Operator's Manual: Power Systems, Inc

®
POWER SYSTEMS, INC.
Operator’s Manual
“E” Option Control Panels
This manual contains standard drawings and schematics.

For specific drawings, please refer to the Owner’s Manual of the unit.
This manual should remain with the unit.

Important Safety Instructions
E Option Control Panels
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 and potential operators of this equipment. !
Study these SAFETY RULES carefully before • Do not handle any kind of electrical device while
installing, operating or servicing this equipment. standing in water, while barefoot, or while hands or
Become familiar with this manual and all literature feet are wet. DANGEROUS ELECTRICAL SHOCK
pertaining to your generator set and related equip- MAY RESULT.
ment. This equipment can operate safely, efficiently • If people must stand on metal or concrete while
and reliably only if it is properly installed, operated installing, operating, servicing, adjusting or repairing
and maintained. Many accidents are caused by failing this equipment, place insulative mats over a dry
to follow simple and fundamental rules or precau- wooden platform. Work on the equipment only while
tions. standing on such insulative mats.
Generac cannot possibly anticipate every possible cir- • Wire gauge sizes of electrical wiring, cables and cord
sets must be adequate to handle the maximum elec-
cumstance that might involve a hazard. The warn-
trical current (ampacity) to which they will be sub-
ings in this manual, and on tags and decals
jected.
affixed to your equipment are, therefore, not
all-inclusive. If you use a procedure, work method or • Before installing or servicing this equipment, make
operating technique Generac does not specifically rec- sure that all power voltage supplies are positively
TURNED OFF at their source. Failure to do so will
ommend, you must satisfy yourself that it is safe for you
result in hazardous and possibly fatal electrical
and others. You also must make sure the procedure,
shock.
work method or operating technique that you choose
does not render the equipment unsafe. • When installed with an automatic transfer switch, the
generator may crank and start anytime without
! GENERAL HAZARDS ! warning. To prevent injuries caused by sudden start-
up, disable the generator’s automatic start circuit
• For safety reasons, Generac recommends that this before working on or around the unit. Then, place a
equipment be installed and serviced by a Generac “Do Not Operate” tag on the generator control panel
Authorized Service Dealer or other competent, quali- and on the transfer switch.
fied electrician or installation technician who is famil- • In case of accident caused by electric shock, imme-
iar with applicable codes, standards and regulations. diately shut down the source of electrical power. If
The operator also must comply with all such codes, this is not possible, attempt to free the victim from
standards and regulations. the live conductor. AVOID DIRECT CONTACT WITH
THE VICTIM. Use a nonconducting implement,
• When working on this equipment, remain alert at all
such as a rope or board, to free the victim from the
times. Never work on the equipment when you are
live conductor. If the victim is unconscious, apply
physically or mentally fatigued.
first aid and get immediate medical help.
• Inspect the equipment regularly, and promptly repair
• Never wear jewelry when working on this equipment.
or replace all worn, damaged or defective parts using
Jewelry can conduct electricity resulting in electric
only factory-approved parts.
shock, or may get caught in moving components
• Before performing any maintenance on the generator causing injury.
or any related equipment, disable the generator to
prevent accidental start-up. Remove the control
panel fuse and then disconnect the battery cables by FIRE HAZARDS
removing the one indicated by a NEGATIVE, NEG or
(–) first. To re-enable the generator, reconnect the • For fire safety, the generator and related equipment
battery cables connecting the one indicated by a must be installed and maintained properly.
NEGATIVE, NEG or (–) last, then re-install the con- Installation always must comply with applicable
trol panel fuse. codes, standards, laws and regulations. Adhere
strictly to local, state and national electrical and
building codes. Comply with regulations the
ELECTRICAL HAZARDS Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the
• Generators produce dangerous electrical voltages equipment is installed in accordance with the man-
and can cause fatal electrical shock. Avoid contact ufacturer’s instructions and recommendations.
with bare wires, terminals, connections, etc., while Following proper installation, do nothing that
the generator and related equipment are running. might alter a safe installation and render the unit
Ensure all appropriate covers, guards and barriers in noncompliance with the aforementioned codes,
are in place before operating the equipment. If you standards, laws and regulations.
must work around an operating unit, stand on an
insulated, dry surface to reduce shock hazard.
Generac® Power Systems, Inc.
Table of Contents
Safety Rules ..............Inside Front Cover Section 3 — Troubleshooting and

Section 1 — General Information..........2 Diagnosis ........................20
Overview ................................................................2 Oil Pressure Sensing ..............................................20
Engine Control ......................................................2 Low Coolant Level ..................................................22
E Option Control Module ......................................2 Coolant Temperature Sensing ................................25
Alarms....................................................................4 Oil Temperature Sensing ........................................27
Alarm Processing....................................................5 AC Voltage Display ..................................................29
Programmable Parameters ....................................6 RPM Sensor and Engine Speed Alarms ..................29
E Panel Modem Setup Procedure ..........................9 Engine Does Not Crank ..........................................31
E Panel RS 232 Cables ..........................................9 Overcrank................................................................34
Additional Panel Components ..............................10 Appendix — Phoenix and
Checking/Replacing the E Panel Control Module Deutsch Connectors ........35
Internal Fuse ....................................................11 Section 4 — Glossary..........................38
User Programmable Inputs ..................................11 E Control Panel Definitions ....................................38
Wiring Examples ..................................................12 Section 5 — Electrical Data ................39
Programming Examples ......................................13 E Panel Drawing Application Matrix ......................39
Section 2 — Operation........................14 Section 6 — Exploded Views and
Output Function Table ............................................14 Parts Lists ......................60
E Panel Master Control Box Configuration Settings15 Section 7 — Notes ..............................76
E Panel Display Map ............................................18
AUTHORIZED SERVICE DEALER LOCATION

To locate the GENERAC AUTHORIZED SERVICE
DEALER nearest you, please call this number:
1-800-333-1322
DEALER LOCATION INFORMATION
CAN BE OBTAINED AT THIS NUMBER.
Generac® Power Systems, Inc. 1

Section 1 — General Information
OVERVIEW The user can program the length of time that the starter
The “E” option control panel is a programmable motor is engaged during a start attempt. After the first
engine control and monitoring system. It allows the attempt, the generator will pause for a programmable
user to customize the generator starting and running length of time before the next attempt. The number of
sequence, monitor engine parameters and configure attempts also is programmable, after which the failed
the alarms. This can be done either through its own to start alarm is activated.
control module, featuring liquid-crystal display The user can program a warm-up time that is active
(LCD) and keypad, or using a PC and RS232 serial after the generator has started. This could be used in
communications. The module includes user pro- conjunction with a programmable relay output to
grammable inputs and outputs that allow it to be tai- inhibit the transfer switch from applying load until
lored to a vast range of applications. All of the setup the generator is ready. The warm-up time can be set
information is stored in nonvolatile (permanent) to zero if this function is not required. This timer is
memory. separate from the alarm hold off timer, which allows
the generator to run for a time before certain alarms
ENGINE CONTROL (such as low oil pressure) are active.
The module has a three-position selector switch that If the generator is in the AUTO mode and a stop com-
selects between “Auto” mode, “Off” and “Manual” start mand is received, a programmable cool-down timer
mode. When the switch is in the OFF position, the can be used to keep the generator running with no
generator will not start, and it will stop if it is running. load for a fixed time. This also can work in conjunc-
When the switch is turned to MANUAL, the generator tion with a relay output to inhibit the transfer switch.
will start immediately and will continue to run until If the timer is set to zero, this function is disabled. If
the switch is turned to the OFF position or a shut- the selector switch is turned to OFF, then the genera-
down alarm is activated. With the switch in the AUTO tor will stop immediately without waiting for the cool-
position, the generator will wait for either the remote down time.
start contacts to close or for a start command to be
sent from the serial link. The generator will run until Certain alarm functions are designated as shutdown
the remote start contacts open, a stop command is alarms. These alarms will stop the generator and
sent down the serial link, a shutdown alarm is acti- inhibit it from starting until the alarm condition has
vated or the switch is turned to the OFF position. The cleared and the alarm has been reset.
remote start contacts always will have priority over
the serial link commands so that the serial link can- E OPTION CONTROL MODULE
not stop the generator if the remote start contacts are
closed. When GenLink® software, which may be OVERVIEW
obtained from a Generac Authorized Service Dealer, is
connected to the E panel via modem, the panel will The LCD on the front of the module (Figure 1.1) fea-
monitor the connection to ensure that the line has not tures a 24-character by two-line display screen that will
dropped. If the E panel detects that the line has been show one of seven pages. There is a keypad with six
dropped, it will disconnect the modem so that it is keys that are used for operating the display and select-
ready for another incoming call. If the generator had ing the various pages. A key-activated switch allows the
been started via the modem connection, then it will be user to select whether the generator is in the “Auto”
stopped immediately unless the remote start contacts mode, “Off” mode or “Manual” run mode. Four LEDs
are closed or the generator is in manual. However, if indicate the following conditions:
the GenLink® software disconnected cleanly (as a • “Power” – Battery power is OK.
result of a user command) with the generator running,
then the generator will continue to run for a another • “Not Auto” – The generator is not in the automatic
three hours unless it receives a stop command. mode.
• “Com Alarm” – A common alarm condition has
When a start command is received, the engine preheat occurred.
will be engaged, if it is selected. The user can program • “Gen Run” – The generator is running.
the preheat to engage for a programmable time before
engaging the starter motor, to engage while the engine is NOTE:
attempting to start, or to do both. In order to protect The “Power” LED will go out immediately if the
the engine from trying to start while it is already run- battery voltage dips below the alarm limit, but the
ning (if the rpm sensor is damaged), an alarm is gener- alarm will not be triggered unless the voltage is
ated if there is oil pressure when the start command is low for more than five minutes.
sent. An alarm also is generated if there is a voltage
output from the generator but the rpm sensor detects
zero engine speed.
2 Generac® Power Systems, Inc.

Figure 1.1 – Control Module Layout When the display is showing certain pages, the user
is able to scroll between relevant items within the
page using the up and down arrow keys. For example,
if the display is showing the “Alarm Log Page,” the
user can use the up and down arrow keys to scroll
between the entries on the alarm log. A description of
each page is given below.
Software Version Page

This page displays the software revision. Pressing the
enter key in this page will perform a display and LED
test.
Generator Command Page

This page displays the command sent to the genera-
KEYPAD tor. The possible commands are as follows:
The keypad consists of six keys labeled as follows:
• Generator switched off
↑ (up), ↓ (down), ← (left), → (right), Enter, and Reset.
The left and right arrow keys are used to select the dif- • Generator in manual mode
ferent pages on the display. The up and down arrow • Generator in auto mode – stop command
keys are used to scroll between options within a page. • Generator in auto mode – remote run command
They also are used for selecting characters when the • Generator in auto mode – serial link run
user is entering messages or parameters for the command
alarms. The left and right arrow keys move the cursor
when the user is entering data. The enter key takes the Generator Status Page
user into a page on the display to change data (when This page displays the current status of the generator.
applicable) and also accepts data that has been entered. Options will be as follows:
It also is used to accept an alarm. The reset key ignores • Stopped – ready to run
data that has been entered and returns the original
• Stopped – start inhibit active
value. It also is used to return from the parameter entry
mode once the user has finished changing the data, and • Pre-heating (with timer counting down)
to reset any latched alarms that have cleared. • Attempting to start (with timer counting down and
number of attempts)
DISPLAY • Pausing before start attempt (with timer counting
down and number of attempts)
The display is organized into a series of pages, each • Started – running up to speed
page displays information about the status of the gen-
• Warming up
erator. For example, the “Alarm Status Message Page”
displays the highest priority current alarm or status • Ready to accept load
condition. The user will be able to scroll between the • All alarms enabled
pages using the left and right arrow keys. Certain • Cooling down
actions also cause the display to change pages, e.g., • Stopping
when an alarm becomes active, the display automat- • Stopped due to alarm
ically will go to the alarm status page and display the If the user has not pressed a key for some time, any
alarm message. change in status will cause this page to be displayed
The back light for the display is normally off. If the provided that there are no active alarms or status
user presses any key, the back light will come on messages from other inputs. If an alarm condition
automatically and remain on for five minutes after occurs, the alarm status page will be displayed auto-
the last key was pressed. It also will come on if any matically.
status message is current, which means the display
will switch to the alarm status page. The back light Alarm Status Message Page
will flash when an alarm or shutdown message is This page displays alarm messages and program-
active, and the audible alarm will sound. mable status messages. Messages are displayed
according to priority, with the shutdown alarms
having highest priority, and status messages having
lowest priority.

If an alarm becomes active, the display will switch to If an alarm condition occurs when the user is enter-
this page and display the highest priority alarm mes- ing data, the data will be ignored, and the display will
sage. The back light and alarm LED will flash, and the show the alarm screen. If a status condition occurs
audible alarm will be activated. The user must press when data is being entered, the display will not
the enter key to accept the alarm, at which time the change.
back light will be on continuously. If the alarm is non- Once the user has finished entering data by pressing
latching, the alarm message will clear as soon as the the Enter key, pressing the Reset key will allow the
condition is cleared. If the alarm is a latching alarm, user to select other pages using the left and right
then the user must press the reset key to clear the mes- arrow keys.
sage. Once a message has cleared, the display will show
the next priority alarm message.
After an alarm has been accepted, the user is able to
ALARMS
All analog channels have alarms associated with
scroll through other active alarm and message them. There is also a coolant level alarm, an emer-
screens using the up and down arrow keys. gency stop alarm and eight user definable inputs that
Alarm Log Page can be used to generate alarms. Alarms can be status
messages, non-latching alarms, latching alarms or
This page displays the last 50 alarm messages. When shutdown alarms. When a new alarm condition
the user selects this page, it displays the latest alarm occurs, the alarm LED and the display back light will
message. Pressing the up or down arrow keys will flash. Also, the alarm relay contacts will close (oper-
allow the user to scroll up and down the list of mes- ating the audible alarm), and the display will show
sages. the alarm message. The user will be able to accept the
alarm (turn off the audible alarm) from the keypad,
Instrumentation Page and if the alarm condition has cleared, he or she also
This page displays one of the analog signal values. will be able to clear the alarm. Non-latching alarms
Pressing the up or down arrow keys will scroll to will clear themselves if the alarm condition is no
other analog display screens. longer present. Latching alarms require the user to
clear the alarm from the keypad even if the alarm
Parameter Entry Page condition is no longer present. Shutdown alarms are
This page allows the user to modify the various set similar to latched alarms, but they also cause the
points and programmable options. See the generator to stop and will not allow it to start again
“Programmable Parameters” section of this manual until the key-switch has been turned to the OFF posi-
for more specific option information. The user must tion to reset the alarm. Status messages are similar
press the Enter key when this page is displayed and to non-latching alarms except that they do not acti-
will then be prompted for a password. The password vate the alarm relay or the alarm LED and are not
is a six-digit number and the default value is 000000. recorded on the alarm log.
However, the user will be able to change the pass- Alarms can be always active, immediately active when
word. Digits will be selected using up and down the generator is commanded to run, or active after
arrow keys, and the cursor will be moved by the left the hold off timer has expired. This timer delays the
and right arrow keys. When the user presses the operation of certain alarms until a programmable
Enter key, the password will be checked. If the pass- time after the engine has started. Some alarms allow
word is correct, the display will show one of the data the user to define the type of alarm and when it is
entry screens. active.
There are four parameter entry menus: “Engine The following chart is a summary of the alarms and
Parameter,” “System Alarm,” “Digital I/O” and “Analog the programmable options:
Input.” The user will be able to scroll through the vari-
ous parameters in each menu using the up and down
arrow keys. The left and right arrow keys are used to
switch between the four menus. When a parameter that
requires changing is displayed, the user presses the
Enter key to enable data entry. A cursor will appear at
the first character that can be altered. The user can
then change the character using the up and down arrow
keys. The user can move to the next character or previ-
ous character using the left and right arrow keys.
Pressing the Enter key will accept the new setting.
Pressing the Reset key will ignore the new setting.

Alarm Message Alarm Active Options Alarm Type Options

Pre-Low Oil Pressure Warning Hold Off Non-Latch
Low Oil Pressure Shutdown Alarm Hold Off Shutdown
Pre-High Coolant Temp. Warning Hold Off Non-Latch
High Coolant Temp. Shutdown Alarm Hold Off Shutdown
Low Coolant Temp. Warning Always Non-Latch
Pre-High Oil Temp. Warning Immediate, Hold Off, Disabled Non-Latch
High Oil Temp. Shutdown Alarm Immediate, Hold Off, Disabled Shutdown
Low Battery Voltage Warning* Always Non-Latch
Overspeed Alarm Immediate Shutdown
Underspeed Hold Off Status, Non-Latch, Latch, or Shutdown
Overcrank Alarm Immediate Shutdown
Over Voltage Hold Off Status, Non-Latch, Latch, or Shutdown
Under Voltage Hold Off Status, Non-Latch, Latch, or Shutdown
Over Frequency Hold Off Status, Non-Latch, Latch, or Shutdown
Under Frequency Hold Off Status, Non-Latch, Latch, or Shutdown
High Fuel Warning Always, Disabled Non-Latch
Low Fuel Warning Always, Disabled Non-Latch
Low Fuel Shutdown Alarm Always, Disabled Shutdown
User Analog Alarms** All Options Available All Options Available
Low Coolant Level Alarm Hold Off Shutdown
Emergency Stop Always Shutdown
RPM Sensor Failure Alarm Always Shutdown
Start Inhibit – Oil Pressure Immediate Shutdown
Oil Pressure Sensor Failure Always Shutdown
Oil Temp. Sensor Failure Always, Disabled Shutdown
Coolant Temp. Sensor Failure Always Shutdown
User Digital Input Alarms*** All Options Available All Options Available
High Battery Voltage Warning Always Non-Latch
* Battery voltage must be below alarm limit for 5 minutes to trigger alarm.
** Each user analog input channel has a high and low alarm.
*** Each user digital input can be programmed to trigger an alarm on high or low level.
ALARM PROCESSING • Disabled: If this option is selected, the alarm is

disabled and has no effect.
INPUT ALARM FUNCTIONS • Always: With this option selected, the alarm is
active regardless of the state of the generator.
The E option panel will monitor the status of the ana- • Immediate: In this mode, the alarm is not active
log and digital inputs, and generate alarm messages when the generator is stationary. It becomes active
as required. Digital alarms and user-defined analog as soon as the generator starts to crank and
alarms are fully programmable. The user is able to remains active until the generator stops.
select the type of alarm, the state of the input that will
• Hold Off: This option waits until a preset time
trigger the alarm, and the alarm message when it is
after the generator is running before becoming
active. The configurations are defined as follows:
active. The hold off time can be set by the user.
Alarm Active Note that the hold off time is common to
all alarms.
The user is able to select when the alarm is active.
The options will be as follows:

ALARM TYPE OTHER ALARMS

Status Overcrank
This type of alarm will display a message on the This alarm is unlike other alarms as it is not associ-
screen. The message will not be logged. This is the ated with an analog or digital signal. The user is able
lowest priority of alarm types. to define the number of crank attempts, the length of
each crank attempt and the rest time between
Warning – Non-Latched cranks. After the last attempt has been made, an
This type of warning will activate the audible alarm, overcrank alarm will be generated. The user must
and flash the alarm LED and display back light. The turn the key-switch to the OFF position to clear the
associated message will be displayed on the screen. alarm.
When the user accepts the warning (by pressing the
Enter key), the back light will stop flashing, and the Coolant Level
alarm LED will be on continuously. The message will be This alarm is generated by the coolant level detector.
displayed on the alarm screen, but the user will be able This device senses whether coolant is present or not.
to scroll through other screens. The LED and message It has no user-definable level setting and is a shut-
will clear when the warning condition clears. This type down alarm that is active after the hold off time.
of warning is logged. There are no user-definable parameters for this
alarm.
Alarm – Latched
This type of alarm will act similarly to the non-latched PROGRAMMABLE PARAMETERS
warning, except that the alarm does not clear when the The E option panel allows the user to configure vari-
alarm condition clears. When the alarm condition ous options to control the generator starting and
occurs, the audible alarm sounds, the LED and back stopping cycles, and the way that the alarms operate.
light flash as before, and the user must accept the Parameters are entered either from the control mod-
alarm to stop them. The alarm will continue to be dis- ule or via the serial link. A description of the pro-
played on the screen even after the alarm condition has grammable parameters follows:
cleared. The user must either press the Reset key or
turn the key-switch to the OFF position to clear the PREHEAT ENABLED
alarm after the alarm condition has cleared. This type This parameter determines how the preheat function
of alarm is logged. works. The preheat can be fully disabled, enabled
before starting only (for the duration of the preheat
Shutdown time), or before and during starting (for the duration
This type of alarm will act similar to the latched of the preheat time and also while the starter is
alarm, but it also will stop the engine when the alarm engaged). Note that if the user wishes to engage the
condition occurs. It can be reset only by turning the preheat during starting but not to have a preheat
key-switch to the OFF position. All shutdown alarms before starting, it is possible to set the preheat time
are latching, and this type of alarm is logged. to zero.
Alarm Status PREHEAT TIME

This is the value at which the alarm is active. For ana- When a start command is received, some engines
log alarms, it is a number corresponding to the alarm require preheating before the generator attempts to
limit. Digital alarms are either “normally open” or start. When the preheat function is enabled, this
“normally closed,” and an alarm is generated when parameter allows the user to determine the time that
the input is not in the normal state. the preheat contact closes before activating the
starter solenoid.
Alarm Message
Each alarm will have a message associated with it. The START TIME
analog alarm messages will be preset, and the digital Once a start command has been received and
alarm messages and user-defined analog messages will the preheat time has expired (if enabled), the starter
be entered via the keypad or the serial link. solenoid will be engaged. This parameter allows the
user to determine how long the starter solenoid is
engaged before the start attempt is regarded as hav-
ing failed. If the generator does not start within this
time, the generator will wait for a preset time before
attempting to start again. The user also can program
the number of start attempts the generator tries.
PAUSE TIME VOLTAGE SCALING FACTOR

If the generator does not start within the pro- The voltage scaling factor is used to scale the sensing
grammed start time, it will pause before trying to voltage applied to CON4-4 and CON4-6.
start again. This parameter determines the length of On generators manufactured prior to the second
that pause. quarter of 2000: Sensing voltage was measured from
START ATTEMPTS line-to-line, so the scaling factor was primarily set to
1.0. On generators manufactured starting the second
This parameter determines the number of times that quarter of 2000: Sensing voltage is measured from
the generator tries to start. If the generator has not the frequency meter, in this case the scaling factor is
started after this number of attempts, an alarm is used so the “E” panel displays line-to-line voltage.
generated. This scaling factor can also be used to “calibrate” the
“E” panel display.
STARTER DISENGAGE SPEED
While the starter is engaged, the engine speed is mon- FLYWHEEL TEETH
itored. Once it reaches this value, the starter motor is
disengaged, and the engine is regarded as having This parameter holds the number of flywheel teeth.
started. This value is used to determine the engine speed
from the magnetic pickup signal.
HOLD OFF TIME
Once the engine has started, some alarm functions USER-DEFINED OUTPUT FUNCTIONS
(such as low oil pressure and under speed) are not There are three user-defined outputs, and the preheat
activated immediately since the engine must be given output also can be used as a user-defined output if the
time to reach a stable condition. This parameter preheat function is disabled. Each output can be pro-
determines the time that elapses before the hold off grammed to signal that an alarm is active, to indicate
alarms are activated. one specific alarm or input condition, to indicate the
status of the key-switch, or to indicate the current sta-
COOL-DOWN TIME tus of the generator. These relay contacts can be used
It is sometimes desirable to run the generator for a to switch up to 30 volts AC or DC at 1 amp.
given time with no load before stopping to allow the
Programming example for user output #2 to be active
engine to cool down. This parameter determines the
on any generator alarm shutdown:
length of time that the generator continues to run
after a stop command is sent in AUTO mode. Note 1. Press the left or right arrow key until the display
that if the key-switch is turned to the OFF position reads “Parameter entry” and press ENTER.
when the generator is running, it will stop immedi- 2. Enter your password and press ENTER.
ately regardless of this setting. This value also should 3. Use the left and right arrow keys to find the
be set to zero if this function is controlled by the “Digital I/O Menu”.
transfer switch. 4. Use the up and down arrow keys to locate “Output
2 Function”. The bottom line of the display will
LOAD ACCEPT VOLTAGE AND FREQUENCY
read the current setting. Press ENTER.
Once the generator has started, the voltage and fre- 5. Use the up and down arrows to scroll through the
quency will ramp up until they reach the values at list until “Generator Alarm Shutdown” is dis-
which the generator can accept load. These parame- played in the bottom line. Press ENTER.
ters allow the user to set the values. The values 6. User output #2 is now programmed to become
should be set slightly lower than the nominal values active (relay energized) on any generator shutdown
to allow for a margin of error in the regulator and alarm.
governor settings. Once the values have been
reached, the warm-up timer is started. 7. Press RESET. This exits the programming mode
and returns you back to the parameter entry
WARM-UP TIME screen.
Some applications require that the generator is NOTE:
allowed to run for a given time before a load is See the “Output Function Table” on Page 14 and
applied. This parameter allows the user to set that the “E” Panel Display Map on pages 18-19 for
time. Note that if this function is controlled elsewhere more detail.
(e.g., within a transfer switch), this time should be set
to zero. The generator is ready to accept load when
this timer expires. This parameter can be assigned to
an output relay.
ANALOG INPUT SCALING FACTORS OIL TEMPERATURE ALARMS

The two user-defined analog inputs can be scaled so The oil temperature has a non-latched warning and a
that the display uses meaningful values rather than the shutdown alarm associated with it. The set-points are
voltage level at the input. The user enters the value to programmable, and the alarms can be immediate,
be displayed when the input voltage is zero and when it hold off or disabled.
is at the maximum value. (An analog input to the E
panel is a voltage sourced input with a zero- to 10-volt COOLANT TEMPERATURE ALARMS
range.) All alarm settings are based on this scaling, and
the instrumentation display shows the input value The coolant temperature input has three associated
based on this scaling too. alarms. The pre-high coolant temperature alarm is a
non-latched, hold-off alarm. The high coolant tem-
perature alarm is a shutdown, hold-off alarm. The
ANALOG INPUT MESSAGES low coolant temperature warning is a non-latched,
This is a message up to 24 characters long that is dis- always active alarm. Set-points for each alarm are
played on the instrumentation display when the cor- programmable.
responding value is being shown.
BATTERY VOLTAGE ALARMS
ANALOG INPUT ALARM MESSAGES The low battery voltage warning set-point is pro-
There is a user-definable message for each alarm grammable. The warning will be activated if the bat-
condition on each analog input. This message is tery voltage is below this value for more than five
shown on the alarm display when the alarm condi- minutes. This is a non-latched, always active alarm.
tion is active and is stored in the alarm log. Note that the “Power” LED on the front panel is extin-
guished immediately if the battery voltage is less than
ANALOG INPUT ALARM SETTINGS this value. The high battery voltage alarm set-point is
also programmable. The warning is active immedi-
Each analog input has two alarms associated with it. ately when the battery voltage is higher than this
One is activated when the input value is higher than value.
the high set-point, and the other is active when the
input is lower than the low set-point. The user also
can define when the alarm is active (or disable it) and ENGINE SPEED ALARMS
the severity of the alarm (from simply displaying a The user can program the overspeed and the under-
status message to shutting down the generator – see speed alarm. The overspeed alarm is an immediate
“Alarm Processing” on Page 5). shutdown alarm. Underspeed is a hold off alarm that
can either be non-latched, latched or shutdown.
DIGITAL INPUT ALARM SETTINGS
Each digital input also can generate an alarm. The GENERATOR VOLTAGE ALARMS
user can program the alarm message, the input state An alarm can be generated for high voltage and low
that generates the alarm, when the alarm is active, voltage. The set-points are user-definable, and the
and the alarm type. A digital input to the E panel is alarms can be either non-latching, latching or shut-
NOT a voltage sourced input, but a dry contact clo- down.
sure to ground. Voltage never should be sourced to a
digital input. The signal options to a digital input are GENERATOR FREQUENCY ALARMS
as follows:
An alarm can be generated for high frequency and
• Open: This signal is an open circuit. low frequency. The set-points are user-definable, and
• Closed: This signal is a contact closure to ground. the alarms can be either non-latching, latching or
shutdown.
OIL PRESSURE ALARMS
The oil pressure input has two associated alarm FUEL LEVEL ALARMS
functions. The pre-low oil pressure warning is a non- Alarms can be generated by an optional fuel level sen-
latched, hold off alarm with a user-definable set- sor. The high fuel level warning is non-latching. There
point. The low oil pressure shutdown is a shutdown, is also a low fuel level warning that is non-latching
hold off alarm with a user-definable set-point. The and a low fuel shutdown alarm. Each of these alarms
shutdown alarm set-point should be the lowest of the has a set-point and can be always active or disabled.
two settings so that the user will have some warning
of a low oil condition before the generator is shut
down.
E PANEL MODEM SETUP PROCEDURE NOTE:

NOTE: Use shielded cable, 100 feet maximum in length.
Generac only supports the US Robotics 56k V90 Connect the shield drain wire to Pin 1 on the E
Sportster modem for connection of the “E” Panel panel end only.
to the phone line. Other modems may work in this Connecting the “E” panel to a modem requires a stan-
application, but have not been tested by Generac. dard modem cable. The cable supplied with the
1. Set modem Dip switches as shown in Figure 1.2. modem should work. If a longer cable is required, the
Power cycle the modem (turn modem off, then on). connectors should be wired as shown in Figure 4.
2. Connect the cable between the “E” panel and the
modem (see Figure 1.4). Figure 1.4 — “E” Panel to Modem Cable
3. Set the “E” panel for “modem connection and Configuration
setup”. Power cycle the “E” panel (remove and
relace front panel fuse).
4. In GenLink, select the proper setup string for the
modem at the PC end (not the “E” panel).
Figure 1.2 — US Robotics 56k V90 Sportster
Dip Switch Settings
NOTE:
The modem is not intended to be mounted inside
the control panel. It should be mounted inside the
enclosure (no vibration) or inside a nearby build-
E PANEL RS232 CABLES ing or shelter if the generator does not have an
enclosure.
The “E” panel can communicate via its RS232 port to
a remote PC. The connection is made either directly NOTE:
to the serial port on a PC, or via a modem and tele-
Use shielded cable, 100 feet maximum in length.
phone line.
Connect the shield drain wire to Pin 1 on the E
The “E” panel has a 9-pin male “D” type connector, panel end only.
and is configured as DTE (Data Terminal
Equipment). The serial ports on most PCs also have SERIAL COMMUNICATIONS
a DTE configuration, and are usually 9-pin “D” type
male connectors. Most modems have a DCE configu- Serial Communication Via Modem
ration (Data Communication Equipment) and a 25-
pin female connector. (Also refer to the appropriate Genlink Manual)
Connecting an “E” panel directly to a PC requires a The control panel has the ability to communicate to a
“Null Modem” connection. This can be achieved with PC via an RS232 serial port. The PC software will be
either a null modem cable, or a standard serial cable able to interrogate the module. The user also will be
with a null modem adapter. Figure 1.3 shows the able to program the parameters on the PC and down-
required pin connections between the two cables for load them to the module if using the Pro version. The
a 9-pin serial connector on the PC. user will be able to start and stop the generator if it is
in AUTO mode.
Figure 1.3 — “E” Panel to PC Cable The module does not have a built-in modem.
Configuration However, software will include the ability to interface
with an external modem. The user can initialize the
modem from the panel. Generac offers a remote
annunciator (models #’s 004391-0, 004392-0 and
004391-1, 004392-1) which allows the E panel to
communicate with both a modem and a remote
annunciator. See the Remote Annunciator Panel man-
ual (part number 0A7450) for a complete description
of these panels.

Remote Annunciator Panel USER PASSWORD

(Refer to manuals 0A7450 and 0A9825) The user can set the password. This is a six-digit
The serial connections can be configured to allow the number and is initially set to 000000.
control panel to connect to a remote
annunciator/remote relay panel, which is configured ADDITIONAL PANEL COMPONENTS
as RS485, to meet NFPA 110. Only one communica- In addition to the control module, the E option panel
tion port is available for either a modem or remote contains the following components (see Figure 1.6):
annunciator.
NOTE: AC VOLTMETER
The following diagram and instructions apply only This meter indicates the generator AC output voltage.
to those units manufactured before January 2000. To determine the nominal rated AC voltage of the
Units manufactured after January 2000 incorpo- unit, refer to the unit’s data plate.
rate a selector switch on the back of the control
NOTE:
module. This switch will allow selection of either
RS232 or RS485 without opening the module. Some generators are re-connectable to a variety of
voltages. Some units may be equipped with a
Altering the Serial Communications Setup rotary “Voltage Selector Switch.” Be sure to read
The E option control panel is capable of being used the “Generator AC Lead Connections” section in
with either a modem or a remote annunciator/ the Owner’s Manual.
remote relay panel, depending on the configuration of
the serial connections. The unit comes set up for con- AC AMMETER
nection to a modem (RS232). In order to use the con- This meter indicates the current draw of connected
trol panel with a remote annunciator/remote relay electrical loads, in amps. Also see “Line-phase
panel (RS485), adhere to Figure 1.5 and the instruc- Selector Switch.” For continuous operation, never
tions that follow. exceed the rated maximum continuous current
1. Remove harness retaining screws, then unplug all capacity of the generator.
five wire harnesses from the back of the E panel
control module. FREQUENCY METER
2. Remove the four phillips head screws retaining the This meter indicates the generator’s AC output fre-
rear cover of the control module. quency in “Hertz” (cycles per second).
3. Open the back of the control module.
4. Locate the DB-9 wire harness that runs from the LINE-PHASE SELECTOR SWITCH
DB-9 connector on the back panel to the black
This four-position switch permits selection of either
header on the lower circuit board inside the con-
trol module. line-to-line or line-to-neutral readings on the panel volt-
meter and ammeter. Switch positions are as follows:
5. Carefully remove the black connector from
the header by pressing the locking tab and Switch Single-phase Units Three-phase units
lifting up. 1 Line E1 to Neutral Line E1 to E2
6. Insert the black connector into the RS485
2 Line E3 to Neutral Line E2 to E3
header (J11). Make sure that the connector is fully
inserted and that the locking tab snaps into place. 3 Line E1 to E3 Line E3 to E1
7. Replace the back panel and the four screws. OFF No Reading No Reading
Figure 1.5 – E Panel Serial Communications Figure 1.6 – E Option Panel Components
Setup Modification

VOLTAGE ADJUST POTENTIOMETER 4. Using a multimeter (e.g., Fluke 87) set to the diode
range, measure between pins 1 (BAT+) and 2 (BAT-
This potentiometer permits the operator to “fine ) of connector CON4 on the module.
adjust” the generator’s AC output voltage on units • With the positive meter lead connected to pin
rated below 400 kW. Adjustment range is plus or 2 and the negative lead to pin 1, the meter
minus five percent. Turn the knob clockwise to should read between 0.4 and 0.6 volts, which
increase voltage, counterclockwise to decrease voltage. indicates that the internal fuse is OK.
ALARM HORN • Reversing the meter leads would give a slowly
increasing voltage reading on the meter, which
This horn sounds an audible warning when an alarm also indicates a good fuse.
condition exists. See the “Alarms” section for further
• An open circuit fuse will give an open circuit
information.
meter reading (.OL on Fluke 87).
DC PANEL FUSE If the meter reads open circuit:
This 15-amp fuse protects the panel components. 5. Remove the four phillips head screws retaining the
This fuse is not to be confused with the control mod- rear cover of the control module.
ule internal fuse discussed in “Checking/Replacing 3. Open the back of the control module.
the E Panel Control Module Internal Fuse.” 4. Locate the internal printed-circuit board mounted
fuse, which is behind and to the left of CON4.
EMERGENCY STOP SWITCH 5. Remove the white plastic cover from the fuse hold-
When pressed, this switch will automatically shut er and remove the fuse.
down the entire generator set. The operator must pull 6. If the fuse has blown, replace the fuse (part
the switch out to its original position to reset it and #0A5705), reassemble the control module, and
allow for generator operation. reinstall the control module and its connections.
7. Reconnect the generator start battery and check if
CHECKING/REPLACING THE E PANEL the control module now functions.
If the fuse blows again, or was not blown when the
CONTROL MODULE INTERNAL FUSE module was opened, or the module still does not
Typically, the main indication of fuse failure is the function, the E panel control module must be
absence of any illuminated front panel LEDs (even replaced.
with the key in the OFF position, the “Power” LED
will be illuminated) and no text visible on the module
display. It should be noted however, that these condi- USER PROGRAMMABLE INPUTS
tions can exist if either: The E panel has eight (8) user programmable inputs.
These inputs can be used for annunciation, pre-
a. The generator start battery is dead (less than five alarm, or shutdown alarms. Four of the inputs,
volts) or disconnected. Battery Charge Fail, Gen Power, Line Power, and
b. The main panel fuse (15 amp) is blown. Programmable Input 4 are set up to annunciate on
c. The battery supply wires (#13 and #0) to the the control panel display and at the optional 20 Light
panel control module are open circuit (discon- Remote Annunciator (Programmable Input 4 will
nected). light the unlabeled “spare” LED). These four inputs
d. The “Power” connector (CON4) is disconnected can be used for other connections if a remote annun-
from the rear of the control module. ciator is not used. The other four inputs, if utilized,
e. The generator start battery connections have been will annunciate at the control panel only.
reversed. Reversal of the battery connections The user programmable input connection points are
WILL blow the internal fuse and is the most like- located inside the E option control panel on a 12-
ly reason for its failure. position strip labeled TB3 (refer to Figures 1.7 and
Before removing or disconnecting the E panel control 1.8 on page 12.). The first four terminals are labeled
module, check that none of the above conditions (a- “prog input gnd”. These are the common ground con-
e) exist. nection points for the user supplied switch devices to
If you are satisfied that the problem lies with the be used for the programmable annunciation.
control module: NOTE:
1. Disconnect the generator start battery. These ground terminals are for user programma-
2. Unplug all four wire harnesses from the back of ble input use only. The are not to be used for
the control module. grounding any other circuits.
3. Loosen, then detach, the two retaining clips secur-
ing the control module and remove the module.
Figure 1.7 — TB3 Units Up to 400 kW The remaining eight terminals on TB3 are for the “pos-
itive” side of each user programmable input switch cir-
cuit. These eight terminals have a five VDC potential
available in an open-circuit condition (whether the
control panel key switch is in the off, manual, or auto
position). The inputs can be programmed to annunci-
ate upon either an open circuit condition (five VDC
potential at the terminal) or a grounded condition
(zero VDC potential at the terminal). This voltage state
is determined by the user supplied switch either open-
ing or closing to cause an annunciation.
Program set-up for the user programmable inputs is
carried out in the Digital I/O Menu of the E module
(please refer to the Display Map on pages 18-19). Each
of the eight inputs has four parameters in which spe-
cific options must be selected to make the annuncia-
tion function properly. These four parameters are
labeled Input Channel Message, Input Channel Setting,
Input Channel Alarm Enable, and Input Channel
Alarm Type. Following is a brief description of each:
• Input Channel Message — for selecting letters and
numbers to spell out what the display will read
upon activation of that specific input.
• Input Channel Setting — for selecting whether
annunciation should activate upon that specific
circuit opening or closing to ground.
• Input Channel Alarm Enable — for enabling or dis-
abling annunciation function of that specific input.
Figure 1.8 — TB3 Units Over 400 kW Also, if enabled, for selecting when annunciation
will be active. The choices are: Disabled, Always,
Immediate and Hold-off. See E Control Panel
Definitions on page 38.
• Input Channel Alarm Type — for selecting the type
of alarm annunciation and the effect it has on the
generators control system. The four choices are:
Status, Non-latched, Latched and Shutdown. See
E Control Panel Definitions on page 14.
WIRING EXAMPLES
◆ USER PROGRAMMABLE INPUT NUMBER 1
On units rated below 400 kW, input number 1 is pro-
grammed for “Battery Charge Fail” annunciation at
the control panel display, and the LED on the 20 Light
Remote Annunciator (if used). A user supplied AC
relay is wired in to be powered up by AC voltage that
supplies the unit Battery Charger (see Figure 1.9).
Figure 1.9 — Battery Charge Fail Wiring

Upon loss of this AC supply voltage, the relay will de- 2. Use the LEFT or RIGHT arrow keys to scroll over
energize. The normally closed contacts on the relay to the PARAMETER ENTRY column.
are to be connected to TB3 in the control panel. One 3. Once at the PARAMETER ENTRY column, press
wire connects to any of the four “Prog Input Gnd” ENTER. Enter the password (if different from the
terminals, the other wire connects to terminal num- factory set password 000000) and press ENTER.
ber 5 (B/C Fail). With the relay de-energized, terminal From the ENGINE PARAMETER MENU, press the
5 will be grounded, signaling the E module to activate RIGHT arrow to get to the DIGITAL I/O MENU.
on Programmable Input 1. 4. Using the UP or DOWN arrows (the column is a
continuous loop), scroll to INPUT CHANNEL 1
◆ USER PROGRAMMABLE INPUTS NUMBERS MESSAGE and press ENTER. Up to 24 letters,
2 AND 3 numbers and other characters can be entered to
spell out what will be displayed upon this input
On units rated below 400 kW, input numbers 2 and 3 becoming active. In this case, enter Battery Charge
are programmed for “Gen Power” and “Line Power” Fail. After entering the message, press ENTER.
respectively, indicating the transfer switch position
5. Press the UP arrow to display INPUT CHANNEL 1
(Standby or Utility). Annunciation will occur at the
SETTING. Press ENTER, the display will read
control panel display and at the Remote Annunciator
Input Function, OPEN=ALARM. The Battery
(if used). These signals will come from a set of spare
Charge Fail annunciation should occur upon the
auxiliary contacts located on the main contactor
user supplied relay de-energizing and its normal-
assembly in the transfer switch. The auxiliary contact
ly-closed contact closing, therefore, select
switch is a set of dry contacts with three terminals:
CLOSED=ALARM by pressing the UP or DOWN
Common, Normally Open, and Normally Closed.
arrow. Press ENTER, the display will read Input
Wires must be connected to these three terminals and
Channel 1 Setting, CLOSED=ALARM.
routed to the generator control panel. These three
wires must not be run in the same conduit as the gen- 6. Press the UP arrow, the display will read Input 1
erator’s main output conductors. The wire connected Alarm Enable, DISABLED, press ENTER. The
to the Common terminal on the auxiliary contacts choices are DISABLED, ALWAYS, IMMEDIATE,
will connect to any of the Prog Input Gnd terminals and HOLD OFF. This alarm should always be
on TB3. The wire connected to the Normally Open active, therefore, scroll up or down and select
terminal on the auxiliary contacts will connect to ter- ALWAYS, and press ENTER.
minal 6 (Gen Power) on TB3. The wire connected to 7. Press the UP arrow, the display will read Input
the Normally Closed terminal on the auxiliary con- Channel 1 Alarm Type, STATUS MESSAGE, press
tacts will connect to terminal 7 (Line Power) on TB3. ENTER. The choices are STATUS MESSAGE,
NON LATCHING ALARM, LATCHING ALARM and
◆ ALL USER PROGRAMMABLE INPUTS SHUTDOWN ALARM. This annunciation for
Battery Charge Fail should be a STATUS message,
On units rated below 400 kW, input numbers 4 therefore, scroll up or down and select STATUS
through 8, and units rated over 400 kW, input num- MESSAGE by pressing ENTER.
bers 1 through 8 can be used for virtually any kind of
annunciation the user wishes to set up, within the Programming for User Input Channel 1, Battery
parameters previously described, via an opened or Charge Fail is now complete. The E module has been
closed switch device. Proper wiring consists of two programmed for a STATUS alarm message that is
wires from the user supplied switch: one wire con- ALWAYS active. Upon loss of AC supply voltage to the
nects to one of the “Prg Inpt Gnd” terminals (1 generators battery charger, the user supplied relay
through 4 on TB3), the other wire connects to a will de-energize, its normally closed contacts will
Programmable Input terminal on TB3. close, grounding TB3 terminal 5 to Prg Input Gnd.
The E module will display BATTERY CHARGE FAIL.
Because it was programmed as a STATUS alarm and
PROGRAMMING EXAMPLES not a LATCHING or SHUTDOWN alarm, the status
message will clear when AC power is restored to the
◆ USER PROGRAMMABLE INPUT NUMBER 1 battery charger.
To be used for Battery Charge Fail annunciation. NOTE:
After properly wiring the circuit as described in
Wiring Examples, program as follows: The Battery Charger Fail LED on the 20 Light
Remote Annunciator (if connected) will also turn
1. Power up the E panel by connecting unit battery on when Input Channel 1 is activated.
(ies) and inserting control panel fuse. The module
will run through a self-test mode. Once it has com-
pleted its self-test, it will display the generator sta-
tus (Stopped, ready to run).
Section 2 — Operation
OUTPUT FUNCTION TABLE

Output Function Name Description
Function ID
00 Output Disabled Output not in use
01 Common Alarm Active for all latched, non-latched and shutdown alarms
02 Low Oil Pressure Warning Active after hold off time
03 Oil Pressure Shutdown Active after hold off time, low oil pressure
04 High Coolant Temp. Warning Active after hold off time
05 Coolant Temp. Shutdown Active after hold off time, high coolant temperature
06 Low Coolant Temp. Alarm
07 High Oil Temp. Warning
08 Oil Temp. Shutdown High oil temperature
09 Low Battery Voltage Must be below set value for five minutes
10 High Battery Voltage
11 Overspeed Shutdown
12 Underspeed Alarm Active after hold off time
13 Over Voltage Alarm Active after hold off time
14 Under Voltage Alarm Active after hold off time
15 Over Frequency Alarm Active after hold off time
16 Under Frequency Alarm Active after hold off time
17 High Fuel Alarm Above the warning set-point
18 Low Fuel Alarm Below the warning set-point
19 Low Fuel & Shutdown Below the shutdown set-point
20 Failed to Start Alarm Overcrank
21 Coolant Level Alarm Low coolant level
22 RPM Sensor Failed Alarm Magnetic pickup failure
23 Start Inhibit Alarm Oil pressure was present at start request
24 Emergency Stop Alarm Emergency stop active
25 Oil Press. Sense Fault Sensor is either open or short circuit
26 Oil Temp. Sense Fault Sensor is either open or short circuit
27 Coolant Temp. Sense Fault Sensor is either open or short circuit
28 Analog Channel 1 High Input at user analog channel 1 is above programmed high set-point
29 Analog Channel 1 Low Input at user analog channel 1 is below programmed low set-point
30 Analog Channel 2 High Input at user analog channel 2 is above programmed high set-point
31 Analog Channel 2 Low Input at user analog channel 2 is below programmed low set-point
32 Digital Channel 1 Active User programmable digital input 1 is active
40 Generator in Auto Key switch in auto position
41 Generator in Manual Key switch in manual position
42 Generator Off Key switch in off position
43 Stopped Generator stopped
44 Shutdown Due to Alarm Generator shutdown
45 Stopped Ready to Run Generator ready to start
46 Running Generator running
47 Ready to Accept Load Generator has reached load accept voltage and frequency set-points, and
the warm-up timer has expired
48 All Alarms Active Generator running

E PANEL MASTER CONTROL BOX CONFIGURATION SETTINGS
ENGINE PARAMETER MENU

Parameter Value Units
RS232 Port Connection Mode (C1)
or RS485 Port Direct Connection Only
Restore All Values to Master Password
Default Settings Required (Factory Only)
Voltage Scaling Factor .05 to 300
Flywheel Teeth 30 to 200 Number
Panel I.D. 000000 to 999999
User Password 000000 to 999999
Preheat Option (P1)
Load Accept Frequency 0 to 90 Hz
Load Accept Voltage 0 to 2000 V
Starter Disengage Speed 0 to 4000 RPM
Number of Start Attempts 0 to 10 Number
Generator Cool Down Time 0 to 600 min.
Generator Warm Up Time 0 to 600 sec.
Alarm Hold Off Time 0 to 15 sec.
Start Attempt Pause Time 5 to 600 sec.
Start Timer 3 to 15 sec.
Preheat Timer 0 to 30 sec.
Available Options: P1 = No Preheat, Before Start, Before and During Start

C1 = Direct Connection, Modem Connection, Modem Connection & Setup
SYSTEM ALARM MENU

Parameter Value Units Active Type
Low Fuel Shutdown Alarm 0 to 100 % (A2) Shutdown Alarm
Fuel Level Low Warning 0 to 100 % (A2) Non-latching Alarm
Fuel Level High Warning 0 to 100 % (A2) Non-latching Alarm
Under Freq. 0 to 100 Hz Hold Off (T1)
Over Freq. 0 to 100 Hz Hold Off (T1)
Under Voltage 0 to 2000 V Hold Off (T1)
Over Voltage 0 to 2000 V Hold Off (T1)
Engine Underspeed Alarm 0 to 4500 RPM Hold Off (T1)
Engine Overspeed Alarm 1000 to 4500 RPM Immediate Shutdown Alarm
Battery Volts High Warning 4 to 30 V Always Non-latching Alarm
Battery Volts Low Warning 4 to 30 V Always Non-latching Alarm
Oil Temp. Shutdown Alarm -5 to 275 Deg. F (A1) Shutdown Alarm
Oil Temp. Warning -5 to 275 Deg. F (A1) Non-latching Alarm
Coolant Temp. Shutdown Alarm -5 to 275 Deg. F Hold Off Shutdown Alarm
Coolant Temp. High Warning -5 to 275 Deg. F Hold Off Non-latching Alarm
Coolant Temp. Low Warning 0 to 245 Deg. F Always Non-latching Alarm
Oil Press. Shutdown Alarm 0 to 100 PSI Hold Off Shutdown Alarm
Oil Press. Warning 0 to 100 PSI Hold Off Non-latching Alarm
Available Options: A1 = Disable, Hold off, Immediate

A2 = Disable, Always
T1 = Shutdown Alarm, Latching Alarm, Non-latching Alarm, Status Message

DIGITAL I/O MENU

Channel Message Setting Alarm Enable Alarm Type
Output 1 (F1)
Output 2 (F1)
Output 3 (F1)
Preheat Output Function (F1)
User Input 1 *1 Battery Charge Fail (S1) (A1) (T1)
User Input 2 *1 Generator Power (S1) (A1) (T1)
User Input 3 *1 Line Power (S1) (A1) (T1)
User Input 4 *2 Backup Low Oil Pressure (S1) (A1) (T1)
User Input 5 *2 Backup High Engine Temp. (S1) (A1) (T1)
User Input 6 *2 Oil Filter Blocked (S1) (A1) (T1)
User Input 7 *2 MLCB (S1) (A1) (T1)
User Input 8 *2 Ruptured Tank (S1) (A1) (T1)
Messages can be a maximum of 24 characters including spaces.
Available Options: A1 = Disabled, Hold Off, Immediate, Always

F1 = See output function table for available options.
S1 = Closed (Low Signal/Contact Closure to Ground), Open (High signal/Open Circuit)
T1 = Shutdown Alarm, Latching Alarm, Non-latching alarm, Status Message
*1 Assigned if used with 20 light Remote Annunciator or Remote Relay Panel Otherwise available for any
customer options.
*2 Factory wired if unit is equipped with these options. Otherwise these inputs are available for any
customer requirements.
ANALOG INPUT MENU

Alarm Msg. (Alarm) (Alarm)
Value at Value at (Display) Message Setpoint Enable Type
0V 10V Title High Low High Low High Low High Low
Analog Channel 1 (A1) (A1) (T1) (T1)
Analog Channel 1 (A1) (A1) (T1) (T1)
Messages can be a maximum of 24 characters including spaces.
Available Options: A1 = Disabled, Hold Off, Immediate, Always

T1 = Shutdown Alarm, Latching Alarm, Non-latching alarm, Status Message

GenLink® Communications Flowchart
TABLE A
Dip Switch Setting
1 Up
2 Down
3 Down
4 Down
5 Up
6 Up
7 Up
8 Down
TABLE B
“E” Panel Pin Modem Pin
1 8
2 3
3 2
4 20
5 7

E-PANEL DISPLAY MAP
E PANEL DISPLAY MAP
GENERATOR
ALARM STATUS ALARM LOG INSTRUMENTATION PARAMETER ENTRY SOFTWARE VERSION GENERATOR COMMAND
STATUS
Stopped ready to run No active messages * Logged Alarm Number 1 Generator Voltage Parameter entry Generac digital panel Generator switch off
XXX Volts Press Enter to Continue Software version X.XX Generator switch off
Or Or * this is true as long as Or or Or or Or Enter Or Enter * Or Turn key to auto mode: Or
there are no messages Generator in auto mode

Thru Hours Run * Display test, stop command
Logged Alarm Number 50 XXXXX.X Hrs all pixels black, all 4 LEDs Turn key to manual mode:
or will be on Attempting to start
Password Attempt number X
Analog Input 2 XXXXXX
X.X Enter
or
Analog Input 1 Engine Parameter Menu Or System Alarm Menu Or Digital I/O Menu Or Analog Input menu
X.X
or or or or
or
Fuel Level Low Fuel Shutdown Enable Input Ch 8 Alarm Type Analog Ch 2 Low Type
X RS485 Port
or Direct Connection only or or or
or
Battery Voltage RS 232 Port Low Fuel Shutdown Setpt Input Ch 8 Alarm enable Analog Ch 2 High Type
XX.X Volts Direct conection XX %
or or or or or
RS 232 Port
Oil Pressure Modem connection Fuel Level Low Enable Input Channel 8 Setting Analog Ch 2 Low Enable
XXX p.s.I or
or RS 232 Port or or or
Modem connection & Setup
Oil Temperature or Fuel Level Low Setpoint Input Channel 8 Message Analog Ch 2 High Enable
XXX deg F XX%
or Restore all values or or or
to default settings
Coolant Temperature or Fuel Level High Enable Input Ch 7 Alarm Type Analog Ch 2 low Setpoint
XXX deg. F X.X
or Voltage Scaling Factor or or or
XXX.XX
Engine Speed or Fuel Level High Setpoint Input Ch 7 Alarm Enable Analog Ch 2 High Setpoint
XXXX Rpm XX% X.X
or Flywheel Teeth or or or
XXX
Generator Frequency or Under Freq Alarm Type Input Channel 7 Setting Analog 2 Low Alarm Msg
XX.XHz
Panel I.D. or or or
XXXXXX
or Under Freq Setpoint Input Channel 7 Message Analog Ch 2 High Alarm Msg
XX.X Hz
User Password or or or
XXXXXX
or Over Freq Alarm Type Input Ch 6 Alarm Type Analog Channel 2 Title
Preheat Option or or or
or Over Freq Setpoint Input Ch 6 Alarm enable Analog Ch 2 Value at 10V

XX.X Hz X.X
Load Accept Frequency or or or
XX.X Hz
or Under Voltage Alarm Type Input Channel 6 Setting Analog Ch 2 value at 0V
X.X
Load Accept Voltage or or or
XXX Volts
or Under Voltage Setpoint Input Channel 6 Message Analog Ch 1 Low Type
XXX Volts
Starter Disengage Speed or or or
XXX RPM
or Over Voltage Alarm Type Input Ch 5 Alarm Type Analog Ch 1 High Type
Number of Start Attempts or or or

X
or Over Voltage Setpoint Input Ch 5 Alarm Enable Analog Ch 1 Low Enable
XXX Volts
Generator Cool Down Time or or or
X Min
or Overspeed Shutdown Setpt Input Channel 5 Setting Analog Ch 1 High Enable
XXXX Rpm
Gen. Warm Up Time or or or
X Sec
or Underspeed Alarm Type Input Channel 5 Message Analog Ch 1 low Setpoint
X.X
Alarm Hold Off Time or or or
XX Sec
or Underspeed Alarm Setpt Input Ch 4 Alarm Type Analog Ch 1 High Setpoint
XXXX Rpm X.X
Start Attempt Pause Time or or or
XX Sec
or Battery Volts High Setpt Input Ch 4 Alarm Enable Analog 1 Low Alarm Msg
XX.X V
Start Timer or or or
XX Sec
or Battery Volts Low Setpt Input Channel 4 Setting Analog Ch 1 High Alarm Msg
XX.X V
Preheat Timer or or or
XX Sec
Coolant Temp low Setpt Input Channel 4 Message Analog Channel 1 Title
XXX Deg F
or or or
Coolant Temp Shutdn Setpt. Input Ch 3 Alarm Type Analog Ch 1 Value at 10V
XXX Deg F X.X
or or or
Coolant Temp High Setpt Input Ch 3 Alarm Enable Analog Ch 1 value at 0V

XXX Deg F X.X
or or
Oil Temp Shutdown Enable Input Channel 3 Setting
or or
Oil Temp. Shutdown Setpt Input Channel 3 Message

XX Deg F
or or
Oil Temp Warn Enable Input Ch 2 Alarm Type
or or
Oil Temp. Warn Setpt Input Ch 2 Alarm Enable

XX Deg F
or or
Oil Press Shutdown Setpt Input Channel 2 Setting

XX Psi
or or
Oil Press Warn Setpt Input Channel 2 Message

XX Psi
or
Input Ch 1 Alarm Type
or
Input Ch 1 Alarm Enable
or
Input Channel 1 Setting
or
Input Channel 1 Message
or
Preheat Output Function
or
Output 3 Function
or
Output 2 Function
or
Output 1 Function

Section 3 — Troubleshooting and Diagnosis
OIL PRESSURE SENSING (Refer to Figure 3.1) TESTING THE CONTROL PANEL
It is relatively easy to do a thorough test of the E
OVERVIEW Panel's Oil Pressure input.
An analog Oil Pressure Sender (OPS) is used for Place the Auto/Off/Manual switch to the Off position
monitoring the engine oil pressure. This sender during this testing.
allows the E panel to measure and display the Engine
oil pressure. Open circuit testing
Refer to the owners manual for the OPS part number This test checks the high end of the oil pressure input
and mounting location. of the E Panel.
Wire number 69 is used to connect the OPS to the E 1. Remove the 69 wire from the control panel termi-
Panel. The Ground for the OPS is made through the nal strip. This simulates a sender open circuit
engine block. condition.
The OPS is a resistive device, whose resistance 2. Look for the following response from the E Panel:
changes based on engine oil pressure. The resistance The back light will flash, the Com Alarm LED will
of the sender results in a voltage being developed flash, and the display will read as follows:
across the sender. As the oil pressure increases, the OIL PRESS SENSE FAULT
resistance will decrease, causing the voltage to PRESS ENTER TO ACCEPT
decrease. This changing voltage is read by the E Panel
and converted into the engine Oil Pressure. 3. Press enter to accept the alarm.
The E Panel will monitor and display oil pressure Short circuit testing
anytime the DC input to the E Panel is present. This test checks the low end of the oil pressure input
of the E Panel.
TROUBLESHOOTING
1. Reconnect the 69 wire to the control panel termi-
Prior to any troubleshooting, the oil pressure param- nal strip.
eters programmed into the E Panel should be Connect a jumper wire between the 69 and 0
checked and verified. The oil pressure input has two positions on the control panel terminal strip. This
different set points associated with it. They are: simulates a sender short circuit condition
Pre-Low Oil Pressure Warning: This is the warning 2. Look for the following response from the E Panel
set point. The generator's alarm will sound, but the 2.1 For units with software version V1.11 and
generator will continue to run. earlier: The back light will flash, the Com
Critical Low Oil Pressure Alarm: This is the alarm Alarm LED will flash, and the display will
set point. The generator will shut down and sound read as follows:
the alarm. OIL PRESS SENSE FAULT
It is important to verify that these parameters are set PRESS ENTER TO ACCEPT
correctly for the specific unit. Check the E Panel set- Press enter to accept the alarm.
tings against the Generator setup sheet. If the gener- 2.2 For units with software version V1.12 and
ator setup sheet is not available, contact Generac's later:
service department for the recommended settings. Use the arrow keys to go to the Oil pressure
display screen.
Figure 3.1 — Oil Pressure Sender Connections The screen should display oil pressure as
Oil Pressure Sender Connections 125 p.s.i.
Refer to the unit's Wiring Diagram for specific connector locations
Control panel testing complete
E Panel E Panel 1. Remove the jumper between the 69 and 0 loca-
CON 2-5
+5V
Set Screw tions on the control panel terminal strip.
Connector
2. If any E Panel alarms are present, press enter to
accept.
Test Results
69 69 69
Oil Pressure
Sender 1. Tests 1and 2 Pass:
69 Location on the (OPS)
69 Location in the
Control Panel Deutsch Connector Move on to the next test "Testing the Oil Pressure
terminal strip ("Sealed Connector" This Ground (0)
Control Panels only) connection is Sender".
made through the
Engine Block

2. If either test 1 or 2 failed: 1.2 Check to see if the sender nut is tightened
2.1 Repeat the open and short circuit testing securely. Be careful not to over tighten the
directly at the back of the E Panel as follows: nut. If the nut is over tightened, the stud will
Open: The 69 wire should be removed from break free and cause incorrect sender read-
CON2-5 ings. This nut should be tightened to 14 to 18
Short: With the 69 wire still removed, insert inch pounds.
a jumper wire into CON2-5. Connect 1.3 Check for any environmental corrosion on
the other end of the jumper to ground the lug or the sender terminal. Generac rec-
(0). ommends the following actions if corrosion is
After testing, remove the jumper wire from found:
CON2-5 and insert the 69 wire back into 1.3.1 Replace the lug.
CON2-5 1.3.2 Replace the sender if possible. If not
2.2 Test results: possible, thoroughly remove all of the
2.2.1 If these tests fail again directly at the corrosion from the sender terminal.
back of the E Panel, then the E Panel 1.3.3 Protect the lug and sender terminal
has failed and should be replaced. with an approved automotive dielectric
2.2.2 If these tests pass at the back of the E grease.
Panel, but failed at the terminal strip, 2. Check the 69 wire in the Deutsch connector (only
then there is a wiring error between the used on the "water tight connector" panels.)
E Panel and the terminal strip. Check 2.1 Refer to appendix A for information on the
this wiring carefully. Deutsch connectors used.
2.2 Refer to the unit's wire diagram for the 69
TESTING THE OIL PRESSURE SENDER location in the Deutsch plug.
The resistance of the OPS can be checked in a power 3. Check the 69 wire on the control panel terminal
down state as follows: strip.
3.1 Check for a proper crimp on both lugs.
1. Remove the control panel fuse to power down the
E panel. 3.2 Check to see if both screws are tightened
securely. These screws should be tightened to
2. Unplug CON2 from the E Panel. 12 inch pounds.
3. Measure the resistance of the oil pressure sender. 4. Check the 69 wire going into CON2 on the back of
This measurement should be made between the the E Panel.
sender terminal and the sender body.
4.1 Check to see if the wire is stripped properly
The sender resistance should measure between 225 inside the green plug. The wire conductor
and 260 Ohms at 0 PSI. should be trapped inside the metal wire
NOTE: clamp. The wire insulation should not be
trapped inside the metal wire clamp.
If the engine has just been stopped, allow suffi-
cient time for the oil pressure to drop to zero 4.2 Check to see if the set screw is tightened
before making this measurement. securely, but do not over tighten. This screw
should be set to 2 to 4 inch pounds.
If the resistance measurement is not in this range, the 5. Check for any wire damage along the entire run
sender has failed. Replace the sender. between the E Panel and the sender.
If the resistance measurement is in this range, move 5.1 Check for any areas along the wire with miss-
on to the next test. ing insulation. This could allow the 69 line to
momentarily come into contact with ground
TESTING THE OIL PRESSURE SENDER causing a false shut down.
CONNECTIONS 5.2 Check to see if the wire is pinched anywhere
along the run. A wire that is pinched between
Visual Inspection the sheet metal can cause the 69 wire to
Carefully check the wiring between the oil pressure resulting in a shut down fault. A pinched wire
sender and the E Panel. may also cause the wire to break inside the
1. Check the 69 wire connection to the OPS. insulation. This could cause the 69 line to
1.1 Check for a proper crimp on the lug. monetarily "open" while running. This will
also result in a shut down fault.

Check the OPS mounting 4.1.2.2 Remove the OPS and check the
conditions of the threads.
The ground return (0) connection for the OPS is Check for an excessive amount
made by the physical connection of the sender to the of pipe sealant on the threads.
engine block. This connection may be made directly, Ensure there is no pipe sealant
or through a series of adapters or fittings. on the end of the sender cover-
Check for the following at each junction point: ing the oil inlet hole. Repeat
step D, measuring the resist-
1. Check for a tight mechanical connection.
ance between the 69 and 0
2. Check for a good electrical connection. locations on the control panel
Resistance measurement terminal strip and comparing
it to the earlier reading.
The resistance of the OPS was measured in "Testing
the Oil Pressure Sender." 4.2 If this measurement is less than 2-3 Ohms
greater than the one taken directly across the
In that test, the resistance was measured directly OPS, and a thorough visual inspection was
across the OPS. This test will now measure that same performed, the wiring is OK.
resistance inside the control panel. This will provide
an additional test of the wiring and connections used LOW COOLANT LEVEL (Refer to Figure 3.2)
to connect the sender to the control panel.
1. Remove the control panel fuse to power down the OVERVIEW
E Panel. A Low Coolant Level (LCL) sensor is placed in the
2. Unplug CON2 from the E Panel. generator's coolant system. This sensor allows the E
3. Measure the resistance between the 69 and 0 loca- Panel to detect a Low Coolant Level condition.
tions on the control panel terminal strip. Wire number 85 is used to connect the LCL to the E
4. Compare this measurement to the measurement Panel. The Ground for the LCL is made through the
taken directly across the OPS. radiator frame or engine block (depending on where
4.1 If this measurement is more than 2-3 Ohms the LCL is located). The LCL is a resistive device
greater than the one taken directly across the whose resistance changes based on the temperature
OPS, there is a problem with the sender con- of the LCL.
nections. You can determine if the problem is The resistance of the LCL results in a voltage being
the 69 connection or the 0 connection as fol- developed across the LCL. This voltage changes as
lows: the resistance changes. This changing voltage is read
4.1.1 Measure the resistance between the by the E Panel.
OPS stud and the 69 wire inside the The LCL is supplied with current from the E Panel.
control panel. If this measurement is This current will cause the LCL to generate heat. If
greater than 2-3 Ohms, replace the the LCL is in coolant, the coolant will keep the LCL
entire wire running between the control from heating up. If the LCL is in air, it will heat up
panel and the OPS stud. telling the E panel there is a low coolant condition.
Repeat step D, measuring the resist- In most systems, a back up High Water Temperature
ance between the 69 and 0 locations on (HWT) switch is wired in parallel with the LCL. This
the control panel terminal strip and switch is a normally open switch whose contacts will
comparing it to the earlier reading. close at a predetermined temperature setting. If this
4.1.2 Measure the resistance between the HWT switch closes, it will result in the E Panel shut-
body of the sender and the 0 location ting down with a "Low Coolant Level" display.
on the control panel terminal strip. If Refer to owners manual for the LCL and HWT part
this measurement is greater than 2-3 numbers and mounting locations.
Ohms, go back and carefully check the
following: The E Panel checks for low coolant level as follows:
4.1.2.1 OPS mounting, including all Software version V1.03 and earlier: Will check for
fittings and adapters. a low coolant level anytime the DC input to the E
Panel is present.
Software version V1.04 and later: Will only check
for a low coolant level once the engine has started and
the hold off timer has expired.
There are no user-definable parameters for the Low
Coolant Level.
TROUBLESHOOTING Short circuit testing

This test checks the low end of the low coolant level
Figure 3.2 — Water Level Sensor Connections input.
1. Reconnect the 85 wire to the control panel termi-
Water Level Sensor Connections
Refer to the unit's Wiring Diagram for specific connector locations nal strip. Connect a jumper wire between the 85
and 0 locations on the control panel terminal
E Panel
CON 2-7
85 Location in the strip. This simulates the HWT switch closing to
Deutsch Connector
Set Screw
Connector
("Sealed Connector" ground.
Control Panels only)
E Panel 2. The E panel should respond as follows:
2.1 E Panels with V1.03 and earlier software:
Supply 85 85 85 85
The E Panel will sound the alarm and display
Low Coolant High Water
Temperature Switch
a low coolant level fault.
Level Sensor
85 Location on the
Control Panel
(LCL) (Normally Open)
HWT 2.2 E Panels with V1.04 and later software: Start
terminal strip the generator and observe the following:
These Ground (0)
2.2.1 The E Panel should start normally.
connections are made
through the Radiator 2.2.2 Once the engine has started, the hold
Frame or Engine Block
off timer will start.
2.2.3 Once the hold off timer expires, the E
TESTING THE CONTROL PANEL
Panel will shut the engine down and
It is relatively easy to do a thorough test of the E display a low coolant alarm.
Panel's Low Coolant Level input.
Control panel testing complete
In most cases it is necessary to run the engine while 1. Shut down the generator engine.
doing this testing.
2. Remove the jumper between the 85 and 0 loca-
tions.
Test Results
Once the engine has started, there will be high
1. Tests 1 and 2 Pass:
voltage inside the generator's control panel
and at CON4 of the E Panel. Move on to the next test "Checking the wiring
between the E Panel and the LCL/HWT".
Open circuit testing 2. If either test 1 or 2 failed:
This test checks the high end of the low coolant level 2.1 Repeat the open and short circuit testing
input. directly at the back of the E Panel as follows:
1. With the generator stopped, remove the 85 wire Open: The 85 wire should be removed from
from the control panel terminal strip. This simu- CON2-7.
lates a sender open circuit condition. Short: With the 85 wire still removed, insert
2. Start the Generator. a jumper wire into CON2-7. Connect
2.1 The generator should not shut down on Low the other end of the jumper to ground
Coolant Level with the 85 wire disconnected. (0).
If the generator does shutdown on low After testing, remove the jumper wire from
coolant level, there is a fault with the E Panel. CON2-7 and insert the 85 wire back into
2.2 With the 85 wire still disconnected, use a DC CON2-7.
volt meter to measure the voltage between the 2.2 Test results:
85 wire (the end still connected to the E 2.2.1 If these tests fail again directly at the
Panel) and ground. This voltage should be 10 back of the E Panel, then the E Panel
volts DC or greater. has failed and needs to be replaced.
If this voltage is below 10 volts DC, there is a 2.2.2 If these tests pass at the back of the E
fault with the E Panel. Replace the E Panel. Panel, but failed at the terminal strip,
2.3 Stop the generator. then there is a wiring error between the
E Panel and the terminal strip. Check
this wiring carefully.

CHECK THE WIRING BETWEEN THE E PANEL 6. Check the 85 wire on the control panel terminal
strip.
AND THE LCL/HWT 6.1 Check for a proper crimp on both lugs.
The Low coolant level input is active low. This means 6.2 Check to see that both screws are tightened
that a short to ground on the 85 line will cause the E securely. These screws should be tightened to
Panel to shut down for Low coolant level. 12 inch pounds.
Very carefully check the 85 wire from the back of the 7. Check the 85 wire going into CON2 on the back of
E Panel out to the LCL and HWT. Check for the fol- the E Panel.
lowing: 7.1 Check to see the wire is stripped correctly.
The wire conductor should be trapped inside
1. Check for any areas along the wire with missing the metal wire clamp. The wire insulation
insulation. This could allow the 85 line to momen- should not be inside the metal wire clamp.
tarily come into contact with ground causing a 7.2 Check to see if the set screw is tightened
shut down. securely. This screw should be set to 2 to 4
2. Check to see if the wire is pinched anywhere along inch pounds.
the run. A wire that is pinched against sheet metal 8. Check the LCL and the HWT mounting. The
can cause the 85 wire to momentarily come into ground return (0) connection for these devices is
contact with ground resulting in a shut down. made by the physical connection of the device
A pinched wire may also cause the wire to break body to the engine block/radiator frame. These
inside the insulation. This could cause the 85 line connections can be made directly or through a
to momentarily "open" while running. This "open" series of adapters or fittings. Check for a good
condition would not result in a false shutdown, mechanical and electrical connection at each junc-
but it could prevent the E Panel from shutting tion point.
down the generator in the event of a true failure.
TESTING THE LCL/HWT
3. Check the 85 wire connection to the LCL
3.1. Check for a proper crimp on the lug. 1. Check the devices while the generator is not run-
3.2 Check for any environmental corrosion on ning.
the lug or the switch terminal. Generac rec- 1.1 Test the resistance of the LCL.
ommends the following actions if corrosion is 1.1.1 Remove the front panel fuse to power
found: down the E Panel.
3.2.1 Replace the lug. 1.1.2 Unplug CON2 from the E Panel.
3.2.2 Replace the sender if possible. If not 1.1.3 Disconnect the 85 wire from the LCL.
possible, thoroughly remove all of the 1.1.4 Measure the resistance of the LCL. This
corrosion from the sender terminal. measurement should be taken from the
3.3.3 Protect the lug and sender terminal sender terminal to the sender body.
with an approved automotive dielectric The sender should measure between
40 and 65 ohms. This resistance will
grease.
vary with temperature. It will be closer
4. Check the 85 wire connection to the HWT switch. to 40 ohms at 30F, and closer to 65
4.1 Check for a proper crimp on the lug. ohms at 120F.
4.2 Check for any environmental corrosion on If the resistance measurement is not in
the lug or the switch terminal. We recommend this range, the sender has failed and
the following actions if corrosion is found: needs to be replaced.
4.2.1 Replace the lug. 1.1.5 Reconnect the 85 wire to the LCL.
4.2.2 Replace the switch if possible. If not 1.2 Test the HWT switch.
possible, thoroughly remove all of the 1.2.1 Disconnect the 85 wire from the HWT
corrosion from the sender terminal. switch.
4.2.3 Protect the lug and switch terminal 1.2.2 Measure the resistance of the HWT
with an approved automotive dielectric switch. This resistance should be taken
grease. from the switch terminal to the switch
5. Check the 85 wire in the Deutsch connector (only body.
used on "water tight connector" panels.) 1.2.3 This resistance should measure "infini-
5.1 Refer appendix A for information on the ty" or "open circuit". If not, the switch
Deutsch connectors used. has failed and needs to be replaced.
5.2 Refer to the unit's wiring diagram for the spe- 1.2.4 Reconnect the 85 wire to the HWT
cific wire location. switch. Plug CON2 back into the E
Panel. Replace the front panel fuse.
2. Check the devices while the generator is running. The WTS is a resistive device whose resistance
If the E Panel is still shutting down on low coolant changes based on coolant temperature. The resist-
level, and both devices check good in the power ance of the sender results in a voltage being devel-
down state, the devices can be checked while the oped across the sender. As the Coolant temperature
engine is running. The following tests will isolate increases, the resistance will decrease, causing the
the two different senders and determine which voltage to decrease. This changing voltage is read by
sender is causing the shutdown. the E Panel and converted into coolant temperature.
NOTE: The E Panel will monitor and display the coolant
It is very important that the wiring between the E temperature anytime the DC input to the E Panel is
Panel and the LCL/HWT was carefully checked as present.
described above. Incorrect wiring or damage to
any of the wiring can result in false test results. TROUBLESHOOTING
2.1 Test the HWT switch. Prior to any troubleshooting, the Coolant
2.1.1 Disconnect the 85 wire connected to Temperature parameters programmed into the E
the LCL. Position the wire such that the Panel should be checked and verified. The coolant
lug will not come into contact with any temperature has three different set points associated
metal surface. with it. They are:
2.2.2 Start and run the generator. If the gen- • Low Coolant Temp Warning: This is a warning set
erator shuts down with a low coolant point. The generator's alarm will sound, but the
level alarm, the HWT switch is the unit will continue to run.
cause. Replace the HWT switch. • Pre-High Coolant Temp Warning: This is a warn-
If the generator does not shut down on ing set point. The generator's alarm will sound, but
alarm, stop the generator and proceed the unit will continue to run.
to the next test. • High Coolant Temp Alarm: This is the alarm set
2.2 Test the LCL sender. point. The generator will shut down and sound the
2.2.1 Reconnect the 85 wire to the LCL. alarm.
It is important to verify that these parameters are set
2.2.2 Disconnect the 85 wire connected to
correctly for the specific unit. Check the E Panel set-
the HWT switch. Position the wire such
tings against the generator setup sheet. If the genera-
that the lug will not come into contact
tor setup sheet is not available, contact Generac's
with any metal surface.
service department for the recommended settings.
2.2.3 Start and run the generator. If the gen-
erator shuts down with a low coolant Figure 3.3 — Water Temperature Sender
level alarm, the LCL is the cause. Connections
Replace the LCL.
If the generator does not shut down on Water Temperature Sender Connections
Refer to the unit's Wiring Diagram for specific connector locations
alarm, stop the generator manually.
2.2.4 Reconnect the 85 wire to the HWT. E Panel E Panel The Sender may
CON 2-6 be located in the
+5V
COOLANT TEMPERATURE SENSING Set Screw
Connector
Radiator or
Engine Block
(Refer to Figure 3.3)

68 68 68 Water
OVERVIEW Temperature
Sender
(WTS)
An analog Water Temperature Sender (WTS) is locat- 68 Location on the 68 Location in the
Control Panel
ed in the engine's cooling system. This sender is con- terminal strip
Deutsch Connector
("Sealed Connector"
This Ground (0)
nected to the E Panel and allows the E Panel to mon- Control Panels only)
connection is
itor and display the temperature of the Coolant sys- made through the
Radiator Frame or
tem. Wire number 68 is used to connect the WTS to Engine Block
the E Panel. The ground for the WTS is made through

the radiator frame or engine block (depending on TESTING THE CONTROL PANEL
where the WTS is located). It is relatively easy to do a thorough test of the E
Refer to the owners manual for the WTS part number Panel's Coolant Temperature input.
and mounting location. Place the Auto/Off/Manual switch to the Off position
during this testing.
Open circuit testing After testing, remove the jumper wire from
CON2-6 and insert the 68 wire back into CON2-
This test checks the high end of the coolant tempera- 6.
ture input of the E Panel. 2.2 Test results:
1. Remove the 68 wire from the control panel termi- 2.2.1 If these tests fail again directly at the
nal strip. This simulates a sender open circuit back of the E Panel, then the E Panel
condition. has failed and should be replaced.
2. Look for the following response from the E Panel. 2.2.2 If these test pass at the back of the E
The E Panel should respond in either one of the Panel, but failed at the terminal strip,
following ways: then there is a wiring error between the
2.1 The Coolant temperature display will read E Panel and the terminal strip. Check
less than 20 F. this wiring carefully.
OR
2.2 The back light will flash, the com alarm LED TESTING THE COOLANT TEMPERATURE
will flash, and the display will read as follows: SENDER CONNECTIONS
OIL TEMP SENSE FAULT
Visual Inspection
PRESS ENTER TO ACCEPT
Carefully check the wiring between the coolant tem-
Short circuit testing perature sender and the E Panel.
This test checks the low end of the coolant tempera- 1. Check the 68 wire connection to the WTS.
ture input of the E Panel. 1.1 Check for a proper crimp on the lug.
1.2 Check to see if the sender nut it tightened
1. If any E Panel alarms are present, press enter to
securely. Be careful not to over tighten the
accept. nut. If the nut is over tightened the stud will
2. Reconnect the 68 wire to the control panel termi- break free and cause incorrect sender read-
nal strip. ings. This nut should be tightened to 6 to 7
3. Connect a jumper wire between the 68 and 0 posi- inch pounds.
tions on the control panel terminal strip. This 1.3 Check for any environmental corrosion on
simulates a sender short circuit condition. the lug or sender terminal. Generac recom-
4. Look for the following response from the E Panel. mends the following actions if corrosion is
The back light will flash, the Com Alarm LED will found:
flash, and the display will read as follows: 1.3.1 Replace the lug.
COOLANT TEMP SENSE FAULT 1.3.2 Replace the sender if possible. If not
PRESS ENTER TO ACCEPT possible, thoroughly remove all of the
corrosion from the sender terminal.
Press enter to accept the alarm. 1.3.3 Protect the lug and sender terminal
Control panel testing complete with an approved automotive dielectric
grease.
1. Remove the jumper between the 68 and 0 loca- 2. Check the 68 wire in the Deutsch connector (only
tions. used on the "water tight connector" panels.)
2. If any E Panel alarms are present, press enter to 2.1 Refer to appendix A for information on the
accept. Deutsch connectors used.
Test Results 2.2 Refer to the units wiring diagram for the 68
location in the Deutsch plug.
1. Tests 1 and 2 pass:
3. Check the 68 wire on the control panel terminal
Move on to the next test "Testing the coolant tem- strip.
perature sender connections". 3.1 Check for a proper crimp on both lugs.
2. If either Test 1 or 2 failed: 3.2 Check to see if both screws are tightened
2.1 Repeat the open and short circuit testing at securely. These screws should be tightened to
the back of the E Panel as follows: 12 inch pounds.
Open: The 68 wire should be removed from 4. Check the 68 wire going into CON2 on the back of
CON2-6. the E Panel.
Short: With the 68 wire still removed, insert 4.1 Check to see if the wire is stripped properly
a jumper wire into CON2-6. Connect inside the green plug. The wire conductor
the other end of the jumper to ground should be trapped inside the metal wire
(0). clamp. The wire insulation should not be
4.2 Check to see if the set screw is tightened The OTS is a resistive device, whose resistance
securely, but do not over tighten. This screw changes based on oil temperature. The resistance of
should be set to 2 to 4 inch pounds. the sender results in a voltage being developed across
5. Check for any wire damage along the entire run the sender. As the oil temperature increases, the
between the E Panel and the sender. resistance will decrease, causing the voltage to
5.1 Check for any areas along the wire with miss- decrease. This changing voltage is read by the E Panel
ing insulation. This could allow the 68 line to and converted to oil temperature.
causing a false shut down. TROUBLESHOOTING
5.2 Check to see if the wire is pinched anywhere
along the run. A wire that is pinched between Prior to any troubleshooting, verify the following:
the sheet metal can cause the 68 wire to 1. Verify the oil temperature option has been ordered
momentarily come into contact with ground and installed on the generator.
causing a false shut down. A pinched wire
may also cause the wire to break inside the 2. Check and verify the Oil Temperature parameters
insulation, this could cause the 68 line to programmed into the E Panel. The oil temperature
momentarily "open" while running. This will has two different set points associated with it.
also result in a false shut down. Pre-High Oil Temp Warning: This is a warning
set point. The generator's alarm will sound but the
Check the WTS mounting generator will continue to run. This parameter
The ground return (0) connection for the WTS is should be Disabled if no sender was fitted.
made by the physical connection of the sender to the High Oil Temp Alarm: This is an alarm set point.
engine block. This connection may be made directly, The generator will shut down and sound the
or through a series of adapters or fittings. alarm. This parameter should be Disabled if no
Check for the following at each junction point: sender was fitted.
It is important to verify that these parameters are set
1. Check for a tight mechanical connection. correctly for the specific unit. Check the E Panel set-
2. Check for a good electrical connection. tings against the Generator setup sheet. If the gener-
Resistance measurements ator setup sheet is not available, contact Generac's
service department for the recommended settings.
Power down the E Panel by removing the front panel
fuse. Figure 3.4 — Optional Oil Temperature Sender
Remove CON2 from the back of the E Panel. Connections
1. Measure the resistance between the WTS stud and
OptionalOil Temperature Sender Connections
the 68 wire inside the control panel. If this meas- Refer to the unit's Wiring Diagram for specific connector locations
urement is greater than 2-3 Ohms, replace the

entire wire running between the control panel and E Panel E Panel
CON 2-4 Set
the WTS stud. +5V
Screw
Connector
2. Measure the resistance between the body of the
sender and the 0 location on the control panel ter-
minal strip. If this measurement is greater than 2 523 523 523
-3 Ohms, go back and carefully check the WTS Oil Temperature

Sender
mounting and the star ground connections on the 523 Location on the 523 Location in the
(OTS)
engine block. Control Panel

terminal strip
Deutsch Connector
("Sealed Connector" This Ground (0)
Control Panels only) connection is made
OIL TEMPERATURE SENSING through the Oil

Pan/Engine Block
(Refer to Figure 3.4)

TESTING THE CONTROL PANEL
OVERVIEW It is relatively easy to do a thorough test of the E
Oil Temperature sensing is an OPTION offered with Panel's Oil Temperature input.
the E Panel. When ordered, an analog Oil Place the Auto/Off/Manual switch to the Off position
Temperature Sender (OTS) is mounted in the oil pan. during this testing.
This sender is connected to the E Panel and allows
the E Panel to monitor and display the temperature
of the engine oil. Wire number 523 is used to connect
the OTS to the E Panel. The ground for the OTS is
made through the oil pan/engine block.
Open circuit testing 2.2 Test results:

This test checks the high end of the oil Temperature 2.2.1 If these tests fail again directly at the
input of the E Panel. back of the E Panel, then the E Panel
has failed and should be replaced.
1. Remove the 523 wire from the control panel ter-
2.2.2 If these tests pass at the back of the E
minal strip. This simulates a sender open circuit
Panel, but failed at the terminal strip,
condition.
then there is a wiring error between the
2. The E Panel should respond in either one of the E Panel and the terminal strip. Check
following ways: this wiring carefully.
2.1 The Coolant temperature display will read
less than 20 F. TESTING THE OIL TEMPERATURE SENDER
OR CONNECTIONS
2.2 The back light will flash, the com alarm LED
will flash, and the display will read as follows: Visual Inspection
OIL TEMP SENSE FAULT Carefully check the wiring between the oil tempera-
PRESS ENTER TO ACCEPT ture sender and the E Panel.
Short circuit testing 1. Check the 523 wire connection to the OTS.
1.1 Check for a proper crimp on the lug.
This test checks the low end of the oil temperature
1.2 Check to see if the sender nut is tightened
input of the E Panel.
securely. Be careful not to over tighten the
1. Reconnect the 523 wire to the control panel ter- nut. If the nut is over tightened the stud will
minal strip. break free and cause incorrect sender read-
2. Connect a jumper wire between the 523 and 0 ings. This nut should be tightened to 6 to 7
locations on the control panel terminal strip. This inch pounds.
simulates a sender short circuit condition. 1.3 Check for any environmental corrosion on
3. Look for the following response from the E Panel. the lug or sender terminal. Generac recom-
The back light will flash, the Com Alarm LED will mends the following actions if corrosion is
flash, and the display will read as follows: found:
OIL TEMP SENSE FAULT 1.3.1 Replace the lug.
PRESS ENTER TO ACCEPT 1.3.2 Replace the sender if possible. If not
possible, thoroughly remove all of the
Press enter to accept the alarm. corrosion from the sender terminal.
Control Panel testing complete 1.3.3 Protect the lug and sender terminal
1. Remove the jumper between the 523 and the 0 with an approved automotive dielectric
locations on the control panel terminal strip. grease.
2. If any E Panel alarms are present, press enter to 2. Check the 523 wire in the Deutsch connector (only
accept. used on the "water tight connector" panels.)
2.1 Refer to appendix A for information on the
Test results Deutsch connectors used.
1. Tests 1 and 2 pass: 2.2 Refer to the unit's wiring diagram for the 523
Move on to the next test "testing the oil tempera- location in the Deutsch plug.
ture sender connections". 3. Check the 523 wire on the control panel terminal
2. If either test 1 or test 2 failed: strip.
2.1 Repeat the open and short circuit testing 3.1 Check for a proper crimp on both lugs.
directly at the back of the E Panel as follows: 3.2 Check to see if both screws are tightened
Open: The 523 wire should be removed from securely. These screws should be tightened to
CON2-4. 12 inch pounds.
Short: With the 523 wire still removed, insert 4. Check the 523 wire going into CON2 on the back
a jumper wire into CON2-4. Connect the of the E Panel.
other end of the jumper to ground (0). 4.1 Check to see if the wire is stripped properly
After testing, remove the jumper wire from inside the green plug. The wire conductor
CON2-4 and insert the 523 wire back into should be trapped inside the metal wire
CON2-4. clamp. The wire insulation should not be

4.2 Check to see if the set screw is tightened The voltage displayed on the E Panel, and the
securely, but do not over tighten. This screw over/under voltage set points are all based on the gen-
should be set to 2 to 4 inch pounds. erators full line to line output voltage. However, in
5. Check for any wire damage along the entire run most cases full line to line voltage is not connected to
between the E Panel and the sender. the E Panel. (Please refer to the unit's wiring diagram
5.1 Check for any areas along the wire with miss- and schematic for complete wiring details.)
ing insulation. This could allow the 523 line The E Panel has a programmable voltage scaling fac-
to momentarily come into contact with tor that is used to scale the sensing voltage applied to
ground causing a false shut down. CON4-4 and CON4-6. This allows the E Panel to dis-
5.2 Check to see if the wire is pinched anywhere play full line to line voltage.
along the run. A wire that is pinched between The scaling factor should be checked if the E Panel is
the sheet metal can cause the 523 wire to not displaying the line to line voltage correctly.
momentarily come into ground causing a false
shut down. A pinched wire may also cause the Check the scaling factor against the generators set up
wire to break inside the insulation, this could sheet. If the set up sheet is not available, contact
cause the 523 line to momentarily "open" Generac's service department for the recommended
while running. This will also result in a false setting.
shut down. The voltage scaling factor can also be used to "cali-
brate" the voltage display.
Check the OTS mounting
The ground return (0) connection for the OTS is Example:
made by the physical connection of the sender to the A 480 volt unit has 240 volts sensing voltage applied
engine block. This connection may be made directly, to E Panel CON4-4 and CON4-6.
or through a series of adapters or fittings.
The E Panels scaling factor should be set to 2.0 to
Check for the following at each junction point: provide a proper line to line display voltage.
1. Check for a tight mechanical connection. If, however, the E Panel displays 490 volts with a scal-
2. Check for a good electrical connection. ing factor of 2.0, the scale factor may be adjusted
slightly to "calibrate" the voltage display. In this case,
Resistance measurements the displayed voltage is roughly 2% high, so the scal-
Power down the E Panel by removing the front panel ing factor should be reduced by 2% to 1.96. Change
fuse. the scaling factor and recheck the voltage display. If
Remove CON2 from the back of the E Panel. necessary, readjust the scaling factor until the voltage
display is properly "calibrated".
1. Measure the resistance between the OTS stud and
the 523 wire inside the control panel. If this meas- Please note the following:
urement is greater than 2-3 Ohms, replace the 1. Software versions V1.07 and earlier had a one
entire wire running between the control panel and decimal point scale factor.
the OTS stud. Software versions V1.08 and later have a two dec-
2. Measure the resistance between the body of the imal point scale factor.
sender and the 0 location on the control panel ter- 2. The E Panel displayed voltage is not used in any
minal strip. If this measurement is greater than 2 way to regulate the generators output voltage. The
-3 Ohms, go back and carefully check the OTS voltage regulator is responsible for regulating gen-
mounting and the star ground connections on the erator voltage.
engine block.
RPM SENSOR AND ENGINE SPEED
AC VOLTAGE DISPLAY ALARMS (Refer to Figures 3.5, 3.6 & 3.7)
The E Panel monitors the generator's AC output volt-
age. This voltage can be viewed locally on the E OVERVIEW
Panel's display, or remotely using Genlink.
The E Panel uses an RPM sensor to monitor engine
There are two user programmable set points for the speed. The RPM sensor is mounted in the blower
Generator output voltage: over voltage and under housing and positioned so the tip of the sensor is
voltage. Both parameters are active after the hold off directly above the engine flywheel teeth. As the fly-
timer has expired. They can be programmed to be a wheel rotates, the sensor will send an electrical pulse
status message, non-latched alarm, latched alarm, or to the E Panel each time a tooth passes the sensor.
shut down alarm. The E Panel will count these pulses and convert them
into engine speed.
Figure 3.5 — RPM Sensor Engine Over Speed

Engine over speed is an immediate alarm with a pro-
Blower grammable set point. Engine over speed is a shut
Housing down alarm.
TROUBLESHOOTING
1. Verify that all the following parameters have been
correctly programmed into the E Panel.
1.1 Number of flywheel teeth. The number of fly-
RPM Sensor wheel teeth is used by the E Panel to convert
Gap - 1/2 to 3/4 (Magnetic Pick Up) the electrical pulses from the RPM sensor,
into engine speed. If this parameter is not
of a turn
Ring Gear programmed correctly, the E Panel will not be
able to monitor engine speed correctly. Verify
If the magnetic pickup is removed for any reason, it the number of flywheel teeth against the gen-
must be installed properly. erator setup sheet. If the generator setup
sheet is not available, contact Generac's serv-
INSTALLATION ice department for the REQUIRED setting.
1.2 Over speed and under speed settings. Verify
1. Rotate the ring gear until a gear tooth face is these settings against the generator setup
directly in the center of the tapped hole on the sheet. If the generator setup sheet is not avail-
blower housing. able, contact Generac's service department
NOTE: for the recommended settings.
Do NOT use the alternator fan to rotate the engine. 2. Check the RPM sensor wiring. A two conductor
shielded cable is used to connect the RPM sensor
2. Gently turn the magnetic pick up clockwise into to the E Panel. It is important to very carefully
the tapped hole until it bottoms on the gear tooth. check this wiring and all connections, including
3. Use a marker to mark a line on the magnetic pick the shield connections.
up threads and blower housing. 2.1 Cable description:
4. Using the lines marked in Step 3 as a guide, turn
the magnetic pick up 1/2 to 3/4 of a turn counter- 2.1.1 Red wire (wire 79). The red wire inside
clockwise. the cable is wire number 79. This wire
is used to connect the RPM signal from
5. Tighten the jam nut securely. the sender to the E Panel.
RELATED ALARMS 2.1.2 Black wire (wire 0). The black wire
inside the cable is the 0 wire that con-
RPM Sensor Loss nects the RPM sensor to the E Panel.
RPM sensor loss is a shut down alarm. There are two Figure 3.6 — Control Panel RPM Sensor
conditions that will result in RPM sensor loss. Connections
1. No RPM signal at crank. The E Panel will monitor Control Panel RPM Sensor Connections
the RPM sensor during the crank cycle. If no sig-
nal is detected within a few seconds of cranking,
the E Panel will display RPM Sensor Failure and Shielded Cable
shut down the engine.

2. RPM sensor loss while running. The E Panel con- Red 79 Wire
Both wires crimped
tinues to monitor the RPM sensor while running. into the same spade
Black 0 Wire
If the signal is lost while running, the E Panel will lug to connect the
Bare Drain Wire
display RPM sensor failure and shut down the shield to ground
engine.
Engine Under Speed
Engine under speed is a hold off alarm with a pro-
grammable set point. The alarm type is programma-
0 Wire
ble as shutdown, latched, non-latched or status. Locations
79 Wire
Location

2.1.3 Shield/Drain wire. The shield is an alu- 3. RPM sensor voltage measurement. The RPM sen-
minum foil shield that surrounds the sor voltage can be measured at the control panel's
two conductors and runs the entire main terminal strip. This voltage should be meas-
length of the cable. The foil shield will ured during crank and run.
be cut even with the cable jacket.
The drain wire is a non insulated wire
that is in physical contact with the Once the engine has started, there will be high
shield and also runs the entire length of voltage inside the generators control panel.
the cable. The drain wire is used to
make the shield connections. 3.1 Using an AC volt meter, measure the voltage
at terminal positions 79 and 0.
The drain wire MUST be connected to This voltage should measure as follows:
system ground to shield the sensitive
During crank: 150 milli volts or greater
RPM sensor signal from noise. This (0.150V)
ground connection is typically made at
During run: 500 milli volts or greater
the control panel main terminal strip.
(0.500V)
Refer to Figure 3.6.
3.2 If the voltages measured are lower than what
2.2 Check the cable at the RPM sensor. Look for is listed above do the following:
breaks, signs of over stress, excessive ten-
sion, etc. 3.2.1 Reset the RPM sensor. Refer to Figure
3.5 for the proper setting.
2.3 Check all of the connection points along the
entire cable run (refer to the unit's wiring dia- NOTE:
grams.) At each connection point, check for The RPM sensor will have to be removed in order
proper wire stripping, lugging, etc. to be set properly. Do not strain (twist) the sender
2.4 Drain wire connections. Carefully check the cable during this process. Units that have a con-
drain wire connections at each connection nector at the sender can simply be disconnected.
point. Figure 3.7 shows the different methods If a connector is not available, the cable will have
that may be used for connecting the drain to be removed from the wire harness and discon-
wire. Note that the drain can be connected to nected at the control panel.
the 0 wire at a connection point, or it can be 3.2.2 Retake the voltage measurements. If
run separately. the voltages are still low, then the RPM
Figure 3.7 — RPM Sensor Engine Connections sender is faulty and should be
replaced.
RPM Sensor Engine Connections ENGINE DOES NOT CRANK

= Red Wire
= Black Wire
This section provides troubleshooting techniques
= Drain Wire that should be used if the engine fails to crank when
Connector Connector a start signal is given.
Housing Housing
CHECK THE E PANEL START SETTINGS

All of the following start related parameters will be
Connector
Pins/Sockets
Connector
Pins/Sockets
found in the Engine Parameters Menu.
H1 H2 These settings should be checked against the
Watertight Connector Watertight Connector
with Seperate Drain with Drain Connected Generator setup sheet. If the generator setup sheet is
to Black (0) Wire not available, contact Generac's service department
for the recommended settings.
Quick-Connect Quick-Connect
1. Number of start attempts. This number defines
Terminals Terminals
the maximum number of times the E Panel will
engage the starter. Verify this number is not set to
zero.
2. Start timer. This number (in seconds) defines the
length of time the E Panel will keep the starter
H3 H4 energized during a start attempt. Verify this num-
Quick-Connect Terminals
with Seperate Drain
Quick-Connect Terminals
with Drain Connected
ber is not set to zero.
to Black (0) Wire 3. Start attempt pause time. This number (in sec-
onds) defines the length of time the E Panel will
pause between start attempts.
4. Preheat option. Check to see how the Preheat 4.1 "Preheating": The E Panel is preheating the
option is set. If it is set as either "before start" or engine. (Only occurs if preheat is enabled.)
"before and during start" the preheat timer The start output will not be active during this
becomes active. time, and the engine should not be cranking.
5. Preheat timer. This number (in seconds) defines 4.2 "Attempting to start": The E Panel is activat-
the length of time the E Panel will preheat prior to ing all the following outputs:
cranking. 4.2.1 Start solenoid output at CON3-2.
Example: 4.2.2 Fuel solenoid output at CON3-1.
Preheat options: the preheat option is set to before 4.2.3 Preheat output at CON3-4 and 3-3
start, and the preheat timer is set to 10. (Only if preheat is enabled.)
Result: When a start signal is given, the E Panel will 4.3 "Pausing before start": This indicates the E
activate the preheat output for 10 seconds. Once that Panel is in a rest cycle between start attempts.
10 seconds is over, it will activate the start and fuel 4.3.1 The start solenoid output will not be
outputs. active.
4.3.2 The fuel solenoid output will not be
TEST THE E PANEL KEY SWITCH active.
NOTE: 4.3.3 The Preheat output will be active (Only
Leave the key switch in each position for a few if preheat is enabled).
seconds. Turning the key too quickly may cause 4.4 The start sequence will now begin cycling
false test results. between "attempting to start" and "pause
before start". This cycling will continue for the
programmed number of cycles.
If the engine has not started by the end of the
The following steps will signal the generator to final cycle, the display will read "failed to
! start and run. start" and issue a shutdown alarm. This fault
1. Place the key switch in the off position. condition is referred to as over crank.
2. Use the left and right arrow keys to go to the 5. TEST RESULTS: Did the E Panel display
Generator Command page. "attempting to start" during the start cycle?
With the key switch in the off position, the display 5.1 NO.
should read "Generator switch off". 5.1.1 Go back and carefully check the start
3. Turn the key switch to the Auto position. The top settings programmed into the E Panel.
line of the display should read "Generator in auto 5.1.2 Is there an alarm condition present
mode". which is preventing the E Panel from
4. Turn the key switch to the manual position. In the initiating the start sequence? If yes,
manual position, the E Panel should begin the they must be cleared before the E Panel
engine starting sequence. The display will contin- will attempt to start.
ue updating to show the user the progress. This is 5.1.3 If all of the programmable start param-
discussed in detail in the next test. eters are correct, and there are no
If however, the E Panel display shows the key alarms present, then the E Panel has
switch is in either the off or auto positions, the E failed and needs to be replaced.
Panel has failed and needs to be replaced. 5.2 YES. — If the E Panel displayed "attempting
WATCH THE E PANEL DISPLAY DURING THE to start" but the engine did not crank, move
on to the next test.
START ATTEMPT
MEASURE THE START SIGNAL IN THE
CONTROL PANEL (REFER TO FIGURE 3.8)
Warning: the following steps will signal the CON3-2 is the start output from the E Panel and
! generator to start and run. should be at +battery (+12V or +24V) whenever the
1. Set the key switch to the off mode. E Panel display reads "attempting to start."
2. Use the left and right arrow keys to go to the Wire #56 is used to connect CON3-2 from the E Panel
screen "Generator switch off". to the starter contactor.
3. Turn the key switch to the manual position.
All measurements in this test are DC volts with
4. The E Panel display will begin displaying the start respect to ground (0) unless otherwise noted.
sequence as follows:
1. Measure the start output directly at CON3-2 on the 1.3 Protect the lugs and terminals with an
back of the E Panel. This should read +12/24V approved automotive dielectric grease.
whenever the E Panel display reads "attempting to 2. Check to see if the terminal nuts are tightened
start." securely, but be careful not to over tighten them.
1.1 If it does not, then the E Panel has failed and 2.1 Coil terminals (10-32 studs and nuts). These
needs to be replaced. nuts should be tightened to 12 to 15 inch
pounds.
Figure 3.8 — Starter Contactor Connections 2.2 Contact terminals (5/16-24 studs and nuts).
Starter Contactor Connections
These nuts should be tightened to 30 to 36
inch pounds.
MEASURE THE START SIGNAL AT THE

The 13/218 wires STARTER CONTACTOR
are + Battery
(12 or 24VDC)
1. Measure the 56 connection at the start contactor.
The 16 wire
connects to the This should read +12/24V whenever the E Panel
Starter Motor
display reads "attempting to start."
1.1 If it does not, then carefully check the 56 wire
between the terminal strip and the starter
The 0 wire
is Ground contactor.
The 56 wire connects to CON 1.2 If it does read +12/24V, but the engine does
3-2 on the E Panel. 56 will be
+ Battery (12 or 24VDC) when not crank, move on to the next test.
the E Panel sends a start
signal to the engine. 2. Check the 0 connection at the starter contactor.
The 0 connection at the starter contactor can be
Normally open contacts will close when
+ Battery will be delivered checked as follows:
the 56 line is at + Battery (12 or 24VDC)
to the Starter Motor via
wire 16 when the normally 2.1 Connect the negative volt meter lead to the 0
+ Battery
Starter Contactor
open contacts close
at the starter contactor.
2.2 Connect the positive volt meter lead to the a
16
13/218
13/218 location inside the control panel.
The 56 wire from the E
Panel will be + Battery (12
2.3 The voltmeter should read +12/24Volts. If it
Ground
or 24VDC) when the E
Panel sends a start signal
does not, there is a problem with the 0 con-
nection to the starter contactor. Very carefully
0 56
check all 0 connections including the star
ground on the engine block.
Schematic 3. Measure the 13/218 wire at the starter contactor.
This should read +12/24V any time the battery is
1.2 If it does read +12/24V, but the engine does connected.
not crank, then there is nothing wrong with
3.1 If it does not, then carefully check the 13/218
the E Panel. Proceed to the next test.
wiring between the battery and the starter
2. Measure the 56 location on the control panels contactor.
main terminal strip. This should read +12/24V
3.2 If it does read +12/24V, but the engine does
whenever the E Panel display reads "attempting to
not crank, move on to the next test.
start."
4. Measure the 16 wire at the starter contactor. This
2.1 If it does not, then carefully check the 56 wire
should read +12/24V whenever the E Panel reads
between the E panel and the terminal strip.
"attempting to start".
2.2 If it does read +12/24V, but the engine does
4.1 If it does not, then the starter contactor is bad
and needs to be replaced.
CHECK THE CONDITION OF THE STARTER 4.2 If it does read +12/24V, but the engine does
CONTACTOR CONNECTIONS 5. Measure the 16 wire at the starter motor. This
1. Check for environmental corrosion on the termi- should read +12/24V whenever the E Panel reads
nals, nuts, or lugs. Generac recommends the fol- "attempting to start".
lowing actions if corrosion is found: 5.1 If it does not, then carefully check the 16 wire
1.1 Replace the lugs. running between the starter contactor and the
1.2 Thoroughly remove all of the corrosion from starter itself.
the contactor terminals.
5.2 If it does read +12/24V, but the engine does Check the fuel output from the E Panel
not crank, then test the starter solenoid and
the starter motor as outlined in the appropri- CON3-1 is the fuel output from the E Panel and
ate engine service manual. should be high (+12 or +24V DC) whenever the E
Panel is displaying "attempting to start."
OVERCRANK Wire number 14/219 is used to connect CON3-1 from
the E Panel to the fuel solenoid. (Wire #14 used in a
FAILED TO START 12 volt system, wire #219 used in a 24 volt system.)
When the E Panel receives a start signal, it initiates All measurements in this test are DC volts with
the programmed starting sequence. The start respect to ground (0) unless otherwise noted.
sequence consists of the number of crank attempts, 1. Measure the fuel output directly at CON3-1 on the
the length of each crank attempt, and the rest time back of the E Panel. This should read +12/24V
between each crank attempt. If the engine has not whenever the E Panel display reads "attempting to
started by the end of the final crank attempt, an start." (crank cycle). This will not read +12/24V
Overcrank alarm is generated, the E Panel will sound when the E Panel display reads "Pausing before
the alarm and display the message "Failed to start". start." (rest cycle).
1.1 If it does not, then the E Panel has failed and
Check the E Panel start settings needs to be replaced.
All of the following start related parameters will be 1.2 If it does, then there is nothing wrong with the
found in the Engine Parameters Menu. E Panel, proceed to the next test.
These settings should be checked against the 2. Measure the 14/219 location on the control panels
Generator setup sheet. If the generator setup sheet is main terminal strip. This measurement should be
not available, contact Generac's service department the same as in step 1.
for the recommended settings. 2.1 If it is not, then carefully check the wiring
1. Number of start attempts: This number defines between the E Panel and the terminal strip.
the maximum number of times the E Panel will There are two basic methods for the 14/219
engage the starter. Verify this number is not set to wiring between the E Panel and the terminal
zero. strip. Refer to the unit's wiring diagram for
the method used.
2. Start timer: This number (in seconds) defines the
length of time the E Panel will keep the starter 2.1.1 Direct wiring: In this method, a wire is
energized during a start attempt. Verify this num- run from CON3-1 on the back of the E
ber is not set to zero. Panel directly to the 14/219 location on
3. Start attempt pause time: This number (in sec- the terminal strip.
onds) defines the length of time the E Panel will 2.1.2 Secondary relay: In this method, a sec-
pause between start attempts. ondary relay is used between the E
4. Preheat option: Check to see how the Preheat Panel and the terminal strip. Refer to
option is set. If it is set as either "before start" or Figure 3.9 for a typical wiring schemat-
"before and during start" the preheat timer ic.
becomes active. 2.2 If it does read correctly: If the 14/219 loca-
5. Preheat timer: This number (in seconds) defines tion on the control panel terminal strip reads
the length of time the E Panel will preheat prior to correctly, there is nothing wrong with the con-
cranking. trol system.
Example: This means the problem is external to the
control panel and may include the fuel sup-
Preheat options: The preheat option is set to before ply, fuel solenoid/injector pump, ignition sys-
and during, and the preheat timer is set to 5. tem, or the wiring connecting these compo-
Result: When a start signal is given, the E Panel will nents.
activate the preheat output for 5 seconds. Once that Refer to the appropriate engine service manu-
5 seconds is over, it will activate the start, fuel and al for further troubleshooting techniques.
preheat outputs.

Figure 3.9 is a typical wiring schematic using a sec- Figure 3.9 — Typical Wiring Schematic Using a
ondary relay for the E Panel fuel output. Refer to the Secondary Fuel Relay
unit’s wiring schematics and diagrams to determine
if a secondary relay is used and for specific connec-
E Panel
tions. CON 3-1
Set Screw
Connector
When the E Panel supplies + battery voltage (12 or This Point is
connected to a +
24VDC) from CON3-1 through wire 14A/219A, the E Panel

14A/219A
Battery supply (13,
15, 218, or 220 wire)
secondary relay is energized. The relay’s normally

Secondary Fuel Relay
open contacts will close, delivering + battery voltage with Normally Open
Contacts
to the 14/219 location on the control panel terminal
strip. The fuel output from the
E Panel will be + Battery Control Panel
(12 or 24VDC) during Terminal Strip
cranking and run
14/219 14/219
Ø
This Point is
connected to 0 on the
Control Panel
Terminal Strip
Appendix — Phoenix and Deutsch Connectors

Phoenix Combicon Connections
The screws
should be set to 2
to 4 inch pounds
All strands of the

wire are secured
firmly inside the
metal clamp
The wire insulation The wire should not Strands of the

should not be be stripped too long wire should not be
trapped inside the loose outside of
metal clamp the metal clamp

HD30 Type
Step 1: Contact Removal Step 2: Wire Stripping
Solid Contacts
Contact Part Wire Gauge Strip Length
1. With rear insert toward Number Range (inches)
you, snap appropriate size
extractor tool over the wire 0460-202-20141 20 AWG .156-.218
of contact to be removed. 0462-201-20141 20 AWG .156-.218
0460-202-16141 16, 18 & 20 AWG .250-.312

0462-201-16141 16, 18 & 20 AWG .250-.312
2. Slide tool along into the
insert cavity until it engages 0460-215-16141 14 AWG .250-.312
contact and resistance is 0462-209-16141 14 AWG .250-.312
felt.
0460-204-12141 12 & 14 AWG .222-.284
0462-203-12141 12 & 14 AWG .222-.284
3. Pull contactwire 0460-204-08141 8 & 10 AWG .430-.492

assembly out of connector. 0462-203-08141 8 & 10 AWG .430-.492
NOTE: Do not twist tool or
insert at an angle. 0460-204-0490 6 AWG .430-.492
0462-203-04141 6 AWG .430-.492
Step 3: Contact Crimping Step 4: Contact Insertion

Use Crimp Tool #HDT48-00
1. Strip insulation from wire.
(See Step 2). 1. Grasp contact approxi-
2. Raise selector knob and mately (25.4 mm) one inch
rotate until arrow is aligned with
behind the contact crimp
wire size to be crimped.
3. Loosen locknut, turn adjust- barrel.
ing screw in until it stops.
4. Insert contact with barrel up.

Turn adjusting screw counter
clockwise until contact is flush 2. Hold connector with rear
with indentor cover. Tighten grommet facing you.
locknut.
5. Insert wire into contact.

Contact must be centered
between indicators. Close 3. Push contact straight into
handles until crimp cycle is connector grommet until a
completed. positive stop is felt. A slight tug
6. Release handles and will confirm that the contact is
remove crimped contact. properly locked in place.
NOTE: For unused wire
7. Inspect terminal to ensure cavities, insert sealing plugs for
that all strands are in crimp full environmental sealing
barrel.NOTE: Tool must be
readjusted for each type/size
of contact. Use HDT04-08 for
size 8 and 4 contacts.
(800) 223-1236
36 Generac® Power Systems, Inc. LADD Instruction Sheet #7008-064

DT Type
Step 1: Contact Removal Step 2: Wire Stripping
Solid Contacts
1. Remove wedgelock using Contact Part Wire Gauge Strip Length

needlenose pliers or a hook Number Range (inches)
shaped wire. Pull wedge
straight out. 0460-202-20141 20 AWG .156-.218
0462-201-20141 20 AWG .156-.218
0460-202-16141 16, 18 & 20 AWG .250-.312

2. To remove the contacts,
0462-201-16141 16, 18 & 20 AWG .250-.312
gently pull wire backwards,
while at the same time
0460-215-16141 14 AWG .250-.312
releasing the locking finger
0462-209-16141 14 AWG .250-.312
by moving it away from the
contact with a screwdriver.
0460-204-12141 12 & 14 AWG .222-.284
0462-203-12141 12 & 14 AWG .222-.284
3. Hold the rear seal in 0460-204-08141 8 & 10 AWG .430-.492

place, as removing the 0462-203-08141 8 & 10 AWG .430-.492
contact may displace the
seal. 0460-204-0490 6 AWG .430-.492
0462-203-04141 6 AWG .430-.492
Step 3: Contact Crimping Step 4: Contact Insertion

Use Crimp Tool #HDT48-00
1. Strip insulation from wire.
1. Grasp crimped contact
(See Step 2).
2. Raise selector knob and
approximately (25.2 mm) one inch
rotate until arrow is aligned with behind the contact barrel.
wire size to be crimped.
3. Loosen locknut, turn adjust-
ing screw in until it stops.
2. Hold connector with rear
grommet facing you.
4. Insert contact with barrel up.
Turn adjusting screw counter
clockwise until contact is flush
with indentor cover. Tighten 3. Push contact straight into
locknut. connector grommet until a click
is felt. A slight tug will confirm
5. Insert wire into contact. that contact is properly locked in
Contact must be centered place.
between indicators. Close
4. Once all contacts are in place,
handles until crimp cycle is
insert wedgelock with arrow pointing
completed.
toward exterior locking mechanism.
6. Release handles and
The wedgelock will snap into place.
remove crimped contact.
Rectangular wedges are not
oriented. They may go in either way.
7. Inspect terminal to ensure NOTE: The receptacle is shown use the
that all strands are in crimp same procedure for plug.
barrel.NOTE: Tool must be
readjusted for each type/size
of contact. Use HDT04-08 for
size 8 and 4 contacts.
(800) 223-1236
Section 4 — Glossary
E CONTROL PANEL DEFINITIONS • LOW: A low signal to a digital input is a contact clo-
Please refer to the following list for an explanation of sure to ground.
terms used in various charts throughout the manual:
• NON-LATCHED: This type of warning will activate
the audible alarm, and flash the alarm LED and
• ALWAYS: With this option selected, the alarm is display back light. The associated message will be
active regardless of the state of the generator. displayed on the screen. When the user accepts the
warning (by pressing the Enter key), the back light
• ANALOG INPUT: An analog input to the E control will stop flashing, and the alarm LED will be on
panel is a voltage sourced input with a zero volt to continuously. The message will be displayed on the
10-volt range. alarm screen, but the user will be able to scroll
through other screens. The LED and message will
• DIGITAL INPUT: A digital input to the E control clear when the warning condition clears. This type
panel is NOT a voltage sourced input, but a dry of warning is logged.
contact closure to ground. Voltage should never be
sourced to a digital input. • SHUTDOWN: This type of alarm will act similar to
the latched alarm, but it also will stop the engine
• DISABLED: If this option is selected, the alarm is when the alarm condition occurs. It can be reset
disabled and has no effect. only by turning the key-switch to the OFF position.
All shutdown alarms are latching, and this type of
alarm is logged.
• HIGH: A high signal to a digital input is
open circuit.
• STATUS: This type of alarm will display a message
on the screen. The message will not be logged. This
• HOLD OFF: This option waits until a preset time is the lowest priority of alarm types.
after the generator is running before becoming
active. The hold off time can be set by the user.
Note that the hold off time is common to • USER INPUT: Any of the eight digital or two ana-
all alarms. log inputs reserved for customer options.
• IMMEDIATE: In this mode, the alarm is not active

when the generator is stationary. It becomes active as
soon as the generator starts to crank and remains
active until the generator stops.
• LATCHED: When the alarm condition occurs, the

audible alarm sounds, the LED and back light
flash as before, and the user must accept the alarm
to stop them. The alarm will continue to be dis-
played on the screen even after the alarm condition
has cleared. The user must either press the Reset
key or turn the key-switch to the OFF position to
clear the alarm after the alarm condition has
cleared. This type of alarm is logged.

E PANEL DRAWING APPLICATION MATRIX
The following table will assist in determining which of the drawings in this manual apply to the particular generator set. Find the specif-
ic generator set configuration on the top row and follow that column down to find which drawings are applicable.
Manufacture Prior to 2nd 2nd Qtr. 2000 Starting 3rd Prior to 3rd Starting 3rd Prior to 2nd Starting 2nd Starting 1st
Date Qtr. 2000 thru 3rd Qtr. Qtr. 2002** Qtr. 2002 Qtr. 2002** Qtr. 2000 Qtr. 2000* *** Qtr. 2003
2002*
Watertight
Connectors No No No Yes Yes No No Yes Yes
Alt. Type Generac Generac Generac Generac Generac Marathon Marathon Marathon Marathon
kW Range <400 kW <400 kW <400 kW <400 kW <400 kW >400 kW >400 kW >400 kW 400 kW Only
0A5502-D (Pg. 52)
0A5501 (Pg. 51) XXX
0A6325-N (Pg. 68)
0C8319-E (Pg. 48)
0C8318 (Pg. 50) XXX
0C8459-J (Pg. 72)
0C8319-E (Pg. 48)
0C8318 (Pg. 50) XXX
0D8765-G (Pg. 66)
0D2378-C (Pg. 44)
0D2379 (Pg. 46) XXX
0D2383-J (Pg. 60)
0D2378-C (Pg. 44)
0D2379 (Pg. 46) XXX
0D8764-H (Pg. 64)
0C1376-D (Pg. 56)
0C1375-C (Pg. 54) XXX
0C3879-B (Pg. 70)
0C8327-C (Pg. 58)
0C8326-B (Pg. 55) XXX
0C8460-G (Pg. 74)
0D4267-A (Pg. 42)
0D4267A-A (Pg. 40) XXX
0D4267C (Pg. 41)
0D4267B-H (Pg. 62)
0D2378-C (Pg. 44)
0D2379 (Pg. 46) XXX
Section 5 — Electrical Data
0D8764-H (Pg. 64)
* Changed the E-panel Voltage Sense Input.

** Changed to a new style hinge.
*** Also refer to the E-plus Panel manual.
This manual contains standard drawings and schematics.

For specific drawings, please refer to the Owner’s Manual of the unit.

Standard diagram. Please refer to the Owner’s Manual of the unit for specific details.
Wiring Diagram (For use with Marathon Alternator) – Drawing No. 0D4267A-A
567 R
589 T
591 V
NOTES:
ALL WIRING 18 AWG UNLESS NOTED. 590 U
REQUIRED WIRING.
OPTIONAL WIRING A
CABLE SHIELDED CABLE 12 AWG
0 G
L
12 AWG
12 AWG
218 E BC3
CABLE B X H
575 S W J
C G B K
68 F
V
A C
For units manufactured with a watertight connector.
H L
573
U F D
P
M
573
N E
T
P
0
86 K
S N
219
85 J
20 354
R SOC
A M
219
C3207 49 W
TB1
ENGINE ON
A
FUSED 15A
D2
FUEL LEVEL
LEVEL SIG.
BATTERY
BATTERY
COOLENT
PROBE
C3208
SPEED
R1 TB3 OPEN D A
(+DC)
(+DC)
(+DC)
START
GND
TB1
SIG.
SIG.
(-)
220 X
PRG INPT GND 1
573
79
0
0
PRG INPT GND
49
PRG INPT GND
0 L
GND A
0 M
TEMP.
523
USED(+)
DEC
T DOWN
OPEN N
TB5 20) 6
C3206
TB4
GRAM
OPEN P
7
C2688
0
GRAM
OPEN R
GND
8
BC2
485+ 1 PRG RLY 1 NO UT 2
(-)
0 OPEN S
GRAM
485-
219 PRG RLY 1 NC
OPEN T
SCREEN
219 PRG RLY 2 COM
86
OPEN U
X H
85 W J
0V
PRG RLY 2 NO
EMP.
OPEN V
+12/24V
5
IL FILTER
LOCKED 12 354
OPEN W G B K
PRG RLY 2 NC V
7 X A C
PRG RLY 3 COM
TB3 0A K L
F
589
589 8
U D

(A7)
PRG RLY 3 NO CABLE 0A J
567
567 9 79A
(A8)
H M
PRG RLY 3 NC
12 AWG
169 E T E
590 12 AWG
168
P N
G S
LEGEND
591
FUEL -
OPEN D R PIN
TB2 OPEN B
BC2 - BULKHEAD CONNECTOR (GOVERNOR) 12 AWG
219 0
BC3 - BULKHEAD CONNECTOR
0
12 AWG C
CABLE 0 A
79 F
A
Wiring Diagram (For use with Marathon Alternator) – Drawing No. 0D4267C

Wiring Diagram (For Use With Marathon Alternator) – Drawing No. 0D4267-A
TB5
C2688
LOCATED ON BOTTOM OF PANEL

485+ 1
485-
C3207
ENGINE ON
FUSED 15A
SCREEN
OIL PRESS.
LEVEL SIG.
BATTERY
BATTERY
TEMP. SIG.
CONTACT
COOLENT
COOLENT
PROBE
SPEED
(+DC)
(+DC)
(+DC)
START
GND
0
TB1
SIG.
0V
(-)
219
220
220
220
573
5 220
79
56
68
69
0
0
+12/24V
1 2 3 4 5 6 13 14 15 16 17 18 19 20
TB1
220
220
220
220
220
218
218
219
219
219
575
573
79
56
68
69
0
0
0
0
0
0
0
0
0
0
0
LOCATED ON BACK OF PANEL
12 AWG
12 AWG
0
219B 12 AWG 219B
RR
87 218 12 AWG
86 30
85
219A
0 CABLE CABLE
219
0
BC1
C3208
C3206
TB4 TB3
TB1
A6577
TB2
S1 1 183
BATTERY
0 1 0 BAT GND (-) 0 1 178 1 PRG INPT GND
S2 2 11 178 GND 0
S3 3 10 0 (-)
0 2 BAT GND (-) 0 2 0 A0 2 PRG INPT GND
S15 5 8 58
219 3 219 DC FUSED (+) 3 220 3 PRG INPT GND
ENGINE ON (15/220)
(+DC) 220
S16 6 7 57 219 4 PRG RLY 1 COM 4 R1 A0 4 PRG INPT GND
ANALOG OIL TEMP.

USER 5 AI1 PRG RLY 1 NO 5 R2 523 5 523
SIG.
INPUT 1
LOCATED IN REAR SHUT DOWN
USER AI2 6 AI2 PRG RLY 1 NC 6 R3 190 6 190
ALARM RLY
OF CONTROL PANEL INPUT 2
PROGRAM
7 PRG RLY 2 COM 7 R4 A1 7 A1
INPUT 1
CB OPEN 8 A7 PRG RLY 2 NO 8 R5 A2 8 A2

INPUT 2
TANK 9 A8 PRG RLY 2 NC 9 R6 A3 9 A3

INPUT 3
BACK-UP
PRG RLY 3 COM 10 R7 A4 10 (A4)
LOW OIL
PRESS.
BACK-UP
85
PRG RLY 3 NO 11 590 A5 11 (A5)
TEMP.
354 OIL FILTER

PRG RLY 3 NC 12 591 A6 12 (A6) BLOCKED
TB2 TB3
NOTE:
THESE TERMINALS ARE
INTENDED ONLY TO BE
USED FOR "DRY CONTACTS"
ASSOCIATED WITH THE
PROGRAMMABLE INPUTS.

Wiring Diagram (For Use With Marathon Alternator) – Drawing No. 0D4267-A
LOCATED ON FRONT OF PANEL NOTES:

ALL WIRING 18 AWG UNLESS NOTED.
REQUIRED WIRING.
OPTIONAL WIRING
12 AWG MC1 CABLE SHIELDED CABLE
CON1 CON3
219B
R15
56A
A1 PRG INPT 1 ALARM HORN N/C

A2 2 PRG INPT 2 ALARM HORN N/O 515
A3 PRG INPT 3 220
A4 4 PRG INPT 4 PRG RLY 3 NC R9
A5 PRG INPT 5 PRG RLY 3 NO R8
A6 6 PRG INPT 6 PRG RLY 3 COM R7
GROUND STUD
ES A7 PRG INPT 7 PRG RLY 2 NC R6

219
A8 8 PRG INPT 8 PRG RLY 2 NO R5

56
0
A0 INPUT GND PRG RLY 2 COM R4

A0 10 INPUT GND PRG RLY 1 NC R3
12 AWG PRG RLY 1 NO R2
AI1 1 USER INPT 1 PRG RLY 1 COM R1
575 FUEL LVL ALARM RLY N/O
AI2 3 USER INPT 2 ALARM RLY COM 220
220 523 4 OIL TEMP STARTER SOL
0
69 5 OIL PRES FUEL SOL 1 219A

F1 68
573
6
7
COOL TEMP
COOL LVL
218 79 8 SPD SNSR +
0
0 9 SPD SNSR - ALT LINE 2 6 S16
219B 183 10 REMOTE STRT 5
0 R15 11 EMRG STOP ALT LINE 1 4 S15
12 SPR INPT 1 3
CABLE
590 13 FUEL SNDR + BAT - 2 0

AA 591 14 FUEL SNDR - BAT + 1 220
CON2 CON4
0
#?-A #?-A
515
#?-B #?-B
CABLE
FERRITE
BEAD
#?-A = #0 OR #S15
#?-B = #220 OR #S16
219
0
S1
S3
S2
57
58
59
0
0
1
20
18
16
14
AM LEGEND
SW1
15
19
AA - AUDIBLE ALARM
67 AM - AMMETER
BC1 - BULKHEAD CONNECTOR (LOWER PANEL)
L1
65
64
67
0
CON1 - PLUG 3.5 10 POS

219 CON3 - PLUG 3.5 16 POS
ES - EMERGENCY STOP SWITCH
F1 - 15 AMP FUSE
HZ - FREQUENCY METER
L1 - PANEL LAMP
MC1 - E-PANEL CONTROLLER ASSEMBLY
S15 RR
S15 64 SW1 - VOLT/AMMETER SWITCH
TB2 - TERMINAL BLOCK 2(12 POS)

HZ VM TB4 - TERMINAL BLOCK 4(9 POS)
S16 VM - VOLTMETER
S16 65

Wiring Diagram (For Use With Generac Alternator) – Drawing No. 0D2378-C
OPTIONAL BASETANK BC4 WIRE COLOR

LEGEND FUNCTION WIRE #'s
HARNESS CONNECTOR 591 8 590
8
0 7 575 WHITE NEUTRAL 0,1,R15,591
7
567 RED NON-FUSED DC
6
0 ORANGE FUSED DC 14,15,219,220
509 4 5 502
5
0 56,56A,57-59,67,89
591
590
509
502
575
567
BROWN CONTROL
0
0
BC2 162,178,183,S1-3,590
2,49,150,A1-8,R1-9
0 79 BLUE SIGNAL/SENSING
1
S15,S16,64,65
0 85
2
BLACK AC/MISC 6
0 523
3
68,69,85,502,509,
0 68 YELLOW UNIT STATUS
4
515,523,567,575,589
0 69
5
13/218
6
49
575
567
14/219
LEGEND
150
56 AVR = AUTOMATIC VOLTAGE REGULATOR
13/218
0 BC1 = BULKHEAD CONNECTOR [LOWER PANEL]
13/218
BC2 = BULKHEAD CONNECTOR [ENGINE1]

150
56
0
BC3 = BULKHEAD CONNECTOR [ENGINE2]
13/218
14/219
14/219
49
BC4 = BULKHEAD CONNECTOR [BASETANK]
COOLNT TEMP
15/220
13/218
14/219
14/219
150
523
567
COOLNT LVL
79
49
56
68
85
1 12 13/218
0
0
RUPT TANK
12
OIL P SEND
1
PRE-HEAT
C ALT W/L
CB1 = AVR CIRCUIT BREAKER
MLCB SW
FUEL LVL
OIL TEMP
2 11
11
0
2
10 49 D1 = FIELD BOOST DIODE

10
3
9 14/219 D2 = C/A EXCITER DIODE

9
14/219
8
R1 = FIELD BOOST RESISTOR

11
10
0
1
20
12
13
14
15
16
17
18
19
2
3
4
6
7
8
6 7 0
7
6
R2 = C/A EXCITER RESISTOR

15/220
TB1 TB1 = TERMINAL BLOCK [20 POS.]

0
15/220
15/220
15/220
15/220
13/218
14/219
14/219
14/219
BC3
150
523
575
567
TB2 = TERMINAL BLOCK [14 POS.]
49
56
68
69
85
1
1
0
0
0
0
0
0 TB3 = TERMINAL BLOCK [12 POS.]

0 TB4 = TERMINAL BLOCK [8 POS.]
15/220
15/220
15/220
0
0
0
0V 1 0
0
0V 2 0 14/219
0 49
0V 3 0 0
0V 4 0
0
0 0
+12/24V 15/220
0
SCREEN 1
SCREEN 6 0 13/218
485- 7 CLEAR
485+ 8 BLACK CABLE
TB4 0 15/220
0
178 CB1 15/220
14/219
0
591
590
567
89
K W
183
178
1
0 1
0
PRG INPT GND

J 0
B 0 0 2
1 178
PRG INPT GND 2
M U BAT GND (-) 0
0
3 PRG INPT GND
49
BAT GND (-) 0 0
N D T 0 4
O S
DC FUSED (+)
(15/220)
15/220
15/220
A1 5
PRG INPT GND
B/C FAIL
R2
P R PRG RLY 1 COM R1
A2 6 GEN POWER
D2
SOC 0
PRG RLY 1 NO 5 R2
A3 7 LINE POWER
A
B
0
183
PRG RLY 1 NC 6 R3
A4 8 PRG INPT 4
R1
C 4 PRG RLY 2 COM
R4 502
D 1 A5 9 PRG INPT 5 29 14/219
E 2 PRG RLY 2 NO 8 R5
F 6 A6 10
0 PRG INPT 6
G S16 PRG RLY 2 NC 9 R6
H A7 11 MLCB
J 178 PRG RLY 3 COM 10
0 R7
D1
162
89
2
K S1 A8 12 RUPT TANK
L S2 PRG RLY 3 NO R8
S15
S16
1
0
4
2
6
M S3
N 57
58
PRG RLY 3 NC
12 R9
TB3 4
O
P 59 590
FUEL +
1
13 590
567 4 AVR
Q NOT USED FUEL- 14 591 589
R 589 591
1
590
6
5
3
2
4
4
4
T NOT USED 591

U NOT USED 591
590 162
W NOT USED
X NOT USED 4 4 4 89
6 6 S15
S1
589
S3
S2
59
58
57
2 2
1 1
589
0 0 0

Wiring Diagram (For Use With Generac Alternator) – Drawing No. 0D2378-C
ES MC1
0 R15
14/219 14A
CON1
56 56A A1 1 PRG INPT 1 SNDR RLY N/C 16
A2 2 PRG INPT 2 SNDR RLY N/O 515
A3 3 PRG INPT 3 SNDR RLY COM 14 15/220
A4 4 PRG INPT 4 PRG RLY 3 NC R9
A5 5 PRG INPT 5 PRG RLY 3 NO 12 R8
A6 6 PRG INPT 6 PRG RLY 3 COM R7
A7 7 PRG INPT 7 PRG RLY 2 NC 10 R6
F1 A8 8 PRG INPT 8 PRG RLY 2 NO 9 R5
0 9 GND PRG RLY 2 COM 8 R4
13/218
0 10 GND PRG RLY 1 NC 7 R3
15/220 PRG RLY 1 NO 6 R2
1 USER INPT 1 PRG RLY 1 COM 5 R1
575 2 FUEL LVL PRE-HEAT N/O 150
3 USER INPT 2 PRE-HEAT COM 3 15/220
S16
523 4 OIL TEMP STARTER SOL 56A
69 5 OIL PRES FUEL SOL 1 14A
68 6 COOL TEMP
85 7 COOL LVL
79
CON4
8 SPD SNSR +
VR1 0
183
9
10
SPD SNSR -
REMOTE STRT
ALT LINE 2 6 S16
0
R15 11 EMRG STOP ALT LINE 1 4
12 SPR INPT 1
BAT - 2
15/220
590
14/219
13/218
13 FUEL SNDR +
BAT + 1
R15
S16
56A
14A
591 14 FUEL SNDR -

89
56
0
CON2
S15
S16
0
15/220
AA
515
0
0
0
0
0
0
0
L1 FERRITE
0
13/218 14/219 BEADS
15/220
PFG
S15
S16
CABLE 0
15/220
S15
S16
15/220 15/220
14/219 14/219
89
WIRE COLOR
LEGEND FUNCTION WIRE #'s LEGEND
WHITE NEUTRAL 0,1,R15,591 AA = AUDIBLE ALARM
RED NON-FUSED DC
ORANGE FUSED DC 14,15,219,220 AM = AMMETER
56,56A,57-59,67,89 ES = EMERGENCY STOP SWITCH
BROWN CONTROL
162,178,183,S1-3,590 F1 = 15 AMP AGC TYPE FUSE
2,49,150,A1-8,R1-9
BLUE SIGNAL/SENSING
S15,S16,64,65 HZ = FREQUENCY METER
BLACK AC/MISC 6 L1 = PANEL LAMP
68,69,85,502,509, MC1 = E-PANEL CONTROL ASSEMBLY
YELLOW UNIT STATUS
515,523,567,575,589
PFG = PANEL FRONT GROUND STUD
SW1 = VOLT/AMMETER SWITCH
S16
S16
S16
S15
S15
S15
VM = VOLT METER
S1
S3
S2
57
58
59
VR1 = VOLTS TRIM POTENTIOMETER

S16
11
18
16
14
3
S16 64 67
SW1 S16
HZ VM AM
64
19
15
12
2
S15
S15 65 0
S15 0
64
65
67
0
65
67
0
0
64
67
0
0 0

Schematic Diagram (For Use With Generac Alternator) – Drawing No. 0D2379
BC1-R
MLCB OPEN 589
BC1-S
GROUND RETURN 0
BC1-A
CT COMMON 0
BC1-N 2
L1 CT 57 3
SEE DWG: 0D2483(390 ALTS.) OR 0D4225(520ALTS.)

BC1-O
L2 CT 7 SW1 AM
LOWER PANEL CONNECTOR

BC1-P
L3 CT 59 11
12
BC1-K 15
L1 VOLTS S1 14
BC1-L
16 VM
BC1-M
L3 VOLTS S3 18
19
S16
2-WIRE BC1-J
S15
START BC1-B
BC1-H
AVR
BC1-G
BC1-F HZ
AVR
POWER BC1-E
2
BC1-D
EXCITER
FIELD BC1-C
4
VR1
CB1
CODE P/N: DESCRIPTION
AA 061286 AUDIBLE ALARM
AM VARIOUS AMMETER
AVR 067680 AUTOMATIC VOLTAGE REGULATOR 50Hz
092952 AUTOMATIC VOLTAGE REGULATOR 60Hz
1
4
5
CB1 VARIOUS AVR CIRCUIT BREAKER POWER
D1 049939 FIELD BOOST DIODE
SENSING
FIELD
D2 025192 CHARGE ALT EXCITER DIODE

ES 098426A EMERGENCY STOP BUTTON
ES1-3 098426C NORMALLY CLOSED CONTACTS
HZ 070042 FREQUENCY METER 50Hz
070042A FREQUENCY METER 60Hz AUTOMATIC
L1 0C8481 PANEL LAMP 12V
070202 PANEL LAMP 24V VOLTAGE
MC1 0A4087 E-PANEL CONTROLLER ASSEMBLY REGULATOR
R1 VARIOUS FIELD BOOST RESISTOR (AVR)
R2 044213 CHARGE ALT EXCITER RESISTOR
SW1 061945 VOLT/AMMETER SWITCH
VOLTMETER 0-300V
070044 VOLTMETER 0-600V D1 R1 R2
082404 VOLTMETER 0-750V
VR1 071361 VOLTS TRIM POTENTIOMETER FIELD BOOST
XXX-X REFERENCE E-PANEL CONNECTOR TERMINATIONS
ALTERNATOR
EXCITATION
WIRE COLOR
FUNCTION WIRE #'s
LEGEND
WHITE NEUTRAL 0,1,R15,591
RED NON-FUSED DC 4,13,29,218
ORANGE FUSED DC 14,15,219,220
56,56A,57-59,67,89
BROWN CONTROL
162,178,183,S1-3
2,49,150,A1-8,R1-9
BLUE SIGNAL/SENSING
S15,S16,64,65
BLACK AC/MISC 6
68,69,85,502,509,515
YELLOW UNIT STATUS
523,567,575,589

BC3-10
CHARGE ALT. W/L CONN. 49
AUX. FUSED DC SUPPLY 15
BC3-1 A1 PROG. INPUT 1
POSITIVE DC FROM BATTERY CON4-1 CON1-1 544 BATT CHRG FAIL
POSITIVE DC FROM BATTERY 13
F1
CON4-4
CON4-6
CON1-2
15A
CON2-10
GROUND FROM ENGINE 0 CON4-2 CON1-3 733 LINE POWER
BC4-5
GROUND FROM ENGINE CON1-4
BC4-4
CON3-14 CON1-5 A5 PROG. INPUT 5
L1
CON1-6 A6 PROG. INPUT 6
BC3-9
FUEL SOLENOID 14 CON3-1 CON1-7 589 MLCB OPEN
BC3-3 ES-3 BC4-6
STARTER SOLENOID 56 A8 PROG. INPUT 8
ES-2 CON3-2 CON1-8
BC4-2
CON3-3 CON1-9 0 GROUND RETURN
BC4-3
PRE-HEAT SOLENOID CON3-4 CON1-10 0 GROUND RETURN
BC2-9
COOLANT TEMP. SENSOR CON2-6
BC2-8
OIL PRESSURE SENSOR 69 CON2-5
OIL TEMP. SENSOR CON2-4 CON3-5 R1
BC4-7 COM
FUEL LEVEL SENSOR CON2-2 CON3-6 PROG. RELAY 1
N/O
MC1
BC4-8
'E' PANEL
FUEL SENDER + CON2-13 CON3-7 R3
N/C
FUEL SENDER - CON2-14
BC2-11
CONTROL BOX
COOLANT LEVEL DETECTOR 85 CON2-7 CON3-8 R4
COM
CON3-9 R5 PROG. RELAY 2
N/O
BC2-12 CON3-10 R6
79 CON2-8 N/C
MAGNETIC RPM SENSOR
0 CON2-9
BC2-2 CON3-11 R7
ES-1 CON2-11 CON3-12 R8 PROG. RELAY 3

N/O
CON3-13 R9
N/C
CON3-15
AA
DSUB-5
DSUB-4
DSUB-3
DSUB-2
DSUB-1
RS232 (DSR)
TB4-8
TB4-7
RS232 (Tx)/RS485-
TB4-6
COMMON
Schematic Diagram (For Use With Generac Alternator) – Drawing No. 0D2379

Wiring Diagram (For Use With Generac Alternator) – Drawing No. 0C8319-E
For units manufactured starting the 2nd quarter of 2000 thru 3rd quarter 2002.
TB4
13A
C2688
TB4
485+ 1
FUEL
+ BAT
FUSED DC
COOLNT TEMP
A3392
COOLNT LVL
PROBE
SPEED
RUPT TANK
GND (-)
PRE-HEAT
OIL P SEND
OIL TEMP
BAT
FUEL LVL
C ALT W/L
13A
13A/15/220
13A/15/220
485- 2
13/218
14/219
14/219
0
523
150
575
567
49
68
69
85
SCREEN 3 0
0V 4 0 TB1
11
20
12
14
15
16
18
19
6
7
+12/24V 5 13A
1
1
0
0
0
0
0
69
79
13
14
14
14
15
15
15
49
56
68
85
150
523
589
575
567
13
15
0
89
CABLE
15
0
183
S15
S16
14
14 14
49 49
CB1
S16
S15
178
89
A6577
1
1
0
TB1
TB3
C8229
TB1
TB2
49
14
BAT GND (-) 0
1 1
183 BAT GND (-) 0
2 0 0 2 PRG INPT GND
162
DC FUSED (+)
3 15 PRG INPT GND 2
(15/220)
15
49
PRG RLY 1 COM R1 0 PRG INPT GND
178
S16
PRG RLY 1 NO 5 R2 A1 5 B/C FAIL
R2
PRG RLY 1 NC
6 R3 A2 6 GEN POWER
D2
15
12
6
9
PRG RLY 2 COM 7 R4 A3 7 LINE POWER

11
14
1
8
589
567
R5
PRG RLY 2 NO
A4 PRG INPT 4
R1
10
13
4
7
S15 PRG RLY 2 NC 9 R6 A5 9 PRG INPT 5
PRG RLY 3 COM 10

0 R7 A6 10 29 14/219
57 PRG INPT 6
SH
S1
S3
58
4 PRG RLY 3 NO R8 A7 MLCB

S15 S3
S2 58
S1
PRG RLY 3 NC
12 R9 A8 RUPT TANK
57
59 FUEL + 1
13 590 D1
S3
58 FUEL- 14 591
S1
TB3 4
162
4
2
TB2 AVR
4
1
6
5
3
2
4
S1
58
59
57
89
1
4
2
6
162
S15
89
1
6
6
S15
4
2
0 0
1

Wiring Diagram (For Use With Generac Alternator) – Drawing No. 0C8319-E
ES
0 R15 MC1
14 14A
56 56A
CON1 CON3
A1 1) PRG INPT 1 16) SNDR RLY N/C
A2 515 15) SNDR RLY N/O
A3 15 14) SNDR RLY COM
A4 R9 13) PRG RLY 3 NC
F1 A5 R8 12) PRG RLY 3 NO
13
A6 R7 11) PRG RLY 3 COM
A7 R6 10) PRG RLY 2 NC
15 A8 R5 9) PRG RLY 2 NO
0 R4 8) PRG RLY 2 COM
0 R3 7) PRG RLY 1 NC
S16 R2 6) PRG RLY 1 NO
R1 5) PRG RLY 1 COM
575 150 4) PRE-HEAT N/O
15 3) PRE-HEAT COM
523 56A 2) STARTER SOL
VR1 69
68
14A 1) FUEL SOL
85 CON4
13 79
15 0 S16 6) ALT LINE 2
0 183
4) ALT LINE 1
89
AA 590
591 14) FUEL SNDR -
0
15
2) BAT -
1) BAT +
0 0
515 CON2
CABLE
15
0
#?-A #?-A
#?-B #?-B
S15 FERRITE
BEAD
S16
#?-A = #0 or #S15
14
#?-B = #15 OR #S16
S1
S3
S2
57
58
59
11
67
18
16
14
3
SW1 AM
L1
19
15
12
2
S16
S16
S15
S15
S16
WIRE COLOR
FUNCTION WIRE #'s
LEGEND
0
67 RED NON-FUSED DC 4,13,29

0 ORANGE FUSED DC 14,15
65 BROWN CONTROL
14
162,178,183,S1-3
64
14
2,49,150,A1-8,R1-9
BLUE SIGNAL/SENSING
BLACK AC/MISC 6
64
65
68,69,85,515,523
YELLOW UNIT STATUS
567,575,589
LEGEND
AA - AUDIBLE ALARM
AVR - AUTOMATIC VOLTAGE REGULATOR
HZ VM AM - AMMETER
CB1 - AVR CIRCUIT BREAKER
CON1- PLUG 3.5 10 POS
14 D1 - FIELD BOOST DIODE
D2 - C/A EXCITER DIODE
ES - EMERGENCY STOP SWITCH
F1 - 15 AMP FUSE
HZ - FREQUENCY METER
L1 - PANEL LAMP
S15 MC1 - E-PANEL CONTROLLER ASSEMBLY
R1 - FIELD BOOST RESISTOR
R2 - C/A EXCITER RESISTOR
0 0
SH - SOCKET HOUSING(MALE/15 CKT)
SW1 - VOLT/AMMETER SWITCH
TB1 - TERMINAL BLOCK 1 (20 POS)
VM - VOLTMETER
VR1 - VOLTS TRIM POTENTIOMETER

Schematic Diagram (For Use With Generac Alternator) – Drawing No. 0C8318

Schematic Diagram (For Use With Generac Alternator) – Drawing No. 0A5501
For units manufactured prior to the 2nd quarter of 2000.

Wiring Diagram (For Use With Generac Alternator) – Drawing No. 0A5502-D

Wiring Diagram (For Use With Generac Alternator) – Drawing No. 0A5502-D

Schematic Diagram (For Use With Marathon Alternator) – Drawing No. 0C1375-C

Schematic Diagram (For Use With Marathon Alternator) – Drawing No. 0C8326-B
For units manufactured starting the 2nd quarter of 2000.
CT COMMON
CODE
ES1-3
L3 VOLTS
L2 VOLTS
SENSING
L1 VOLTS
2-WIRE
MC1
SW1
SIGNAL
AM
AA
VM
HZ
RR
D3
SH
ES
START
F1
L1
FREQ.
L3 CT
L2 CT
L1 CT
S15
178
S16
57
S1
QTY
0
3
2
1
PIN #
SH
14
15
10
7
5
9
1
PART NO.
VARIOUS
VARIOUS
VARIOUS
98426A
98426C
94261E
A4087
86035
70202
32300
55089
61945
61286
S3
S2
58
57
59
S1
E-PANEL CONTROLLER ASSEMBLY
HZ
NORMALLY CLOSED CONTACTS
SURGE SUPPRESSING DIODE

EMERGENCY STOP BUTTON
VOLT/AMMETER SWITCH
18
16
14
1
FREQUENCY METER
PANEL FUSE (15A)
SW1
RUN RELAY (70A)
SOCKET HOUSING
DESCRIPTION
AUDIBLE ALARM
PANEL LAMP
15
19
VOLTMETER
2
AMMETER
64
65
67
0
AM
VM
RR
0
85
86
219A
183
S15
S16
CON3-1
CON2-10
CON4-4
CON4-6
15A
F1
POSITIVE DC FROM BATTERY 218 220 220 CON4-1
218
CON1-1
GROUND FROM ENGINE 0 0 CON4-2
CON1-2
CON1-3
RR
30
0 219
L1
CON1-4
87
11 12 CON1-5
FUEL STOP SOLENOID 219 219B
ES-3
11 12 CON1-6
CON3-2
'E' PANEL CONTROL BOX
ES-2
AUX. FUSED DC SUPPLY 220 CON3-3
CON1-7
SHUT DOWN ALARM RELAY
CON1-8
ANALOG USER INPUT 1 AI1

CON1-9
MC1
GND 0
CON1-10 PRG INPT GND
FUEL LEVEL SENDER +VDC 220
SIG. 575 575 CON2-2
FUEL SENDER + 590 590 CON2-13

CON3-5
FUEL SENDER - 591 591 CON2-14 COM
CON3-6 PROG. RELAY 1
ANALOG USER INPUT 2 AI2 AI2 CON2-3 N/O
CON3-7 R3
OIL TEMP. SENSOR 523 523 CON2-4 N/C
OIL PRESSURE SENSOR 69 69 CON2-5

CON3-8
COOLANT TEMP. SENSOR 68 68 CON2-6 COM
CON3-9 PROG. RELAY 2
COOLANT LEVEL DETECTOR 573 573 CON2-7 N/O
CON3-10 R6
79 79 CON2-8 N/C
MAGNETIC RPM SENSOR
0 0 CON2-9
11 12 CON3-11
0 R15 CON2-11
ES-1
DSUB-4
DSUB-5
DSUB-3
DSUB-2
DSUB-1
ES CON3-12 PROG. RELAY 3
CON3-13
AA
515 CON3-15 N/C

COMMON
RS232 (DTR)
RS232 (Tx)/RS485-
RS232 (Rx)/RS485+
RS232 (DSR)

Wiring Diagram (For Use With Marathon Alternator) – Drawing No. 0C1376-D
LOCATED ON BOTTOM OF PANEL
NOTES:
ALL WIRING 18 AWG UNLESS NOTED.
REQUIRED WIRING.
OPTIONAL WIRING C3207
ENGINE ON
FUSED 15A
LOW FUEL
LEVEL SIG.
BATTERY
BATTERY
TEMP. SIG.
SHIELDED CABLE
COOLENT
COOLENT
CABLE
PROBE
SPEED
(+DC)
(+DC)
GND
TB1
SIG.
(-)
218
218
218
219
219
219
220
220
220
573
79
68
69
0
0
1 2 3 4 6 7 8 9 10 12 13 14 15 16 17 18 20
TB1
219
219
219
218
218
220
220
220
220
575
573
79
56
69
68
0
0
0
0
0
0
LOCATED ON BACK OF PANEL
12 AWG
12 AWG
219B 12 AWG
RR
87 218 12 AWG
86 30
85
219A
0 CABLE
SH
178
C3206
C3208
59 13 15 183
TB1
TB4 TB3
A6577
TB2
S3
57 10 12 58 BATTERY
0 1 0 BAT GND (-) 0 1 178 1 PRG INPT GND
S2 GND 0 C B
(-)
S15 7 9 S16 0 2 BAT GND (-) 0 2 0 0 2 PRG INPT GND
S1 NOTE:
4 5 6 219 3 219 DC FUSED (+) 3 220 C PRG INPT GND THESE TERMINALS ARE
ENGINE ON (15/220) INTENDED ONLY TO BE
(+DC) 220
0 1 2 3 4 PRG RLY 1 COM 4 R1 0 4 PRG INPT GND
ASSOCIATED WITH THE
OIL TEMP.
5 AI1 PRG RLY 1 NO 5 R2 523 5 523
SIG.
PROGRAMMABLE INPUTS.
INPUT 1
SHUT DOWN
AI2 6 AI2 PRG RLY 1 NC 6 R3 190 6 190
ALARM RLY
INPUT 2
LEGEND
PROGRAM
PRG RLY 2 COM 7 R4 A1 A1
INPUT 1
AA - AUDIBLE ALARM MAIN LINE 589 PROGRAM

8 A7 PRG RLY 2 NO 8 R5 A2 8 A2
AM - AMMETER CB OPEN (A7) INPUT 2
CON1 - PLUG 3.5 10 POS RUPTURED 567 PROGRAM

TANK (A8) 9 A8 PRG RLY 2 NC 9 R6 A3 9 A3
INPUT 3
BACK-UP
CON4 - PLUG 3.5 6 POS TB4 PRG RLY 3 COM 10 R7 A4
86
(A4)
PRESS.
BACK-UP
ES - EMERGENCY STOP SWITCH PRG RLY 3 NO 11 R8 A5 11
85
HI ENGINE
(A5)
F1 - 15 AMP FUSE TEMP.
354
HZ - FREQUENCY METER PRG RLY 3 NC 12 R9 A6 12 (A6)
OIL FILTER
BLOCKED
L1 - PANEL LAMP
TB2 TB3
RR - RUN RELAY
SH - SOCKET HOUSING(MALE/15 CKT)
SW1 - VOLT/AMMETER SWITCH
VM - VOLTMETER

Wiring Diagram (For Use With Marathon Alternator) – Drawing No. 0C1376-D
LOCATED ON FRONT OF PANEL

MC1
12 AWG ALARM HORN N/C

ALARM HORN N/O 515
ALARM HORN COM 220
219B
R15
56A
PRG RLY 3 NC R9
PRG RLY 3 NO R8
PRG RLY 3 COM R7
PRG RLY 2 NC R6
PRG RLY 2 NO R5
PRG RLY 2 COM R4
PRG RLY 1 NC R3
ES D PRG RLY 1 NO R2
219
56
PRG RLY 1 COM R1

0
ALARM RLY N/O 190

ALARM RLY COM 220
12 AWG STARTER SOL
FUEL SOL 219A
220
ALT LINE 2 6 S2
F1 ALT LINE 1 S1
218
CABLE
BAT - 0
BAT + 220
0
AA
515
L1
219
S1
S1
S3
S2
S2
59
57
58
0
0
1
16
5
18
14
20
AM
SW1
15
19
67
65
67
64
S15 64
HZ VM
S16 65

Wiring Diagram (For Use With Marathon Alternator) – Drawing No. 0C8327-C

Wiring Diagram (For Use With Marathon Alternator) – Drawing No. 0C8327-C

Section 6 — Exploded Views and Parts Lists
Control Panel (For Use With Generac Alternator) – Drawing No. 0D2383-J
For units manufactured prior to the 3rd quarter 2002, with a watertight connector.
Standard drawing. Please refer to the Owner’s Manual of the unit for specific details.
34
VIEW A DETAIL 1
HINGE ASSEMBLY
RECTIFIER ASSEMBLY
54 56 SCALE: NONE MIC
SCALE: NONE
68 13
3
11
60
63 63
59 60 59 60 2 E
17 43
22 23
20 21 21 87
50 52
14
64 65
66 67 6
A3392
BAT
1 36
24
35 29
25
26
61
37 46
D3153
27
75 71 31 32
37 76
44 28 83
64
18
66
16
A A
54 56 68
50 52 50 52
x4 x4 84
45 15
59 60 60
63 63 58 59 33 59 60
60 63 62
86
55 56
ALL DIRECTLY EXCITED MACHINES 5 OHM 25W

UPTO 100KW WITH 12 OR 24V DC SYSTEMS P/N: 048352
UPTO 100KW WITH 12V DC SYSTEMS P/N: 057405 50 51 41 40 38 39 50 51

ALL BRUSHLESS & PME MACHINES 50 OHM 25W

OVER 100KW WITH 12 OR 24V DC SYSTEMS P/N: 086266
TABLE B-AVR POWER(DPE) CIRCUIT BREAKER DATA AVR BEHIND COVER

54 57
ALL DIRECTLY EXCITED MACHINES 7A GOVERNOR CONTROL

19 TO 45KW P/N: 048467 BEHIND COVER
ALL BRUSHLESS & PME MACHINES 5.5A

19 TO 26KW P/N: 054450
21 TO 41KW P/N: 048505 19
ALL BRUSHLESS & PME MACHINES 7A
45 TO 100KW P/N: 048476
OVER 100KW P/N: 048476
TABLE C:AMMETER TABLE D: VOLTAGE METER

CONTROL PANEL LEFT S
AMMETER AMMETER VOLT. VOLTAGE VOLTAGE
VOLTAGE
P/N: RANGE CODE METER P/N: METER RANGE
070056 0-150A A 120/240V 1 PHASE 070043 0-300V
070057 0-300A D 120/240V 1,3 PHASE 070043 0-300V
070058 0-400A G 120/208V 3 PHASE 070043 0-300V
070059 0-600A J 120/240V 3 PHASE 070043 0-300V
070060 0-800A K 277/480V 3 PHASE 070044 0-600V
075323 0-1000A M 110/220V 1 PHASE 070043 0-300V
075324 0-1600A N 115/200V3 PHASE 070043 0-300V
075325 0-2000A P 100/200V 3 PHASE 070043 0-300V
075326 0-3000A R 231/400V 3 PHASE 070044 0-600V
070045 0-200A L 600V 3 PHASE 082404 0-750V

Control Panel (For Use With Generac Alternator) – Drawing No. 0D2383-J
ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION
1 0D2370 1 BOTTOM E PANEL W/SEALED CONS 45 0D3471 2 DECAL COVER DEUTSCH (RECT)
2 0A6324 1 PANEL FRNT E W/SLKSCRN (ELECTRONIC GOVERNOR HARNESS
3 0A6322 1 PANEL RIGHT SIDE E IF EQUIPPED)
4 0A6321 1 PANEL LEFT SIDE E 46 0C5141 2 CONN DEUTSCH GASKET 8/12POS
5 0E3550 1 CHASSIS, UNIVERSAL DT
6 0D2382 1 HARNESS E-PANEL W/SEALED CONS 50 022155 14 WASHER LOCK #6
7 044213 1 RES 10R 5% 12W 51 0C2428 14 SCREW TAPTITE PH 6-32 X 1/2 Z/YC
8 025192 1 RECTIFIER MSC 2A 600V 1N5062 52 0C2323 10 SCREW TAPTITE PH 6-32 X 5/8 ZYC
9 070370 2 WASHER MICA .203 53 022471 4 NUT HEX #8-32 STEEL
10 023762 1 WASHER SHAKEPROOF EXT #10 STL 54 022264 8 WASHER LOCK M4
11 055444 1 HEATSINK 13.3L 55 038150 4 WASHER FLAT #8 ZINC
12 030468 1 WASHER STEP NYLON .20 56 036918 8 SCREW PPHM #8-32 X 1/2
13 049939 1 RECTIFIER MSC 12A 600V 1N1206R 57 0A2284 4 SCREW SWAGE 8-32 X 1/2 Z/YC
14 0A3392 1 DECAL TERMINAL BLOCK 58 022158 2 NUT HEX #10-32 STEEL
15 0C8229 1 DCL-E PNL TS#2 (W/FS) 59 022152 14 WASHER LOCK #10
16 0A6577 1 DECAL T STRIP 3 E PNL 60 023897 15 WASHER FLAT #10 ZINC
17 0D3153 1 DECAL T STRIP TB4 W/SEALED CON 61 024469 2 SCREW TAPTITE #10-32 X 3/8 BP
18 0A2273 1 HINGE RAM PANEL 62 033120 1 SCREW HHC #10-32 X 3/8
19 0C1229 1 DECAL CUST CONN BOX 63 033121 13 SCREW HHC #10-32 X 1/2
20 0E2693A 1 SWITCH MUSHRM HEAD/ARROWS 64 022507 4 SCREW HHC 1/4-20 X 1/2 G5
40MM 65 022097 4 WASHER LOCK M6-1/4
21 0E2693C 3 CONTACT BLOCK D5-3 X 01 W/2 1417 66 022473 4 WASHER FLAT 1/4 ZINC
22 032300 1 HOLDER FUSE 67 040479 4 VIB MNT 1.0 X 1.0 X 1/4-20
23 022676 1 FUSE 15A X AGC15 68 036261 4 RIVET POP .125 X .129-.133/#30
24 055349 1 INSULATOR 69 0C8243 1 WASHER LOCK HDPDEUTSCH
25 071361 1 POT 5K 10% 2.25W PNL 70 0C8244 1 NUT HDP DEUTSCH
26 050123 1 KNOB PLASTIC .25 SHAFT
27 061286 1 SOUNALERT BUZZER ADDITIONAL PARTS (BASE TANK UNITS)
28 061945 1 SWITCH SELECTOR 6A AMP/V 71 074908 4 SCREW HHTT M-5-0. 8 X 10 BP
29 0A4087 1 MASTER CTRL BOX E-PNL 75 0D3306 1 HARNESS BASETANK FOR E-PANEL
30 0E3703 1 LIGHT PANEL WITH LUG 76 0C5141 1 CONN DEUTSCH GASKET 8/12 POS
31 0C8481 1 BULB-PANEL LIGHT-12V DT
083288 1 LIGHT 28VDC .17A MIN BAYNT MNT
32 070082 1 BLOCKER LIGHT PANEL SPECIAL PARTS
33 0A2275 1 DOOR-STOP RAM PANEL 80 064733 2 BRACKET RESISTOR MNTNG FOR
34 030809 1 GROMMET 11/16 X 1/8 X 7/16 25W
35 028739 2 TIE WRAP 3.9" X .10" NAT'L UL 81 SEE TABLE A 1 RESISTOR #2
36 0A2400A 1 TRUNKING 180MM 82 SEE TABLE B 1 FIELD CIRCUIT BREAKER
37 074908 8 SCREW HHTT M5-0.8 X 10 BP 83 SEE TABLE C 1 AMMETER
38 0A1441B 1 COVER PLATE, AVR 84 SEE TABLE D 1 VOLTMETER AC
39 0C1127 1 DECAL AVR COVER 85 070042 1 METER FREQUENCY 55-65HZ
40 0A1441C 1 COVER PLATE EGOV 070042A 1 FREQUENCY METER 240V 45-55HZ
41 0A3394 1 DECAL ELEC GOVERNOR 86 067680 1 ASSY VOLTAGE REGULATOR 60HZ
42 0A5705 REF. FUSE 5A X LTTL215005 (NOT 092952 1 ASSY VOLTAGE REGULATOR 50HZ
SHOWN) 87 0E3783 1 DECAL WARNING REMOVE FUSE
43 0D3243 1 CBL ASSY-RS485 E PNL W/SEALED
44 0D3471 2 DECAL COVER DEUTSCH (RECT)

Control Panel (For Use With Marathon Alternator) – Drawing No. 0D4267B-H
36 3
52 53 54
43 44 45
33
52 53 54
14 56 57 41
18 58 59
43 44 45 21 22
7
37 28 29
12 13 20 63
64 65 66 43 45 46
6
19
25 26 27 38
20 60 61 62 63 11
23 24
45
64 65 66 68 72
43 44 45
8
65 68 43 44 45
73
9
74
42 43
2
1 16 VIEW A
17 43 44 45
10
43 44 45 15
51 53 54
31
5 52 53 54 55
52 53 54 55 75
47 48 49 50
30
52 53 54
47 48 49
41 32
35
42 43
GOVERNOR CONTROL
BEHIND COVER
42 43
34
39 4
VIEW A
CONTROL PANEL LEFT SIDE
HINGE ASSEMBLY
OUTSIDE VIEW
SCALE: NONE

Control Panel (For Use With Marathon Alternator) – Drawing No. 0D4267B-H
For units manufactured with a watertight connector
1 0D4650 1 "E" PANEL BOTTOM/BACK W/TCONN 35 0A3394 1 DECAL ELEC GOVERNOR

2 0C3872 1 FR0NT E PANEL 400KW 36 030809 1 GROMMET 11/16 X 1/8 X 7/16
3 0A6322 1 PANEL RIGHT SIDE E 37 029333 1 TIE WRAP 7.4" X .19" NATL UL
4 0A6321 1 PANEL LEFT SIDE E 38 074130 1 LUG DIS SN-PLG I-T 22-18 CU
5 0A6323 1 CHASSIS AVR & E-GOV 39 036261 4 RIVET POP .125 X ..275 AL
6 0D4267D 1 HARNESS "E" CONTROL PNL WT CON 40 040479 4 MOUNT VIBR 1.0 X 1.0 X 1/4-20
7 0A4087 1 MSTR CTRL BOX E-PNL 41 0A2273 1 HINGE RAM PANEL
8 070060 1 AMMETER 0-800 42 036901 8 SCREW PPHM #6-32 X 3/8
0A6798A 1 AMMETER 0-1600 43 022155 17 WASHER LOCK #6
0A6798B 1 AMMETER 0-2000 44 022985 18 WASHER FLAT #6 ZINC
9 070043 1 VOLTMETER 0-300V 45 0C2428 16 SCREW PHTT #6-32 X 1/2 ZYC
070044 1 VOLTMETER 0-600V 46 022188 10 NUT HEX #6-32 STEEL
082404 1 VOLTMETER 0-750V 47 036918 8 SCREW PPHM #8-32 X 1/2
10 0C1212C 1 FREQUENCY METER 120V 55-65HZ 48 022264 8 WASHER LOCK M4
0C1212B 1 FREQUENCY METER 277V 55-65HZ 49 038150 8 WASHER FLAT #8 ZINC
0C1212A 1 FREQUENCY METER 346V 55-65HZ 50 022471 4 NUT HEX #8-32 STEEL
070042A 1 FREQUENCY METER 240V 45-55HZ 51 033120 1 SCREW HHC #10-32 X 3/8
11 074386 1 SWITCH SELECT VOLT/AMP 3PH 52 033121 13 SCREW HHC #10-32 X 1/2
12 0D4654 1 CONN DEUTSCH PLUG 21 PIN 53 022152 16 WASHER LOCK #10
13 0D4655 1 CONN DEUTSCH RECEPT 21 PIN 54 023897 16 WASHER FLAT #10 ZINC
14 0C3207 1 DECAL T STRIP 1 E PNL 55 022158 3 NUT HEX #10-32 STEEL
15 0A6576 1 DECAL T STRIP 2 E PNL 56 022287 4 SCREW HHC 1/4-20 X 3/4 G5
16 0C3208 1 DECAL T STRIP 3 E PNL 57 022097 4 WASHER LOCK M6-1/4
17 0C3206 1 DECAL T STRIP 4 E PNL 58 022473 4 WASHER FLAT 1/4-M6 ZINC
18 0C4110 1 RELAY 24V 50A W/DIODE 59 047246 4 FLAT WASHER SPECIAL
19 061286 1 SOUNALERT BUZZER 60 0C8237 1 CONN DTCH HDP24-21PN
20 0C8243 2 WASHER LOCK HDP DEUTSCH 61 0D4655 1 CONN DEUTSCH RECEPT 21 PIN
21 0E2693A 1 SWITCH MUSHRM HEAD/ARROWS 40MM 62 0C8241 3 PIN SIZE 12 DEUTSCH
22 0E2693C 3 CONTACT BLOCK D5-3 X 01 W/2 1417 63 0C8242 4 SOCKET SZ 12 DEUTSCH
23 091472 1 DUCT WIRING 1 X 1.5 6 FT (9.5”) 64 0C8244 2 NUT HDP DEUTSCH
24 091472A 1 COVER WIRE DUCT 1 IN (9.5”) 65 0C5144 1 5 CONN DEUTSCH PIN #16-18 BLKHD
25 0E3703 1 LIGHT PANEL WITH LUG 66 0D4651 1 5 PIN SIZE 14-16 1060-14-0122
26 083288 1 LIGHT 28VDC .17A MIN BAYNT MNT 67 0C5137 1 CONN DEUTSCH RECEPT BK/FLN
27 070082 1 BLOCKER LIGHT 68 0C5141 1 CONN DEUTSCH GASKET BLKHD
28 032300 1 HOLDER FUSE 69 0C5142 1 CONN DEUTSCH RECEPT WDGE BLKHD
29 022676 1 FUSE 15A X AGC15 70 0C5145 1 CONN DEUTSCH PLUG BLKHD BLK
30 0D4167 1 CONTROLLER B-C#:DPG-2107 (DSL) 71 0C5148 1 CONN DEUTSCH WEDGE LOCK 12-WAY
31 0A2275 1 DOOR-STOP RAM PANEL 72 0C5185 6 CONN DEUTSCH SOCKET #16-20 DTM
32 0A1441B 1 COVER PLATE AVR 73 044213 1 RES 10R 5% 12W
33 0C2688 1 DECAL TERM STRIP TB4 74 025192 1 RECTIFIER MSC 2A 600V 1N5062
34 0A1441C 1 COVER PLATE E GOV 75 036904 4 SCREW PPHM #6-32 X 3/4

Control Panel (For Use With Generac Alternator) – Drawing No. 0D8764-H
For units manufactured starting the 3rd quarter 2002, with a watertight connector.
34
VIEW A DETAIL 1
HINGE ASSEMBLY
RECTIFIER ASSEMBLY
SCALE: NONE MICA
SCALE: NONE
12
9 9
68 13
58
11
10
63 63 D
59 60 59 60 2
17 43
22 23 47
20 21 21 21
50 52 50 52
64 65 14
64 65
67
66 67 6
FUEL
+ BAT
FUSE
A3392
BAT
1 36
24
35 29
50
25
52
26
61
46 87
D3153
0V 82
0V
27 30
75 0V
32
87 0V
76 +12/24V
37 37
SCREE
81
44
485-
28 83
485+
64 65
64
67 18
PRG RLY 3 NO
66 67 52 PRG RLY 3 NC
FUEL + 8
FUEL -
EE
ETAIL
1
4
16
A A
68
50 52 50 52 51
84
45 15 85
59 60 59 60
63 63 58 59 33 59 60
60 63 62
TSUJDA EGATLOV
53 54 86
55 56
50 51 41 40 38 39 50 51
TABLE A-FIELD BOOST RESISTOR DATA

54 57
UPTO 100KW WITH 12V DC SYSTEMS P/N: 057405 AVR BEHIND COVER
GOVERNOR CONTROL
UPTO 100KW WITH 24V DC SYSTEMS P/N: 083364 BEHIND COVER

OVER 100KW WITH 12 OR 24V DC SYSTEMS P/N: 086266
19
ALL DIRECTLY EXCITED MACHINES 7A
19 TO 45KW P/N: 048467
19 TO 26KW P/N: 054450
21 TO 41KW P/N: 048505
ALL BRUSHLESS & PME MACHINES 7A CONTROL PANEL LEFT SIDE
45 TO 100KW P/N: 048476
OVER 100KW P/N: 048476
TABLE C:AMMETER TABLE D: VOLTAGE METER

AMMETER AMMETER VOLT. VOLTAGE VOLTAGE
VOLTAGE
P/N: RANGE CODE METER P/N: METER RANGE
070056 0-150A A 120/240V 1 PHASE 070043 0-300V
070057 0-300A 120/240V 1,3 PHASE 070043 0-300V
070058 0-400A 120/208V 3 PHASE 070043 0-300V
070059 0-600A J 0-300V
070060 0-800A 277/480V 3 PHASE 070044 0-600V
075323 0-1000A 0-300V
075324 0-1600A 070043 0-300V
075325 0-2000A 0-300V
075326 0-3000A R 231/400V 3 PHASE 070044 0-600V
070045 0-200A L 600V 3 PHASE 082404 0-750V

Control Panel (For Use With Generac Alternator) – Drawing No. 0D8764-H
For units manufactured starting the 3rd quarter 2002, with a watertight connector.
1 0D8756 1 BOTTOM, E PANEL W/SEALED CONS 43 0D3243 1 CBL ASSY-RS485 E PNL W/SEALED
2 0D8754 1 "E" PANEL FRONT W/SILK SCREEN 44 0D3471 2 DECAL COVER DEUTSCH (RECT)
3 0A6322 1 PANEL RIGHT SIDE E 45 0D3471 2 DECAL COVER DEUTSCH (RECT)
4 0A6321 1 PANEL LEFT SIDE E (ELECTRONIC GOVERNOR HARNESS
5 0E3550 1 CHASSIS, UNIVERSAL IF EQUIPPED)
6 0D2382 1 HARNESS E-PANEL W/SEALED CONS 46 0C5141 2 CONN DEUTSCH GASKET 8/12POS
7 044213 1 RES 10R 5% 12W DT
8 025192 1 RECTIFIER MSC 2A 600V 1N5062 47 0E3783 1 DECAL, WARNING REMOVE FUSE
9 070370 2 WASHER MICA .203 50 022155 14 WASHER LOCK #6
10 023762 1 WASHER SHAKEPROOF EXT #10 STL 51 0C2428 14 SCREW TAPTITE PH 6-32X1/2 Z/YC
11 055444 1 HEATSINK 13.3L 52 0C2323 10 SCREW TAPTITE PH 6-32X5/8 ZYC
12 030468 1 WASHER STEP NYLON .20 53 022471 4 NUT HEX #8-32 STEEL
13 049939 1 RECTIFIER MSC 12A 600V 1N1206R 54 022264 8 WASHER LOCK M4
14 0A3392 1 DECAL TERMINAL BLOCK 55 038150 4 WASHER FLAT #8 ZINC
15 0C8229 1 DCL-E PNL TS#2 (W/FS) 56 036918 4 SCREW PPHM #8-32 X 1/2
16 0A6577 1 DECAL T STRIP 3 E PNL 57 0A2284 4 SCREW SWAGE 8-32 X 1/2 Z/YC
17 0D3153 1 DECAL T STRIP TB4 W/SEALED CON 58 022158 2 NUT HEX #10-32 STEEL
18 0D6947 1 HINGE CONTINUOUS 59 022152 14 WASHER LOCK #10
19 0C1229 1 DECAL CUST CONN BOX 60 023897 15 WASHER FLAT #10 ZINC
20 0E2693A 1 SWITCH MUSHRM HEAD/ARROWS 61 024469 2 SCREW TAPTITE #10-32 X 3/8 BP
40MM 62 033120 1 SCREW HHC #10-32 X 3/8
21 0E2693C 3 CONTACT BLOCK D5-3 X 01 W/2 1417 63 033121 13 SCREW HHC #10-32 X 1/2
22 032300 1 HOLDER FUSE 64 022507 4 SCREW HHC 1/4-20 X 1/2 G5
23 022676 1 FUSE 15A X AGC15 65 022097 4 WASHER LOCK M6-1/4
24 055349 1 INSULATOR 66 022473 4 WASHER FLAT 1/4 ZINC
25 071361 1 POT 5K 10% 2.25W PNL 67 040479 4 VIB MNT 1.0 X 1.0 X 1/4-20
26 050123 1 KNOB PLASTIC .25 SHAFT 68 036261 6 RIVET POP .125 X .129-.133/#30
27 061286 1 SOUNALERT BUZZER 69 0C8243 1 WASHER LOCK HDPDEUTSCH
28 061945 1 SWITCH SELECTOR 6A AMP/V 70 0C8244 1 NUT, HDP DEUTSCH
29 0A4087 1 MASTER CTRL BOX E-PNL
30 0E3703 1 LIGHT PANEL WITH LUG ADDITIONAL PARTS (BASE TANK UNITS)
31 0C8481 1 BULB-PANEL LIGHT-12V 75 0D3306 1 HARNESS BASETANK FOR E-PANEL
083288 1 LIGHT 28VDC .17A MIN BAYNT MNT 76 0C5141 1 CONN DEUTSCH GASKET 8/12 POS
32 070082 1 BLOCKER LIGHT DT
33 0A2275 1 DOOR-STOP RAM PANEL
34 030809 1 GROMMET 11/16 X 1/8 X 7/16 PANEL SPECIAL PARTS
35 028739 2 TIE WRAP 3.9" X .10" NAT'L UL 81 SEE TABLE A 1 RESISTOR #2
36 0A2400A 1 TRUNKING 180MM 82 SEE TABLE B 1 FIELD CIRCUIT BREAKER
37 064733 2 RES MTG BRACKET 83 SEE TABLE C 1 AMMETER
38 0A1441B 1 COVER PLATE, AVR 84 SEE TABLE D 1 VOLTMETER AC
39 0C1127 1 DECAL AVR COVER 85 070042 1 METER FREQUENCY 55-65HZ
40 0A1441C 1 COVER PLATE EGOV 070042A 1 FREQUENCY METER 240V 45-55HZ
41 0A3394 1 DECAL ELEC GOVERNOR 86 067680 1 ASSY VOLTAGE REGULATOR 60HZ
42 0A5705 REF. FUSE 5A X LTTL215005 (NOT 092952 1 ASSY VOLTAGE REGULATOR 50HZ
SHOWN) 87 074908 12 SCREW HHTT M5-0.8 X 10 BP

Control Panel (For Use With Generac Alternator) – Drawing No. 0D8765-G
For units manufactured starting the 3rd quarter of 2002.
46
SEE VIEW "B"
56 59 60
32 33
C
14 72 29
16 24 25
86
SEE VIEW "C"
26
78 81
20
27
48 50
6
85
19
28
41 47
48 75 22
48 50 30 31 62
75
1
85
9
34
82 83
10
68 69 70 71
2
17
67
75
VIEW A
79 80 2 37 36 35
40
38
55 59 60
56 59 60 61
5
52 58
56 59 60
51 52 53 54
MICA
12
64 64
63
42
13 61
45
10
13
49 50
AVR BEHIND COVER
11 GOVERNOR CONTROL
BEHIND COVER ALIGNMENT
TAB
49 50
43 23
65
44 DETAIL 1
60 VIEW A
HINGE ASSEMBLY FOR LOWER PANEL
SCALE: NONE HOUSING SOCKET
SCALE: NONE
4
DETAIL 2
RECTIFIER ASSEMBLY
SCALE: NONE
CONTROL PANEL LEFT SIDE 84

UPTO 100KW WITH 12V DC SYSTEMS P/N: 057405
UPTO 100KW WITH 24V DC SYSTEMS P/N: 083364
48 81 74 ALL BRUSHLESS & PME MACHINES 75 OHM 25W
81 OVER 100KW WITH 12 OR 24V DC SYSTEMS P/N: 086266
50
74 TABLE B-AVR POWER(DPE) CIRCUIT BREAKER DATA
ALL DIRECTLY EXCITED MACHINES 7A
19 TO 45KW P/N: 048467
19 TO 26KW P/N: 054450
VIEW "C" ALL BRUSHLESS & PME MACHINES

45 TO 100KW
4.5A
P/N: 048476
VIEW "B" ALL BRUSHLESS & PME MACHINES
OVER 100KW
4.5A
P/N: 048476

Control Panel (For Use With Generac Alternator) – Drawing No. 0D8765-G
For units manufactured starting the 3rd quarter of 2002.
1 0D8759 1 PANEL BOTTOM/BACK (E-PANEL) 37 061945 1 SWITCH 6A AMP/V SELECTOR
2 0D8754 1 "E" PANEL FRONT W/SILK SCREEN 38 067680 1 ASSY VOLTAGE REGULATOR 60HZ
3 0A6322 1 CONTROL PANEL RIGHT SIDE 092952 1 ASSY VOLTAGE REGULATOR 50HZ
4 0A6321 1 CONTROL PANEL LEFT SIDE 40 0A2275 1 DOOR-STOP RAM PANEL
5 0E3550 1 CHASSIS UNIVERSAL 41 0A2400A 1 TRUNKING 180MM
6 0C8320 1 HARNESS E PNL. WAUK (W/FS) 42 0A1441B 1 COVER PLATE AVR
7 SEE TABLE B 1 CIRCUIT BREAKER 43 0C1127 1 DECAL AVR COVER
8 044213 1 RESIST MISC 10R X 12W 44 0A1441C 1 COVER PLATE E-GOV
9 025192 1 RECTIFIER MSC 2A 600V 1N5062 45 0A3394 1 DECAL E-GOV COVER
10 SEE TABLE A 1 RESISTOR 2 46 030809 1 GROMMET 11/16 X 1/8 X 7/16
11 055444 1 HEAT SINK 47 028739 2 TIE WRAP 4" WHITE
12 030468 1 WASHER STEP NYLON .20 48 0C2323 10 SCREW PHM SWAGE 6-32 X 5/8 Z/YC
13 049939 1 RECTIFIER MSC 12A 600V 1N1206R 49 036901 4 SCREW PPHM #6-32 X 3/8
14 039271 1 FITTING 90 DEGREE 3/4 50 022155 7 WASHER LOCK #6
15 034616 1 FITTING STRAIGHT 3/4 51 036918 8 SCREW PPHM #8-32 X 1/2
16 0A3392 1 DECAL TERMINAL STRIP 52 022264 8 WASHER LOCK M4
17 0C8229 1 DECAL E PNL TS#2 (W/FS) 53 038150 4 WASHER FLAT #8 ZINC
18 0A6577 1 DECAL TERMINAL STRIP TB3 54 022471 4 NUT HEX #8-32 STEEL
19 0C2688 1 DECAL TERMINAL STRIP TB4 55 033120 1 SCREW HHM 10-32 X 3/8
20 048850 REF. BLOCK TERM 20A 5 X 6 X 1100V 56 033121 9 SCREW HHM 10-32 X 1/2
22 061286 1 AUDIBLE ALARM 58 0A2284 4 SCREW SWAGE 8-32 X 1/2 Z/YC
23 055089 1 CONN ELEC AMP M-N-L 15PLUG PNL 59 022152 10 WASHER LOCK #10
24 0E2693A 1 SWITCH MUSHRM HEAD/ARROWS 60 023897 11 WASHER FLAT #10 ZINC
40MM 61 022158 2 NUT HEX #10-32 STEEL
25 0E2693C 3 CONTACT BLOCK D5-3 X 01 W/2 1417 62 074130 1 LUG DIS SN-PLG I-T 22-18 CU
26 071361 1 POTENTIOMETER PNL 5K +/-10% 63 036261 6 RIVET POP .125 X .129-.133/#30
2.25W 64 070370 2 WASHER MICA .203
27 050123 1 KNOB PLASTIC .25 SHAFT 65 023762 1 WASHER SHAKEPROOF EXT #10 STL
28 055349 1 INSULATOR 67 040479 4 MOUNT VIBR 1.0 X 1.0 X 1/4-20
29 0A4087 1 MASTER CONTROL BOX 68 022287 4 SCREW HHC 1/4-20 X 3/4 G5
30 0C8481 REF. BULB-PANEL LIGHT-12V 69 022097 4 WASHER LOCK M6-1/4
0E3703 REF. LIGHT PANEL WITH LUG 70 022473 4 WASHER FLAT M6-1/4 ZINC
083288 REF. LIGHT 28VDC .17A MIN BAYNT MNT 71 047246 4 WASHER FLAT 1/4 SPECIAL
31 070082 1 LIGHT BLOCKER 72 0D6947 1 HINGE CONTINUOUS
32 032300 1 FUSE HOLDER 74 022188 2 NUT HEX #6-32 STEEL
33 022676 1 FUSE 15A X AGC15 75 0C2428 8 SCREW TAPTITE PH #6-32 X 1/2 ZYC
34 070054 1 AMMETER AC 0-50 * 0A5705 1 FUSE 5A X LTTL215005 HLDRA4017
070055 1 AMMETER AC 0-100 (NOT SHOWN)
070056 1 AMMETER AC 0-150 78 057335 REF. BLOCK TERM 20A 20 X 6 X 1100V
070057 1 AMMETER AC 0-300 79 0C4167 REF. BLOCK TERM 20A 14 X 6 X 1100V
070059 1 AMMETER AC 0-600 81 0441140156 REF. WIRE ASSEMBLY
070060 1 AMMETER AC 0-800 82 084717 1 ASSY TIME DELAY (13.3L GAS ONLY)
075323 1 AMMETER AC 0-1000 83 036908 1 SCREW PPHM #6-32 X 1-1/4 (13.3L
075324 1 AMMETER AC 0-1600 GAS ONLY)
075325 1 AMMETER AC 0-2000 84 0C1229 1 DECAL WARNING
35 070043 1 METER VOLT AC 0-300 85 024469 2 SCREW HHTT #10-32 X 3/8 CZ_
070044 1 METER VOLT AC 0-600 86 0F3783 1 DECAL WARNING REMOVE FUSE
36 070042 1 METER FREQUENCY 55-65HZ
070042A 1 METER FREQUENCY 240V 45-55HZ

Control Panel (For Use With Generac Alternator) – Drawing No. 0A6325-N

Control Panel (For Use With Generac Alternator) – Drawing No. 0A6325-N
1 0A6320 1 CONTROL PANEL BOTTOM 40 0A2275 1 FRONT PANEL STAY

2 0A6324 1 CONTROL PANEL FRONT 41 0A2400A 1 TRUNKING 180MM
3 0A6322 1 CONTROL PANEL RIGHT SIDE 42 0A1441B 1 COVER PLATE, AVR
4 0A6321 1 CONTROL PANEL LEFT SIDE 43 0A3393 1 DECAL, AVR COVER
5 0A6323 1 CHASSIS AVR/E GOV. 44 0A1441C 1 COVER PLATE, E-GOV
6 0A6326 1 HARNESS E PNL. MAIN 45 0A3394 1 DECAL, E-GOV COVER
7 SEE TABLE B 1 CIRCUIT BREAKER 46 030809 1 GROMMET 1/8-11/16
8 044213 1 RESISTOR 10 OHM 12W 47 028739 2 TIE WRAP 4"
9 025192 1 DIODE 600V 2A 48 0A1661 8 POP RIVET
10 SEE TABLE A 1 RESISTOR 2 49 036901 3 #6-32 X 3/8" PPHMS
11 055444 1 HEAT SINK 50 022155 9 #6/M3 LOCK WASHER
12 030468 1 STEP WASHER - NYLON 51 036918 4 #8-32 X 1/2" PPHMS
13 049939 1 RECTIFIER 52 022264 4 #8/M4 LOCK WASHER
14 039271 1 90° CONNECTOR 3/4" 53 038150 8 #8/M4 FLAT WASHER
15 034616 1 STRAIGHT CONNECTOR 3/4" 54 022471 4 #8-32 HEX NUT
16 0A3392-C 1 DECAL, TERMINAL STRIP 55 033120 1 #10-32 X 3/8" HHMS
17 0A6576 1 DECAL, TERMINAL STRIP TB2 56 033121 16 #10-32 X 1/2" HHMS
18 0A6577 1 DECAL, TERMINAL STRIP TB3 58 033147 1 #10-32 X 1" HHMS
19 0C2688 1 DECAL, TERMINAL STRIP TB4 59 022152 17 #10/M5 LOCK WASHER
20 048850 1 TERMINAL BLOCK, 5 POS TB4 60 023897 17 #10/M5 FLAT WASHER
22 061286 1 AUDIBLE ALARM 61 022158 4 #10-32 HEX NUT
23 055089 1 HOUSING SOCKET 15 - CKT 62 074130 1 LUG, PIN 4MM 22/18
24 0E2693A 1 SWITCH MUSHRM HEAD/ARROWS 63 036261 4 POP RIVET
40MM 64 070370 2 MICA WASHER
25 0E2693C 3 CONTACT BLOCK D5-3X01 W/2,1417 65 023762 1 WASHER EXTERNAL SHAKE PROOF
26 071361 1 POTENTIOMETER 66 022985 6 #6/M3 FLAT WASHER
27 050123 1 KNOB 67 040479 4 VIBRATION DAMPENER
28 055349 1 INSULATOR 68 022287 4 1/4-20 X 3/4" HHMS
29 0A4087 1 MASTER CONTROL BOX 69 022097 4 1/4/M6 LOCK WASHER
30 070202 1 PANEL LIGHT 70 022473 4 1/4/M6 FLAT WASHER
31 070082 1 LIGHT BLOCKER 71 047246 4 1/4 FLAT WASHER SPECIAL
32 032300 1 FUSE HOLDER 72 0A2273 1 HINGE
33 022676 1 FUSE 15-A 73 036902 4 #6-32 X 1/2" PPHMS
34 070045 1 AMMETER 74 022188 4 #6-32 HEX NUT
35 070043 1 VOLT METER AC 0-300 75 0C2428 20 #6-32 X 1/2" TAPTITE
070044 1 VOLT METER AC 0-600 76 024413 1 #10-32 X 1/2" TAPTITE
36 070042 1 FREQUENCY METER 60 HZ 77 0C2720 1 #10-32 X 3/8" TAPTITE
070042A 1 FREQUENCY METER 50 HZ * 0A5705 1 INTERNAL MODULE FUSE, 5A (NOT
37 061945 1 VOLT/AMP SWITCH SHOWN)
38 SEE TABLE C 1 AVR ASSEMBLY 78 060164 1 SOCKET DPDT P& B
39 SEE TABLE C 1 OPTIONAL ELECTRICAL GOVERNOR 79 057335 1 TERMINAL STRIP
39A 098941A 1 HOUSING, CONNECTOR 80 055911 2 TERMINAL STRIP
39B 098942A 1 COVER, CONNECTOR HOUSING 81 0C2212 4 SCREW TAPTITE PH M4-0.7X16 ZYC

Control Panel (For Use With Marathon Alternator) – Drawing No. 0C3879-B
36 3
52 53 54
12 14 40 56 57 41
58 59
52 53 54 43 44 45 21 22
7
18 37 28 29
43 45 46
6
19
25 26 27 38
11
23 45
43 44 8
13 9
1
2
16 VIEW A
17 43 44 45
10
43 44 45 15
51 53 54
31
5 52 53 54 55
52 53 54 55
47 48 49 50
30
53 54
47 48 49
32
35
41
42 43
AVR BEHIND COVER
GOVERNOR CONTROL
BEHIND COVER
42 43
33
34
39
CONTROL PANEL LEFT SIDE
OUTSIDE VIEW VIEW A
HINGE ASSEMBLY
SCALE: NONE
SLOT WIRE 20
# #
1 0
2 1
15
12
3 2
11
14
4 4
5 S1
13
10
1
7
6 6
7 S15
ALIGNMENT
8
TAB
9 S16
DETAIL 1
11 S3 WIRE NUMBERS/LOCATIONS
12 58 FOR LOWER PANEL
13 59 HOUSING SOCKET
14 178 SCALE: NONE
15 183 REAR VIEW

Control Panel (For Use With Marathon Alternator) – Drawing No. 0C3879-B
1 0C2616 1 E PANEL BOTTOM 400> 31 0A2275 1 DOOR-STOP RAM PANEL

2 0C3872 1 FRONT E PANEL 400> 32 0A1441B 1 COVER PLATE, AVR
3 0A6322 1 PANEL RIGHT SIDE E 33 0C1127 1 DECAL AVR COVER
4 0A6321 1 PANEL LEFT SIDE E 34 0A1441C 1 COVER PLATE EGOV
5 0A6323 1 CHASSIS AVR & E-GOV 35 0C1126 1 DECAL ELEC GOVERNOR COVER
6 0C1377 1 HARNESS E-PANEL 400> 36 030809 1 GROMMET 11/16 X 1/8 X 7/16
7 0A4087 1 MASTER CONTROL BOX E-PANEL 37 029333 1 TIE WRAP UL 7.4" X .19" NATL
8 SEE NOTE 1 AMMETER 38 074130 1 LUG DIS SN-PLG I-T 22-18 CU
9 SEE NOTE 1 VOLT METER AC 39 036261 4 RIVET POP .125 X .275 AL
10 SEE NOTE 1 FREQUENCY METER 40 040479 4 VIB MNT 1.0 X 1.0 X 1/4-20
11 074386 1 SWITCH SELECT VOLT/AMP 3PH 41 0A2273 1 HINGE RAM PANEL
12 0A9234 1 GEDNEY CONN 1IN 90 42 036901 4 SCREW PPHM #6-32 X 3/8
13 034616 1 FITTING STRAIGHT 3/4 43 022155 18 WASHER LOCK #6
14 0C3207 1 DECAL T STRIP 1 E PNL 44 022985 12 WASHER FLAT #6 ZINC
15 0A6576 1 DECAL T STRIP 2 E PNL 45 0C2428 14 SCREW PHTT #6-32 X 1/2 ZYC
16 0C3208 1 DECAL T STRIP 3 E PNL 46 022188 1 NUT HEX #6-32 STEEL
17 0C3206 1 DECAL T STRIP 4 E PNL 47 036918 8 SCREW PPHM #8-32 X 1/2
18 0C4110 1 RELAY 24V 50A W/DIODE 48 022264 8 WASHER LOCK #8-M4
19 061286 1 SOUNALERT BUZZER 49 038150 8 WASHER FLAT #8 ZINC
20 055089 1 CONN PLUG PNL 15P AMP M-N-L 50 022471 4 NUT HEX #8-32 STEEL
21 0E2693A 1 SWITCH MUSHRM HEAD/ARROWS 51 033120 1 SCREW HHC #10-32 X 3/8
40MM 52 033121 17 SCREW HHC #10-32 X 1/2
22 0E2693C 3 CONTACT BLOCK D5-3 X 01 W/2 1417 53 022152 20 WASHER LOCK #10
23 091472 1 DUCT WIRING 1 X 1.5 6 FT (9.5") 54 023897 20 WASHER FLAT #10 ZINC
24 091472A 1 COVER WIRE DUCT 1 IN (9.5") 55 022158 7 NUT HEX #10-32 STEEL
25 083287 1 LIGHT HLDR CLR LNS W/O BULB 56 022287 4 SCREW HHC 1/4-20 X 3/4 G5
26 083288 1 LIGHT 28VDC .17A MIN BAYNT MNT 57 022097 4 WASHER LOCK M6-1/4
27 070082 1 BLOCKER LIGHT 58 022473 4 WASHER FLAT 1/4-M6 ZINC
28 032300 1 HOLDER FUSE 59 047246 4 FLAT WASHER SPECIAL
29 022676 1 FUSE 15A X AGC15
30 084752 1 CONTROLLER GOVERNOR NOTE: CONTACT GENERAC SERVICE FOR CORRECT PART NUMBER
ELECTRONIC FOR YOUR UNIT.

Control Panel (For Use With Generac Alternator) – Drawing No. 0C8459-J
46
SEE VIEW "B"
F
56 59 60
32 33
14 72 29
16 24
SEE VIEW "C"
26
78 81
2
27
48
6
48
19
28
47
48
22
48 50 30 31 62
1
48
34
82 83
68 69 70 71
2
17
67
VIEW A
79 80
37 36 35
40
38
55 59 60
56 59 60 61
5
52 58
56 59 60
51 52 53 54
MICA
5
6 SLOT
63
42 # #
13 61
45 1 0
2
49 50 4
AVR BEHIND COVER S1
11 GOVERNOR CONTROL
BEHIND COVER ALIGNMENT
S15 TAB
49 50 S2
43 S16 23
65
44 DETAIL 1
60 VIEW A
HINGE ASSEMBLY FOR LOWER PANEL
SCALE: NONE HOUSING SOCKET
15 183
SCALE: NONE
4
DETAIL 2
RECTIFIER ASSEMBLY
SCALE: NONE

48 81 74
81 OVER 100KW WITH 12 OR 24V DC SYSTEMS P/N: 086266
50
74
7A
P/N: 048467
5.5A
P/N: 054450
VIEW "C" P/N: 048505

4.5A
VIEW "B" P/N: 048476

4.5A
P/N: 048476

Control Panel (For Use With Generac Alternator) – Drawing No. 0C8459-J
1 0A6320 1 CONTROL PANEL BOTTOM 37 061945 1 SWITCH 6A AMP/V SELECTOR
2 0A6324 1 CONTROL PANEL FRONT 38 067680 1 ASSY VOLTAGE REGULATOR 60HZ
3 0A6322 1 CONTROL PANEL RIGHT SIDE 092952 1 ASSY VOLTAGE REGULATOR 50HZ
4 0A6321 1 CONTROL PANEL LEFT SIDE 40 0A2275 1 DOOR-STOP RAM PANEL
5 0E3550 1 CHASSIS, UNIVERSAL 41 0A2400A 1 TRUNKING 180MM
6 0C8320 1 HARNESS E PNL. WAUK (W/FS) 42 0A1441B 1 COVER PLATE AVR
7 SEE TABLE B 1 CIRCUIT BREAKER 43 0C1127 1 DECAL AVR COVER
8 044213 1 RESIST MISC 10RX12W 44 0A1441C 1 COVER PLATE E-GOV
9 025192 1 RECTIFIER MSC 2A 600V 1N5062 45 0A3394 1 DECAL E-GOV COVER
10 SEE TABLE A 1 RESISTOR 2 46 030809 1 GROMMET 11/16 X 1/8 X 7/16
11 055444 1 HEAT SINK 47 028739 2 TIE WRAP 4" WHITE
12 030468 1 WASHER STEP NYLON .20 48 0C2323 12 SCREW PHM SWAGE 6-32 X 5/8 Z/YC
13 049939 1 RECTIFIER MSC 12A 600V 1N1206R 49 036901 4 SCREW PPHM #6-32 X 3/8
14 039271 1 FITTING 90DEGREE 3/4 50 022155 7 WASHER LOCK #6
15 034616 1 FITTING STRAIGHT 3/4 51 036918 8 SCREW PPHM #8-32 X 1/2
16 0A3392 1 DECAL TERMINAL STRIP 52 022264 8 WASHER LOCK M4
17 0C8229 1 DECAL E PNL TS#2 (W/FS) 53 038150 4 WASHER FLAT #8 ZINC
18 0A6577 1 DECAL TERMINAL STRIP TB3 54 022471 4 NUT HEX #8-32 STEEL
19 0C2688 1 DECAL TERMINAL STRIP TB4 55 033120 1 SCREW HHM 10-32 X 3/8
20 048850 REF. BLOCK TERM 20A 5 X 6 X 1100V 56 033121 13 SCREW HHM 10-32 X 1/2
22 061286 1 AUDIBLE ALARM 58 0A2284 4 SCREW SWAGE 8-32 X 1/2 Z/YC
23 055089 1 CONN ELEC AMP M-N-L 15PLUG PNL 59 022152 14 WASHER LOCK #10
24 0E2693A 1 SWITCH MUSHRM HEAD/ARROWS 60 023897 15 WASHER FLAT #10 ZINC
40MM 61 022158 2 NUT HEX #10-32 STEEL
25 0E2693C 3 CONTACT BLOCK D5-3 X 01 W/2 1417 62 074130 1 LUG DIS SN-PLG I-T 22-18 CU
26 071361 1 POTENTIOMETER PNL 5K +/-10% 63 036261 4 RIVET POP .125 X .129-.133/#30
2.25W 64 070370 2 WASHER MICA .203
27 050123 1 KNOB PLASTIC .25 SHAFT 65 023762 1 WASHER SHAKEPROOF EXT #10 STL
28 055349 1 INSULATOR 67 040479 4 MOUNT VIBR 1.0 X 1.0 X 1/4-20
29 0A4087 1 MASTER CONTROL BOX 68 022287 4 SCREW HHC 1/4-20 X 3/4 G5
30 0C8481 REF. BULB-PANEL LIGHT-12V 69 022097 4 WASHER LOCK M6-1/4
0E3703 REF. LIGHT PANEL WITH LUG 70 022473 4 WASHER FLAT M6-1/4 ZINC
083288 REF. LIGHT 28VDC .17A MIN BAYNT MNT 71 047246 4 WASHER FLAT 1/4 SPECIAL
31 070082 1 LIGHT BLOCKER 72 0A2273 1 HINGE RAM PANEL
33 022676 1 FUSE 15A X AGC15 75 0C2428 8 SCREW TAPTITE PH #6-32 X 1/2 ZYC
34 070054 1 AMMETER AC 0-50 * 0A5705 1 FUSE 5A X LTTL215005 HLDRA4017
070055 1 AMMETER AC 0-100 (NOT SHOWN)
070057 1 AMMETER AC 0-300 79 0C4167 REF. BLOCK TERM 20A 14 X 6 X 1100V
070059 1 AMMETER AC 0-600 81 0441140156 REF. WIRE ASSEMBLY
070060 1 AMMETER AC 0-800 82 084717 1 ASSY TIME DELAY (13.3L GAS ONLY)
075323 1 AMMETER AC 0-1000 83 036908 1 SCREW PPHM #6-32 X 1-1/4 (13.3L
075324 1 AMMETER AC 0-1600 GAS ONLY)
075325 1 AMMETER AC 0-2000 84 0C1229 1 DECAL WARNING
35 070043 1 METER VOLT AC 0-300 85 0E3783 1 DECAL WARNING REMOVE FUSE
070044 1 METER VOLT AC 0-600
36 070042 1 METER FREQUENCY 55-65HZ
070042A 1 METER FREQUENCY 240V 45-55HZ

Control Panel (For Use With Marathon Alternator) – Drawing No. 0C8460-G
45
64
43
36 3
52 53 54
64 65
68 65
12 14 40 56 57 41
59
55 53 43 45 60 67 21 22
7
37 28 29
45
6
19
25 26 27 38
11
23 45
43 8
16
9
2
1 VIEW A
17 67 63 45 15 45 61 67 45 62 67 10
51 53 54
31
5 52 53 54 55
52 53 54 55
48 49 50
30
52 53 54
47 48 49
SLOT 20
# #
1 0
2 1
15
12
3 2 41
11
14
5 S1
10
13
1
7
6
7
ALIGNMENT
8 S2
TAB
9 S16
10 57 DETAIL 1
11 S3 WIRE NUMBERS/LOCATIONS 39
12 58 FOR LOWER PANEL
59 HOUSING SOCKET VIEW A
14 SCALE: NONE HINGE ASSEMBLY
15 REAR VIEW SCALE: NONE
32
35
42 43
AVR BEHIND COVER
GOVERNOR CONTROL
BEHIND COVER
(IF SO EQUIPPED)
42 43
33
34

OUTSIDE VIEW

Control Panel (For Use With Marathon Alternator) – Drawing No. 0C8460-G
1 0C2616 1 CONTROL PANEL BOTTOM 35 0A3394 1 DECAL ELECTRONIC GOVERNOR
2 0C3872 1 CONTROL PANEL FRONT 36 030809 1 GROMMET 11/16 X 1/8 X 7/16
3 0A6322 1 CONTROL PANEL RIGHT SIDE 37 029333 1 TIE WRAP 7" WHITE
4 0A6321 1 CONTROL PANEL LEFT SIDE 38 074130 1 LUG DIS SN-PLG I-T 22-18 CU
5 0E3550 1 CHASSIS, UNIVERSAL 39 036261 4 RIVET POP .125 X .129-.133/#30
6 0C8328 1 HARNESS E PANEL MAIN 40 040479 4 MOUNT VIBR 1.00 X 1.00 X 1/4-20
7 0A4087 1 MASTER CONTROL BOX 41 0A2273 1 HINGE RAM PANEL
8 SEE NOTE 1 AMMETER 42 036901 4 SCREW PPHM #6-32 X 3/8
9 SEE NOTE 1 VOLT METER AC 43 022155 7 WASHER LOCK #6
10 SEE NOTE 1 FREQUENCY METER 45 0C2323 12 SCREW TAPTITE PH 6-32 X 5/8 ZYC
11 074386 1 SWITCH VOLT/AMP 47 036918 4 SCREW PPHM #8-32 X 1/2
12 0A9234 CONNECTOR 90 DEGREE ELBOW 48 022264 8 WASHER LOCK M4
13 034616 1 FITTING STRAIGHT 3/4 49 038150 4 WASHER FLAT M4
14 0C3207 1 DECAL TERM STRIP TB1 50 0A2284 4 SCREW SWAGE 8-32 X 1/2 Z/YC
15 0C8229 1 DECAL TERM STRIP TB2 51 033120 1 SCREW HHM 10-32 X 3/8
16 0C3208 1 DECAL TERM STRIP TB3 52 033121 17 SCREW HHM 10-32 X 1/2
17 0C3206 1 DECAL TERM STRIP TB4 53 022152 20 WASHER LOCK #10
18 0C4110 1 RELAY 24V 50A W/DIODE 54 023897 20 WASHER FLAT #10 ZINC
19 061286 1 ALARM AUDIBLE 55 022158 6 NUT HEX #10-32 STEEL
20 055089 1 CONN ELEC AMP M-N-L 15PLUG PNL 56 022287 4 SCREW HHC 1/4-20 X 3/4 G5
21 098426A 1 SWITCH EMERGENCY STOP 57 022097 4 WASHER LOCK M6-1/4
22 098426C 3 CONTACT EMERGENCY STOP 58 022473 4 WASHER FLAT M6-1/4 ZINC
SWITCH 59 047246 4 WASHER FLAT 1/4 SPECIAL
23 091472 9.5" WIRE DUCT1 X 1.5 60 057335 1 BLOCK TERM 20 POS TB1
24 091472A 9.5" WIRE DUCT COVER 1" 61 0C4167 1 BLOCK TERM 20A 14 X 6 X 1100V
25 0E3703 1 LIGHT PANEL WITH LUG 62 055911 1 BLOCK TERM 20A 12 X 6 X 1100V
26 083288 1 LIGHT 28VDC .17A MIN BAYNT MNT 63 061520 1 BLOCK TERM 20A 9 X 6 X 1100V
27 070082 1 LIGHT BLOCKER 64 0441140156 1 WIRE ASSY 18AWG #0
29 022676 1 FUSE 15A X AGC15 66 0C1229 1 DECAL WARNING
30 067710 1 CONTROLLER ELECTRONIC 67 046669 17 BLOCK TERM JUMPER
GOVERNOR 68 0E3783 1 DECAL, WARNING REMOVE FUSE
31 0A2275 1 DOOR-STOP RAM PANEL
32 0A1441B 1 COVER PLATE AVR NOTE: CONTACT GENERAC SERVICE FOR CORRECT PART NUMBER
33 0C1127 1 DECAL AVR COVER FOR TOUR UNIT.
34 0A1441C 1 COVER PLATE ELECTRONIC
GOVERNOR

Section 7 — Notes

Section 7 — Notes

GENERAC® POWER SYSTEMS, INC.
P.O. BOX 8
WAUKESHA, WI 53187
Part No. 0A7605 Revision K (06/17/03) Printed in U.S.A.

Operator's Manual: Power Systems, Inc

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®

POWER SYSTEMS, INC.

This manual contains standard drawings and schematics.

This manual should remain with the unit.

Safety Rules ..............Inside Front Cover Section 3 — Troubleshooting and

AUTHORIZED SERVICE DEALER LOCATION

Generac® Power Systems, Inc. 1

2 Generac® Power Systems, Inc.

 Software Version Page

 Generator Command Page

Generac® Power Systems, Inc. 3

4 Generac® Power Systems, Inc.

Alarm Message Alarm Active Options Alarm Type Options

ALARM PROCESSING • Disabled: If this option is selected, the alarm is

Generac® Power Systems, Inc. 5

 ALARM TYPE  OTHER ALARMS

 Alarm Status  PREHEAT TIME

 PAUSE TIME  VOLTAGE SCALING FACTOR

 ANALOG INPUT SCALING FACTORS  OIL TEMPERATURE ALARMS

E PANEL MODEM SETUP PROCEDURE NOTE:

Generac® Power Systems, Inc. 9

 Remote Annunciator Panel  USER PASSWORD

10 Generac® Power Systems, Inc.

12 Generac® Power Systems, Inc.

OUTPUT FUNCTION TABLE

14 Generac® Power Systems, Inc.

E PANEL MASTER CONTROL BOX CONFIGURATION SETTINGS

ENGINE PARAMETER MENU

Available Options: P1 = No Preheat, Before Start, Before and During Start

SYSTEM ALARM MENU

Available Options: A1 = Disable, Hold off, Immediate

Generac® Power Systems, Inc. 15

DIGITAL I/O MENU

Available Options: A1 = Disabled, Hold Off, Immediate, Always

ANALOG INPUT MENU

Available Options: A1 = Disabled, Hold Off, Immediate, Always

16 Generac® Power Systems, Inc.

Generac® Power Systems, Inc. 17

18 Generac® Power Systems, Inc.

or Over Freq Setpoint Input Ch 6 Alarm enable Analog Ch 2 Value at 10V

Number of Start Attempts or or or

Coolant Temp High Setpt Input Ch 3 Alarm Enable Analog Ch 1 value at 0V

Oil Temp Shutdown Enable Input Channel 3 Setting

Oil Temp. Shutdown Setpt Input Channel 3 Message

Oil Temp Warn Enable Input Ch 2 Alarm Type

Oil Temp. Warn Setpt Input Ch 2 Alarm Enable

Oil Press Shutdown Setpt Input Channel 2 Setting

Oil Press Warn Setpt Input Channel 2 Message

Input Ch 1 Alarm Type

Input Ch 1 Alarm Enable

Input Channel 1 Setting

Input Channel 1 Message

Preheat Output Function

Generac® Power Systems, Inc. 19

20 Generac® Power Systems, Inc.

Generac® Power Systems, Inc. 21

 TROUBLESHOOTING  Short circuit testing

Generac® Power Systems, Inc. 23

(Refer to Figure 3.3)

Software Version Page

Generator Command Page

ALARM TYPE OTHER ALARMS

Alarm Status PREHEAT TIME

PAUSE TIME VOLTAGE SCALING FACTOR

ANALOG INPUT SCALING FACTORS OIL TEMPERATURE ALARMS

Remote Annunciator Panel USER PASSWORD

TROUBLESHOOTING Short circuit testing

Open circuit testing 2.2 Test results:

Figure 3.5 — RPM Sensor Engine Over Speed

CHECK THE E PANEL START SETTINGS

MEASURE THE START SIGNAL AT THE

3. Pull contactwire 0460-204-08141 8 & 10 AWG .430-.492