Views For Product Manual Leap Power

LEAP POWER SOLUTIONS, LLC
888 S Greenville Ave #302, Ph: (469) 757-1787

Richardson, TX 75081 E-mail: info@leap-power.com
United States
This drawing is not to be copied, printed or to be made

otherwise available to any unauthorized person without
our specific permission. Use of the drawing not before
approval. If details not comprehensible, the drawing not
complete or with questions call Leap Power Solutions, LLC
PRODUCT MANUAL VIEWS

DUAL GENLEAP
Sheet Scale Size Drawing no. Revision
1/32 1:20 A3 005-30005 A

Source Filename:
FUEL LEVER IN START POSITION
COOLING FAN
FAN DRIVE PULLEY
INTAKE MANIFOLD
EXAUST MANIFOLD
ENGINE STOP LEVER LEVER
OIL FILLER PLUG
INJECTION PUMP
SPEED CONTROL LEVER

United States
CRANK BATTERY STARTER WATER DRAIN COCK FUEL FEED PUMP

FLYWHEEL This drawing is not to be copied, printed or to be made
(INSIDE SHROUD) otherwise available to any unauthorized person without
ALTERNATOR OIL LEVEL GAUGE OIL DRAIN PLUG our specific permission. Use of the drawing not before
OIL FILTER CARTRIDGE OIL PAN complete or with questions call Leap Power Solutions, LLC
GenLeap Generator Details PRODUCT MANUAL VIEWS

OIL PRESSURE SWITCH
SHOWN WITH DOORS REMOVED DUAL GENLEAP
2/32 1:20 A3 005-30005 A

Source Filename: C:\Leap Power\GenLeap\GenLeap Rev C\3D drawing of the fuel tank 2014-3-17\K6.514.3.17\2JKB9023
FUEL LINE FROM FUEL TANK INSTALLATION
3/8 ID FUEL LINE

FROM FUEL TANK

United States
FUEL FILTER
ON POSITION HOSE CLAMP


DUAL GENLEAP
3/32 1:20 A3 005-30005 A

FUEL RETURN HOSE INSTALLATION
HOSE CLAMP
3/16 ID FUEL RETURN LINE

United States


DUAL GENLEAP
4 / 32 1:20 A3 005-30005 A
Source Filename:
E-BOX CONTROLLER INSTALLATON
E-BOX
DO NOT RUN SYSTEM
FIRST OPEN E-BOX AND REMOVE TEST CERTIFICATE

AND SPARE PARTS BAG.
NOTE: ITEMS 42, 43, 44 AND 63 ARE SHIPPED IN A

ZIPLOCK BAG. BAG IS ATTACHED TO ONE OF THE
MOUNTING HOLES IN THE BASE WITH A CABLE TIE.
43 NYLON LOCK NUT M6
44 FLAT WASHER M6
42 VIBRADERM MOUNT M6 LEAP POWER SOLUTIONS, LLC

United States
63 TOUCH SCREEN PENCIL
MOUNTING OF E-BOX IN GENLEAP CABINET


DUAL GENLEAP
5/32 1:20 A3 005-30005 A

AS ON JAS
J1EP
J3P
J4S
J8P
J9A
J9B
J10P
JE1P

United States
TO ENGINE CONNECTIONS
PD2 TO DC DISTRIBUTION 1 MAIN BATTERY

TEMPERATURE SENSOR
E-BOX WIRING PRODUCT MANUAL VIEWS

DUAL GENLEAP
6/32 1:20 A3 005-30005 A

E-BOX WIRING TO GENERATOR
E-BOX ENGINE CONNECTOR TYPE COMMENTS

1. J10P J10S 4 POSITION 48V IN CRANK CHARGER (OPTIONAL)
2. J8P J8S 8 POSITION ALTERNATOR WIRE
3. JE1P JE1S 2 POSITION MAG SPEED SENSOR
4. J1EP J1ES 2 POSITION COOLANT SENSOR
5. J4S J4P 2 POSITION ACTUATOR - SPEED CONTROL
6. J3P J3S 2 POSITION STOP SOLENOID
7. J9A(S) J9A(P) 3 POSITION +12V, GLOW Richardson, TX 75081 E-mail: info@leap-power.com
United States
8. J9B(S) J9B(P) 3 POSITION -12V, OIL PSI
FROM TO CONNECTOR TYPE COMMENTS

REDUNDANT GENERATOR This drawing is not to be copied, printed or to be made
9. JAS JAP 4 POSITION CONNECTION VIA 003-30031 our specific permission. Use of the drawing not before
EXTENSION CABLE approval. If details not comprehensible, the drawing not
OPTIONAL 48VDC CRANK
10. J7P J7S BULLET TERMINAL CHARGES 15V OUTPUT
11 PD2(P) PD2(S) 8 POSITION DC DISTRIBUTION PRODUCT MANUAL VIEWS
12. P1 PD1 2 POSITION OUTPUT CONNECTORS DUAL GENLEAP
5 WIRE WHITE KUBOTA REGULATOR
13. RP201 (MALE) RP201 (FEMALE) 6 POSITION Sheet Scale Size Drawing no.
CRANK CHARGER
Revision
8 / 32 1:20 A3 005-30005 A
Source Filename:
COOLANT SENSOR WIRES
FROM E-BOX J1EP TO J1ES
KEEP COOLANT SENSOR WIRES
AWAY FROM EXHAUST AND MUFFLER AREA
COOLANT SENSOR

United States


DUAL GENLEAP
9 /32 1:20 A3 005-30005 A

RUBBER SEALS
CONNECTOR INSTALLED
THROUGH RUBBER SEALS
AS SHOWN

United States
GENERATOR BOTTOM ACCESS HOLES


DUAL GENLEAP
10/32 1:100 A3 005-30005 A

United States

1/1 1:1 A3 A
Cranking Battery Charger Installation
TOP
LEAP POWER CRANK

CHARGER BOARD
12V CRANK BATTERY
USE EXISTING HARDWARE TO MOUNT

CHARGER BOARD ASSEMBLY IF NOT USING
KUBOTA REGULATOR CHARGER.
KUBOTA
REGULATOR
CHARGER
Standard Charger for GEN-W4806-C011

12V CRANK BATTERY
CRANKING BATTERY LEAP POWER SOLUTIONS, LLC

TEMPERATURE SENSOR TO E-BOX 888 S Greenville Ave #302, Ph: (469) 757-1787
United States
BATT - J7S J7P

J10S
BATT + TO BATTERY
CHARGER BOARD ASSEMBLY PRODUCT MANUAL VIEWS

PART NUMBER PWA-PVCRK-A001 DUAL GENLEAP
Scale
Sheet Size Drawing no. Revision
11/32 1:100 A3 005-30005 A

AIR INTAKE FILTER
LEAP POWER CRANK

CHARGER BOARD

LEFT SIDE OF GENERATOR 888 S Greenville Ave #302, Ph: (469) 757-1787
United States
12V CRANK BATTERY


DUAL GENLEAP
12/32 1:50 A3 005-30005 A

Source Filename:
Cranking Charger Wiring Kubota Dynamo

United States


DUAL GENLEAP
13/32 1:50 A3 005-30005 A

Source Filename:
12V CRANK BATTERY INSTALLATION
12V CRANK BATTERY

BATTERY TRAY
TYPICAL BATTERY STRAP

United States


DUAL GENLEAP
14/32 1:100 A3 005-30005 A

GENERATOR CABINET INSTALLATION
1090
1909
936.00
2702.00

United States
820

830
1130
DUAL GENLEAP
15/32 1:20 A3 005-30005 A

Source Filename: C:\Leap Power\GenLeap\GenLeap Rev C\3D DRAWING OF THE FUEL TANK 2014-3-17\K6.514.3.17\Cabinet for Product Manual
22.2
22.2
2X 50.0
SIDE ACCESS FOR

CUSTOMER WIRING
AND FUEL
34.0 BOTTOM ACCESS 2X 25.0

FOR CUSTOMER
WIRING AND FUEL
FRONT VIEW
TOP VIEW
United States


DUAL GENLEAP
16/32 1:50 A3 005-30005 A

1130.00 900.00
GENERATOR
BASE OUTLINE

United States

4X 16.00 HOLES IN SLAB otherwise available to any unauthorized person without
FOR M11 FLOOR ANCHORS approval. If details not comprehensible, the drawing not
780.00
830.00 PRODUCT MANUAL VIEWS
DUAL GENLEAP
GENERATOR ANCHOR BOLT TEMPLATE Sheet Scale Size Drawing no. Revision
17/32 1:10 A3 005-30005 A

Source Filename: C:\Leap Power\GenLeap\GenLeap Rev C\Floor Template for Generator
BATTERY CABINET INSTALLATION
4X 18.00
350.00
4X 20.00 4X 20.00
130.00
130.00
350.00
BOTTOM VIEW
FLOOR ANCHORS MOUNT LEAP POWER SOLUTIONS, LLC
ON OUTSIDE FLANGE
United States
REAR VIEW

600AH NP200-12 004-40000
REV A BATTERY CABINET
DUAL GENLEAP
18 /32 1:20 A3 005-30005 A

Source Filename: C:\Leap Power\Battery Cabinet\Battery Cabinet 600 AH NP200-12\Original version from China\Final Assembly
6X 16.00 HOLES IN SLAB
FOR M11 FLOOR ANCHORS
890.00
662.00
762.00
331.00

United States
GENERATOR 936.00
BASE OUTLINE
600AH NP200-12 004-40000 REV A BATTERY CABINET

WITH OUTSIDE MOUNTING TABS ANCHOR BOLT TEMPLATE This drawing is not to be copied, printed or to be made

DUAL GENLEAP
19/32 1:5 A3 005-30005 A

Source Filename: C:\Leap Power\GenLeap\GenLeap Rev C\Floor Template for Battery Cabinet - Outside ears
BATTERY CABINET INSTALLATION
4X 18.00
350.00
130.00
4X 20.00
4X 20.00
6X 25.00
130.00
350.00
BOTTOM VIEW
FLOOR ANCHORS MOUNT
FROM INSIDE OF CABINET
United States
REAR VIEW
600AH NP200-12 004-40000 This drawing is not to be copied, printed or to be made

REV B BATTERY CABINET otherwise available to any unauthorized person without

DUAL GENLEAP
20/32 1:50 A3 005-30005 A

Source Filename: C:\Leap Power\Battery Cabinet\Battery Cabinet 600 AH NP200-12\004-40000 Final Assembly
842.00
4x 16.00 HOLES IN SLAB
FOR FLOOR ANCHORS
780.50
695.00 764.00

United States
GENERATOR
BASE OUTLINE
600AH NP200-12 004-40000 REV B BATTERY CABINET This drawing is not to be copied, printed or to be made
ANCHOR BOLT TEMPLATE otherwise available to any unauthorized person without

DUAL GENLEAP
21/32 1:5 A3 005-30005 A

Source Filename: C:\Leap Power\GenLeap\GenLeap Rev C\Floor Template for Battery Cabinet
M11 HARDWARE
FLOOR ANCHOR
16mm DIAMETER
M11 THREAD
VIEW A
TYPICAL FLOOR ANCHOR
CABINET
A
United States

CONCRETE SLAB our specific permission. Use of the drawing not before
FLOOR ANCHOR INSTALLATION complete or with questions call Leap Power Solutions, LLC

DUAL GENLEAP
Anchor Bolt Assembly for views 22/32 1:50 A3 005-30005 A

Source Filename: C:\Leap Power\GenLeap\GenLeap Rev C\Anchor Bolt Assembly for views
DC DISTRIBUTION 200A
PWR-DT200-C011
BREAKER OR FUSE MAXIMUM RATING
BAT 1 FUSE 200 A
GEN A CB 125 A
GEN B CB 125 A
LOAD 1 FUSE 200 A
LOAD 2 CB 30 A
LOAD 3 CB 30 A
LOAD 4 CB 10A / 30 A
E-BOX CB 10 A
FERRULE, 2 GA-6 GA WIRE
FERRULE, 4 GA-12 GA WIRE
RING TERMINAL 5/16

4 GA WIRE M6 NUT LEXAN SAFETY COVER
OVER REAR PANEL
United States


DUAL GENLEAP
23/32 1:50 A3 005-30005 A

Source Filename: C:\Leap Power\GenLeap\DC Dist 3U 200A\Distribution PWR-DT200-C011 Assy Rev A5
SURGE PROTECTION AND EARTH GROUNDING
SPD1-2 SURGE PROTECTOR BREAKERS

GREEN IN WINDOW IS OK. RED IN WINDOW
IS SURGE PROTECTION FAULT. BREAKER
NEEDS TO BE REPLACED
12 AWG GREEN / YELLOW WIRES

CONNECT TO EARTH GROUND

United States

SURGE PROTECTION WIRING AND GROUNDING
DUAL GENLEAP
25 / 32 1:50 A3 005-30005 A
Source Filename: C:\Leap Power\GenLeap\DC Dist 3U 200A\Distribution PWR-DT200-C011 Assy Rev A5
United States

1/1 1:1 A3 A
BATTERY CABINET INTEGRATION
DETAIL F
FAN WIRES FOR CABINET FAN

WITH BULLET CONNECTORS
REAR VIEW FRONT VIEW

MOUNT DISTRIBUTION INTO CABINET Richardson, TX 75081 E-mail: info@leap-power.com
WITH M5 X 10mm PAN HEAD SCREWS United States


DUAL GENLEAP
DETAIL F 26/32 1:20 A3 005-30005 A
Source Filename: C:\Leap Power\Battery Cabinet\Battery Cabinet 600 AH NP200-12\004-40000 Final Assembly
United States


DUAL GENLEAP
27/32 1:20 A3 005-30005 A

Source Filename:
REQUIRED TOOL LIST
TOOL USED ON
HAMMER DRILL AND 12mm MASONRY BIT
SOCKET WRENCH
INSTALLING FLOOR ANCHORS FOR BATTERY CABINET
SOCKET WRENCH EXTENSION
M11 HEX SOCKET
PHILLIPS SCREWDRIVER MOUNTING DC DISTRIBUTION INTO BATTERY CABINET WITH M4 SCREWS
SOCKET WRENCH, M6 HEX SOCKET CONNECTIONS TO +48 POSITIVE BUS
4 GA FERRULE CRIMPER, FLAT HEAD SCREWDRIVER CONNECTIONS TO UIK 35 TERMINAL BLOCK
12 GA FERRULE CRIMPER, FLAT HEAD SCREWDRIVER CONNECTIONS TO UIK 16 TERMINAL BLOCK
CONNECTOR PIN REMOVAL TOOL REMOVING CONNECTOR TO PASS WIRES THROUGH CABINET OPENINGS.
PHILLIPS SCREWDRIVER REMOVING TERMINALS FROM ANDERSON CONNECTORS

United States


DUAL GENLEAP
28/32 1:50 A3 005-30005 A

Source Filename:
HOW TO REMOVE CRIMPED WIRES FROM HOUSING HOW TO INSTALL CRIMPED WIRES INTO HOUSING
FRONT VIEW OF CONNECTOR WITHOUT CONTACTS
INSERT EACH CRIMPED WIRE INTO HOUSING UNTIL

IT LOCKS INTO PLACE IN THE HOUSING.
NOTE SPRING LOCATED
IN HOUSING
REAR VIEW OF CONNECTOR WITHOUT CONTACTS
COMPLETED CONNECTOR ASSEMBLY
INSERT SMALL SCREWDRIVER TO ONE SIDE OF

CONTACT AND DEPRESS SPRING. WTIH THE OTHER HAND
PULL CRIMPED WIRE FROM HOUSING FROM REAR. LEAP POWER SOLUTIONS, LLC
United States


DUAL GENLEAP
CRIMPED WIRES AND CONTACTS ARE REMIOVED
29/32 1:50 A3 005-30005 A

Source Filename:
OIL FILL PLUG
ENGINE OIL CHECK OIL WITH DIPSTICK
FULL OIL MARK
ADD OIL MARK
OIL OK BETWEEN MARKS
Coolant Change
Lubricating Oil Lubricating Oil Coolant Type Coolant Capacity
Lubricating Oil Type Schedule
Capacity Change Schedule
50% Long Life Coolant 2.8 Liters Every Two Years
Above 25 C First oil change +50% Clean Soft Water
SAE-30 or SAE10W-30, 2.5 Liters after 50 hours
SAE15W-40 Operation LEAP POWER SOLUTIONS, LLC
Additional oil Richardson, TX 75081 E-mail: info@leap-power.com
0 C - 25 C changes every United States
SAE-20 or SAE10W-30, 200-400 hours of
SAE15W-40 operation
Below 0 C
SAE10 or SAE10W-30,
SAE15W-40 This drawing is not to be copied, printed or to be made

DUAL GENLEAP
30/32 1:50 A3 005-30005 A

Source Filename:
RADIATOR COOLANT
RADIATOR ADD COOLANT
COOLANT
OVERFLOW
BOTTLE

United States


DUAL GENLEAP
31/32 1:50 A3 005-30005 A

Source Filename: $PRPSHEET:{SW-Folder Name}$PRPSHEET:{SW-File Name}
-BAT
4 AWG 72" long
-VE FAN
4 AWG, 72" long
P1 PD1A +VE FAN
PD1B
4AWG 1 2 1 2 1 2 +BAT
+48VDC BUS
48" Long -48VDC TB
EARTH
P1 GROUND
REAR OF DC DISTRIBUTION PD4

MAIN BAT TEMP
60" long PD2 PD3 60" long cable
GEN A DC DISTRIBUTION
AS AP
+BAT
PD4 + - + - + - Customer
Equipment
3S4 3S3 3S2
4AWG DualGen
Connection -BAT -BAT
48" Long PD2
Cable +BAT
+ - + - + - -BAT
Standard 60" 3S1 2S4 2S3
length *
-BAT
+BAT 888 S Greenville Ave #302, Ph: (469) 757-1787
+ - + - + - Richardson, TX 75081 E-mail: info@leap-power.com
United States
AS BP 2S2 2S1 1S4
60" long cable

-BAT
GEN B + - + - + - This drawing is not to be copied, printed or to be made
1S3 1S2 1S1 our specific permission. Use of the drawing not before
MAIN BAT TEMP
Dual GenLeap Wiring Diagram
24 AWG
*All optional lengths available from Factory. Above example is for co-located cabinets. Sheet Scale Size Drawing no. Revision
PD1A, PD1B, BAT Temp, and distribution connections to batteries and load will be field installed by the customer. Not supplied. 32/32 1:20 A3 005-30005 A
Source Filename: C:\Leap Power\Battery Cabinet\Battery Cabinet 600 AH NP200-12\Battery Cabinet Block Diagram

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LEAP POWER SOLUTIONS, LLC

888 S Greenville Ave #302, Ph: (469) 757-1787

This drawing is not to be copied, printed or to be made

PRODUCT MANUAL VIEWS

1/32 1:20 A3 005-30005 A

ENGINE STOP LEVER LEVER

OIL FILLER PLUG

SPEED CONTROL LEVER

LEAP POWER SOLUTIONS, LLC

CRANK BATTERY STARTER WATER DRAIN COCK FUEL FEED PUMP

GenLeap Generator Details PRODUCT MANUAL VIEWS

2/32 1:20 A3 005-30005 A

3/8 ID FUEL LINE

LEAP POWER SOLUTIONS, LLC

This drawing is not to be copied, printed or to be made

PRODUCT MANUAL VIEWS

3/32 1:20 A3 005-30005 A

3/16 ID FUEL RETURN LINE

LEAP POWER SOLUTIONS, LLC

This drawing is not to be copied, printed or to be made

PRODUCT MANUAL VIEWS

FIRST OPEN E-BOX AND REMOVE TEST CERTIFICATE

NOTE: ITEMS 42, 43, 44 AND 63 ARE SHIPPED IN A

43 NYLON LOCK NUT M6

42 VIBRADERM MOUNT M6 LEAP POWER SOLUTIONS, LLC

This drawing is not to be copied, printed or to be made

PRODUCT MANUAL VIEWS

5/32 1:20 A3 005-30005 A

LEAP POWER SOLUTIONS, LLC

PD2 TO DC DISTRIBUTION 1 MAIN BATTERY

E-BOX WIRING PRODUCT MANUAL VIEWS

6/32 1:20 A3 005-30005 A

E-BOX ENGINE CONNECTOR TYPE COMMENTS

FROM TO CONNECTOR TYPE COMMENTS

LEAP POWER SOLUTIONS, LLC

This drawing is not to be copied, printed or to be made

PRODUCT MANUAL VIEWS

9 /32 1:20 A3 005-30005 A

LEAP POWER SOLUTIONS, LLC

GENERATOR BOTTOM ACCESS HOLES

This drawing is not to be copied, printed or to be made

PRODUCT MANUAL VIEWS

10/32 1:100 A3 005-30005 A

This drawing is not to be copied, printed or to be made

Sheet Scale Size Drawing no. Revision

LEAP POWER CRANK

12V CRANK BATTERY

USE EXISTING HARDWARE TO MOUNT

Standard Charger for GEN-W4806-C011

CRANKING BATTERY LEAP POWER SOLUTIONS, LLC

BATT - J7S J7P

CHARGER BOARD ASSEMBLY PRODUCT MANUAL VIEWS

11/32 1:100 A3 005-30005 A

LEAP POWER CRANK

LEAP POWER SOLUTIONS, LLC

This drawing is not to be copied, printed or to be made

PRODUCT MANUAL VIEWS

12/32 1:50 A3 005-30005 A

LEAP POWER SOLUTIONS, LLC

This drawing is not to be copied, printed or to be made

PRODUCT MANUAL VIEWS

13/32 1:50 A3 005-30005 A

12V CRANK BATTERY