Circuit Breaker Installation, Electrical Connections

6.3.2Circuit Breaker Installation

Note: Wire material. Use stranded copper for all wiring. Use wire gauges and insulation, conductor temperature ratings, sheath stripping, conductor support and protection, conductor terminals and splices, and overcurrent protection (circuit breakers, fuses) that conform to standards and codes.

Note: Wire protection. Use rubber grommets and cable ties as necessary to protect and secure the wiring from sharp objects, the exhaust system, and any moving parts.

1.Turn the generator set off and disconnect the generator set engine starting battery, negative (--) lead first.

2.Remove the screws and remove the access cover.

3.Remove the screws and nuts to remove the circuit breaker cover plate. Save the mounting hardware.

4.Install the circuit breaker from the inside of the cutout panel and mount it using the existing screws. Position the circuit breaker with ON in the normal upright position or to the left side. Cover the cutout opening, if applicable, with the circuit breaker coverplate. Use the existing screws and nuts.

5.See Section 8 for voltage reconnection.

6.Install insulation boots over the stator lead terminals if the kit includes insulation boots.

Note: See Figure 6-2 for electrical connections.

7.Make the recommended connections for the following three reconnection systems using circuit breakers.

Two-pole circuit breaker with a single-voltage system (example: 120 volt, 3 wire).

Attach stator leads marked 2 and 4 to the side of the circuit breaker marked LINE. Install the jumper

lead across the LINE side of the circuit breaker terminals (see Section 8). Attach stator leads 1 and 3 to L0.

Two-pole circuit breaker with a dual-voltage system (example: 120/240 volt, 3 wire).

Attach stator leads marked 1 and 4 to the side of the circuit breaker marked LINE. Do not use a jumper

lead (see Section 8). Attach stator leads 2 and 3 to L0.

Single-pole circuit breaker with a single-voltage system (example: 240 volt, 2 wire).

Attach the stator lead marked 1 to the side of the circuit breaker marked LINE (see Section 8). Bolt together leads 2 and 3 and tape to insulate from ground. Attach the stator lead marked 4 to L0.

8.Connect the stator lead(s) used for neutral connection to the L0 stud. See Figure 6-2.

9.Connect the side of the circuit breaker marked LOAD to the transfer switch or vehicle. Attach insulation boots to the black leads if the kit includes insulation boots. With a single-pole circuit breaker use one black lead L1. With a two-pole circuit breaker use two black leads L1 and L2. Connect the neutral white lead to the L0 stud. Connect the equipment ground green lead to the GRD stud. See Figure 6-2.

10.Replace the circuit breaker box access panel.

11.Reconnect the generator set engine starting battery, negative (--) lead last.

12.For voltage adjustments, refer to the procedure in Section 8.2.

	Generator-End View
	2
1
	GM34867A-A
1.	Neutral (L0) connection
2.	Ground (GRD) connection

Figure 6-2 Electrical Connections

16 Electrical System

TP-6335 9/04