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Generac Power Systems quietpact 85d Owner's Manual

Liquid-cooled recreational vehicle generator
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Owner's Manual and

Installation Instructions

Quietpact™ 85D Liquid-cooled Recreational
Vehicle 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.
 S AVE this Manual. Provide this manual to any operator of the generator.

www.generac.com or 1-888-Generac

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Summary of Contents for Generac Power Systems quietpact 85d

  • Page 1: Installation Instructions

    Owner's Manual and Installation Instructions Quietpact™ 85D Liquid-cooled Recreational Vehicle 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. ...

  • Page 2: Table Of Contents

    Table of Contents Part I – Owner’s Manual Part II – Installation Instructions Introduction ..........Inside Front Cover Safety Rules .................18 Read This Manual Thoroughly ............IFC Contents ..................IFC General Information ...............20 Operation and Maintenance .............IFC Purpose and Scope of the Manual ........20 How to Obtain Service ..............IFC Safety ..................20 Authorized Service Dealer Locator Number ..........

  • Page 3: Introduction

    The operator (i.e., the driver) is responsible for the proper and safe use of the vehicle and its equipment, and for the safety of all vehicle Thank you for purchasing this model by Generac Power Systems, occupants. Before using this equipment, we strongly recommend Inc.

  • Page 4: Safety Rules

    Safety Rules SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be  copied and posted in potential hazard areas of the recreational vehicle. Safety should be stressed to all operators and potential operators of this equipment. Study these SAFETY RULES carefully before installing, operating, •...
  • Page 5 Safety Rules ELECTRICAL HAZARDS EXPLOSION HAZARDS • The generator covered by this manual produces dangerous • Do not smoke around the generator. Wipe off any fuel or oil electrical voltages and can cause fatal electrical shock. Avoid spills immediately. Ensure that no combustible material is left contact with bare wires, terminals, connections, etc., while in the generator compartment, or on or near the generator, as the unit is running.

  • Page 6: General Information

    General Information GENERATOR IDENTIFICATION Please record the following information from the generator DATA LABEL or information label, located below the user control panel. 1. Model Number ____________________ 2. Serial Number _________________ 3. kW Rating _________________________ 4. Rated Voltage _________________ 5. Phase _____________________________ 6.

  • Page 7: Generator Applicability

    General Information GENERATOR APPLICABILITY GENERATOR AC CONNECTION These generators have been designed and manufactured for sup- SYSTEM plying electrical power to recreational vehicles. DO NOT modify This generator is equipped with dual-stator AC power windings. the generator nor use it for any application other than for what it These two-stator windings supply electrical power to customer was designed.
  • Page 8 General Information NOTE: Ethylene glycol base antifreeze is poisonous.  DO NOT use mouth to siphon coolant from Some installations using a “shared” fuel tank may have a gen- the radiator, recovery bottle, or any contain- erator fuel pickup tube that is shorter than the vehicle’s engine er.

  • Page 9: Operation

    Operation 1.5.6 GENERATOR 2.1.1 HOURMETER Rated Maximum Continuous AC Output at ... This indicates the length of time the engine/generator has operat- 85º F (29º C) Ambient ..........8,500 Watts (8.5 kW) ed, in hours and tenths of hours. Use the hourmeter to ensure that 100º...

  • Page 10: Optional Remote Start/Stop

    Operation OPTIONAL REMOTE START/ 2.3.4 COOLANT LEVEL STOP Check the engine coolant level prior to initial use and at recom- mended intervals. Refer to the “Coolant” and “Engine Coolant” This generator is equipped with a plug-in connector that can sections for procedures and recommendations. be interfaced with an optional remote panel provided inside the vehicle.

  • Page 11: Starting The Generator

    Operation STARTING THE GENERATOR APPLYING LOADS TO GENERATOR NOTE: When applying electrical loads to the generator, observe these Read the vehicle manufacturer’s instructions. The owner/ guidelines: operator should become familiar with the vehicle in which this generator is installed. Differences exist between vehicles. For •...

  • Page 12: Protection Systems

    Operation PROTECTION SYSTEMS Figure 2.3 – Solid-state Voltage Regulator The engine has several safety switches that cause it to automati- cally shut down, under the following conditions: low oil pressure, high coolant temperature, and engine overspeed. See Figure 2.2 for the location of these devices. If automatic shutdown does occur, refer to “Troubleshooting Guide”.

  • Page 13: Maintenance

    Maintenance CHECKING THE ENGINE OIL CHANGING THE ENGINE OIL LEVEL AND/OR OIL FILTER Check the engine crankcase oil level every eight hours of opera- tion, or at least once daily, before using the generator. For oil capacities and requirements, see “Engine Oil Requirements”. To Never operate the engine with the oil level ...

  • Page 14: Servicing The Engine Air Filter

    Maintenance SERVICING THE ENGINE Figure 3.3 – Spark Arrestor Muffler Maintenance AIR FILTER To access the engine air filter (Figure 3.2), remove the front service door, located beneath the unit, by retracting the two latches and pivoting the door downward. Loosen the hose clamp at the base of the air filter and remove the filter.

  • Page 15: Cleaning The Generator

    Maintenance CLEANING THE GENERATOR Keep the generator as clean and as dry as possible. Dirt and mois-  DO NOT dispose of the battery in a fire. The ture that accumulate on internal generator windings have adversely battery is capable of exploding. Storage bat- affect insulation resistance.

  • Page 16: Cooling System

    Maintenance • Spilled electrolyte is to be washed down with an acid-neutralizing agent. A common practice is to use a solution of 1 pound (500 grams) Do not use any chromate base rust inhibitor  bicarbonate of soda to 1 gallon (4 liters) of with ethylene glycol base antifreeze;...
  • Page 17 Maintenance 3.12.2 RETURN TO SERVICE To return the unit to service after storage, proceed as follows: Check the tag on the engine for oil viscosity and classification. Verify that the correct recommended oil is used in the engine (see "Engine Oil Requirements"). If necessary, drain and refill with the proper oil.

  • Page 18: 3.13 Service Schedule

    Maintenance 3.13 SERVICE SCHEDULE ATTENTION: It is recommended that all service work be performed by the nearest Authorized Service Dealer. SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action Inspect Change Clean D = Daily W = Weekly R = Replace/Adjust as Needed M = Monthly Y = Yearly * = To Be Completed by an...

  • Page 19: Part Ii - Installation Instructions

    PART II – INSTALLATION INSTRUCTIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!

  • Page 20: Safety Rules

    Safety Rules DANGER: For fire safety, installation of a generator into a recreational vehicle must comply strictly  with NFPA 70 (latest edition), “National Electrical Code”, Article 551, and NFPA 1192 (latest edition), “Standard for Recreational Vehicles”. In addition, installation must comply with the manufacturer’s instructions and recommendations.
  • Page 21 Safety Rules ELECTRICAL HAZARDS FIRE HAZARDS • For fire safety, the generator must be installed and maintained • The generator covered by this manual produces dangerous properly. Installation always must comply with applicable electrical voltages that can cause fatal electrical shock. Avoid codes, standards, laws, and regulations.

  • Page 22: General Information

    General Information PURPOSE AND SCOPE EQUIPMENT DESCRIPTION Instructions and information in this section pertain to liquid-cooled OF THE MANUAL generators, designed specifically for installing in recreational vehi- These Installation Instructions have been prepared especially for cles. This unit operates 120/240-volt, single-phase, 60-Hertz, AC the purpose of familiarizing installers and owners of the applicable electrical loads that require up to 70.8 amps at 120 volts or 35.4 equipment with the product's installation requirements.

  • Page 23: Major Features And Dimensions

    General Information Figure 1.2 – Major Features and Dimensions (Drawing 0G6806-A)

  • Page 24: Installation

    Installation LOCATION AND SUPPORT • Whether the generator is mounted above the horizontal support tubing or suspended below the tubing, the supporting frame Be sure the installation complies with all standards and codes used must be structurally sound. listed in the "Standards Booklets" section of this manual. •...

  • Page 25: Generator Compartments

    Installation 2.1.4 GENERATOR RESTRAINT Figure 2.3 – Typical Compartment Construction Use four 3/8"-16 hardened steel bolts (Grade 5) to fasten the genera- tor to the supporting frame or the support tubing. These bolts must pass through (a) the generator mounting base, (b) the compartment floor (if a compartment is used), and (c) the supporting framework (Figure 2.2).
  • Page 26 Installation • Seams and joints of the galvanized steel (whether used as a liner or for the compartment itself) must be lapped and  DO NOT install sound insulation or any mechanically secured. Such seams may be manufactured, absorbent material on the compartment floor welded, bolted, riveted, or screwed.
  • Page 27 Installation 2.2.4 COMPARTMENT FLOOR CUTOUTS Figure 2.5 – Typical Noise Abatement Provide openings in the generator compartment for the following items (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"...

  • Page 28: Cooling And Ventilating Air

    Installation COOLING AND VENTILATING 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 It is absolutely essential that an adequate flow of air for cooling, square inches (975 cm 2 ) (see Figure 2.8).

  • Page 29: Diesel Fuel System

    Installation 2.3.4 TESTING THE INSTALLATION Figure 2.10 – Air Inlet Using Duct work 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.
  • Page 30 Installation 2.4.2 GENERATOR FUEL SUPPLY LINES Because diesel fuels are less volatile than gasoline or gaseous fuels, they are considered safer from the standpoint of storage and handling. As a result, installers may tend to be careless in Rigid Fuel Lines their installation practices, which can result in poor engine per- Those lines used to supply fuel from a tank to the generator must formance.

  • Page 31: Exhaust System

    Installation EXHAUST SYSTEM 2.5.2 EXHAUST SYSTEM SAFETY The generator exhaust system must be safely and properly • Maintain a clearance of at least 3 inches (76 mm) between installed. Only approved exhaust system parts must be used. A exhaust system parts and any combustible material (such as, properly installed exhaust system must be vapor-tight, quiet, and wood, felt, cotton, organic fibers, or other like material).

  • Page 32: Electrical Connections

    Installation • Use exhaust system parts recommended by the manufacturer. • If neutral conductors are used, they must be the same size as Using unapproved exhaust mufflers and exhaust system parts other leg wires. is the responsibility of the person(s) installing such unauthor- •...
  • Page 33 Installation Figure 2.14 – Generator AC Output Leads Remove the 12 AWG jumper wire from between line breakers CB1 and CB1A, as shown in Figure 2.15. Install a "tie bar" between the two-line breaker switch handles. T1 (Red) T2 Neutral (White) T3 (Black) ...
  • Page 34 Installation 2.6.7 ISOLATING DIFFERENT POWER SOURCES • Carefully prepare conduit ends to prevent sharp edges from cutting through wiring insulation. Connections from the junction box must terminate in a double- • Route conduit so it does not interfere with generator movement. pole, double-throw transfer switch (Figure 2.17).

  • Page 35: Battery Installation

    Installation Figure 2.18 – Installation With Isolation Receptacle BATTERY INSTALLATION 2.7.3 BATTERY CABLE CONNECTIONS Connect the battery cable from the battery post or terminal, 2.7.1 RECOMMENDED BATTERY indicated by a POSITIVE, POS, or (+), to the insulated lug on Install a battery that meets the following requirements: the unit frame (Figure 2.19).

  • Page 36: Optional Accessories

    Installation 2.7.4 BATTERY COMPARTMENT • If the electrolyte contacts the eyes, immediately flush eyes thoroughly with water, and seek Install the generator battery in its own, vented compartment. Place medical attention. the battery compartment away from any source of heat, sparks, •...

  • Page 37: Post-Installation Startup Checks

    Post-installation Start-up Checks POST INSTALLATION TESTS The generator set was factory-tested and adjusted. It is not neces- The generator set was thoroughly tested and  sary to adjust the unit any further, except under special circum- adjusted at the factory before shipping. No stances.

  • Page 38: Installation Checklist

    Post-installation Start-up Checks INSTALLATION CHECKLIST EXHAUST SYSTEM ❑ Exhaust system complies with all applicable codes. LOCATION AND SUPPORT ❑ Exhaust system is properly and safely installed. ❑ Generator is properly located. ❑ Generator is properly supported. ELECTRICAL CONNECTIONS ❑ Generator is properly restrained. ❑...

  • Page 39: Troubleshooting

    Troubleshooting TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank. 1. System control fuse blown 1. Replace fuse. 2. Loose corroded or defective 2. Tighten, clean, or replace, battery cables as necessary. 3. Defective engine Start/Stop 3. Replace Start/Stop switch. switch 4.

  • Page 40: Electrical Data

    Electrical Data Schematic - 120/240 VAC Output - Drawing No. 0G7332-C...
  • Page 41 Electrical Data Schematic - 120/240 VAC Output - Drawing No. 0G7332-C...
  • Page 42 Electrical Data Schematic - 120/240 Dual Voltage - Drawing No. 0G7333-D...
  • Page 43 Electrical Data Schematic - 120/240 Dual Voltage - Drawing No. 0G7333-D...
  • Page 44 Electrical Data Schematic - 120/240 Dual Voltage - Drawing No. 0G7333-D...
  • Page 45 Electrical Data Schematic - 120/240 Dual Voltage - Drawing No. 0G7333-D...

  • Page 46: Exploded Views And Parts Lists

    Exploded Views & Parts Lists Engine, Alternator & Starter Assy. - Drawing No. 0G7350-B...
  • Page 47 Exploded Views & Parts Lists Engine, Alternator & Starter Assy. - Drawing No. 0G7350-B ITEM PART NO. QTY. DESCRIPTION 0C5598 BEARING CARRIER FRONT 0C9674 BEARING CARRIER UPPER 0C6055H ROTOR ASSEMBLY 0C6054H STATOR ASSEMBLY 031971 BEARING #6205 2NSE C3 E SRI2 S 073159 BALL BEARING 066386...
  • Page 48 Exploded Views & Parts Lists Enclosure - Drawing No. 0G7351-B...
  • Page 49 Exploded Views & Parts Lists Enclosure - Drawing No. 0G7351-B ITEM PART NO. QTY. DESCRIPTION 0G60920ST03 ENCLOSURE PANEL RH,WELDMENT 0G72980ST03 ENCLOSURE PANEL, TOP 0G60790ST03 ENCLOSURE PANEL LH 0G60810ST03 ENCLOSURE PANEL,FRONT 0G60610ST03 ENCLOSURE PANEL REAR,WELDMENT 0G7389 INSULATION, FRONT PANEL 0G7390 INSULATION, LH SIDE PANEL 0G7391 INSULATION, RH SIDE PANEL 0G7392...
  • Page 50 Exploded Views & Parts Lists Cooling System - Drawing No. 0G7352-B...
  • Page 51 Exploded Views & Parts Lists Cooling System - Drawing No. 0G7352-B ITEM PART NO. QTY. DESCRIPTION 0G64760ST03 COVER PLATE,SCRL WLDMNT 0G64470ST03 HOUSING, FAN SCROLL WLDMNT 0C4552 FAN, SQUIRREL CAGE 0C4554 SHAFT, FAN 0C4555 BEARING CARRIER 0C4557 KEY SQ 3/16 X 5/8 STEEL 0C4556A PULLEY, FAN DIA.
  • Page 52 Exploded Views & Parts Lists Fuel & Electrical Systems - Drawing No. 0G7355-A...
  • Page 53 Exploded Views & Parts Lists Fuel & Electrical Systems - Drawing No. 0G7355-A ITEM PART NO. QTY. DESCRIPTION 0C6946A FUEL PUMP ASSY REWRK 052219 BARBED STR 1/8NPT X 5/16 069598B BULKHEAD FITTING 1/8 NPT 022097 WASHER LOCK M6-1/4 038750 SCREW HHC M6-1.0 X 30 C8.8 056739 RELAY SOLENOID 12VDC PNL MNT 049813...
  • Page 54 Exploded Views & Parts Lists Customer Controls Assy. - Drawing No. 0G7356-B...
  • Page 55 Exploded Views & Parts Lists Customer Controls Assy. - Drawing No. 0G7356-B ITEM PART NO. QTY. DESCRIPTION 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...
  • Page 56 Exploded Views & Parts Lists Exploded Views & Parts Lists Base Frame - Drawing No. 0D2357-C ????? - Drawing No. 0????? TORQUE SPECIFICATIONS CHART ITEM # TORQUE 18 FT-LBS STARTER GRD. CABLE ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0D2126 Base Frame Weldment...
  • Page 57 Exploded Views & Parts Lists Electrical Enclosure Assy. - Drawing No. 0G7353-B ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0G71570ST03 WELDMENT, CONTROLLER BOX 0G7846 HARN ENG CONTROL PANEL 1.1L RV 071914 BLOCK MARATHON 4 POS 600V 0C3992 SCREW HHTT M4-0.7 X 16 BP 0830490SRV ASSY PCB POTTED REG W/FIN...
  • Page 58 Exploded Views & Parts Lists Intake & Exhaust System - Drawing No. 0G7354-A ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 075674 GASKET EXHAUST ADAPTOR 022129 WASHER LOCK M8-5/16 0F28730173 045771 NUT HEX M8-1.25 G8 CLEAR ZINC 0E9581A AIR CLEANER, 152.4MM 058443 SCREW CRIMPTITE 1/4-20 X 5/8...
  • Page 59 Exploded Views & Parts Lists Camshaft - Drawing No. 0F6230 ITEM PART NO. QTY. DESCRIPTION 0F28730164 CAMSHAFT ASSEMBLY 0709390233 CAMSHAFT GEAR 0709390195 0709390234 GEAR 0709390235 SPACER 0709390236 BALL BEARING 0709390237 SLIDER 0709390238 PLATE 0709390241 BOLT 0709390240 BOLT...
  • Page 60 Exploded Views & Parts Lists Oil Pump - Drawing No. 0F6231 ITEM PART NO. QTY. DESCRIPTION 0709390250 IDLER GEAR ASSEMBLY 0709390251 THRUST WASHER 0709390252 SPRING 0709390253 ROTOR 0709390254 OIL PUMP COVER 0709390255 0.10MM SHIM 0709390532 0.15MM SHIM 0709390533 0.20MM SHIM 0709390258 0.50MM SHIM 0709390259...
  • Page 61 Exploded Views & Parts Lists Cylinder Head - Drawing No. 0G7500-A ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0G23210107 CYLINDER HEAD ASSEMBLY 0G23210108 0F28730119 SEALING CAP 0G23210109 HEAD GASKET, 1.2mm THICK 0F28730120 SEALING CAP 0G23210110 HEAD GASKET, 1.3mm THICK 0F28730121 STUD BOLT 0F28730125...
  • Page 62 Exploded Views & Parts Lists Engine Block - Drawing No. 0G7501-A ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0G23210152 OIL PAN 0F28730143 HEAD COVER 0709390140 BOLT 0F28730144 OIL STOPPER 0G23210153 BOLT 0709390186 SCREEN 0F28730176 SEAL WASHER FOR THERMO SWITCH 0F28730145 SCREW 0G6451...
  • Page 63 Exploded Views & Parts Lists Water Pump - Drawing No. 0G7502-A ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0F28730169 WATER PUMP ASSEMBLY 0G23210154 THERMOSTAT CASE 0F28730170 GASKET 0F28730180 BOLT 0F28730171 BOLT 0F28730181 THERMOSTAT 0F28730172 BOLT 0F28730183 THERMOSTAT COVER 0F28730174 RUBBER HOSE 0F28730184...
  • Page 64 Exploded Views & Parts Lists Cylinder Block - Drawing No. 0G7503-A ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0G23210100 CYLINDER BLOCK 0709390116 DOWEL PIN 0709390104 BLANK PLUG 0709390117 DOWEL PIN 0F28730101 SEALING CAP 0709390118 SPRING PIN 0F28730102 SEALING CAP 0F28730111 STUD BOLT...
  • Page 65 Exploded Views & Parts Lists Rocker Arm Assy. - Drawing No. 0G7504-A ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0F28730128 ROCKER ARM ASSEMBLY 0G23210132 OIL PIPE 0F28730129 INTAKE ROCKER ARM 0F28730146 GASKET 0F28730130 EXHAUST ROCKER ARM 0709390165 EYE BOLT 0709390173 SCREW...
  • Page 66 Exploded Views & Parts Lists Crankshaft, Piston & Flywheel - Drawing No. 0G7505-A ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0G23210113 COMPLETE CRANKSHAFT 0709390198 BOLT 0709390194 CRANKSHAFT GEAR 0G23210124 BOLT 0709390195 0G23210125 BOLT 0709390196 DOWEL PIN 0G23210126 STANDARD PISTON RING KIT 0709390226 SPRING PIN...
  • Page 67 Exploded Views & Parts Lists Timing & Governor - Drawing No. 0G7506-A ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0F28730186 HOUSING, TIMING GEAR 0709390304 0709390286 SPRING PIN 0709390305 SNAP RING 0F28730187 GASKET 0F28730194 O-RING 0709390288 OIL SEAL 0709390307 SPRING 0G23210146...
  • Page 68 Exploded Views & Parts Lists Injector Pump - Drawing No. 0G7507-A ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0G23210133 INJECTION PUMP ASSEMBLY 0F28730173 0F28730201 ADJUSTING SHIM SET 0F28730209 GLOW PLUG 0F28730173 0F28730210 0F28730202 BOLT 0G23210140 CONNECTOR 0F28730203 GASKET 0F28730214 GASKET...
  • Page 69 Exploded Views & Parts Lists Fuel Supply - Drawing No. 0G7508-A ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0F28730215 FUEL FILTER SUPPORT ASSEMBLY 068736 275MM HOSE, 3/16” SAE 30R2 0G23210155 FUEL FILTER 068736 240MM HOSE, 3/16” SAE 30R2 0C8008 HOSE, 5/16”...

  • Page 70: Warranty

    YOUR WARRANTY RIGHTS AND OBLIGATIONS The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), Generac Power Systems, Inc. (GENERAC), and the engine manufacturer for this equipment, Ishikawajima Shibaura Machinery Co., Ltd. (ISM), are pleased to explain the federal and California emission control system warranty on your engine.
  • Page 71 Warranty OBLIGATIONS AND RIGHTS OF THE MANUFACTURER AND OWNER The new model year, class of diesel engine, and emission application determination for your engine are identified on the emission control information label affixed to the right-hand side of your engine's timing gear case. The warranty period begins on the date the new equipment is sold to the first retail purchaser.
  • Page 72 NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. For a period of 3 (three) years of operation from the date of original sale or 1,000 hours, whichever occurs first, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Facility, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below.
  • Page 76 0G71570ST03 WELDMENT, CONTROLLER BOX 071914 BLOCK MARATHON 4 POS 600V 0830490SRV ASSY PCB POTTED REG W/FIN 0F5752H RES WW 20R 5% 15W QK CONN 093642 ASSY MARINE CNTL BRD 065795 RECTIFIER-BATT CHARG 048512 CIRCT BRK 5 X 1 ETA 46-500-P 027565 TAPE UL PERMACEL P247 1.0 066849C...
  • Page 78 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...
  • Page 80 0D2126 Base Frame Weldment 0D2131 Door, Service Rear 0C5088 Door, Service Front 0C5644 Slide Latch Flush 056326 Vinyl Trim –Black 180mm 029451 Rubber Tape 1/8 x ½”(26.6”LG) 0C7857 Grommet 1/8 x 13/32 070936E Vibration Mount 0C6721 Gasket, Cleanout 0C6722 Plate, Cleanout 042907 HHCS M8-1.25 x 16 022129...
  • Page 82 0G64760ST03 COVER PLATE,SCRL WLDMNT 0G64470ST03 HOUSING, FAN SCROLL WLDMNT 0C4552 FAN, SQUIRREL CAGE 0C4554 SHAFT, FAN 0C4555 BEARING CARRIER 0C4557 KEY SQ 3/16 X 5/8 STEEL 0C4556A PULLEY, FAN DIA. 114.8MM 0C4553 BEARING, 2-ROW BALL 049869 WASHER FLAT M16 081810 NUT HEX M16-1.5 G8 YEL CHR 070265 WASHER LOCK M16...
  • Page 84 0G23210107 CYLINDER HEAD ASSEMBLY 0F28730119 SEALING CAP 0F28730120 SEALING CAP 0F28730121 STUD BOLT 0F28730122 INTAKE VALVE 0709390151 EXHAUST VALVE 0709390153 VALVE GUIDE SEAL (INTAKE) 0709390154 SPRING 0709390155 RETAINER 0709390156 0709390152 VALVE GUIDE SEAL (EXHAUST) 0G23210108 0G23210109 HEAD GASKET, 1.2mm THICK 0G23210110 HEAD GASKET, 1.3mm THICK 0F28730125...
  • Page 86 0G23210152 OIL PAN 0709390140 BOLT 0G23210153 BOLT 0F28730176 SEAL WASHER FOR THERMO SWITCH 0G6451 DIPSTICK TUBE 0D7124 O-RING 0F28730117 BOLT 0F28730114 GASKET, OIL PAN 0F28730167 O-RING 0709390245 TUBING 0709390246 SUCTION FILTER 0F28730168 BOLT 0F28730142 GASKET 0F28730143 HEAD COVER 0F28730144 OIL STOPPER 0709390186 SCREEN 0F28730145...
  • Page 88 0F28730169 WATER PUMP ASSEMBLY 0F28730170 GASKET 0F28730171 BOLT 0F28730172 BOLT 0F28730174 RUBBER HOSE 0F28730175 CLAMP 0709390266 PLUG 0F28730176 SEAL WASHER 0D2791 THERMO SWITCH 0F28730178 GASKET 0G23210154 THERMOSTAT CASE 0F28730180 BOLT 0F28730181 THERMOSTAT 0F28730183 THERMOSTAT COVER 0F28730184 GASKET 0F28730202 BOLT 0709390247 PULLY 0F28730217 PLATE...
  • Page 90 0G23210100 CYLINDER BLOCK 0709390104 BLANK PLUG 0F28730101 SEALING CAP 0F28730102 SEALING CAP 0F28730103 SEALING CAP 0F28730104 SEALING CAP 0709390106 BLANK PLUG 0709390105 BLANK PLUG 0F28730105 COMPLETE IDLE GEAR SHAFT 0G23210101 BUSHING – STANDARD 0G23210102 0.25mm U.S. BUSHING 0G23210103 0.50mm U.S. BUSHNG 0F28730110 BEARING 0709390113...
  • Page 92 0F28730128 ROCKER ARM ASSEMBLY 0F28730129 INTAKE ROCKER ARM 0F28730130 EXHAUST ROCKER ARM 0709390173 SCREW 0709390174 0F28730131 ROCKER ARM SHAFT 0709390177 SPRING 0F28730132 BOLT 0709390181 STUD BOLT 0F28730133 042574 ADAPTER 0G23210132 OIL PIPE 0F28730146 GASKET 0709390165 EYE BOLT 0F28730137 GASKET 0F28730138 O-RING 0F28730139 SHIM...
  • Page 94 0G23210113 COMPLETE CRANKSHAFT 0709390194 CRANKSHAFT GEAR 0709390195 0709390196 DOWEL PIN 0709390226 SPRING PIN 0G23210114 BEARING HOLDER ASSEMBLY 0G23210115 BEARING HOLDER ASSEMBLY 0G23210116 BEARING HOLDER ASSEMBLY 0709390199 DOWEL PIN 0G23210117 STANDARD METAL BEARING 0G23210118 0.25 STANDARD METAL BEARING 0G23210119 0.50 STANDARD METAL BEARING 0G23210120 STANDARD UPPER METAL BEARING 0G23210121...
  • Page 96 0F28730186 HOUSING, TIMING GEAR 0709390286 SPRING PIN 0F28730187 GASKET 0709390288 OIL SEAL 0G23210146 GOVERNOR LEVER ASSEMBLY 0709390290 TENSION LEVER 0709390291 SNAP RING 0709390136 WASHER 0709390292 COTTER PIN 0G23210147 SPRING 0709390294 0F28730190 O-RING 0709390296 GOVERNOR LEVER 0709390297 BOLT 0F28730173 0F28730191 SHAFT 0F28730192 O-RING 0709390301...
  • Page 98 0G23210133 INJECTION PUMP ASSEMBLY 0F28730201 ADJUSTING SHIM SET 0F28730173 0F28730202 BOLT 0F28730203 GASKET 0G23210134 INJECTOR ASSEMBLY 0F28730205 COMPLETE RETURN PIPE 0G23210135 COMPLETE INJECTION PIPE 0G23210136 COMPLETE INJECTION PIPE 0G23210137 COMPLETE INJECTION PIPE 0G23210138 COMPLETE CLAMP 0G23210139 BOLT 0F28730173 0F28730209 GLOW PLUG 0F28730210 0G23210140 CONNECTOR...
  • Page 102 0C6946A FUEL PUMP ASSY REWRK 052219 BARBED STR 1/8NPT X 5/16 069598B BULKHEAD FITTING 1/8 NPT 022097 WASHER LOCK M6-1/4 038750 SCREW HHC M6-1.0 X 30 C8.8 056739 RELAY SOLENOID 12VDC PNL MNT 049813 NUT HEX M6 X 1.0 G8 YEL CHR 055934D CLAMP VINYL 1.06 X .406 Z 022473...
  • Page 104 0G60920ST03 ENCLOSURE PANEL RH,WELDMENT 0G72980ST03 ENCLOSURE PANEL, TOP 0G60790ST03 ENCLOSURE PANEL LH 0G60810ST03 ENCLOSURE PANEL,FRONT 0G60610ST03 ENCLOSURE PANEL REAR,WELDMENT 0G7389 INSULATION, FRONT PANEL 0G7390 INSULATION, LH SIDE PANEL 0G7391 INSULATION, RH SIDE PANEL 0G7392 INSULATION, TOP FRONT PANEL 0G7393 INSULATION, TOP REAR PANEL 0G7394 INSULATION, LIFT LUG COVER 0G73380AD12...
  • Page 106 075674 GASKET EXHAUST ADAPTOR 0F28730173 0E9581A AIR CLEANER, 152.4MM 0F4366 HOSE, AIR INLET TIER 2 DIESEL 0C4727 MUFFLER, 1.0 L D, RV 025145 BOLT U 5/16-18 X 1.25 W/SADDLE 0G69970ST03 RAIL, ENGINE LH 0C5022 INSUL.,EXHAUST QP75 035685 CLAMP HOSE #28 1.32-2.25 0C4878 OUTLET EXHAUST-FLEX 0C6243...

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