®
POWER SYSTEMS, INC.
Owner’s Manual
100 and 200 Amp
“V”Type and “Y”Type
Transfer Switch
Models: 09227-0, 09228-0,
09229-0, and 09230-0
This manual should remain with the unit.
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Table of Contents
• Because jewelry conducts electricity, wearing it
may cause dangerous electrical shock. Remove all
jewelry (such as rings, watches, bracelets, etc.)
before working on this equipment.
• If you must work on this equipment while standing
on metal or concrete, place insulative mats over a
dry wood platform. Work on this equipment only
while standing on such insulative mats.
Safety Rules..........................................Inside Front Cover
Section 1 — General Information ..................................2
1.1 Introduction ............................................................2
1.2 Equipment Description ..........................................2
1.3 Transfer Switch Data Plate......................................2
1.4 Transfer Switch Enclosure......................................2
1.5 Safe Use Of Transfer Switch....................................2
Section 2 — Installation ....................................................3
2.1 Introduction to Installation......................................3
2.2 Unpacking ..............................................................3
2.3 Mounting ................................................................3
2.4 Connecting Power Source and Load Lines ..............3
2.4.1 2-Pole Mechanisms ......................................4
2.4.2 3-Pole Mechanisms ......................................4
2.5 Connecting Start Circuit Wires................................5
2.6 Auxiliary Contacts ..................................................5
2.7 Optional Accessories ..............................................5
Section 3 — Operation..................................................................5
3.1 Functional Tests and Adjustments ..........................6
3.2 Functional Tests ......................................................6
3.3 Manual Operation....................................................6
3.3.1 “V” Type Transfer Switches ..........................6
3.3.2 “Y” Type Transfer Switches ..........................7
3.4 Voltage Checks ........................................................7
3.5 Generator Tests Under Load ..................................8
Section 4 – Notes ..........................................................................9
Section 5 – Wiring Diagrams & Electrical
• Never work on this equipment while physically or
mentally fatigued.
• Keep the transfer switch enclosure door closed and
bolted at all times. Only qualified personnel
should be permitted access to the switch interior.
• In case of an accident caused by electric shock,
immediately shut down the source of electrical
power. If this is not possible, attempt to free the
victim from the live conductor but AVOID DIRECT
CONTACT WITH THE VICTIM. Use a nonconduct-
ing implement, such as a rope or board, to free the
victim from the live conductor. If the victim is
unconscious, apply first aid and get immediate
medical help.
• When an automatic transfer switch is installed for
a standby generator set, the generator engine may
crank and start at any time without warning. To
avoid possible injury that might be caused by such
sudden start-ups, the system’s automatic start cir-
cuit must be disabled before working on or around
the generator or transfer switch. For that purpose,
a SAFETY DISCONNECT is provided inside the
transfer switch. Always set that switch to its MAN-
UAL position before working on the equipment.
Then place a “DO NOT OPERATE” tag on the
transfer switch and on the generator.
Schematics ..............................................................10
Section 6 – Exploded Views & Parts Lists ............................14
Section 7 – Warranty..................................................Back Cover
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Section 1 — General Information
Generac “V” Type and “Y” Type Transfer Switch
1.1 INTRODUCTION
1.3 TRANSFER SWITCH DATA PLATE
Affixed permanently to the transfer switch door is a
DATA PLATE. Use the transfer switch only within the
specific limits shown on the DATA PLATE and on
other decals and labels that may be affixed to the
switch. This prevents damage to equipment, possible
injury to personnel, and provides long and trouble-
free life for the equipment.
This manual has been prepared especially for the
purpose of familiarizing personnel with the design,
application, installation, operation and servicing of
the applicable equipment. Read the manual carefully
and comply with all instructions. This will help to
prevent accidents or damage to equipment that might
otherwise be caused by carelessness, incorrect appli-
cation, or improper procedures.
When requesting information or ordering parts for
this equipment, make sure to include all information
from the DATA PLATE.
Every effort has been expended to make sure that the
contents of this manual are both accurate and cur-
rent. Generac, however, reserves the right to change,
alter or otherwise improve the product at any time
without prior notice.
When requesting information or ordering parts for this
equipment, make sure to include all information from
the DATA PLATE.
Record your Model and Serial numbers in the space
provided below for future reference.
1.2 EQUIPMENT DESCRIPTION
The pre-packaged transfer switch is designed to use
with pre-packaged standby generator control panels.
It is used for transferring critical electrical loads from
a NORMAL (utility) power source to a STANDBY
(emergency generator) power source. Such a transfer
of loads occurs automatically when the NORMAL
power source fails or is subsequently reduced and
the STANDBY source voltage and frequency have
reached an acceptable level. The transfer switch pre-
vents electrical feedback between two different power
sources (such as the NORMAL and STANDBY
sources) and, for that reason, codes require it in all
standby electric system installations.
MODEL #
SERIAL #
1.4 TRANSFER SWITCH ENCLOSURE
The standard switch enclosure is
a
National
Electrical Manufacturer's Association (NEMA) 1 type.
NEMA 1 type enclosures primarily provide protection
against contact with the enclosed equipment and
against a limited amount of falling dirt.
Once the transfer is completed, the STANDBY power
source then powers electrical loads connected to the
transfer switch. When NORMAL source voltage above
an acceptable (preset) level has been restored, circuit
board action in the pre-packaged control panel initi-
ates re-transfer back to NORMAL power source. After
this re-transfer, the circuit board signals to open the
start circuit to the generator, which shuts down the
engine. The circuit board is then "armed" and ready
for the next drop in NORMAL source voltage.
1.5 SAFE USE OF TRANSFER SWITCH
Before installing, operating or servicing this equip-
ment, read the SAFETY RULES (inside front cover)
carefully. Comply strictly with all SAFETY RULES to
prevent accidents and/or damage to the equipment.
Generac recommends you make a copy of the SAFE-
TY RULES and post them near the transfer switch.
Also, be sure to read all instructions and information
you may find on tags, labels and decals affixed to the
equipment.
NOTE:
Keep in mind the pre-packaged transfer switch is
without any kind of electronic controls. It receives
signals solely from circuit boards contained in the
prepackaged control panel.
Two publications that outline the safe use of transfer
switches are the following:
• National Electrical Code
• UL 1008, STANDARD FOR SAFETY-AUTOMATIC
TRANSFER SWITCHES
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Section 2 — Installation
Generac “V” Type and “Y” Type Transfer Switch
2.1 INTRODUCTION TO INSTALLATION
This equipment has been wired and tested at the fac-
tory. Installing the switch includes the following pro-
cedures:
Handle transfer switches carefully when
installing. Do not drop the switch. Protect the
switch against impact at all times, and against
construction grit and metal chips. Never install
a transfer switch that has been damaged.
!
• Mounting the enclosure.
• Connecting power source and load leads.
• Connecting the generator start circuit.
• Installing/connecting any options and accessories.
• Testing functions.
Install the transfer switch as close as possible to the
electrical loads that are to be connected to it. To pre-
vent switch distortion, level all mounting points. If
necessary, use washers behind mounting holes to
level the unit.
2.2 UNPACKING
Carefully unpack the transfer switch. Inspect closely
for any damage that might have occurred during
shipment. The purchaser must file with the carrier
any claims for loss or damage incurred while in tran-
sit.
2.4 CONNECTING POWER SOURCE
AND LOAD LINES
DANGER
Check that all packing material is completely
removed from the switch prior to installation.
Make sure to turn OFF both the normal (Utility)
and standby (generator) power supplies before
trying to connect power source and load lines
to the transfer switch. Supply voltages are
extremely high and dangerous. Contact with
such high voltage power supply lines causes
extremely hazardous, possibly lethal, electrical
shock.
Attach any lifting device to the transfer switch mount-
ing holes or brackets only. DO NOT LIFT THE
SWITCH AT ANY OTHER POINT.
2.3 MOUNTING
Transfer switch components are generally mounted
in a standard NEMA 1 type enclosure (Figure 2.1).
Other options are available such as NEMA 34 and
NEMA 12.
Wiring diagrams and electrical schematics are pro-
vided in this manual. Power source and load connec-
tions are made at a transfer mechanism, inside the
switch enclosure.
Figure 2.1 — Mounting Dimensions for Enclosures
14.32
19.92
1.1
7.09
6.72
7.63
2.12
15.62
20.59
19.37
25.07
24.07
MOUNTING DIMENSIONS - 200 & 400 AMP UNITS
MOUNTING DIMENSIONS - 100 AMP,2-POLE UNIT
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Section 2 — Installation
Generac “V” Type and “Y” Type Transfer Switch
Figure 2.4 — 3-Pole Transfer Mechanism
2.4.1 2-POLE MECHANISMS
‹
These switches (Figures 2.2 and 2.3) are used with a
single phase system, when the single phase NEU-
TRAL line is to be connected to a Neutral Lug and is
not to be switched.
Figure 2.2 — 100 Amp 2-pole Transfer
Mechanism
Solderless, screw-type terminal lugs are standard.
Conductor sizes must be adequate to handle the max-
imum current to which they will be subjected; based
on the 75°C column of tables, charts, etc. used to size
conductors. The installation must comply fully with
all applicable codes, standards and regulations.
Before connecting wiring cables to terminals, remove
any surface oxides from the cable ends with a wire
brush. If ALUMINUM conductors are used, apply cor-
rosion inhibitor to conductors. After tightening ter-
minal lugs, carefully wipe away any excess corrosion
inhibitor.
Figure 2.3 — 200 Amp 2-pole Transfer
Mechanism
All power cables should enter the switch next to
transfer mechanism terminals. Standard terminal
lugs on the transfer mechanism are solderless,
screw-type.
Connect power source load conductors to clearly
marked transfer mechanism terminal lugs as follows
(Figure 2.5 on page 5):
1. Connect NORMAL (utility) power source cables to
switch terminals N1, N2, N3, etc.
2. Connect STANDBY source power cables to trans-
fer switch terminals E1, E2, E3, etc.
3. Connect customer LOAD leads to switch termi-
nals T1, T2, T3, etc.
Conductors must be properly supported, of approved
insulative qualities, protected by approved conduit,
and of the correct wire gauge size in accordance with
applicable codes.
2.4.2 3-POLE MECHANISMS
N
This switch (Figure 2.4) is also used with a single
phase system, when the single phase NEUTRAL line
is to be connected to a Neutral Lug and is not to be
switched.
Tighten terminal lugs to the following torques:
100 Amp Switch: 50 INCH-POUNDS
200 Amp Switch: 250 INCH-POUNDS
Make sure to maintain proper electrical 1/2-inch
clearance between live metal parts and grounded
metal.
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Section 2 — Installation
Generac “V” Type and “Y” Type Transfer Switch
Figure 2.5 — Transfer Switch Interconnections (Drawing #79963-B)
00
NEUTRAL
CONNECTION
N3, E3 AND T3 NOT
USED ON SINGLE PHASE
SYSTEMS
E1
CB2
E2
TRANSFER
SWITCH
NEUTRAL
LUG
E3
UTILITY 1
UTILITY 2
LOAD 2
NOTE:
23
POWER LEADS AND
TRANSFER SWITCH
LEADS MUST BE
194
RUN IN TWO
DIFFERENT CONDUITS.
REMOTE TEST
SWITCH (OPTIONAL)
- OPEN SWITCH TO TEST -
SWITCH TYPE, SPST
ELECTRICAL RATINGS,
2A @ 250Vac MIN.
AC GENERATOR
CONTROL PANEL
Figure 2.6 — Auxiliary Contact Schematic
2.5 CONNECTING START CIRCUIT
WIRES
Control system interconnections (Figure 2.5) consist
of UTILITY 1 and 2, LOAD 1 and 2; and leads 23 and
194. Control system interconnection leads must be
run in a conduit that is separate from the AC power
lead. Recommended wire gauge sizes for this wiring
depends on the length of the wire, as recommended
below:
MAXIMUM WIRE LENGTH
RECOMMENDED WIRE
SIZE
460 feet (140m)
No. 18 AWG.
No. 16 AWG.
No. 14 AWG.
No. 12 AWG.
461 to 730 feet (223m)
731 to 1,160 feet (354m)
1,161 to 1,850 feet (565m)
Auxiliary contacts are rated 15 amperes at 125, 250 or
480 volts AC; 0.5 ampere at 125 volts DC; 0.25 ampere
at 250 volts DC. DO NOT EXCEED THE RATED
VOLTAGE AND CURRENT OF THE CONTACTS.
Contact operation is shown in the following chart:
NOTE:
The preceding start circuit connections apply to
the standard 2-wire start system only Your transfer
switch may be equipped with a 3-wire connection
system.
Switch Position
Utility
Closed
Open
Standby
2.6 AUXILIARY CONTACTS
Common (4) to Normally Closed (6)
Common (4) to Normally Closed (5)
Open
If desired, you can access a set of Auxiliary Contacts
on the Transfer Switch to operate customer acces-
sories, remote advisory lights, or remote annunciator
devices. A suitable power source must be connected
to the COMMON (C) terminal. The contacts labeled 1,
2 and 3 (Figure 2.6) are connected at the factory for
operation of transfer switch advisory lights. Contacts
4, 5 and 6 are available for customer use.
Closed
2.7 OPTIONAL ACCESSORIES
Note any optional accessories that may be installed
on the transfer switch or are to be installed in the
standby electric system in conjunction with the
switch. Complete the necessary connections for these
accessories.
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Section 3 — Operation
Generac “V” Type and “Y” Type Transfer Switch
3.1 FUNCTIONAL TESTS AND
3.3 MANUAL OPERATION
The pre-packaged transfer switch has a choice of two
transfer mechanisms - the "V" type (Model 9227-0)
and the "Y" type (Models 9228, 9229 and 9230).
ADJUSTMENTS
Following transfer switch installation and intercon-
nection, inspect the entire installation carefully. A
competent, qualified electrician should make the
inspection.
3.3.1 “V” TYPE TRANSFER SWITCHES
N
Test manual operation for “V” type transfer switches
as follows:
The installation should comply strictly with all appli-
cable codes, standards, laws and regulations. All
electrical connections must be correct and in compli-
ance with applicable codes and standards.
1. Check that the generator's Auto/Off/Manual
switch has been set to OFF position.
2. Turn OFF the UTILITY power supply to the trans-
fer switch, using whatever means provided (such
as the UTILITY source main line circuit breaker).
3. Set the generator's main circuit breaker to its
OFF or OPEN position.
Make sure the standby generator is ready. This
includes checking engine oil level, coolant level, fuel
supply, batteries and other items specified in the
OWNER'S MANUAL for specific generators.
Complete all functional tests as outlined in the FUNC-
TIONAL TESTS section. Do this before placing the
transfer switch into service.
DANGER
FAILURE TO TURN OFF ALL A POWER VOLTAGE
SUPPLIES TO THE TRANSFER SWITCH BEFORE
ATTEMPTING MANUAL OPERATION RESULTS IN
EXTREMELY HAZARDOUS AND POSSIBLY FATAL
ELECTRICAL SHOCK.
3.2 FUNCTIONAL TESTS
Following transfer switch installation, the entire
standby electric system should be inspected and test-
ed. Have all necessary adjustments completed at this
time. Functional tests of the transfer switch include
these tests: (a) Manual Operation, (b) Voltage Checks
and (c) Electric Operation.
4. Remove the manual transfer handle from the
enclosure.
5. Place open slot of the manual transfer handle on
the small tab of the transfer switch operating
lever (Figure 3.1).
6. Pull manual transfer handle downward, then
move it back to original position. If handle is
down, LOAD is connected to UTILITY power
source. If handle is up, LOAD is connected to
STANDBY power.
7. Move the transfer switch main contacts to both
positions several times. Leave the transfer switch
in the UTILITY position and connect LOAD to the
UTILITY power source (manual operation lever is
up).
To avoid damaging the transfer switch, perform
!
functional tests In the exact order given.
Before proceeding with functional tests, read and be
sure you understand all instructions in this section.
Also, read the instructions and information on tags
and decals affixed to the transfer switch. Note any
options and accessories that might be installed or
provided with the switch and review their operation.
DANGER
Figure 3.1 — Transfer Switch Operation
(“V” Type)
DO NOT ATTEMPT MANUAL OPERATION OF THE
TRANSFER SWITCH UNTIL AFTER ALL POWER
VOLTAGE SUPPLIES TO THE SWITCH HAVE BEEN
TURNED OFF. FAILURE TO TURN OFF POWER
VOLTAGE SUPPLIES MAY RESULT IN DANGER-
OUS AND POSSIBLE FATAL ELECTRICAL SHOCK.
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Section 3 — Operation
Generac “V” Type and “Y” Type Transfer Switch
3.3.1 “Y” TYPE TRANSFER SWITCHES
A manual handle was shipped with the transfer
switch. Test manual operation for “Y” type transfer
switches as follows (Figure 3.2):
N
3.4 VOLTAGE CHECKS
1. Turn ON the UTILITY power supply to the trans-
fer switch with whatever means provided (such as
the UTILITY maim line circuit breaker).
1. Check that the generator's Auto/Off/Manual
switch has been set to OFF position.
2. Attach the square opening of the manual handle
over the square shaft at lower right corner of
transfer mechanism.
3. Move the manual handle UP. When movement
stops at NEUTRAL, return handle to its original
position and actuate again.
DANGER
PROCEED WITH CAUTION. THE TRANSFER
SWITCH IS NOW ELECTRICALLY HOT. CONTACT
WITH LIVE TERMINALS RESULTS IN EXTREMELY
HAZARDOUS AND POSSIBLY FATAL ELECTRICAL
SHOCK.
2. With an accurate AC voltmeter, check for correct
voltage across terminal lugs N1 and N2; N1 to
NEUTRAL; and finally N2 to NEUTRAL (Figure
2.5 on Page 5).
3. When certain that UTILITY supply voltage is correct
and compatible with transfer switch ratings, turn
OFF the UTILITY supply to the transfer switch.
4. On the generator panel, set the Auto/Off/Manual
switch to MANUAL position. The generator
should crank and start.
4. Observe the changeover display on transfer
mechanism as follows:
• If utility arrow is aligned with GREEN band, load
is connected to UTILITY (normal) power source.
• If STANDBY arrow is aligned with GREEN band,
LOAD is connected to STANDBY (emergency)
source.
5. Repeat steps 3 and 4 several times, being sure the
switch main contacts actuate normally to all posi-
tions.
5. Let the generator stabilize and warm up at no-
load for at least five minutes.
6. When certain that switch operates normally, actu-
ate the main contacts to their UTILITY (normal)
source.
6. Set the generator's main circuit breaker (CBI ) to
its ON or CLOSED position.
NOTE:
DANGER
LOAD must be connected to UTILITY source
before proceeding. That is, the GREEN BAND
must be next to the UTILITY arrow and the RED
band must be next to the STANDBY arrow.
PROCEED WITH CAUTION. A GENERATOR OUT-
PUT VOLTAGE IS NOW BEING DELIVERED TO
TRANSFER SWITCH TERMINALS. CONTACT WITH
LIVE TERMINALS RESULTS IN EXTREMELY DAN-
GEROUS AND POSSIBLY FATAL ELECTRICAL
SHOCK.
Figure 3.2 — Manual Operation of “Y” Type
Transfer Switch
7. With an accurate AC voltmeter and frequency
meter, check the no-load, voltage and frequency
meter at transfer switch terminal lugs E1, E2 and
NEUTRAL. Readings should be as follows:
a. Frequency ........................61-63 Hz
b. Terminals E1 and E2 ......242-253 volts
c. Terminal E1 to Neutral ....121-126 volts
d. Terminal E2 to Neutral ....121-126 volts
8. Set the generator's main circuit breaker (CBI ) to
its OFF or OPEN position.
9. To shut down the generator, set its
Auto/Off/Manual switch to OFF position.
NOTE:
Do NOT proceed until generator AC output voltage
and frequency are correct and within stated limits.
If the no-load voltage is correct but no-load fre-
quency is incorrect, the engine governed speed
probably requires adjustment. If no-load frequen-
cy is correct but voltage is not, the voltage regula-
tor may require adjustment.
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Section 3 — Operation
Generac “V” Type and “Y” Type Transfer Switch
5. When checkout under load is complete, set main
3.5 GENERATOR TESTS UNDER LOAD
1. Set the generator's main circuit breaker to its
OFF or OPEN position.
circuit breaker of the generator to its OFF or
OPEN position.
6. Let the generator run at no-load for several min-
utes. Then, shut down by setting the
Auto/Off/Manual switch to its OFF position.
7. With the manual transfer handle, move the
switch's main contacts back to their utility posi-
tion, i.e., load connected to utility power supply.
Handle and operating lever of transfer switch
should be in down position.
8. Turn on the utility power supply to transfer
switch, using whatever means provided (such as
a utility main line circuit breaker). The utility
power source now powers the loads.
2. Manually actuate the transfer switch main con-
tacts to their STANDBY position.
3. To start the generator, set the Auto/Off/Manual
switch to MANUAL. When engine starts, let it sta-
bilize for a few minutes.
4. Turn the generator's main circuit breaker to its
ON or CLOSED position. The generator now pow-
ers all LOAD circuits. Check generator operation
under load as follows:
• Turn ON electrical loads to the full rated
wattage/amperage capacity of the generator. DO
NOT OVERLOAD.
• With maximum rated load applied, check voltage
and frequency across transfer switch terminals
E1 and E2. Voltage should be greater than 230
volts; frequency should be greater than 58 Hz.
• Let the generator run under rated load for at
least 30 minutes. With unit running, listen for
unusual noises, vibration, overheating, etc., that
might indicate a problem.
9. Set the generator's Auto/Off/Manual switch to its
AUTO position. The system is now set for fully
automatic operation.
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Section 4 — Notes
Generac “V” Type and “Y” Type Transfer Switch
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Section 5 — Electrical Schematics and Wiring Diagrams
Interconnection Diagram - Drawing No. 074106-A
A D 2
A D 1
T I L I T Y 2
T I L I T Y 1
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Section 5 — Electrical Schematics and Wiring Diagrams
200 Amp, 2-Pole Transfer Switch - Drawing No. 074498-B
2
1
2
1
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Section 5 — Electrical Schematics and Wiring Diagrams
3-Pole Transfer Switch - Drawing No. 074499-B
2
1
2
1
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Section 5 — Electrical Schematics and Wiring Diagrams
Transfer Switch - Drawing No. 081222-B
A D 2
A D L 1
2
1
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Section 6 — Exploded Views and Parts Lists
Transfer Switch - Drawing No. 078589-H
DECAL
DECAL
44
26
15
9
38 39 40 41
DECAL
6
42
DECAL
25
24
43
23
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Section 6 — Exploded Views and Parts Lists
Transfer Switch - Drawing No. 078589-H
ITEM
PART NO.
QTY.
DESCRIPTION
1
62642
62677
64198
C2267
49226
23897
57073
27628
22131
C2266
79954
79955
79956
63552
62684
62704
62704
63378
74991
75353
A2595
47822
A1661
64113
63321
57329
63306
61675
47411
22473
76063
75506
79959
79957
79958-A
79957-A
69254
28739
C2265
22264
22985
63617
62702
62702
26902
26902
26902
22142
27482
22129
22259
67210A
22097
75506
1
1
1
4
6
4
1
1
1
2
1
1
1
9
9
4
6
5
1
1
1
1
2
1
1
1
1
1
4
4
1
1
1
1
1
1
4
5
4
4
2
1
2
3
-
SWITCH TRANSFER-#79953
SWITCH TRANSFER-#79953-A
SWITCH TRANSFER-#79953-B
M5-.8 x 12 SWAGEFORM HHC
WASHER, LOCK-M5
WASHER, FLAT-M5
LUG, NEUTRAL
2
3
4
5
6
7
8
9
NUT, HEX .375-16
WASHER, LOCK 3/8"
M5-.8 x 16 SWAGEFORM PPH
DECAL, SWITCH RATING-#79953
DECAL, SWITCH RATING #79953-A
DECAL, SWITCH RATING-#79953-B
DEVICE, ANTI-ROTATION-#79953
LUG, SOLDERLESS-#79953
LUG, SOLDERLESS-#79953-A
LUG, SOLDERLESS-#79953-B
HOLD DOWN, TIE WRAP
DECAL, MANUAL OPERATIONS
DECAL, UL COMPONENT RECOGNITION
DECAL, TERMINAL STRIP
STRIP, TERMINAL
POP RIVET
STUD, WING
HANDLE, TRANSFER SWITCH
LUG, GROUND
MONITOR, POWER 3-PHASE
SOCKET, RELAY OCTAL
M6-1.0 x 16 HHCS
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27**
28
M6 FLAT WASHER
ENCLOSURE
COVER, ENCLOSURE
DECAL, UL INFORMATION
ASSEMBLY, WIRE HARNESS-#79953
ASSEMBLY, WIRE HARNESS-#79953-A
ASSEMBLY, WIRE HARNESS-#79953-B
CRIMPTITE
WRAP, TIE
M4-.7 x 12 SWAGEFORM PPH
WASHER, LOCK-M4
29**
30**
31
32
33
34
35
36
WASHER, FLAT-M4
RELAY, 12VDC 10A.
LUG, SOLDERLESS-#79953-A
LUG, SOLDERLESS-#79953-B
TAPTITE, #8 x 1/4"-#79953
TAPTITE, #8 x 1/4"-#79953-A
TAPTITE, #8 x 1/4"-#79953-B
5/16" x 3/4" HHCS
5/16" SHAKEPROOF WASHER
5/16" LOCK WASHER
5/16"-18 HEX NUT
37
6
7
1
1
1
1
1
4
1
38
39
40
41
42
43
44
DECAL, GROUND
M6 LOCK WASHER
COVER
®
Generac Power Systems, Inc. 15
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Section 6 — Exploded Views and Parts Lists
Transfer Switch - Drawing No. 078589-H
48
49
36
TO RETAIN COVER
23
21
22
A
A
3
DETAIL A-A
20
DECAL
(POWER TERMINAL LUG ASSY)
A
DECAL
14
A
45
47
(BOTTOM POWER TERMINALS)
40 41
43
42
34
5
6
11
1
46
TERM. STRIP
REF. ONLY
44
39
DECAL
30
DECAL
37
DECAL
®
16 Generac Power Systems, Inc.
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Section 6 — Exploded Views and Parts Lists
Transfer Switch - Drawing No. 078589-H
ITEM
PART NO.
QTY.
DESCRIPTION
1
2*
3
4
5
6
7
8
9
79849
74975
71340
C2267
49226
51713
63617
27628
C2265
A1661
22264
38150
75353
57073
C2266
22152
64113
77441
77440
22131
36932
77033
74138
77052
77029
A2595
81238
77032
77036
79840
79846
22471
81221
73591
73590
47411
83736
95282
62684
22142
27482
22129
22259
67210A
A9457
74975
C2212
22473
22097
1
1
1
4
4
4
1
1
2
2
6
6
1
1
2
8
1
-
1
1
6
6
2
2
1
1
1
1
1
1
4
4
1
4
4
4
1
1
1
1
1
1
1
1
1
1
4
4
4
ENCLOSURE
COVER, ENCLOSURE
SWITCH, TRANSFER 100A. 2-POLE
M5-.8 x 12 SWAGEFORM HHC
M5 LOCK WASHER
M5 FLAT WASHER
RELAY, 12V. DC 10A.
NUT, .375-16
M4-.7 x 12 SWAGEFORM PPH
POP RIVET
#8 LOCK WASHER
#8 FLAT WASHER
10
11
12
13**
14
15
16
17
18
19
20
21
22
23
24
25**
26
27*
28**
29**
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
DECAL, UL COMPONENT RECOGNITION
LUG, NEUTRAL
M5-.8 x 16 SWAGEFORM PPH
WASHER, LOCK #10
STUD, WING
HANDLE, TRANSFER SWITCH
COVER, POWER TERMINAL
WASHER, FLAT .375 NOM.
PPHMS 10-32 x 1/4"
LUG, SOLDERLESS
MALE DISCONNECT ADAPTOR (BENT)
MALE DISCONNECT ADAPTOR
DECAL, MANUAL OPERATIONS
DECAL, TERMINAL STRIP
HARNESS, WIRE
DECAL, TRANSFER SWITCH RATING
DECAL, UL INFORMATION
COVER, RELAY & TERM. BLOCK
STANDOFF HEX S/S
HEX NUT #8-32
DECAL, NAME PLATE UL
FUSE HOLDER
FUSE 2A. 600V.
M6-1.0 x 16 HHCS
DECAL, CSA
DECAL, LIVE CIRCUIT WARNING
LUG, GROUND
5/16"-18 x 3/4" HHCS
5/16" SHAKEPROOF WASHER
5/16" LOCK WASHER
5/16"-18 HEX NUT
DECAL, GROUND
DECAL, NEUTRAL
COVER
M4-.7 x 16 SWAGEFORM PPH
M6 FLAT WASHER
M6 LOCK WASHER
®
Generac Power Systems, Inc. 17
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Section 7 — Warranty
Generac “V” Type and “Y” Type Transfer Switch
GENERAC POWER SYSTEMS STANDARD TWO-YEAR LIMITED WARRANTY
FOR GENERAC TRANSFER SWITCH SYSTEMS
NOTE: ALL UNITS MUST HAVE A START-UP INSPECTION PERFORMED BY AN AUTHORIZED GENERAC DEALER.
For a period of 2 (two) years from the date of sale/start date, Generac Power Systems, Inc. will, at its option, repair or
replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or a Generac Power
Systems Authorized Warranty Service Facility, is found to be defective under normal use and service, in accordance with
the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be returned
to, and examined by the nearest Generac Power Systems Authorized Warranty Service Facility. All transportation costs
under the warranty, including return to the factory, are to be borne and prepaid by the purchaser/owner. This warranty
applies only to Generac Power Systems Transfer Switch applications, as Generac Power Systems, Inc. have defined
Transfer Switch application, provided said Transfer Switch has been initially installed and inspected on-site by a Generac
Power Systems Authorized Service Dealer or branch thereof. A scheduled maintenance agreement with a local Authorized
Generac Power Systems Dealer is highly recommended to verify adequate service has been performed on the unit
throughout the warranty period.
WARRANTY SCHEDULE
• YEAR ONE — 100% (one hundred percent) coverage on mileage*, labor, and parts listed.
• ALL COMPONENTS
• YEAR TWO — 100% (one hundred percent) coverage on parts listed.
• ALL COMPONENTS — *PARTS ONLY
• *Travel allowance is limited to 300 miles maximum, or 7.5 hours maximum (per occurrence), round trip, to the nearest
authorized Generac Service Facility.
• A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a
non Generac genset is substituted for use and directly causes damage to the Generac Transfer Switch, no warranty
coverage shall apply.
• All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty, Policies, and
Procedures Flat Rate Manual.
• Units that have been resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
1. Any unit built/manufactured prior to January 1, 2002.
2. Unit enclosure is only covered against rust or corrosion the first year of the warranty provision.
3. Costs of normal maintenance i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up.
4. Use of Non-Generac replacement part(s) will void the warranty in its entirety.
5. Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze.
6. Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or
sizing.
7. Failures caused by any external cause or act of God such as collision, fire, theft, freezing, vandalism, riot or wars, lightning,
earthquake, windstorm, hail, volcanic eruption, water or flood, tornado, hurricane, terrorist acts or nuclear holocaust.
8. Products that are modified or altered in a manner not authorized by Generac Power Systems in writing.
9. Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in
repair or replacement of the defective part(s).
10. Failure due to misapplication, misrepresentation, or bi-fuel conversion.
11. Telephone, telegraph, teletype or other communication expenses.
12. Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific
unit warranty period.
13. Rental equipment used while warranty repairs are being performed i.e. rental generators, cranes, etc..
14. Overtime labor or more than one person performing repairs.
15. Any and all expenses incurred investigating performance complaints unless defective Generac materials and or work-
manship were the direct cause of the problem.
16. *Engine coolant heaters (block-heaters), heater controls and circulating pumps after the first year.
17. *Starting batteries, fuses, light bulbs, and engine fluids, tires, brakes and overnight freight cost for replacement part(s).
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC
POWER SYSTEMS MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICU-
LAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may
not apply to you.
GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED
ABOVE. IN NO EVENT SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL
DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may
not apply to you. Purchaser/owner agrees to make no claims against Generac Power Systems, Inc. based on negligence.
This warranty gives you specific legal rights. You also may have other rights that vary from state to state.
GENERAC® POWER SYSTEMS, INC. • P.O. BOX 8 • WAUKESHA, WI 53187
PH: (262) 544-4811 • FAX: (262) 544-4851
Bulletin 0166260SBY / Printed in USA 5.02
Part No. 078590
Revision D (05/29/02)
Printed in U.S.A.
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