)1
2
3
(1)4
5
6
7
8
9
10
11
12
13
14
(1)1
2
3
(1)4
5
6
7
8
9
10
11
12
13
14
(1)1
2
3
(1)4
5
6
7
8
9
10
11
12
13
14
PART#
QTY.
DESCRIPTION
UL CIRCUIT BREAKER (K -FRAME)

0H9378FST0R
1
MD1,MODULE COVER 390 K-FRAME
0C2454
7
REF
1
CIRCUIT BREAKER
0J00680ST0R
1
022145
4
022129
4
WASHER LOCK M8-5/16
042907
4
0J0679
1
0J0546
1
0D3719C
REF
0D3719D
REF
046580
4
022473
4
022097
4
WASHER LOCK M6-1/4
049813
4
UL CIRCUIT BREAKER (L -FRAME)
0H9378GST0R
1
MD1,MODULE COVER 390 L-FRAME
0C2454
7
REF
1
CIRCUIT BREAKER
0J00680ST0R
1
022145
4
022129
4
WASHER LOCK M8-5/16
042907
4
0J0679
1
0J0546
1
0D3719C
REF
0D3719D
REF
046580
4
022473
4
022097
4
WASHER LOCK M6-1/4
049813
4
UL CIRCUIT BREAKER (LG-FRAME)
0H9378HST0R
1
MD1,MODULE COVER 390 LG-FRAME
0C2454
7
REF
1
CIRCUIT BREAKER
0J00680ST0R
1
022145
4
022129
4
WASHER LOCK M8-5/16
042907
4
0J0679
1
0J0546
1
0D3719C
REF
0D3719D
REF
0J4467
4
SCREW SHC M5-0.8 X 100 C12.9
051713
4
WASHER FLAT M5
049226
4
WASHER LOCK M5
051716
4
NOTES (UNLESS OTHERWISE SPECIFEID):

(1) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)
CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE
SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
REVISION: H-9731-C
DATE: 9/23/11
Page 6 of 6
EXPLODED VIEW: EV CONBOX 390 MODULE
GROUP A
DRAWING #: 0J1339
APPLICABLE TO:
ITEM
PART#
QTY.
(1)1
(1)2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
(3)(2)18
(3)(2)19
(3)(2)20
(3)(2)21
22
23
0H95790ST0R
0J17560ST0R
0A4456
061383
0E1534A
056326
045772
067210A
0H8006
0A9457
0C2454
024526
022129
022145
0441140781
022131
049541
0J0455
0J0394
0J0574
0J5462
061383
067210A
1
1
3
1
2
2
1
1
1
1
4
4
4
4
1
4
2
REF
REF
REF
REF
1
1
DESCRIPTION
MD1 / MD2 CB MODULE 390 ALT
WIRE TUNNEL, MD1-2 390 ALT
LUG SLDLSS 3/0-#4 X 13/32 CU
PLUG PLASTIC 1.50"
TRIM VINYL BLACK 1/8GP (6LG)
DECAL GROUND LUG
DECAL CAUTION ELEC SHOCK SM
DECAL NEUTRAL
SCREW HHTT 5/16-18 X 3/4 CZ
WASHER LOCK M8-5/16
WIRE ASM, GND 2/0 WIRE 3/8 LUG
BLOCK, TERM 14 POS X 8 X 1600V
DECAL, TB4 HV CUSTOMER CONN
DECAL, CUSTOMER WIRE #10
LUG SLDLSS 3/0-#4 X 13/32 CU
DECAL GROUND LUG
(2) WILL BE INSTALLED ON PRIMARY CB MODULES ONLY. NOT REQUIRED WITH LOAD CENTER.
(3) NOT REQUIRED IF EQUIPPED WITH LOAD CENTER.
REVISION: H-8919-B
DATE: 05/11/11
PAGE 2 OF 2
EXPLODED VIEW: 390, BOARD SOLID LEAD TERM BRL
GROUP A
DRAWING #: 0J1479
APPLICABLE TO:
ITEM
PART#
QTY.
1
2
3
4
5
6
7
8
9
10
11
12
13
42
43
44
45
051769
049808
VARIES
055173
022129
022145
0G0724
0A2601
0A2602
0A1138
021941
VARIES
052891
068407
0A5580
0A1633
VARIES
022131
046526
057642
068113
0H8394A
043123
051779
022304
053559
068406
070274
087271
087272
068404
068405
092950
020151
090063
090152
023365
033143
090064
033133
063837
028739A
085662D
022661L
042914
087712
0H9157
0A2110
0A4089
0A1786
9
6
REF
6
8
8
1
1
1
1
1
REF
2
2
4
4
REF
12
12
12
1
1
4
4
2
1
1
1
1
1
1
1
1
1
1
1
3
2
1
1
6
2
1
1
2
2
2
2
1
.5CC
50
51
52
53
54
55
56
57
58
0A2491
0A2497
0A2496
056326
022097
022473
045757
047411
0A2110
KIT 0A4089 PARTS

2
2
2
8.4 FT.
6
6
2
4
12
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
REVISION: H-9012-B
DATE: 5/20/11
DESCRIPTION
WASHER LOCK M12
WASHER FLAT M12
FLEX PLATE
SCREW HHC M8-1.25 X 20 G10.9
WASHER LOCK M8-5/16
FAN MACHINED 390 SAE ALTERATOR
SCREW HHC M16-2.0 X 45 G8.8
WASHER FLAT .688ID X 3.25OD
KEY SQ 3/8 X 2-1/2 STEEL
COUPLER 390 SAE
ROTOR PER ORDER (SEE BOM)
SCREW HHC M12-1.75 X 80 C8.8 (1.25 STACK)
SCREW HHC M14-2.0 X 140 G8.8
WASHER,390 SAE ALT.
STATOR PER ORDER (SEE BOM)
WASHER LOCK M10
CARRIER REAR BRG 15"
390, BOARD SOLID LEAD TERM BRL
WASHER LOCK M14
WASHER FLAT 1/2 ZINC
KEY SQ 3/8 X 2-3/4 STEEL
ASSY EXCITER 1.25"STK
ASSY EXCITER 2.00" STK
EXCITER FIELD 1.25 STK
EXCITER FIELD 15" 2" LG
COLLAR SLIP FIT 390 MM
CLAMP VINYL .312 X .203 Z
BRIDGE SUPPORT DIODE 15"
ASSY BRIDGE RECTIFIER
WASHER SHAKEPROOF INT #8
SCREW HHM #8-32 X 7/8
CAP END ROTOR 390MM
SCREW HHM #8-32 X 3/8
SCREW HHC M12-1.75 X 30 C10.9
TIE WRAP 3.9" X .10" BLK UL
TIE WRAP UL 17.7 X .35 BLK HT
SLEEVING UL #0 .330 ID
HOLLOW DOWEL PIN, 1/2 X 1-1/4
SCREW SWAGE 1/4-20 X 1/2 Z/YC
ASSY SCROLL 390 SAE
ADH LOCTITE #8931 AA W/S
SHROUD ALT SHEET METAL
SCREEN SHROUD SAE
BRKT TENSIONER SAE SCROLL
TRIM VINYL BLACK 1/8GP
WASHER LOCK M6-1/4
Page 2 of 2
EXPLODED VIEW: EV 390 ALTERNATOR TOWER ASM
GROUP A
DRAWING #: 0J1584
APPLICABLE TO:
ITEM
(1)1
(1)2
(1)2A
(1)3
(3)4
5
(1)6
7
8
9
(2)10
11
(3)12
(3)13
14
15
16
(3)17
18
19
20
PART#
QTY.
DESCRIPTION
0H9429AST0R
0H94310ST0R
0H9431AST0R
0H94320ST0R
0J0481
0J0481A
0J0481B
0J0481C
0J0481D
0J0481E
0J0481F
0J0481G
N/A
0J01360ST0R
0J5464
022097
022473
056326
0C2454
022145
022129
042907
045771
024983
0J1857
0J1857A
0C1229
0H9845
052250
1
1
1
1
2/3
2/3
2/3
2/3
2/3
2/3
2/3
2/3
MAIN, ALT TOWER 390 LONG

TOP, ALT TOWER 390 SINGLE CB
TOP, ALT TOWER 390 DUAL CB
COVER, ALT TOWER 390
XFMR CURRENT 50A W/BRKT UL RCG
XFMR CURRENT 100A W/BRKT UL G
XFMR CURRENT 150A W/BRKT UL
1
2
4
4
2/4
12
4/8
2/3
2/3
2/3
4
2/3
2/3
1
1
1
PLATE, WIRE HARN BLOCKOFF

WASHER LOCK M6-1/4
TRIM VINYL BLACK 1/8GP (6LG)
WASHER LOCK M8-5/16
SCREW HHTT 1/4-20 X 3/4 CZ
CT BRKT 1.1" WINDOW FRAME
CT BRKT 2.25" WINDOW FRAME
DECAL WARNING ELECTRICAL SHOCK
HARN 390/520 CONBOX H-PANEL (NOT SHOWN)
TAPE FOAM 1X1 (49 LG)
NOTES (UNLESS OTHERWISE SPECIFIED):

(3) QTY. REQUIRED FOR 1 PHASE / QTY. REQUIRED FOR 3 PHASE.
REVISION: H-9332-C
DATE: 7/19/11
PAGE 2 OF 2
DPE Breaker and Field Boost Resistor Table for Gensets with H-Panel Control & 12V Battery
VOLTAGE
FREQUENCY
EXCITATION
SIZE
direct
120/240 1
60 Hz
PME/brushless
390 mm or
smaller
520 mm
direct
120/208 3
60 Hz
PME/brushless
390 mm or
smaller
520 mm
direct
120/240 3
60 Hz
PME/brushless
390 mm or
smaller
520 mm
direct
277/480 3
60 Hz
PME/brushless
390 mm or
smaller
520 mm
direct
346/600 3
60 Hz
PME/brushless
390 mm or
smaller
520 mm
direct
110/220 1
50 Hz
PME/brushless
390 mm or
smaller
520 mm
direct
100/200 3
50 Hz
PME/brushless
390 mm or
smaller
520 mm
direct
115/200 3
50 Hz
PME/brushless
390 mm or
smaller
520 mm
direct
231/400 3
50 Hz
PME/brushless
390 mm or
smaller
520 mm
kW RATING
1kW - 8.9kW
9kW - 45kW
1kW - 15kW
16kW - 18kW
19kW - 26kW
27kW - 41kW
45kW - 130kW
any
1kW - 8.9kW
9kW - 45kW
1kW - 15kW
16kW - 18kW
19kW - 26kW
27kW - 41kW
45kW - 130kW
any
1kW - 8.9kW
9kW - 45kW
1kW - 15kW
16kW - 18kW
19kW - 26kW
27kW - 41kW
45kW - 130kW
any
1kW - 8.9kW
9kW - 45kW
1kW - 15kW
16kW - 26kW
27kW - 41kW
45kW - 130kW
any
1kW - 8.9kW
9kW - 45kW
1kW - 15kW
16kW - 18kW
19kW - 26kW
27kW - 130kW
any
1kW - 8.9kW
9kW - 45kW
1kW - 15kW
16kW - 18kW
19kW - 26kW
27kW - 130kW
any
1kW - 8.9kW
9kW - 45kW
1kW - 15kW
16kW - 18kW
19kW - 26kW
27kW - 130kW
any
1kW - 8.9kW
9kW - 45kW
1kW - 15kW
16kW - 18kW
19kW - 26kW
27kW - 130kW
any
1kW - 8.9kW
9kW - 45kW
1kW - 15kW
16kW - 18kW
19kW - 26kW
27kW - 41kW
45kW - 130kW
any
DPE BREAKER
PART NO.
SIZE
048512
5A
048467
7A
053623
2.5A
049350
4A
054450
5.5A
048505
6A
048476
4.5A
048476
4.5A
048512
5A
048467
7A
053623
2.5A
049350
4A
054450
5.5A
048505
6A
048476
4.5A
048476
4.5A
048512
5A
048467
7A
053623
2.5A
049350
4A
054450
5.5A
048505
6A
048476
4.5A
048476
4.5A
048512
5A
048467
7A
053623
2.5A
054450
5.5A
048505
6A
048476
4.5A
048476
4.5A
048512
5A
048467
7A
053623
2.5A
049350
4A
054450
5.5A
048476
4.5A
048476
4.5A
048512
5A
048467
7A
053623
2.5A
049350
4A
048476
4.5A
048505
6A
048476
4.5A
048512
5A
048467
7A
053623
2.5A
049350
4A
048476
4.5A
048505
6A
048476
4.5A
048512
5A
048467
7A
053623
2.5A
049350
4A
048476
4.5A
048505
6A
048476
4.5A
048512
5A
048467
7A
053623
2.5A
049350
4A
054450
5.5A
048505
6A
048476
4.5A
048476
4.5A
FIELD BOOST RESISTOR

PART NO.
SIZE
0F5752E
5 ohm
0F5752B
25 ohm
0F5752D
75 ohm
0F5752E
5 ohm
0F5752B
25 ohm
0F5752D
75 ohm
0F5752E
5 ohm
0F5752B
25 ohm
0F5752D
75 ohm
0F5752E
5 ohm
0F5752B
25 ohm
0F5752D
75 ohm
0F5752E
5 ohm
0F5752B
25 ohm
0F5752D
75 ohm
0F5752E
5 ohm
0F5752B
25 ohm
0F5752D
75 ohm
0F5752E
5 ohm
0F5752B
25 ohm
0F5752D
75 ohm
0F5752E
5 ohm
0F5752B
25 ohm
0F5752D
75 ohm
0F5752E
5 ohm
0F5752B
25 ohm
0F5752D
75 ohm
1
2
3
4
0D3483
0A2110
0D3484
074908
1
10
1
4
FAN GUARD
BOTTOM COVER, FANGUARD
SCREW HHTT M5-0.8 X 10 BP
1
2
3
4
5
6
7
8
10
11
12
13
14
(2) 15
(2) 17
(2) 18
047411
022097
022473
084918G
(1) 084918H
0G0015
042568
055934D
084427
049813
050967
022129
042907
0C4905
0A6283
0G0015
0C4905
044117
2
4
4
1
1
2
2
1
1
2
1
1
1
1
1
2
1
1

WASHER LOCK M6-1/4
HEATER ENG 1500W 120V
HEATER ENG 1500W 240V
CLAMP, HOSE 5/8" DOUBLE WIRE
CLAMP VINYL 1.06 X .406 Z
BRACKET HEATER
HOSE 5/8 ID RIA 250F (31LG)
WASHER LOCK M8-5/16
BARBED EL 45 3/8NPT X 5/8OD
HOSE PREFORMED BLOCK HEATER
CLAMP, HOSE 5/8" DOUBLE WIRE
BARBED EL 45 3/8NPT X 5/8OD (GEAR BOX)
BARBED STR 3/8NPT X 5/8 (DIRECT DRIVE)
(1) USED ON R VOLTAGE GENERATORS ONLY.

(2) USED ON NON-DUEL FUEL NATURAL GAS & LP VAPOR UNITS
ONLY.
1A
058665
058665A
058208
061119
061119A
1
1
1
1
1
BATTERY 12VDC 90-AH 27F

BATTERY SERVICE DRY
BATTERY 12VDC 24F 525 CCA
BATTERY BCI GRP 31
31E BATTERY SERVICE DRY
2A
B
C
0A4010
0A4010
099049
2
2
2
SCREW HHC M8-1.25 X 60 C8.8 FT

SCREW HHC M8-1.25 X 60 C8.8 FT
J BOLT BATTERY TRAY
3A
B
C
052858
052858
022129
2
2
2
NUT LOCK FL M8-1.25

NUT LOCK FL M8-1.25
WASHER LOCK M8-5/16
4A
B
C
049820
049820
045771
2
2
2
NUT LOCK HEX M8-1.25 NYL INS

NUT LOCK HEX M8-1.25 NYL INS
5A
B
C
022145
022145
058653
4
4
2

WASHER FLAT M8
6A
B
C
059473
059473
059568B
2
2
2
HOLD DOWN BATTERY

HOLD DOWN BATTERY
BATT HOLD DOWN BAR 368MM
7A
B
061902
061902
2
2
HOLD DOWN BATTERY (60-100KW)

HOLD DOWN BATTERY (60-100KW)
B
C
EXPLODED VIEW: EV RADIATOR BLOCKOFF 6.8L
GROUP C
DRAWING #: 0J1133
APPLICABLE TO:
ITEM
PART#
QTY.
DESCRIPTION
(1)1
(1)2
(1)3
(1)4
5
6
7
8
0J11370ST0R
0J11350ST0R
0J11360ST0R
0J11340ST0R
N/A
0C2454
052250
052250
1
1
1
1
RADIATOR BLOCKOFF 6.8L TOP

RADIATOR BLOCKOFF 6.8L LEFT
RADIATOR BLOCKOFF 6.8L RIGHT
RADIATOR BLOCKOFF 6.8L BOTTOM
8
2
2

TAPE FOAM 1X1 (29LG)
TAPE FOAM 1X1 (34LG)

REVISION: H-9343-C
DATE: 7/19/11
PAGE 2 OF 2
EXPLODED VIEW: EV 6.8L G3 CCI MOUNTING BASE
GROUP C
DRAWING #: 0J2569
APPLICABLE TO:
ITEM
PART#
QTY.
(2)1
2
3
0J03380ST0R
0J03390ST0R
0J03400ST0R
0J03410ST0R
0J03420ST0R
0J0342AST0R
0J03430ST0R
0J0343AST0R
024310
052252
052257
052259
055597
052251A
052860
9
10
11
0D2007
0D2006
REF
REF
REF
051756
046526
022131
025507
038805J
059984
060079
022132
059676
059675
045771
0C3168
022129
052243
052647
022131
046526
030985
078944
044118
0G0015
065386
044117
057765
057772
0536210360
043107
022145
050331
050331A
03880400AA
038804J
1
1
1
1
1
1
1
1
1
4
2
4
2
4
2
4
2
4
2
4
2
1
1
REF
REF
REF
1
1
1
1
1
2
2
4
2
2
1
1
1
4
4
9
9
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
12
13
14
15
16
(1)17
(1)18
(1)19
(1)20
(1)21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
REVISION: H-9768-C
DATE: 10/4/11
DESCRIPTION
MTG BASE G6.8L 390 DD CCI
MTG BASE G6.8L 390 DD DUAL CCI
MTG BASE G6.8L 390 GB CCI
MTG BASE G6.8L 390 GB DUAL CCI
MTG BASE G6.8L 520 GB CCI
MTG BASE G6.8 520 GB MPS
MTG BASE G6.8L 520 GB DUAL CCI
MTG BASE G6.8L 520 GB DUAL MPS
PLUG STD PIPE 1/2 STEEL SQ HD
DAMPENER VIBRATION
DAMPENER VIBRATION (520 ALT G/B)
SPACER .49 X .62 X 1.87 PWDR/ZINC
SPACER .49 X .62 X 1.87 PWDR/ZINC (520 ALT G/B)
WASHER FLAT M12
WASHER FLAT M12 (520 ALT G/B)
SCREW HHC M12-1.75 X 85 G8.8
SCREW HHC M12-1.75 X 85 G8.8 (520 ALT G/B)
DAMPENER VIBRATION 50 WHITE
DAMPENER VIBRATION 50 WHITE (520 ALTG/B ONLY)
NUT LOCKING M12-1.75
NUT LOCKING M12-1.75 (520 ALT G/B ONLY)
ENGINE MOUNT 6.8L RH SIDE
ENGINE MOUNT 6.8L LH SIDE
KIT VARMIT GUARD
KIT VARMIT GUARD
KIT VARMIT GUARD
WASHER LOCK M10
WASHER LOCK EXT 7/16 STL
CABLE BATT BLK #1 X 30.00 NEG
SCREW HHC M14-2.0 X 120 G8.8 (520 ALT G/B)
NUT LOCK HEX M14-2.0 NYL INSRT (520 ALT G/B)
WASHER FLAT 9/16 ZINC (520 ALT G/B)
MOUNT LOWER VIBRATION (520 ALT G/B)
MOUNT UPPER VIBRATION (520 ALT G/B)
5/16 SPECIAL L/WASH
WASHER LOCK M8-5/16
SCREW SHC M10-1.5 X 25 C12.9
WASHER LOCK M10
NIPPLE CLOSE 1/2 X 1.125
VALVE BALL
BARBED STR 1/2 NPT X 5/8
CLAMP HOSE 7/8" OD DOUBLE WIRE
HOSE 5/8 ID SAE100R6 (11LG)
BARBED STR 3/8 NPT X 5/8
ADP OIL DRN M14-1.50
WASHER NYLON .565
WIRE ASSEM #4GA GRD
BATT POST COVER BLK BATT POST COVER RED +
CABLE BATT RED #1 X 44.00 (G/B)
CABLE BATT RED #1 X 40.50
Page 2 of 4
GROUP C
DRAWING #: 0J2569
APPLICABLE TO:
ITEM
PART#
QTY.
43
44
075763
050277
1
1
DESCRIPTION
BOOT BATTERY CABLE
DECAL OIL DRAIN

(1) 520 G/B ONLY
REVISION: H-9768-C
DATE: 10/4/11
Page 3 of 4

DRAWING #: 0J2569
APPLICABLE TO:
GROUP C
THIS PAGE LEFT INTENTIONALLY BLANK
REVISION: H-9768-C
DATE: 10/4/11
Page 4 of 4
1
2
3
4
5
6
7
8
9
10
11
12
0D2513D
0D2513E
0F5419
0F4268
0F4270A
0F6977
037561
047411
022097
049811
0F4269
022473
0A4256
1
1
1
1
1
1
1
4
4
4
1
1
1
AIR CLNR BTM PLT W/CPLR 8.1L

PLATE AIR CLEANER W/COUPLER
ELEMENT AIR FILTER
TOP PLATE VENTURI
HOLD DOWN AIR CLEANER PLATED
PLATE AIR CLEAN TOP 5.4L/6.8L
NUT WING 1/4-20 NYLK
WASHER LOCK M6-1/4
WASHER FLAT M6
GASKET MIXER BODY
INDICATOR FILTER MINDER
EXPLODED VIEW: EV ENGINE COMM PARTS 6.8L L/H
GROUP D
DRAWING #: 0J2563
APPLICABLE TO:
ITEM
PART#
QTY.
DESCRIPTION
1
2
3
4
(2 5
(2)6
7
0F3017
039253
022129
022145
0D5419
0D7055
0D3488G
0D3488K
0D3488
0D3488J
057795B
065386
0F3287
0H3074
0J7330
0E9868A
0G5954
0F3216
0F3216A
0F3216C
0F3216D
055476
0F4612
0D6658
029333A
022097
022473
042568
0D8027
0D8025
0D8026
0D8030
0F2846
0D8029
0D8028
045771
0H0923
022131
046526
064416
045772
0F3217
0F2776A
0F6151
0F4308
0F3158
0G0015
0E0502
0G0866
0F4301
0F5512
047527
0F5114
0E8286
0F3113
0F6317
077996
036943
1
3
5
5
REF
REF
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
REF
2
3
3
5
4
1
3
1
1
1
1
2
REF
2
1
1
1
1
2
1
1
1
3 / 6(4)
1
1
1
1
1
1
1
1
1
1
2
BRACKET,D.C. ALTERNATOR LOWER

WASHER LOCK M8-5/16
OIL FILTER, FORD V-10 ENGINE
DIPSTICK TUBE, FORD 6.8L
BELT SERPENTINE 65.0" (1800 RPM)
BELT SERPENTINE (68.3"LG) (3600 RPM)
BELT SERPENTINE (67.16" LG) (3000 RPM)
SERPENTINE, BELT (65.3" LG) (2300 RPM)
BARBED EL 90 5/8 PLASTIC
HOSE COOL 5/8 ID 100R6 (16.75LG)
BRACKET DC ALTERNATOR UPPER
HARN ENG G6.8L H-100 CPL EMSN (USE WITH PROBE P/N 0H1827)
HARN ENG G6.8L G3 PM-PC CCI (USE WITH PROBE P/N 0H1827)
ALTERNATOR DC W/OUT PULLEY
GROMMET 15.87 X 31.75 X 11
PULLEY 80 OD DC ALTERNATOR (1800 RPM)
BUSHING REDUCER 3/8 TO 1/8 GAL
SENDER OIL PRESSURE 1/8"NPT
DIPSTICK 6.8L FORD
TIE WRAP UL 7.4" X .19" BLK
WASHER LOCK M6-1/4
BOLT WATER PUMP PULLEY
BOLT GROOVED IDLER PULLEY
BOLT BELT TENSIONER
TENSIONER ENG. AUTOMATIC BELT
PULLEY WATER PUMP G3
PULLEY ENGINE WATER PUMP (GEAR BOX)
PULLEY GROOVED ENGINE IDLER
ENGINE G6.8L G3 V-10 (2009/10)
WASHER LOCK M10
SCREW HHC M10-1.5 X 45 G8.8 FT
SPACER DC ALTERNATOR PULLEY
BRACKET SIGNAL CONDITIONER
CAP RUBBER (100KW & 130KW)
BRACKET DC ALT STABILIZER
OIL COOLER FORD (150KW 3600RPM)
TEMPERATURE SENDER, DELPHI
HOSE OIL COOLER PREFORMED 3/4 (150KW 3600RPM)
HOSE OIL COOLER (150KW 3600RPM)
REFLEX WRAP 13MM 13 X 460
BARBED STR 1/2NPT X 3/4
DECAL, REFER TO OWNERS MANUAL
ELBOW 45D STREET 1/2NPT BRASS
ASSY PCB HSB CTRL IGN MODULE
MOUNT IGN MODULE
CAP ANTIFREEZE 5/8"ID X 1.2"LG (80/100/130KW)
SCREW PPHM #10/32 X 2
8
9
10
(3)11
12
13
14
15
16
(2)17
(3)(1)18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
(4)38
39
40
(4)41
(4)42
(3)43
(4)44
45
(4)46
47
48
49
50
REVISION: H-9768-C
DATE: 10/10/11
Page 2 of 4
GROUP D
DRAWING #: 0J2563
APPLICABLE TO:
ITEM
PART#
QTY.
51
52
53
54
023897
022152
022158
0G9378
0H0777
2
2
2
1
1
DESCRIPTION
WASHER FLAT #10 ZINC
WASHER LOCK #10
NUT HEX #10-32 STEEL
DECAL SORE EPA CERTIFICATION
DECAL LSI EPA CERTIFICATION
(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
REVISION: H-9768-C
DATE: 10/10/11
Page 3 of 4

DRAWING #: 0J2563
APPLICABLE TO:
GROUP D
REVISION: H-9768-C
DATE: 10/10/11
Page 4 of 4
EXPLODED VIEW: EV ENGINE COMM PARTS 6.8L R/H
GROUP D
DRAWING #: 0J2563A
APPLICABLE TO:
ITEM
PART#
QTY.
(3)1
2
(1)3
4
5
6
7
(1)8
9
10
11
(1)12
13
14
15
16
17
18
19
20
21
22
23
24
25
(2)26
27
28
29
029333A
0D5418
052625
065386
087599
042568
0F2776A
022131
034339
052648
0D9913
046526
055934M
070008
0G0015
049821
022129
022097
052647
0D2244M
070006
022473
0D2608
0D5623
0D5417
0D3808
0D4255
070010
0D6344
0D6686
0D3803
0D3805
0A8240
021113
0E0992A
078637
047411
062303
048191
2
1
6/11
1
1
2
2
8/6
1
8
18
21/19
1
10
2
3
3
3
8
1
30
3
10
2
REF
2
2
2
1
1
1
1
3
1
10
A/R
1
1
0/2
30
31
32
33
34
35
36
(1)37
DESCRIPTION
TIE WRAP UL 7.4"X .19" BLK (NOT SHOWN)
STARTER MOTOR FORD V-10 ENGINE
SCREW SHC M10-1.5 X 35 G12.9
HOSE COOL 5/8 ID 100R6 (14LG)
PLUG PLASTIC 3/8 NPT
BRACKET, SIGNAL CONDITIONER
BARBED EL 90 3/8NPT X 5/8
SCREW SHC M10-1.5 X 20 G12.9
SCREW SHC M8-1.25 X 35 SS
WASHER LOCK M10
CLAMP VINYL .75 X .343 Z
WASHER FLAT M8 SS
SCREW SHC M8-1.25 X 30 G12.9
WASHER LOCK M8-5/16
WASHER LOCK M6-1/4
SCREW SHC M10-1.5 X 25 G12.9
ASSEMBLY MAGPICKUP (3/8-24 MALE)
WASHER LOCK M8 SSTL
SCREW HHC 5/16-18 X 1/2 SSTL
HEAT SHIELD EXHAUST
SCREW HHC M10-1.0 X 25 G10.9
EXH MANIFOLD MACH 6.8L V-10
GASKET EXHAUST MANIFOLD
SCREW HHC M8-1.25 X 35 SS G8.8
ASSEMBLY 6.8L FLYWHEEL (D/D UNITS)
ASSY 6.8L G-BOX FLYWHEEL (G/B UNITS)
FLYWHEEL HOUSING MACH 6.8L V10
COVER FLYWHEEL MACH 6.8L V-10
FLEX PLATE SAE10 2.2
PLATE, DAMPNER RETNR
PLUG EXPANSION 14 OD
ADHESIVE LOCTITE 620
ADAPTOR 1/4" NPT TO 3/8" NPT
DOWEL PIN M10 X 24
(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.
REVISION: H-9768-C
DATE: 10/10/11
Page 2 of 2
EXPLODED VIEW: EV B GROUP COOLING SYSTEM
GROUP D
DRAWING #: 0J2567
APPLICABLE TO:
ITEM
PART#
QTY.
(1)1
(1)2
3
4
5
6
7
(1)8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
0J06070ST0R
0J06060ST0R
0G1286A
046627
0D3520
0D3521
042561
0J06270ST0R
042907
051768
049808
052860
052250
035685
0D2149
0D7975
076749
048031C
029032
0D3293A
046526
022131
045771
022129
0C2454
0F2776A
0H1827
022145
049814
0G7895B
077043H
0A4456
022142
050276
0G3269
0G3266
0H3852
1
1
1
1
1
1
2
1
8
6
6
6
2
2
1
1
1
2
1
1
6
6
8
20
2
1
1
8
7
1
1
1
4
1
2
1
1
DESCRIPTION
RADIATOR SUPPORT LH 6.8L
RADIATOR SUPPORT RH 6.8L
RADIATOR, R/H-IN L/H-OUT
CAP RADIATOR 14PSI
HOSE, LOWER RADIATOR
HOSE, UPPER RADIATOR
CLAMP HOSE #36 1.88 - 2.75
ASSY VENTURI 6.8L B/C-GRP
SCREW HHC M12-1.75 X 25 C8.8
WASHER FLAT M12
NUT TOP LOCK FL M12-1.75
TAPE FOAM 1 X 1 (27"LG)
CLAMP HOSE #28 1.32-2.25
SPACER, FAN 6.8L
WATER BOTTLE BRACKET
TANK COOLANT RECOVERY
CLAMP HOSE BAND 1/4
HOSE 9/32 ID (31"LG)
FAN, COOLING 22" DIA KYSOR
WASHER LOCK M10
WASHER LOCK M8-5/16
BRACKET, SIGNAL CONDITIONER
PROBE COOLANT LEVEL 3/8-18NPTF
HARN RADIATOR GND 46"
CONDUIT FLEX .25"ID (46LG)
SCREW HHC 5/16-18 X 3/4 G5
DECAL RADIATOR DRAIN
DECAL WARNING FAN BI
DECAL WARNING COOLANT EGLY BI
HOSE HOLDER PLASTIC (.4-.5 ID)
REVISION: H-9635-B
DATE: 9/6/11
Page 2 of 2
EXPLODED VIEW: FUEL 6.8L 70KW NG/LPV EMS
GROUP E
DRAWING #: 0J0146
APPLICABLE TO:
ITEM
PART#
QTY.
1
2
3
049721
065908
0H6135B
0H6135C
052617
022304
051769
045773
042568
0F6155
030131
088963
0D2698
057823
057147
049811
0D1509
050279
050280
0H2353
0E4390
0E4392
0F0960
0F3885
0G3167
0F3691B
026073A
0D2157
039294
022097
026915
0G46350ST03
039130
0C2454
039450
0G4588
077879
077879
0F1866A
4
1
1
1
2
2
2
2
2
1
2
1
1
4
2
2
1
1
1
1
1
1
1
1
2
1
1
4
2
10
1
1
1
2
2
1
2
1
1
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
REVISION: H-9610-C
DATE: 9/12/11
DESCRIPTION
SCREW HHC M6-1.0 X 35 G8.8 BLK
SUPPORT NAT GAS SOLENOID
REG 6.8L 70KW LPV CONF EMSN
REG 6.8L 70KW NG CONF EMSN
SCREW HHC M12-1.75 X 20 G8.8
WASHER LOCK M12
HARNESS,FUEL JUMPER SINGLE REG
ELBOW 90D 1-1/4 NPT
NIPPLE PIPE 1.25NPTX5.5 BL IRN
GASKET ADAPTER THROT BODY
CLAMP HOSE #10 .56-1.06
HOSE 3/4 ID LPG & NG (40.5 LG)
WASHER FLAT M6
DECAL INLET PRESSURE
DECAL FUEL INLET NG (NATURAL GAS APPLICATION)
DECAL FUEL INLET LPG (LP VAPOR APPLICATION)
ASSY,ADAPTER,THROTTLE BODY
GASKET, GOVERNOR ACTUATOR
ACTUATOR BOSCH 60, GOVERNOR
REDUCER 3.0" TO 2.75" TURBO
MIXER, 40/60MM ACTUATOR ASSY
O-RING 2-3/4 X 3/32 X 2-15/16
VENTURI, THROTTLE 36MM
PLUG STD PIPE 1/4 STEEL SQ HD
CLAMP HOSE #44 2.31-3.25
WASHER LOCK M6-1/4
NIPPLE CLOSE 3/4 X 1.375
BRACKET, HOSE RISER
NIPPLE CLOSE 1.25NPT X 1.625
SCREW THF M6-1 X 16 N WA Z/JS
BARBED EL 90 3/16 X 1/8
PIPE TEE W/ BRACKET WELDED
HOSE VACUUM 5/32 (7.5LG)
HOSE VACUUM 5/32 (10.5LG)
BARBED EL W/VENT (.052")
Page 2 of 2
EXPLODED VIEW: EV ENCL SAE B-GRP
GROUP F
DRAWING #:0J1935
ITEM
(1)1
(1)2
(1)3
(1)4
(1)5
6
(1)7
(1)8
9
10
11
(1)12
13
(1)14
15
16
(1)17
(1)18
19
20
(1)21
22
(1)23
(1)24
25
(1)26
(1)27
28
29
30
31
32
(1)33
34
(1)35
(1)36
37
38
39
40
41
(1)42
43
44
45
(1)46
(1)47
(1)48
(1)49
(1)50
(1)51
PART#
QTY.
0H98350ST0R
0J15800ST0R
0H41870AL0R
0J16010ST0R
0H98180ST0R
0C3594
0J15810ST0R
0H98270ST0R
0J0992
022097
0C3594A
0C33360ST0R
0E3257
0C33330ST0R
0C3393
0C6748
0C33340ST0R
0C33350ST0R
049813
0C2634
0J2037AAL0R
022473
0H98160ST0R
0J15830ST0R
022769
0C34000ST0R
0J11680ST0R
066760
0C6749
022145
0A9881
0A3359
0J43750ST0R
0C2454
0J43740ST0R
0H98260ST0R
022129
042907
022127
0J0993A
080490
0J15820ST0R
027529
0E7222
087233
0C25960AL0R
0C34420ST0R
0C34440ST0R
0C34430ST0R
0J17870ST0R
0J18000ST0R
1
1
1
8
1
8
1
2
4
13
8
1
12
1
2
16
1
2
12
1
1
13
1
3
4
2
1
1
16
2
1
64
1
89
1
4
2
2
1
8
16
3
8
2
24
1
1
1
1
3
3
REVISION: H-9591-B
DATE: 8/26/11
DESCRIPTION
REAR SOUND BAFFLE, C-GRP
DOOR LH SOLID
EXHAUST RH B-GROUP
BRACKET, ROD GUIDE
CORNER POST LH REAR
ASSY M6 HINGE R/H
DOOR RH SOLID
CENTER SUPPORT DOORS B-GRP
T-HANDLE, 2-POINT DBL DOOR
WASHER LOCK M6-1/4
ASSY M6 HINGE L/H
DUCT FRONT PANEL RAW
SCREW HWHTF M6-1.0 X 16
DUCT FRONT LH RAW
SCREW SHOULDER M8-1.25 X 20
NUT HEX LOCK M4-0.7 SS NYL INS
DUCT FRONT RH RAW
DUCT BOTTOM RAW
COVER ACCESS GEN2000
ASSY, ROOF B-GRP
CORNER POST RH REAR
DOOR RH LOUVERED
WASHER LOCK INT #10
COVER EXHAUST RAW
BRACE FRONT TOP
STRIP SEALANT 1/8 X 1
SCREW PPHM M4-0.7 X 12 SS
TRIM VINYL SEAL
SCREW BHSC M6-1.0 X 16 SS
CORNER POST RH FRONT B-GRP
CORNER POST LH FRONT B-GRP
BRACE SIDE TOP & BOTTOM
WASHER LOCK M8-5/16
ROLLER ROD, T-HANDLE
WASHER FLAT #8 SS
DOOR LH LOUVERED
NUT HEX LOCK 1/4-20 NY INS
RAIN SHIELD,DOOR JAMB
RIVET POP .1875 X .450 SS
DUCT REAR TOP
DUCT REAR RH
DUCT REAR PANEL
DUCT REAR LH
DOOR BAFFLE, A-GRP
DOOR BAFFLE, A-GRP
Page 2 of 4
GROUP F
DRAWING #:0J1935
ITEM
PART#
QTY.
60
61
62
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
83
84
85
86
0J1765BV
0J1765BU
0J1765BA
0J1765P
0J1765BW
0J1765BT
0J1765AU
0J1765BL
0J1765BK
0J1765BJ
0J1765AS
0J1765W
0J1765V
0J1765BX
0J1765U
0J1765AT
0J1765BY
0J1765BZ
0J1765CA
0J1765CB
0J1765BQ
0J1765BS
0J1765BP
0J1765CF
0J1765CG
1
2
2
2
1
1
2
1
1
1
8
1
1
3
3
2
2
1
1
1
2
2
1
3
3
DESCRIPTION
INSULATION REAR DUCT
INSULATION REAR DUCT
INSULATION FRONT DUCT BOTTOM
INSULATION REAR DUCT RH SIDE
INSULATION REAR DUCT TOP
INSULATION REAR BAFFLE
INSULATION REAR CORNER POST
INSULATION ROOF
INSULATION ROOF
INSULATION ROOF
INSULATION BTM SIDE BRACE
INSULATION RH DOOR SOLID
INSULATION LH DOOR SOLID
INSULATION DOOR
INSULATION LH DOOR LOUVERED
INSULATION CTR DOOR SPT
INSULATION FRONT CORNER POST
INSULATION FRONT CENTER PANEL
INSULATION FRONT DUCT LH SIDE
INSULATION FRONT DUCT
INSULATION FRONT DUCT
INSULATION DOOR BAFFLE
INSULATION DOOR BAFFLE

CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM
FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).
REVISION: H-9591-B
DATE: 8/26/11
Page 3 of 4
GROUP F
DRAWING #:0J1935
ITEM
PART#
QTY.
DESCRIPTION
REVISION: H-9591-B
DATE: 8/26/11
Page 4 of 4
EXPLODED VIEW: EV EXHAUST 6.8L C-GRP
GROUP F
DRAWING #: 0J4245
APPLICABLE TO:
ITEM
(1)1
2
3
4
5
6
7
8
9
10
11
12
13
(2)14
15
16
17
18
19
20
21
22
23
24
25
26
27
(2)28
(2)29
PART#
QTY.
0J42720ST0R
0C5737
0D6929
0D3197
(2)0D5027A
0J3460
(2)0J3460A
0J3458
0A5215B
0J3459
0J3457
0D3159
0A6765
0C3433A
058623
0F9071
051756
046526
022131
0F2773A
090388
0J4403
083218
0G6401
0F4710
088775
039287
022145
067989
0H4954
072252
2
2
4
1
1
1
1
1
2
1
1
2
2
4
2
1
8
8
8
2
2
1
1
6
6
6
4
8
4
1
1
DESCRIPTION
ASSY, 6.8L C-GRP EXHAUST BRACE
BRACKET, HEAT SHIELD
MTG BAND CATALYST-MUFFLER
MUFFLER 6.8L G3 C-GRP
CATALYST MUFFLER 6.8L C-GRP
PIPE, 6.8L RH MUFFLER
PIPE, 6.8L RH MUFFLER (W/O2)
PIPE, 6.8L LH MUFFLER
FLEX PIPE 2.5"
PIPE, 6.8L RH EXHAUST MANIFOLD
PIPE, 6.8L LH EXHAUST MANIFOLD
FLANGE, EXHAUST
RING GASKET 2.5DIA
CLAMP BAND 2.5"
BOLT U 3/8-16 X 2.75
SENSOR OXYGEN
WASHER LOCK M10
EXHAUST BLANKET 1130MM LONG
SCREW HHTT M6-1.0 X 12 ZINC
HEAT SHIELD C-GRP
RAIN CAP 4.00/4.19
SCREW HHC M10-1.5 X 45 SS FTH
WASHER LOCK M10 SS
WASHER FLAT 3/8 SS
NUT HEX FL WHIZ M8-1.25
HARN OXYGEN SENSOR EXTEN 50" (NOTSHOWN)
GROMMET 1.37 X .06 X 1.00

(2) USED IN EMISSIONS APPLICATIONS ONLY.
REVISION: H-9944-D
DATE: 11/3/11
PAGE 2 OF 2
EXPLODED VIEW: EV KIT H-PANEL MODEM
GROUP H
DRAWING #: 0G0616
ITEM
PART#
QTY.
0F2144
(1) 0J7331
079224
051713
049226
051716
0A5332
1
1
2
2
2
2
1
1
2
3
4
5
6
DESCRIPTION
ASSY PCB H-PANEL MODEM
ASSY PCB H-PANEL MODEM
SCREW PPHM M5-0.8 X 30 SS
WASHER FLAT M5
WASHER LOCK M5
CONN EL DSUB-MIN FE KIT
(1) WHEN USING MODEM P/N 0J7331, THE H-PANEL FIRMWARE MUST BE AT VERSION 3.8A OR LATER.
REVISION: H-9832-B
DATE: 10/18/11
Page 2 of 2
EXPLODED VIEW: EV 390 ALT SHROUD KIT
GROUP H
DRAWING #: 0H5179
APPLICABLE TO:
ITEM
PART#
QTY.
(1)1
0H47970ST03
0H4797AST03
0H4797BST03
0H78890ST03
0C2454
0E1534A
2
2
2
2
8/10
4
(2)2
3
DESCRIPTION
SHROUD 390 ALT X 76MM
PLUG PLASTIC 1.50"
(1)NOTE:
0H47970ST03 INCLUDED IN KIT #0H5178
0H4797AST03 INCLUDED IN KIT #0H5178A
0H4797BST03 INCLUDED IN KIT #0H5178B
0H78890ST03 INCLUDED IN KIT #0H5178C
(2) QTY DETERMINED BY SHROUD MOUNTING REQUIREMENTS.
REVISION: H-6171-B
DATE: 3/5/10
Page 2 of 2
EXPLODED VIEW: EV, NEUTRAL BLOCK 0-250A
GROUP H
DRAWING #: 0J1047
APPLICABLE TO:
ITEM
PART#
QTY.
1
2
3
4
5
6
7
8
9
057073
0H9690
0F8451
0C2266
022131
022237
022241
067989
043107
NEUTRAL BLOCK (250A)

2
1
1
4
2
2
2
1
1
1
2
3
4
5
6
7
8
9
10
DESCRIPTION
JUNCTION BLOCK 3/8-16
NEUTRAL, BRACKET (60-100A)
LUG SLDLSS 300 MCM-6 AL/CU
SCREW PHTT M5-0.8 X 16 ZP
WASHER LOCK 3/8
NUT HEX FL WHIZ M8-1.25
NEUTRAL BLOCK (300A - 600A)

057073
2
0H9689A
1
BUS BAR, NTRL BLK 520 0-600A
0A7822
2
LUG SLDLSS 600/250-1/0X1/4-28
0C2266
4
022511
2
SCREW HHC 3/8-16 X 1-1/4 G5
022237
4
WASHER LOCK 3/8
022241
4
022131
2
045335
4
022097
4
WASHER LOCK M6-1/4
1
2
3
4
5
6
7
8
9
10
NEUTRAL BLOCK (700A 1200A)

057073
2
0H9689
1
BUS BAR, NTRL BLK 520 600-1600
0A7822
4
LUG SLDLSS 600/250-1/0X1/4-28
0C2266
4
022511
5
SCREW HHC 3/8-16 X 1-1/4 G5
022237
7
WASHER LOCK 3/8
022241
7
022131
2
045335
8
022097
8
WASHER LOCK M6-1/4
1
2
3
4
5
6
7
8
NEUTRAL BLOCK (1400A 2500A)

0C6937M
2
INSULATOR, STANDOFF 600V3/8-16
0J4583
2
BUS BAR, 1/4"X6"X10"
031578
3
SCREW HHC 3/8-16 X 1-1/2 G8
022131
10
022237
7
WASHER LOCK 3/8
022241
3
023152
2
029745
2
SCREW HHC 3/8-16 X 1 G5
REVISION: H-8638-B
DATE: 4/5/11
PAGE 2 OF 2
Notes
Notes
Notes
GENERAC POWER SYSTEMS, INC.

211 MURPHY DR. P.O. BOX 310
EAGLE, WI 53119

13633160200

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Stationary Emergency Generator

READ THIS MANUAL THOROUGHLY

The operator is responsible for proper and safe use

OPERATION AND MAINTENANCE

After this heading, read instructions that, if not

Operating instructions presented in this manual

After this heading, read instructions that, if not

HOW TO OBTAIN SERVICE

After this heading, read instructions that, if not

When the generator requires servicing or repairs,

These safety warnings cannot eliminate the hazards

This symbol points out potential fire hazard.

Introduction ...........................Inside Front Cover

Section 2 Installation ......................................9

Read This Manual Thoroughly ...........................................................IFC

STATIONARY EMERGENCY GENERATOR INSTALLATION.......................9

Operation and Maintenance ...............................................................IFC

Safety Rules .......................................................2

BASIC STATIONARY EMERGENCY GENERATOR

IDENTIFICATION RECORD ....................................................................4

STATIONARY EMERGENCY GENERATOR AC

Data Label .......................................................................................4

TRANSFER SWITCH START SIGNAL CONNECTIONS ..........................11

XPL Label ........................................................................................4

EQUIPMENT DESCRIPTION ..................................................................5

PREPARATION BEFORE START-UP .....................................................12

Section 3 Operation ......................................13

Section 5 Warranty .................................................17

Engine Coolant Heaters ....................................................................8

SG 6.8 Liter 04.09

Important Safety Instructions

This product contains or emits chemicals

Study these SAFETY RULES carefully before installing, operating

lethal voltages are generated by

of the generator are rotating and/or hot

Important Safety Instructions

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

In case of accident caused by electric shock, immediately

Section 1 General Information

Figure 1.1 Data Label

Generator Model Number

Stationary Emergency Generator Model Number

Groups and Assembly Numbers

Section 1 General Information

OIL PRESSURE SENDER

This equipment is a revolving field, alternating current generator

This sender monitors oil pressure in the engine. If oil pressure

The generators revolving field is directly connected to and driven

LOW FUEL PRESSURE SWITCH (GAS UNITS ONLY)

STANDARD GENERATOR FEATURES

This normally closed (N.C.) switch is held open by fuel pressure

The rotor insulation system is Class H rated, and the stator

ENGINE PROTECTIVE DEVICES

The Stationary Emergency Generator may be required to operate

COOLANT TEMPERATURE SENDER

LOW COOLANT LEVEL SENSOR

After a pre-specified duration of cranking, this function ends the

RPM SENSOR LOSS SHUTDOWN

Section 1 General Information