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FIGURE 2-28. 4000W/60HZ GENERATOR INSTALLATION - GM ENGINES
ITEM PART NUMBER QTY DESCRIPTION REV
1001153265 Ref 4000W/60HZ GENERATOR INSTALLATION - GM ENGINES B 1 0100011 AR Compound, Locking 2 0100019 AR Compound, Locking 3 0480142 1 Belt, Generator 4 0641407 4 Bolt 1/4 x 7/8 5 3931016 4 Capscrew #10 x 1 6 0641516 3 Bolt 5/16 x 2 7 0641808 4 Bolt 1/2 x 1 8 0700820 1 Bolt M8 x 60 9 0701016 1 Bolt M10 x 40 10 0811608 4 Screw 3/8 x 1 11 0860038 1 Box, Switch 12 1001138566 1 Box, Control 13 1001152457 1 Junction Box Assembly 13 3300396 1 Cover, Breaker 13 4360070 1 Breaker, Circuit - 15Amp 13 4460425 1 Connector, Strain Relief (LH Side) 13 4460426 1 Connector, Strain Relief (RH Side) 14 0902888 1 Bracket, Junction Box 15 0962520 1 Bushing, Split 16 1001129858 1 Generator Assembly 16 70003709 1 Ring, Retaining (External) 16 70003708 1 Ring, Retaining (Internal) 16 70001966 1 Bearing 16 70004092 1 Endbell (Shaft End) 16 70004171 1 Key 16 70004676 1 Rotor 16 70004684 1 Stator 16 70004678 1 Endbell (Rear) 16 70004679 1 Cover, Endbell (Rear) 16 70004680 1 Enclosure, Wiring 16 70004685 1 Cover, Enclosure 16 70004682 1 Switch, Reset (Located on Enclosure Cover) 16 70004098 1 Connector, Strain Relief (Located on Enclosure Cover) 17 3251102 1 Nameplate, Generator 18 3300454 4 Nut 1/4 19 3311005 4 Nut #10 20 3311508 3 Nut 5/16 21 3580312 1 Pulley, Idler 22 3580314 1 Pulley, Drive 23 3580348 1 Tensioner, Belt with Pulley 24 3910606 4 Screw #6 x 3/8 25 3960422 1 Gasket 26 4060802 1 Guard, Switch 27 4360336 1 Switch, Toggle 28 4460346 1 Receptacle 29 4568735 1 Tube, Spacer 30 4711400 4 Washer 1/4 31 4751500 3 Washer 5/16 32 4711800 4 Washer 1/2
ITEM PART NUMBER QTY DESCRIPTION
33 4751000 4 Washer #10 34 4811900 1 Washer M8 35 4891600 1 Washer 3/8 36 1001152532 1 Generator Harness (See ELECTRICAL SECTION for Breakdown) 37 1001132055 1 Diagram, Wiring (Not Shown) (See ELECTRICAL SECTION for Breakdown) 38 1001141181 1 Bracket, Motor Mounting 39 1001110873 1 Cover 40 2820031 33 ft/ 10.1m Heat Shrink 41 1705387 3 Decal - Hazardous Voltage 42 3251243 1 Decal - 120V-60Hz 43 1705374 1 Decal - 240V-60Hz 44 0100020 AR Sealant 45 4460071 1 Connector, Strain Relief
REV
ITEM PART NUMBER QTY
DESCRIPTION
1001146620 Ref 7500W/60HZ GENERATOR INSTALLATION - CATERPILLAR
ENGINE
1 0100011 AR Compound, Locking 2 0100019 AR Compound, Locking 3 0480129 1 Belt 4 0641403 1 Bolt 1/4 x 3/8 6 0860038 2 Box, Switch 7 0861538 1 Control Box Assembly 7 7024488 1 Card, Circuit - Generator Power 7 See Note NSS Fuse (Note: Not Available - Purchase Locally) 7 7024489 1 Card, Circuit - Control 7 70000619 1 Harness, Circuit Card 8 0861542 1 Junction Box Assembly (See Items 101-128 for Breakdown) 9 0641808 4 Bolt 1/2 x 1 10 0701217 3 Bolt M12 x 45 11 0902888 1 Bracket 12 2820031 AR Heat Shrink (Not Shown) 13 3300454 4 Nut 1/4 14 3311505 3 Nut 5/16 15 0962520 1 Bushing 16 2460048 1 Generator Assembly 16 70001100 1 Rotor (Includes p/n 70001384 & 70000863) (Not Shown) 16 70001384 1 Bearing, Ball Radial (Not Shown) 16 70000863 1 Fan (Not Shown) 16 70002088 1 Stator (Not Shown) 16 70002297 1 Stud 16 70003631 1 Brushholder Assembly (Not Shown) 16A 70004171 1 Key 16B 70001966 1 Bearing, Ball Radial (Located in Belt Tensioner Endbell) 16B 70003708 1 Ring, Internal Retaining (Located in Belt Tensioner Endbell) 16B 70003709 1 Ring, External Retaining (Located in Belt Tensioner Endbell) 16C 70001953 1 Endbell, Belt Tensioner 16D 70004169 1 Endbell, Brush Block 16E 70004169 1 Shroud 16E See Note NSS Insulator, Endbell (Note: Not Available for Purchase) 16E 7027799 1 Block, Connector - 6 Position (Not Shown) 16E 70002460 1 Nut, Brass (Attaches p/n 7027799 to Cover) (Not Shown) 16E 7024485 1 Breaker, Circuit 30Amp (Not Shown) 16E 70001696 1 Boot, Breaker (Not Shown) 16E 7026626 1 Connector - 6 Position (Includes Seal) (Not Shown - Plugs into Item 39) 16E 7026597 1 Connector, with Leads (Not Shown) 16E 7026188 1 Clamp, Cable Options (Not Shown) 16E 70004169 1 Plate, End Panel 16E 70001974 1 Decal - Terminal Connections 16F 70001973 1 Decal - Warning Moving Parts 17 4711400 14 Washer 1/4 18 3910606 8 Screw #6 x 3/8 19 3311405 7 Nut 1/4
REV
A
ITEM PART NUMBER QTY DESCRIPTION
20 3960422 2 Gasket 21 3580316 1 Pulley 22 3580317 1 Pulley 23 3580318 1 Pulley 24 4060802 1 Guard, Switch 25 0641618 1 Bolt 3/8 x 2-1/4 26 4360336 1 Switch, Toggle 27 0641516 3 Bolt 5/16 x 2 28 4460071 2 Connector, Strain Relief 29 4460346 1 Receptacle 30 4460958 1 Receptacle, Female Twist-Lock 31 4711500 10 Washer 5/16 32 4761500 4 Washer 5/16 33 4922925 1 Harness, Generator 33 4460225 1 Plug, Male - 6 Position (Plugs into Generator) 33 See Note NSS Socket, Female (Use with 4460225) 33 See Note NSS Seal, Plug (Use with 4460225) 33 See Note NSS Seal, Interface (Use with 4460225) 35 1001112586 1 Diagram, Wiring (Not Shown) (See Items 301-304 for Breakdown) 36 4711600 5 Washer 3/8 37 4711800 4 Washer 1/2 38 0641407 4 Bolt 1/4 x 7/8 39 4791400 1 Washer 1/4 40 1001110872 1 Cover, Receptacle 41 4751000 4 Washer #10 42 0721004 2 Screw #10 x 1/2 43 3740080 2 Relay 44 1001110873 1 Cover, Receptacle 45 0641508 4 Bolt 5/16 x 1 46 3311005 2 Nut #10 47 3574163 1 Bracket 48 0641408 5 Bolt 1/4 x 1 0861542 Ref JUNCTION BOX ASSEMBLY 101 0861541 1 Box, Junction 102 1060494 2 ft/.6m Cable, Electrical - 12/3 103 1060708 2.5 ft/ 0.8m Cable, Electrical - 10/3 104 1705376 1 Decal - Wiring Schematic 105 3300396 1 Cover, Fuse 106 3310601 2 Nut #6-32NC 107 1060343 1.5 ft/ 0.5m Cable, Electrical - 10/4 109 3910610 2 Bolt 6-32 x 5/8 110 4360070 1 Circuit Breaker - 15Amp 116 4460425 2 Strain Relief, Terminal 117 4460426 2 Connector, Strain Relief 121 4750600 4 Washer #6 122 4760600 2 Washer #6 125 1671092 1 Cover (60Hz Spec Only) 126 4460963 1 Connector 128 1001121340 1 Terminal Block Assembly (See Items 401-410 for Breakdown) 0273380 Ref DECAL INSTALLATION
REV
D
ITEM PART NUMBER QTY
DESCRIPTION
202 1705375 1 Decal - 240V - 3 Phase - 60Hz 203 1705387 3 Decal - Hazardous Voltage 204 1705460 2 Decal - SkyPower 1001112586 Ref ELECTRICAL DIAGRAM COMPONENTS 301 1001152429 Ref Generator Harness 301A 4460375 7 Terminal 301B 4460967 1 Plug, Male - 3 Position 301B 4460465 3 Socket, Female 301C Ref Component Options: 301C 2400060 1 Fuseholder (Not Shown) 301C 2400064 1 Fuse - 5Amp (Not Shown) 301D 4460742 1 Connector - 2 Position (Not Shown) 301D 4460743 2 Terminal (Not Shown) 304 4922641 1 Switch Harness Ref TERMINAL BLOCK ASSEMBLY NPN Ref Gray Terminal Block Assembly (Complete Assembly Not
Available - Purchase Individual Components)
1001121340 Ref Tan Terminal Block Assembly 401 Ref Marker Strip #1 Options: 401 4460411 2 Gray Terminal Block Assembly 401 70002818 2 Tan Terminal Block Assembly 402 Ref Marker Strip #2 Options: 402 4460412 AR Gray Terminal Block Assembly 402 70002819 4 Tan Terminal Block Assembly 403 Ref Marker Strip #3 Options: 403 4460413 2 Gray Terminal Block Assembly 403 70002820 2 Tan Terminal Block Assembly 404 Ref Marker Strip #4 Options: 404 4460414 2 Gray Terminal Block Assembly 404 70002821 2 Tan Terminal Block Assembly 405 Ref Marker Strip #5 Options: 405 4460415 AR Gray Terminal Block Assembly 405 70002822 4 Tan Terminal Block Assembly 406 Ref Terminal, End Barrier Options: 406 4460956 1 Gray Terminal Block Assembly 406 70002823 1 Tan Terminal Block Assembly 407 Ref Terminal, End Block Options: 407 4460607 2 Gray Terminal Block Assembly 407 70002824 2 Tan Terminal Block Assembly 408 Ref Terminal, Block Options: 408 4460957 AR Gray Terminal Block Assembly 408 70002825 7 Tan Terminal Block Assembly 409 Ref Terminal, Cross Connector Jumper Options: 409 4461001 2 Gray Terminal Block Assembly 409 70002826 2 Tan Terminal Block Assembly 410 3641533 1 Rail, Relay
REV
B B
A
ITEM PART NUMBER QTY
DESCRIPTION
Ref 7500W GENERATOR INSTALLATION - CATERPILLAR ENGINE
MACHINES (ROMANIAN BUILT MACHINES)
1001147837 Ref 50Hz Spec 1001147838 Ref 50Hz 110/220V Spec 1 0100011 AR Compound, Locking 2 0100019 AR Compound, Locking 3 0480126 1 Belt 4 0641403 1 Bolt 1/4 x 3/8 5 4711400 4 Washer 1/4 6 0641508 4 Bolt 5/16 x 1 7 0641516 3 Bolt 5/16 x 2 8 0861567 1 Junction Box Assembly (See Items 101-128 for Breakdown) 9 0641808 4 Bolt 1/2 x 1 10 0701217 3 Bolt M12 x 45 11 0861572 1 Control Box Assembly 11 7024488 1 Card, Circuit - Generator Power 11 See Note NSS Fuse (Note: Not Available - Purchase Locally) 11 7024489 1 Card, Circuit - Control 11 70000619 1 Harness, Control Box (Internal) 12 0902888 1 Bracket 13 2820031 AR Heat Shrink 14 3252764 1 Nameplate 15 0962520 1 Bushing 16 2460048 1 Generator Assembly 16 70001100 1 Rotor (Includes p/n 70001384 & 70000863) (Not Shown) 16 70001384 1 Bearing, Ball Radial (Not Shown) 16 70000863 1 Fan (Not Shown) 16 70002088 1 Stator (Not Shown) 16 70002297 1 Stud 16 70003631 1 Brushholder Assembly (Not Shown) 16A 70004171 1 Key 16B 70001966 1 Bearing, Ball Radial (Located in Belt Tensioner Endbell) 16B 70003708 1 Ring, Internal Retaining (Located in Belt Tensioner Endbell) 16B 70003709 1 Ring, External Retaining (Located in Belt Tensioner Endbell) 16C 70001953 1 Endbell, Belt Tensioner 16D 70004169 1 Endbell, Brush Block 16E 70004169 1 Shroud 16E See Note NSS Insulator, Endbell (Note: Not Available for Purchase) 16E 7027799 1 Block, Connector - 6 Position (Not Shown) 16E 70002460 1 Nut, Brass (Attaches p/n 7027799 to Cover) (Not Shown) 16E 7024485 1 Breaker, Circuit 30Amp (Not Shown) 16E 70001696 1 Boot, Breaker (Not Shown) 16E 7026626 1 Connector - 6 Position (Includes Seal) (Not Shown - Plugs into Item 39) 16E 7026597 1 Connector, with Leads (Not Shown) 16E 7026188 1 Clamp, Cable Options (Not Shown) 16E 70004169 1 Plate, End Panel 16E 70001974 1 Decal - Terminal Connections 16F 70001973 1 Decal - Warning Moving Parts
REV
A A
ITEM PART NUMBER QTY DESCRIPTION
17 3300454 4 Nut 1/4 18 3311505 3 Nut 5/16 19 3311405 1 Nut 1/4 20 4060802 1 Guard, Switch 21 3580316 1 Pulley 22 3580317 1 Pulley 23 0641408 1 Bolt 1/4 x 1 24 4360336 1 Switch, Toggle 25 0641618 1 Bolt 3/8 x 2-1/4 26 0721004 2 Screw #10 x 1/2 27 4711500 10 Washer 5/16 28 3311005 2 Nut #10 29 3574163 1 Bracket 30 3580319 1 Pulley 31 3740080 2 Relay 32 4761500 4 Washer 5/16 33 4922925 1 Harness, Generator 33 4460225 1 Plug, Male - 6 Position (Plugs into Generator) 33 See Note NSS Socket, Female (Use with 4460225) 33 See Note NSS Seal, Plug (Use with 4460225) 33 See Note NSS Seal, Interface (Use with 4460225) 35 1001112586 1 Diagram, Wiring (Not Shown) (See Items 301-304 for Breakdown) 36 4711600 1 Washer 3/8 37 4711800 4 Washer 1/2 38 4751000 4 Washer #10 39 4791400 1 Washer 1/4 40 0641407 4 Bolt 1/4 x 7/8 41 Ref Box, Switch Options: 41 0860038 2 50Hz (110/220V) 41 See Note 2 50Hz (Supply Locally) 42 3910606 8 Screw #6 x 3/8 43 3960422 2 Gasket 44 Ref Connector, Strain Relief Options: 44 4460051 1 50Hz (110/220V) 44 See Note 1 50Hz (Supply Locally) 45 Ref Connector, Strain Relief Options: 45 4460071 1 50Hz (110/220V) 45 See Note 1 50Hz (Supply Locally) 46 Ref Receptacle Options: 46 4460346 1 50Hz (110/220V) 46 See Note 1 50Hz (Supply Locally) 47 Ref Receptacle, Female Twist-Lock Options: 47 4460958 1 50Hz (110/220V) 47 See Note 1 50Hz (Supply Locally) 48 Ref Shield, Cover Options: 48 1001110872 1 50Hz (110/220V) 48 See Note 1 50Hz (Supply Locally) 49 Ref Shield, Cover Options: 49 1001110873 1 50Hz (110/220V) 49 See Note 1 50Hz (Supply Locally) 0861542 Ref JUNCTION BOX ASSEMBLY D
REV
ITEM PART NUMBER QTY DESCRIPTION
101 0861541 1 Box, Junction 102 1060494 2 ft/ 0.6m Cable, Electrical - 12/3 103 1060708 2.5 ft/ 0.8m Cable, Electrical - 10/3 104 1705376 1 Decal - Wiring Schematic 105 3300396 1 Cover, Fuse 106 3310601 2 Nut #6-32NC 107 1060343 1.5 ft/ 0.5m Cable, Electrical - 10/4 109 3910610 2 Bolt 6-32 x 5/8 110 4360070 1 Circuit Breaker - 15Amp 116 4460425 2 Strain Relief, Terminal 117 4460426 2 Connector, Strain Relief 121 4750600 4 Washer #6 122 4760600 2 Washer #6 125 1671092 1 Cover (60Hz Spec Only) 126 4460963 1 Connector 128 1001121340 1 Terminal Block Assembly (See Items 401-410 for Breakdown) 0272589 Ref DECAL INSTALLATION A
202 1705461 1 Decal - 240V - 3 Phase 203 1705489 3 Decal - Hazardous Voltage 204 1705460 2 Decal - SkyPower 1001112586 Ref ELECTRICAL DIAGRAM COMPONENTS 301 1001152429 Ref Generator Harness 301A 4460375 7 Terminal 301B 4460967 1 Plug, Male - 3 Position 301B 4460465 3 Socket, Female 301C Ref Component Options: 301C 2400060 1 Fuseholder (Not Shown) 301C 2400064 1 Fuse - 5Amp (Not Shown) 301D 4460742 1 Connector - 2 Position (Not Shown) 301D 4460743 2 Terminal (Not Shown) 304 4922641 1 Switch Harness Ref TERMINAL BLOCK ASSEMBLY NPN Ref Gray Terminal Block Assembly (Complete Assembly Not
Available - Purchase Individual Components)
1001121340 Ref Tan Terminal Block Assembly 401 Ref Marker Strip #1 Options: 401 4460411 2 Gray Terminal Block Assembly 401 70002818 2 Tan Terminal Block Assembly 402 Ref Marker Strip #2 Options: 402 4460412 AR Gray Terminal Block Assembly 402 70002819 4 Tan Terminal Block Assembly 403 Ref Marker Strip #3 Options: 403 4460413 2 Gray Terminal Block Assembly 403 70002820 2 Tan Terminal Block Assembly 404 Ref Marker Strip #4 Options: 404 4460414 2 Gray Terminal Block Assembly 404 70002821 2 Tan Terminal Block Assembly 405 Ref Marker Strip #5 Options: 405 4460415 AR Gray Terminal Block Assembly 405 70002822 4 Tan Terminal Block Assembly
REV
B B
A
ITEM PART NUMBER QTY
DESCRIPTION
406 Ref Terminal, End Barrier Options: 406 4460956 1 Gray Terminal Block Assembly 406 70002823 1 Tan Terminal Block Assembly 407 Ref Terminal, End Block Options: 407 4460607 2 Gray Terminal Block Assembly 407 70002824 2 Tan Terminal Block Assembly 408 Ref Terminal, Block Options: 408 4460957 AR Gray Terminal Block Assembly 408 70002825 7 Tan Terminal Block Assembly 409 Ref Terminal, Cross Connector Jumper Options: 409 4461001 2 Gray Terminal Block Assembly 409 70002826 2 Tan Terminal Block Assembly 410 3641533 1 Rail, Relay
