INSTALLATION INSTRUCTIONS

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1 TT-07 9/0 INSTALLATION INSTRUCTIONS Original Issue Date: 9/0 Model: 7/RY, 0/RY/RZ, 0/CCE/CCZ, and 8/0/.E Generator Sets Market: Residential/Commercial and Marine Subject: Ignition Module Service Kit GM789 Introduction Use ignition module service kit GM789 to replace ignition module 0 or A-0 on model 7/RY, 0/RY/RZ, 0/CCE/CEZ, and 8/0/.E generator sets. Ignition control module GM779-S and MAP module GM777-S are required to replace ignition control module 0. Use the adapter plates and hardware included in the kit to mount the new ignition module and MAP module onto the existing bracket on the unit. Refer to the Engine Service Manual, TP-, for ignition system diagnostic and test information. Marine and mobile generator sets use a different installation procedure than residential/commercial generator sets. Be sure to use the appropriate procedure for your generator set. Read the entire installation procedure and compare the kit parts with the parts list at the end of this publication before beginning installation. Note: Perform the steps in the order shown. See Figure, Figure, and Figure for exploded kit illustrations. 9. Ignition control module GM779-S. Ignition control module adapter plate GM789. Stud X-0-. Existing bracket. Screw X-0-7. Nut X-0-7. MAP module GM777-S 8. MAP module adapter plate GM Fuse (part of engine harness GM7770-S) 8 7 TT07 Figure Ignition Module Kit with the Existing Bracket for the 7/RY

2 9. Ignition control module GM779-S. Stud X-0-. Ignition control module adapter plate GM789. Existing bracket. Screw X-0-7. Nut X-0-7. MAP module GM777-S 8. MAP module adapter plate GM Fuse (part of engine harness GM7770-S) 8 TT07 Figure Ignition Module Kit with the Existing Bracket for the 0/RY/RZ 7. MAP module GM777-S. Nut X-0-. MAP module adapter plate GM789. Stud X-0-. Existing bracket. Ignition control module adapter plate GM Ignition control module GM779-S 8. Screw X Fuse (part of engine harness GM7770-S) TT07 Figure Ignition Module Kit with the Existing Bracket for the 0/CCE/CEZ and the 8/0/.E TT-07 9/0

3 Safety Precautions Observe the following safety precautions while installing the kit. WARNING. Disconnect and remove the existing ignition module.. Mount the MAP module (GM777-S) onto the MAP module adapter plate (GM789) using two studs (X-0-) and two nuts (X-0-) as shown in Figure.. Insert one stud (X-0-) through the center hole of the ignition control module adapter plate (GM789). See Figure. Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or connected equipment, disable the generator set as follows: () Move the generator set master switch to the OFF position. () Disconnect the power to the battery charger. () Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer. Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable the generator set as follows: () Place the generator set start/stop switch in the STOP position. () Disconnect the power to the battery charger, if () Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch. Installation Procedures. Models 7/RY and 0/RY/RZ Refer to Figure for model 7RY or RY generator sets. Refer to Figure for model 0/RY/RZ generator sets.. Place the generator set master switch in the OFF position.. Disconnect the power to the battery charger, if 7. Use one stud (X-0-) with a nut (X-0-) and one screw (X-0-7) with a nut (X-0-) to attach the new ignition control module (GM779-S) to adapter plate GM789 as shown in Figure. Tighten the nuts before proceeding.. Stud (X-0-). MAP module adapter plate (GM789). MAP module (GM777-S). Nuts (X-0-) Figure TT07 Mount the MAP Module onto Adapter Plate GM789. Insert this stud (X-0-) before attaching the ignition control module to the adapter plate.. Screw X-0-7. Nut X-0-0. Ignition control module GM779-S. Adapter plate GM789. Stud X-0- Figure Mount the Ignition Control Module onto Adapter Plate GM789 TT07. Disconnect the generator set engine starting battery(ies), negative (--) lead first. TT-07 9/0

4 8. Assemble the ignition control module and MAP module with their adapter plates to the existing bracket as shown in Figure. Insert one screw (X-0-7) through the MAP adapter plate. Use a nut (X-0-) on that screw and a nut on the stud that was inserted through the ignition control module adapter plate in step to secure the parts. 9. Use a nut (X-0-) to attach the fuse holder to the ignition control module adapter plate. See Figure. The fuse holder is attached to the engine wiring harness (GM7770-S). See Figure Disconnect and discard the old engine wiring harness. Connect the new engine wiring harness (GM7770-S). See Figure 7.. Check that the generator set master switch is in the OFF position.. Reconnect the generator set engine starting battery, negative (--) lead last.. Ignition module with adapter plate. Existing bracket (7/RY model shown). MAP module mounted on adapter plate GM789. Fasteners installed in previous steps Figure TT07 Attach the Modules with Adapter Plates to the Existing Bracket (7/RY model shown). Reconnect power to the battery charger, if IGNITION CONTROL MODULE (REF. GM779) CRANK POSTION SENSOR IGNITION COIL COOLANT SENDER GROUND FUSE HOLDER (0 AMP--FUSE) POSITIVE BATTERY MANIFOLD AIR PRESSURE MODULE (REF. GM777) GM7770 Figure 7 Engine Harness TT-07 9/0

5 . Models 8/0/.E and 0/CCE/CEZ RefertoFigure.. Place the generator set start/stop switch in the STOP position.. Disconnect the power to the battery charger, if. Disconnect the generator set engine starting battery(ies), negative (--) lead first.. Disconnect and remove the existing ignition module.. Mount the MAP module (GM777-S) onto the MAP module adapter plate (GM789) using two studs (X-0-) and two nuts (X-0-) as shown in Figure 8. Note: For some older model generator sets, it may be necessary to shorten the studs used in this location to avoid interference with the actuator. Cut mm (/8 in.) from the end of each stud, if necessary.. Insert one stud (X-0-) through the upper left corner (as viewed in Figure 9) of the ignition control module adapter plate (GM789). 7. Use one stud (X-0-) and one nut (X-0-) to attach plates GM789 and GM789 to the existing bracket as shown in Figure Use one nut (X-0-) to attach the new ignition control module (GM779-S) to the stud at the upper corner of plate GM789. Insert two screws (X-0-7) through the remaining ignition control module mounting holes. Secure with nuts (X-0-). See Figure 0.. MAP module GM777-S. Adapter plate GM789. Studs X-0-. Nuts X-0- Figure 8 Mount MAP Module onto Adapter Plate TT07. Insert this stud before attaching adapter plates to existing bracket.. MAP module mounted on adapter plate GM789. Existing bracket (marine model shown). Adapter plate GM789 Figure 9 Attach Adapter Plates to the Existing Bracket TT07. Bracket with MAP module. Adapter plate GM789. Ignition control module. Screw (X-0-7). Nut (X-0-). Stud Figure 0 Attach the Ignition Control Module TT-07 9/0

6 9. Use one nut (X-0-) to attach the fuse holder on the end of the new engine harness (GM7770-S) to the stud at the upper left corner of the ignition control module. See Figure. 0. Disconnect the old wiring harness from the engine and connect the new one (GM7770-S). See Figure 7.. Check that the generator set start/stop switch is in the STOP position.. Reconnect the generator set engine starting battery, negative (--) lead last. Parts List Ignition Module Kit Kit: GM789 Qty. Description Part Number Ignition control module GM779-S Harness, wiring GM7770-S Manifold, air pressure module GM777-S Plate, adapter GM789 Plate, adapter GM789 Screw, slotted round head machine X-0-7 Stud, self-clinching, 0- x. in X-0-7 Nut, flange whiz, 0- (EXP) X-0-. Reconnect power to the battery charger, if. Assembled ignition control module, MAP module, and bracket. Fuse holder (part of engine wiring harness GM7770-S). Nut (X-0-). Stud (X-0-) with nut Figure Attach the Fuse Holder TT07 TT-07 9/0

INSTALLATION INSTRUCTIONS

TT-338 /0 INSTALLATION INSTRUCTIONS Original Issue Date: /0 Model: Transfer Switches with Programmable Controllers Market: ATS Subject: Transformer Kits GM6369 (480 V) and GM6859 (600 V) Introduction A