Generac Power Systems quietpact 85d Owner'S Manual Download

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080825

SWITCH RKR DPST

0C45400ST03

COVER ENG CONTRL BOX

0C1457

HOURMETER

032300

HOLDER FUSE

055920

SWITCH SPST SPADE PNL MNT

043181

SCREW PHM M3-0.5 X 10MM

022159

WASHER LOCK #4

022676

FUSE 15A X AGC15

0G7396

DECAL, ENGINE CONTROL BOX

0C7341

BOOT/NUT,PRE-HT SWCH

049226

WASHER LOCK M5

0C7340

BOOT, CIRCUIT BREAKER

0G7845

HARN CONTROL PANEL 1.1L G15 RV

051714

NUT HEX M3-0.5 G8 YEL CHR

0C44760ST03

BOX, ENG CONTROL RV

0C50960ST03

FRAME, CONTROL PANEL

0D4372

PLUG, OIL FILL

0F2664K

ASSY, DIPSTICK W/ TWIST 1.1L

0C5210

HOSE 3/8 ID LOW PRES OIL/WATER (5.31”LG)

0C5209

HOSE 1ID LOW PRES OIL/WATER (9.84”LG)

0C7649

CLAMP HOSE .38-.87

057824

CLAMP HOSE #16 .87-1.50

0C3992

SCREW HHTT M4-0.7 X 16 BP

022985

WASHER FLAT #6 ZINC

084135

RUBBER GROMMET,WIRES

0C6440

GASKET, ENGINE CNTRL

0G6873

CB 0040A 2P

049813

NUT HEX M6 X 1.0 G8 YEL CHR

076040

SCREW PPHM M5-0.8 X 16

051713

WASHER FLAT M5

022097

WASHER LOCK M6-1/4

036900

SCREW PPHM #6-32 X 1/4

0D9283

GASKET, HOURMETER

0D9391

GASKET ROCKER SWITCH VPS

022155

WASHER LOCK #6

Summary of Contents for quietpact 85d

Page 1: ...hicle Generator ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION DEADLY EXHAUST FUMES NEVER operate the generator set with the vehicle inside any garage or other enclosed area ONLY use OUTSIDE far away from windows doors and vents SAVE this Manual Provide this manual to any operator of the generator ...

Page 2: ... Maintenance 13 3 7 Cooling System 14 3 8 Engine Coolant 14 3 9 Major Service Manual 14 3 10 Drive Belt 14 3 11 Exercising the Generator 14 3 12 Out of Service Procedure 15 3 13 Service Schedule 16 Part II Installation Instructions Safety Rules 18 General Information 20 1 1 Purpose and Scope of the Manual 20 1 2 Safety 20 1 3 Standards Booklets 20 1 4 Equipment Description 20 1 5 Generator Engine ...

Page 3: ...s equipment and for the safety of all vehicle occupants Before using this equipment we strongly recommend that the operator read this manual and thoroughly understand all instructions We also strongly recommend instructing other occu pants in the vehicle to properly start and operate the generator This prepares them to operate the equipment in case of an emergency CONTENTS This manual contains per...

Page 4: ...detector The exhaust system must be installed in accordance with the genset instal lation manual Make sure there is ample fresh air when operat ing the genset in a confined area The engine exhaust fumes contain carbon monoxide which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death Thus the exhaust system must be installed properly in...

Page 5: ...de Article 551 and NFPA 1192 latest edition Standard for Recreational Vehicles along with all applicable codes standards laws and regulations Adhere strictly to local state and federal electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instruct...

Page 6: ...ICATION 1 2 Pole 40 amp Circuit Breaker 2 Hourmeter 3 Oil Fill Opening and Plug 4 Oil Dipstick 5 Engine Start Stop Switch 6 15 amp Fuse 7 Engine Preheat Switch 8 Fuel Filter 9 Air Filter 10 Oil Filter 11 Starter Motor 12 Preheat Contactor 13 Starter Contactor 14 Radiator 15 Coolant Recovery Tank 16 Muffler 17 Battery Connections 18 Fuel Connections 19 Alternator 20 Fuel Pump 21 Centrifugal Cooling...

Page 7: ...ts and amps multiply volts times amps to obtain watts volts x amps watts Some electric motors require more watts of power or amps of current for starting than for continuous operation 1 3 SAFETY Before attempting to use the generator set carefully read the Safety Rules section of this manual Comply strictly with these rules to prevent accidents and damage to equipment and or property We suggest co...

Page 8: ... ant always add the recommended 50 50 mixture DO NOT remove the radiator pressure cap while the engine is hot otherwise serious burns from boiling liquid or steam could result Ethylene glycol base antifreeze is poisonous DO NOT use mouth to siphon coolant from the radiator recovery bottle or any contain er Wash hands thoroughly after handling NEVER store used antifreeze in an open con tainer becau...

Page 9: ...START posi tion Release the switch when the engine starts To stop an operat ing engine press and hold the switch in the STOP position until the engine shuts off The switch s center position is the RUN position 2 1 3 FUSE The 15 amp fuse protects the engine s DC control circuit against electrical overload If the fuse element has melted open due to overloading the engine cannot be cranked If the fus...

Page 10: ...kup tube Such an arrangement causes the generator engine to run out of fuel while adequate fuel for the vehicle engine remains in the tank 2 3 4 COOLANT LEVEL Check the engine coolant level prior to initial use and at recom mended intervals Refer to the Coolant and Engine Coolant sections for procedures and recommendations 2 3 5 COOLING AND VENTILATING AIR Air inlet and outlet openings in the gene...

Page 11: ...tely after running under load This can overheat and damage the engine and or gen erator 3 Press and hold the Start Stop switch in the STOP position until the engine shuts off 2 6 APPLYING LOADS TO GENERATOR When applying electrical loads to the generator observe these guidelines Before applying electrical loads let the generator stabilize and warm up for a minute or two DO NOT overload the generat...

Page 12: ...e is regulated at 120 volts voltage to frequency ratio is 2 to 1 Figure 2 3 Solid state Voltage Regulator The voltage regulator also incorporates a voltage surge protection circuit This circuit prevents troublesome surges in the generator AC output voltage Voltage surge is a common cause of damage to electronic equipment 2 8 ADDITIONAL INFORMATION 2 8 1 ATTENTION REQUIRED AFTER SUBMERSION If the r...

Page 13: ...un the engine until it is thoroughly warmed up for at least five minutes then shut OFF the engine 2 Immediately after the engine shuts OFF remove the front service door located beneath the unit by retracting the two latches and pivoting the door downward If space allows remove the front panel by removing the four retaining bolts Be careful not to let the panel fall 3 Remove the air filter see Serv...

Page 14: ... 250 mm below the rear floor pan additional piping may be added to direct the muffler exhaust away from the cooling air discharge flow beneath the unit 6 Start and run the engine for approximately 15 minutes 7 Shut down the engine and allow the piping to cool 8 Remove the 3 8 NPT coupling and piping 9 Apply a graphite base anti seize compound to the cleanout pipe threads 10 Reinstall the hex pipe ...

Page 15: ...ccording to the required precau tions Keep unauthorized personnel away from batteries Damage will result if the battery connections are made in reverse DO NOT dispose of the battery in a fire The battery is capable of exploding Storage bat teries release explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite ...

Page 16: ...y contain er Wash hands thoroughly after handling NEVER store used antifreeze in an open con tainer because animals are attracted to the smell and taste of antifreeze even though it is poisonous to them Do not use any chromate base rust inhibitor with ethylene glycol base antifreeze other wise chromium hydroxide green slime will form and cause overheating Engines that have been operated with a chr...

Page 17: ...distilled water DO NOT USE TAP WATER IN THE BATTERY Recharge the battery to 100 percent state of charge or if defective replace the battery 3 Clean and wipe the entire generator 4 Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incorrectly 5 Turn OFF all electrical loads Add fuel if necessary and then start the engine 6 Allow the unit to warm up thorough...

Page 18: ...EVERY 100 H M Coolant level X AFTER 25 H D BEFORE USE Coolant X EVERY 500 H Y Enclosure louvers X X EVERY 250 H 6 M EXHAUST Exhaust system X EVERY 100 H M Retorque Exhaust Manifold X EVERY 750 H Clean out Muffler Spark Arrestor X EVERY 150 H Y BATTERY Electrolyte fluid level X AFTER 25 H W Charge and condition X R X W EVERY 250 H 6 M FAN ALTERNATOR BELTS Tension and condition X R EVERY 750 H ENGIN...

Page 19: ...PART II INSTALLATION INSTRUCTIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION ...

Page 20: ...tallation initial startup and maintenance of this equipment is carried out by an Authorized Service Dealer The engine exhaust fumes contain carbon monoxide which can be DEADLY This dangerous gas if breathed in sufficient con centrations can cause unconsciousness or even death This exhaust system must be installed properly in strict compliance with applicable codes and standards Following installat...

Page 21: ...electricity resulting in electric shock or may get caught in moving components causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Adm...

Page 22: ...es replac es ANSI A119 2 NFPA 501C available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 2 NFPA 70 NFPA Handbook of the National Electric Code available same as Item 1 3 ANSI RVIA EGS 1 Engine Generator Sets for Recreational Vehicle Safety Requirements available from the Recreational Vehicle Industry Association 1896 Preston White Drive Reston VA 22090 4 Califor...

Page 23: ...21 Figure 1 2 Major Features and Dimensions Drawing 0G6806 A General Information ...

Page 24: ...train the generator set should consist of at least two horizontal beams These beams should consist of a 1 1 2 inch square 11 gauge steel tubing OR b 1 1 2 inch 11 gauge angle iron The generator can be installed so that it sits on top of the horizontal support tubing if the vehicle design permits Another method is to suspend the generator below the horizontal support tubing by means of suitable str...

Page 25: ...ucted of any material The manufacturer recommends that the compartment be constructed of 1 2 inch thick plywood not strandboard with the floor made of a double thickness of 1 2 inch plywood having the grain of the wood at cross section for added strength Figure 2 3 Figure 2 3 Typical Compartment Construction If constructing a compartment line the exterior underside of the compartment floor with 26...

Page 26: ...plosive vapors and liq uids and will become a fire hazard Using a combination of sound insulating materials can often reduce noise more effectively than a single material For example a sheet of lead or visco elastic material along with a layer of other acoustical material is more effective than when a single material is used 2 2 3 ACOUSTICS For additional noise abatement the installer may wish to ...

Page 27: ...ems Figure 2 6 Engine exhaust and cooling air outlets Generator cooling air inlet and front service door Four holes for passage of generator mounting bolts See the Generator Restraint section Rear service door Fuel lines and exhaust piping must not pen etrate into the vehicle living area Figure 2 6 Compartment Floor Cutout Installation ...

Page 28: ...erator and across the radiator then discharges that air out the bottom see Figure 2 7 Figure 2 7 Airflow Through Engine Generator 2 3 2 COOLING AIR INLET OPENINGS The minimum size of the air inlet opening whether the generator is housed in a conventional compartment or not is at least 150 square inches 975 cm2 see Figure 2 8 This rule applies whether inlet air is brought in through an opening in t...

Page 29: ...187 5 square inches 1 218 75 cm2 2 3 4 TESTING THE INSTALLATION The manufacturer recommends testing the installation to be sure adequate cooling airflow is available to the unit before placing the unit into service If the unit shows signs of overheating enlarge the air openings Never place a unit into service until absolutely certain that cooling and ventilation is adequate NOTE The installation m...

Page 30: ...ting periods DO NOT tee the generator fuel supply line into the vehicle engine fuel supply line If this is done the generator will be starved of fuel when both engines are operating at the same time Also while the vehicle engine is not running generator operation may drain the vehicle engine supply line making it dif ficult to start the vehicle engine 2 4 2 GENERATOR FUEL SUPPLY LINES Rigid Fuel L...

Page 31: ...ling an unapproved muffler or an unapproved exhaust system part or modifying an exhaust system in any way that might cause a hazard is liable for any damage injury or warranty expense that might be caused by such unap proved installation or modification 2 5 2 EXHAUST SYSTEM SAFETY Maintain a clearance of at least 3 inches 76 mm between exhaust system parts and any combustible material such as wood...

Page 32: ...utral conductors are used they must be the same size as other leg wires Route power supply conductors from generator AC output leads T1 red T2 white T3 black and the green ground wire through approved flexible conduit to the electrical junction box on the compartment wall If a flexible metal conduit is used between the generator and the compartment junction box the conduit end that terminates at t...

Page 33: ...block Reroute stator lead 33 from the line side terminal of CB1A renamed as CB1 in Figure 2 16 to the ground stud location previously occupied by stator lead wire 44 2 Move smaller gauge 18 AWG wire labeled 11 not shown from the top of CB1 to the top of CB1A Renumber this wire 44 3 Reroute stator lead wire 44 removed in step 1 to the line side terminal on CB1 4 Renumber ground wire 44 located betw...

Page 34: ...s Contact the manufacturer or dealer for recommendations 2 6 7 ISOLATING DIFFERENT POWER SOURCES Connections from the junction box must terminate in a double pole double throw transfer switch Figure 2 17 An alternate method for isolating different power sources includes using an isolating receptacle Figure 2 18 Whichever method is used be certain that both power sources are NOT connected at the sa...

Page 35: ...tarter and glow plugs Select battery cables based on a cable length and b prevail ing ambient temperatures Generally the longer the cable and the colder the weather the larger the cable size must be as shown in the chart CABLE LENGTH in Feet meters CABLE SIZE 0 to 10 0 to 3 2 11 to 15 3 4 to 4 5 0 16 to 20 4 5 to 6 000 For warm weather use No 2 cable up to 20 feet 2 7 3 BATTERY CABLE CONNECTIONS 1...

Page 36: ...t is electrically conductive and corrosive The following procedures are to be observed Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water If the electrolyte contacts the eyes immediately flush eyes thoroughly with water and seek medical attention Spilled electrolyte is to be washed down with an acid neutralizing agent A common pr...

Page 37: ...nal temperatures to stabilize 4 Carefully inspect the engine generator for fuel oil and exhaust system leaks Before proceeding to the next step correct any leakage immediately 5 When all tests and adjustments at no load are completed apply electrical loads and check for proper operation under load See the Testing Under Load section Run the unit at least 30 minutes with loads applied 6 Turn off all...

Page 38: ...al code requirements and all National Electrical Codes Junction box is properly installed Wiring meets all standards All connections are correct Conduit is properly installed and sealed Generator is properly bonded to the vehicle BATTERY INSTALLATION Recommended battery is installed Recommended cables are installed Cables are clean and tight Cables are connected properly Proper ventilation is prov...

Page 39: ... Plugged fuel filter or fuel line 3 Clean or replace fuel filter or line 4 Water in fuel 4 Drain fuel system and refill 5 Improper preheat 5 Preheat unit The engine starts but shuts 1 Low engine oil level 1 Check oil and add oil as needed down when the Start Stop 2 Overheated engine 2 Check cooling system for leaks switch is released 3 Defective Start Stop Switch 3 Disconnect Remote Harness on pan...

Page 40: ...38 Electrical Data Schematic 120 240 VAC Output Drawing No 0G7332 C ...

Page 41: ...39 Schematic 120 240 VAC Output Drawing No 0G7332 C Electrical Data ...

Page 42: ...40 Electrical Data Schematic 120 240 Dual Voltage Drawing No 0G7333 D ...

Page 43: ...41 Schematic 120 240 Dual Voltage Drawing No 0G7333 D Electrical Data ...

Page 44: ...42 Electrical Data Schematic 120 240 Dual Voltage Drawing No 0G7333 D ...

Page 45: ...43 Schematic 120 240 Dual Voltage Drawing No 0G7333 D Electrical Data ...

Page 46: ...44 Exploded Views Parts Lists Engine Alternator Starter Assy Drawing No 0G7350 B ...

Page 47: ... 0C7933 1 GUARD FLYWHEEL 25 068485 4 SCREW HHC M12 1 25 X 20 G8 8 26 051769 6 WASHER LOCK M12 27 0C4537 2 ENGINE BRACKET 28 022304 2 WASHER FLAT 1 2 ZINC 29 023316 1 SCREW HHC 1 2 13 X 4 G5 30 049451 1 FENDER WASHER 7GA 31 042633 1 SCREW HHC 3 8 24 X 1 G5 32 046526 11 WASHER LOCK M10 33 052212 6 SCREW HHC M10 1 25 X 25 G8 8 34 069673J 1 NUT LOCK FLG 5 16 18 35 051756 5 SCREW HHC M10 1 5 X 20 G8 8 ...

Page 48: ...46 Exploded Views Parts Lists Enclosure Drawing No 0G7351 B ...

Page 49: ...ELECTRICAL ACCESS 15 0C6362 1 GASKET COVER ELECT 16 0D7176 33 WASHER SELF LOCKING 1 DIA 12GA 17 0G4933 57 SCREW SWT 1 4 20 X 5 8 W W 18 0C50960ST03 1 FRAME CONTROL PANEL BLACK 19 0C7023 1 DECAL BATTERY 20 0C7024 1 DECAL RADIATOR CAP 21 0C7025 1 DECAL REMOTE 22 0C7026 1 DECAL COOLANT 23 0C7027 1 DECAL FUEL RETURN SUPPLY 24 0C7028 1 DECAL OIL FILL LEVEL 25 0C7029 1 DECAL LIFTING LUG 26 0C7030 1 DECA...

Page 50: ...48 Exploded Views Parts Lists Cooling System Drawing No 0G7352 B ...

Page 51: ...49A 1 V BELT 61 0 GREEN 27 0C5108 1 FILLER NECK ASY RAD 28 0C6236 1 HOSE TEE 29 0C7384 1 HOSE COUPLING 30 0C5543 1 HOSE RADIATOR LWR 31 0C4460 1 HOSE WATER PUMP LWR 32 0F4352 1 COOLANT HOSE TIER 2 DIESEL 33 0C5544 1 HOSE LWR INTERMEDIAT 34 086133A 8 CLAMP HI TORQUE 1 1 75 35 035473 2 CLAMP HOSE 12 50 1 25 36 050968 1 HOSE COOL 3 4 ID 20R3 28 3 LG 37 059981 1 SCREW HHC M10 1 5 X 30 C10 9 38 046526 ...

Page 52: ...50 Exploded Views Parts Lists Fuel Electrical Systems Drawing No 0G7355 A ...

Page 53: ...P HOSE 38 87 13 047411 1 SCREW HHC M6 1 0 X 16 C8 8 14 0C7968 1 NUT HEX JAM 3 8 16 BRASS 15 022237 1 WASHER LOCK 3 8 16 075763 3 BOOT BATTERY CABLE 17 075763A 3 BOOT BATTERY CABLE 18 023484F 2 BUSHING SNAP SB 1000 12 19 022127 1 NUT HEX 1 4 20 STEEL 20 0536210201 1 ASSY WIRE 13 22 00 21 0536210197 1 ASSY WIRE 16 11 50 22 0A2053 1 SCREW HHC M6 1 0 X 65 C8 8 23 0742600158 1 WIRE ASSY GROUND DIESEL R...

Page 54: ...52 Exploded Views Parts Lists Customer Controls Assy Drawing No 0G7356 B ...

Page 55: ...0 5 G8 YEL CHR 15 0C44760ST03 1 BOX ENG CONTROL RV 16 0C50960ST03 1 FRAME CONTROL PANEL 17 0D4372 1 PLUG OIL FILL 18 0F2664K 1 ASSY DIPSTICK W TWIST 1 1L 19 0C5210 1 HOSE 3 8 ID LOW PRES OIL WATER 5 31 LG 20 0C5209 1 HOSE 1ID LOW PRES OIL WATER 9 84 LG 21 0C7649 2 CLAMP HOSE 38 87 22 057824 2 CLAMP HOSE 16 87 1 50 23 0C3992 4 SCREW HHTT M4 0 7 X 16 BP 24 022985 4 WASHER FLAT 6 ZINC 25 084135 1 RUB...

Page 56: ...1 1 Rubber Tape 1 8 x 26 6 LG 7 0C7857 4 Grommet 1 8 x 13 32 8 070936E 4 Vibration Mount 9 0C6721 1 Gasket Cleanout 10 0C6722 1 Plate Cleanout 11 042907 8 HHCS M8 1 25 x 16 12 022129 8 Washer Split Lk M8 ITEM PART NO QTY DESCRIPTION 13 022097 3 Washer Split Lk 1 4 M6 14 043146 2 HHCS M6 1 00 x 10 15 0C7561 1 Carriage Bolt 3 8 16 x 55mm 16 0A4456 1 3 8 Special Lock Washer 17 0C7968 3 Hex Nut 3 8 16...

Page 57: ...6 11 022264 2 WASHER LOCK 8 M4 12 051715 2 NUT HEX M4 0 7 G8 YEL CHR 13 040213 4 PCB SUPPORT SNAP IN 1 4 14 049441 1 SCREW HHTT 6 32 X 3 8 CZ 15 0G7440 1 HARNESS AC OUTPUT ITEM PART NO QTY DESCRIPTION 16 0G7846 1 HARN ENG CONTROL PANEL 1 1L RV 17 0C3992 4 SCREW HHTT M4 0 7 X 16 BP 18 0C7022 1 DECAL CUSTOMER CONNECTION 19 038150 4 WASHER FLAT 8 ZINC 20 0C6359 1 GASKET ELECT ENCLOS 21 049813 6 NUT H...

Page 58: ...ST FLEX 11 0C6243 1 GASKET EXH OUTLET 12 0C6244 1 PLATE EXH OUTLET 13 051730 2 SCREW HHC M8 1 25 X 60 C8 8 14 071956 2 WASHER FLAT M8 ITEM PART NO QTY DESCRIPTION 15 022129 10 WASHER LOCK M8 5 16 16 045771 5 NUT HEX M8 1 25 G8 CLEAR ZINC 17 058443 3 SCREW CRIMPTITE 1 4 20 X 5 8 18 0C5105 1 BRACKET SUPPORT 19 022145 5 WASHER FLAT 5 16 M8 ZINC 20 039253 2 SCREW HHC M8 1 25 X 20 C8 8 21 043107 4 SCRE...

Page 59: ...EM PART NO QTY DESCRIPTION 1 0F28730164 1 CAMSHAFT ASSEMBLY 2 0709390233 1 CAMSHAFT GEAR 3 0709390195 1 KEY 4 0709390234 1 GEAR 5 0709390235 3 SPACER 6 0709390236 1 BALL BEARING 7 0709390237 1 SLIDER 8 0709390238 1 PLATE 9 0709390241 1 BOLT 10 0709390240 1 BOLT ...

Page 60: ...T WASHER 3 0709390252 1 SPRING 4 0709390253 1 ROTOR 5 0709390254 1 OIL PUMP COVER 6 0709390255 AR 0 10MM SHIM 0709390532 AR 0 15MM SHIM 0709390533 AR 0 20MM SHIM 0709390258 AR 0 50MM SHIM 7 0709390259 1 SPRING 8 0709390260 1 COLLAR 9 0709390261 1 SNAP RING 10 0709390262 1 FRONT PLATE 11 0F28730165 1 GASKET 12 0F28730166 3 BOLT AR AS REQUIRED ...

Page 61: ...390151 3 EXHAUST VALVE 7 0709390153 3 VALVE GUIDE SEAL INTAKE 8 0709390154 6 SPRING 9 0709390155 6 RETAINER 10 0709390156 12 KEY 11 0709390152 3 VALVE GUIDE SEAL EXHAUST ITEM PART NO QTY DESCRIPTION 12 0G23210108 6 CAP 13 0G23210109 1 HEAD GASKET 1 2mm THICK 0G23210110 1 HEAD GASKET 1 3mm THICK 14 0F28730125 11 HEAD BOLT 15 0F28730126 3 HEAD BOLT 16 0709390162 2 LIFTING EYE 17 0G23210111 2 BOLT 18...

Page 62: ...T 8 0F28730114 1 GASKET OIL PAN 9 0F28730167 1 O RING 10 0709390245 1 TUBING 11 0709390246 1 SUCTION FILTER 12 0F28730168 2 BOLT 13 0F28730142 1 GASKET ITEM PART NO QTY DESCRIPTION 14 0F28730143 1 HEAD COVER 15 0F28730144 1 OIL STOPPER 16 0709390186 1 SCREEN 17 0F28730145 4 SCREW 18 0F28730146 3 GASKET 19 0F28730147 3 CAP NUT 20 0709390188 1 CAP 21 0709390189 1 O RING 22 0F28730148 1 BREATHER VALV...

Page 63: ...F28730174 1 RUBBER HOSE 7 0F28730175 2 CLAMP 8 0709390266 1 PLUG 9 0F28730176 1 SEAL WASHER 10 0D2791 1 THERMO SWITCH 11 0F28730178 1 GASKET ITEM PART NO QTY DESCRIPTION 12 0G23210154 1 THERMOSTAT CASE 13 0F28730180 4 BOLT 14 0F28730181 1 THERMOSTAT 16 0F28730183 1 THERMOSTAT COVER 17 0F28730184 1 GASKET 18 0F28730202 1 BOLT 19 0709390247 1 PULLY 20 0F28730217 1 PLATE 21 0F28730218 4 BOLT ...

Page 64: ...5mm U S BUSHING 0G23210103 1 0 50mm U S BUSHNG 12 0F28730110 1 BEARING 13 0709390113 1 EXPANSION PLUG 14 0709390114 1 BALL BEARING 15 0709390131 1 SNAP RING 16 0709390115 2 DOWEL PIN ITEM PART NO QTY DESCRIPTION 17 0709390116 2 DOWEL PIN 18 0709390117 2 DOWEL PIN 19 0709390118 2 SPRING PIN 20 0F28730111 2 STUD BOLT 21 0F28730112 1 STUD BOLT 22 0F28730113 1 STUD BOLT 23 0G23210104 1 OIL SEAL 24 070...

Page 65: ...9390174 6 NUT 6 0F28730131 1 ROCKER ARM SHAFT 7 0709390177 2 SPRING 8 0F28730132 2 BOLT 9 0709390181 3 STUD BOLT 10 0F28730133 3 NUT 11 042574 1 ADAPTER ITEM PART NO QTY DESCRIPTION 12 0G23210132 1 OIL PIPE 13 0F28730146 4 GASKET 14 0709390165 2 EYE BOLT 15 0F28730137 1 GASKET 16 0F28730138 1 O RING 17 0F28730139 4 SHIM 18 0F28730140 1 PLUG 19 0F28730141 1 SCREW 20 028916 1 90 STREET ELBOW 21 0A85...

Page 66: ...ING 11 0G23210120 3 STANDARD UPPER METAL BEARING 0G23210121 3 0 25 STANDARD UPPER METAL BEARING 0G23210122 3 0 50 STANDARD UPPER METAL BEARING ITEM PART NO QTY DESCRIPTION 12 0709390198 4 BOLT 13 0G23210124 2 BOLT 14 0G23210125 2 BOLT 15 0G23210126 3 STANDARD PISTON RING KIT 16 0G23210127 3 STANDARD PISTON KIT WITH RINGS 17 0709390217 3 PISTON PIN 18 0709390218 6 SNAP RING 19 0G23210128 3 CONNECTI...

Page 67: ...3 NUT 16 0F28730191 1 SHAFT 17 0F28730192 2 O RING 18 0709390301 1 SNAP RING 19 0709390302 1 BRACKET 20 0F28730218 2 BOLT 21 071944 1 BOLT ITEM PART NO QTY DESCRIPTION 22 0709390304 1 ARM 23 0709390305 1 SNAP RING 24 0F28730194 1 O RING 25 0709390307 1 SPRING 26 0709390308 1 WASHER 27 0G23210149 2 NUT 28 0709390310 1 STOP LEVER 29 0F28730195 5 BOLT 30 0F28730180 3 BOLT 31 0F28730150 2 BOLT 32 0221...

Page 68: ...RETURN PIPE 8 0G23210135 1 COMPLETE INJECTION PIPE 9 0G23210136 1 COMPLETE INJECTION PIPE 10 0G23210137 1 COMPLETE INJECTION PIPE 11 0G23210138 4 COMPLETE CLAMP 12 0G23210139 2 BOLT ITEM PART NO QTY DESCRIPTION 13 0F28730173 2 NUT 14 0F28730209 3 GLOW PLUG 15 0F28730210 3 NUT 16 0G23210140 1 CONNECTOR 17 0F28730214 1 GASKET 18 0709390264 2 BOLT 19 0709390343 1 SEAL WASHER 20 0F28730212 1 SCREW 21 ...

Page 69: ...ITTING 8 074808 1 FUEL BLEED FITTING 9 052233 2 1 8 NPT TEE BRASS 10 039450 2 1 8 NPT x 3 16 90 DEG BARBED FITTING 11 030096 1 1 8 NPT x 3 16 BARBED STRAIGHT FITTING ITEM PART NO QTY DESCRIPTION 12 068736 275MM HOSE 3 16 SAE 30R2 13 068736 240MM HOSE 3 16 SAE 30R2 14 074823 4 HOSE CLAMP 15 074819 1 FUEL BLEED FITTING 16 0709390651 5 FUEL BLEED GASKET 17 0709390662 2 HOLLOW BOLT 18 0F28730216 2 BAN...

Page 70: ...n all other states the applicable warranty period is two 2 years or 1 500 hours whichever comes first If any emission related part on your engine is defective the part will be repaired or replaced by a Generac Authorized Warranty Service Facility on behalf of ISM PARTS COVERED This emission control system warranty applies to the following engine emission control parts Fuel Injection Pump Fuel Inje...

Page 71: ...anty statement explains your rights and obligations under the Emission Control System Warranty which is provided to you by Generac and ISM pursuant to federal law Note that this warranty shall not apply to 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 This warranty is in place of all othe...

Page 72: ...of normal maintenance adjustments installation and start up Repairs or diagnostics performed by individuals other than Generac authorized dealers not authorized in writing by Generac Power Systems Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation and ...

Page 73: ......

Page 74: ... X 20 G8 8 26 051769 6 WASHER LOCK M12 27 0C4537 2 ENGINE BRACKET 28 022304 2 WASHER FLAT 1 2 ZINC 29 023316 1 SCREW HHC 1 2 13 X 4 G5 30 049451 1 FENDER WASHER 7GA 31 042633 1 SCREW HHC 3 8 24 X 1 G5 32 046526 11 WASHER LOCK M10 33 052212 6 SCREW HHC M10 1 25 X 25 G8 8 34 069673J 1 NUT LOCK FLG 5 16 18 35 051756 5 SCREW HHC M10 1 5 X 20 G8 8 36 049813 1 NUT HEX M6 X 1 0 G8 YEL CHR 37 043107 2 SCR...

Page 75: ......

Page 76: ...15 2 NUT HEX M4 0 7 G8 YEL CHR 13 040213 4 PCB SUPPORT SNAP IN 1 4 14 049441 1 SCREW HHTT 6 32 X 3 8 CZ 15 0G7440 1 HARNESS AC OUTPUT 16 0G7846 1 HARN ENG CONTROL PANEL 1 1L RV 17 0C3992 4 SCREW HHTT M4 0 7 X 16 BP 18 0C7022 1 DECAL CUSTOMER CONNECTION 19 038150 4 WASHER FLAT 8 ZINC 20 0C6359 1 GASKET ELECT ENCLOS 21 049813 6 NUT HEX M6 X 1 0 G8 YEL CHR 22 023484D 3 BUSHING SNAP SB 875 11 23 0C739...

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Page 78: ...16 0C50960ST03 1 FRAME CONTROL PANEL 17 0D4372 1 PLUG OIL FILL 18 0F2664K 1 ASSY DIPSTICK W TWIST 1 1L 19 0C5210 1 HOSE 3 8 ID LOW PRES OIL WATER 5 31 LG 20 0C5209 1 HOSE 1ID LOW PRES OIL WATER 9 84 LG 21 0C7649 2 CLAMP HOSE 38 87 22 057824 2 CLAMP HOSE 16 87 1 50 23 0C3992 4 SCREW HHTT M4 0 7 X 16 BP 24 022985 4 WASHER FLAT 6 ZINC 25 084135 1 RUBBER GROMMET WIRES 26 0C6440 2 GASKET ENGINE CNTRL 2...

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Page 80: ... Plate Cleanout 11 042907 8 HHCS M8 1 25 x 16 12 022129 8 Washer Split Lk M8 13 022097 3 Washer Split Lk 1 4 M6 14 043146 2 HHCS M6 1 00 x 10 15 0C7561 1 Carriage Bolt 3 8 16 x 55mm 16 0A4456 1 3 8 Special Lock Washer 17 0C7968 3 Hex Nut 3 8 16 Brass 18 047411 2 HHCS M6 1 00 x 16 19 049813 2 Nut Hex M6 0 1 0 20 0C5443 1 Block Terminal Battery Post 21 0C7423 1 STUD 3 8 16 X 2 1 4 BRASS 22 022131 1 ...

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Page 82: ... ASY RAD 28 0C6236 1 HOSE TEE 29 0C7384 1 HOSE COUPLING 30 0C5543 1 HOSE RADIATOR LWR 31 0C4460 1 HOSE WATER PUMP LWR 32 0F4352 1 COOLANT HOSE TIER 2 DIESEL 33 0C5544 1 HOSE LWR INTERMEDIAT 34 086133A 8 CLAMP HI TORQUE 1 1 75 35 035473 2 CLAMP HOSE 12 50 1 25 36 050968 1 HOSE COOL 3 4 ID 20R3 28 3 LG 37 059981 1 SCREW HHC M10 1 5 X 30 C10 9 38 046526 2 WASHER LOCK M10 39 047411 3 SCREW HHC M6 1 0 ...

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Page 84: ...153 3 VALVE GUIDE SEAL INTAKE 8 0709390154 6 SPRING 9 0709390155 6 RETAINER 10 0709390156 12 KEY 11 0709390152 3 VALVE GUIDE SEAL EXHAUST 12 0G23210108 6 CAP 13 0G23210109 1 HEAD GASKET 1 2mm THICK 0G23210110 1 HEAD GASKET 1 3mm THICK 14 0F28730125 11 HEAD BOLT 15 0F28730126 3 HEAD BOLT 16 0709390162 2 LIFTING EYE 17 0G23210111 2 BOLT 18 0G23210112 3 VALVE SEAT INTAKE MM MILLIMETER ...

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Page 86: ...9 0F28730167 1 O RING 10 0709390245 1 TUBING 11 0709390246 1 SUCTION FILTER 12 0F28730168 2 BOLT 13 0F28730142 1 GASKET 14 0F28730143 1 HEAD COVER 15 0F28730144 1 OIL STOPPER 16 0709390186 1 SCREEN 17 0F28730145 4 SCREW 18 0F28730146 3 GASKET 19 0F28730147 3 CAP NUT 20 0709390188 1 CAP 21 0709390189 1 O RING 22 0F28730148 1 BREATHER VALVE 23 0F28730149 4 BOLT 24 0F28730150 3 BOLT 25 0F28730132 2 B...

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Page 88: ...730175 2 CLAMP 8 0709390266 1 PLUG 9 0F28730176 1 SEAL WASHER 10 0D2791 1 THERMO SWITCH 11 0F28730178 1 GASKET 12 0G23210154 1 THERMOSTAT CASE 13 0F28730180 4 BOLT 14 0F28730181 1 THERMOSTAT 16 0F28730183 1 THERMOSTAT COVER 17 0F28730184 1 GASKET 18 0F28730202 1 BOLT 19 0709390247 1 PULLY 20 0F28730217 1 PLATE 21 0F28730218 4 BOLT ...

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Page 90: ...mm U S BUSHNG 12 0F28730110 1 BEARING 13 0709390113 1 EXPANSION PLUG 14 0709390114 1 BALL BEARING 15 0709390131 1 SNAP RING 16 0709390115 2 DOWEL PIN 17 0709390116 2 DOWEL PIN 18 0709390117 2 DOWEL PIN 19 0709390118 2 SPRING PIN 20 0F28730111 2 STUD BOLT 21 0F28730112 1 STUD BOLT 22 0F28730113 1 STUD BOLT 23 0G23210104 1 OIL SEAL 24 0709390124 1 DRAIN COCK 25 0709390125 1 CONNECTOR 26 0G23210156 1...

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Page 92: ...ER ARM SHAFT 7 0709390177 2 SPRING 8 0F28730132 2 BOLT 9 0709390181 3 STUD BOLT 10 0F28730133 3 NUT 11 042574 1 ADAPTER 12 0G23210132 1 OIL PIPE 13 0F28730146 4 GASKET 14 0709390165 2 EYE BOLT 15 0F28730137 1 GASKET 16 0F28730138 1 O RING 17 0F28730139 4 SHIM 18 0F28730140 1 PLUG 19 0F28730141 1 SCREW 20 028916 1 90 STREET ELBOW 21 0A8584 1 OIL PRESSURE SWITCH ...

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Page 94: ...L BEARING 0G23210121 3 0 25 STANDARD UPPER METAL BEARING 0G23210122 3 0 50 STANDARD UPPER METAL BEARING 12 0709390198 4 BOLT 13 0G23210124 2 BOLT 14 0G23210125 2 BOLT 15 0G23210126 3 STANDARD PISTON RING KIT 16 0G23210127 3 STANDARD PISTON KIT WITH RINGS 17 0709390217 3 PISTON PIN 18 0709390218 6 SNAP RING 19 0G23210128 3 CONNECTING ROD ASSEMBLY 20 0709390220 3 BUSHING 21 0709390221 6 CONNECTING R...

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Page 96: ...28730192 2 O RING 18 0709390301 1 SNAP RING 19 0709390302 1 BRACKET 20 0F28730218 2 BOLT 21 071944 1 BOLT 22 0709390304 1 ARM 23 0709390305 1 SNAP RING 24 0F28730194 1 O RING 25 0709390307 1 SPRING 26 0709390308 1 WASHER 27 0G23210149 2 NUT 28 0709390310 1 STOP LEVER 29 0F28730195 5 BOLT 30 0F28730180 3 BOLT 31 0F28730150 2 BOLT 32 022129 4 WASHER LOCK M8 5 16 33 0709390314 2 COVER 34 0G23210151 1...

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Page 98: ...ETE INJECTION PIPE 9 0G23210136 1 COMPLETE INJECTION PIPE 10 0G23210137 1 COMPLETE INJECTION PIPE 11 0G23210138 4 COMPLETE CLAMP 12 0G23210139 2 BOLT 13 0F28730173 2 NUT 14 0F28730209 3 GLOW PLUG 15 0F28730210 3 NUT 16 0G23210140 1 CONNECTOR 17 0F28730214 1 GASKET 18 0709390264 2 BOLT 19 0709390343 1 SEAL WASHER 20 0F28730212 1 SCREW 21 0F28730176 1 SEAL WASHER FOR THERMO SWITCH 22 0F28730213 1 SO...

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Page 100: ...TTING 9 052233 2 1 8 NPT TEE BRASS 10 039450 2 1 8 NPT x 3 16 90 DEG BARBED FITTING 11 030096 1 1 8 NPT x 3 16 BARBED STRAIGHT FITTING 12 068736 275MM HOSE 3 16 SAE 30R2 13 068736 240MM HOSE 3 16 SAE 30R2 14 074823 4 HOSE CLAMP 15 074819 1 FUEL BLEED FITTING 16 0709390651 5 FUEL BLEED GASKET 17 0709390662 2 HOLLOW BOLT 18 0F28730216 2 BANJO FITTING 19 028414A 1 1 8 NPT x 1 4 BARBED STRAIGHT FITTIN...

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Page 102: ... 14 0C7968 1 NUT HEX JAM 3 8 16 BRASS 15 022237 1 WASHER LOCK 3 8 16 075763 3 BOOT BATTERY CABLE 17 075763A 3 BOOT BATTERY CABLE 18 023484F 2 BUSHING SNAP SB 1000 12 19 022127 1 NUT HEX 1 4 20 STEEL 20 0536210201 1 ASSY WIRE 13 22 00 21 0536210197 1 ASSY WIRE 16 11 50 22 0A2053 1 SCREW HHC M6 1 0 X 65 C8 8 23 0742600158 1 WIRE ASSY GROUND DIESEL RV 24 075234 1 RES WW LUG 1R 5 25W 25 030340 1 HOSE ...

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Page 104: ...ECT 16 0D7176 33 WASHER SELF LOCKING 1 DIA 12GA 17 0G4933 57 SCREW SWT 1 4 20 X 5 8 W W 18 0C50960ST03 1 FRAME CONTROL PANEL BLACK 19 0C7023 1 DECAL BATTERY 20 0C7024 1 DECAL RADIATOR CAP 21 0C7025 1 DECAL REMOTE 22 0C7026 1 DECAL COOLANT 23 0C7027 1 DECAL FUEL RETURN SUPPLY 24 0C7028 1 DECAL OIL FILL LEVEL 25 0C7029 1 DECAL LIFTING LUG 26 0C7030 1 DECAL MAX HOT MIN COLD 27 0C2340 1 DECAL WARNING ...

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Page 106: ...T 12 0C6244 1 PLATE EXH OUTLET 13 051730 2 SCREW HHC M8 1 25 X 60 C8 8 14 071956 2 WASHER FLAT M8 15 022129 10 WASHER LOCK M8 5 16 16 045771 5 NUT HEX M8 1 25 G8 CLEAR ZINC 17 058443 3 SCREW CRIMPTITE 1 4 20 X 5 8 18 0C5105 1 BRACKET SUPPORT 19 022145 5 WASHER FLAT 5 16 M8 ZINC 20 039253 2 SCREW HHC M8 1 25 X 20 C8 8 21 043107 4 SCREW HHC M8 1 25 X 25 C8 8 22 035586 2 CLAMP HOSE 20 87 1 75 23 0756...

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