Appendix 3 Exploded Views and Parts Lists
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1 Engine, Alternator Drive and Starter Assembly Drawing No. 0D5057-A 40 Generac Power Systems, Inc.
2 Engine, Alternator Drive and Starter Assembly Drawing No. 0D5057-A 1 0C BEARING CARRIER, FRONT 2 0C BEARING CARRIER, UPPER 3 0C6055H 1 ROTOR ASSEMBLY 4 0D5030H 1 STATOR ASSEMBLY BALL BEARING BALL BEARING BRUSH HOLDER TAPTITE M5-0.8 X 16MM 9 0C BOLT, STATOR 10 0C /16 SPECIAL LOCK WASHER 11 0C LUG, LIFT 12 0C RAIL, ENGINE RH 13 0C PULLEY, 4.5" FLAT 14 0C BELT, V-RIB STARTER MOTOR 16 0C SPACER, STARTER D 1 PULLEY, ALTERNATOR 18 0D FLYWHEEL ASSEMBLY HHCS M X 55MM WASHER, VIBRATION ISOLATOR WASHER, SPLIT LK -M NUT, HEX M SHCS 5/16"-18 X 1-1/2" 24 0C GUARD, FLYWHEEL HHCS M X 20MM WASHER, SPLIT LK -M C ENGINE BRACKET ½" FLAT WASHER ½"-13 X 4" HHCS FENDER WASHER 7GA HHCS 3/8-24 X 1" LOCKWASHER M HHCS M X 25MM J 2 5/16 FLANGE NUT HHCS M X 20MM M6 HEX NUT HHCS M X 25MM EARTH STRAP HHCS M X 20MM 40 0A ¼" SPECIAL LOCK WASHER M8 FLANGE NUT 42 0C TAPTITE, M6-1.0 X 8MM 43 0C ENGINE, 1.0L DIESEL WASHER, FLAT M M 1 CLAMP, VINYL COATED, ¾" 46 0A HHCS M X 25MM 47 0C TENSIONER, SE-F18-4.5" ½"-13 X1-3/4" HHCS ½"-13 FLANGE NUT FLAT WASHER, 5/16" Generac Power Systems, Inc. 41
3 Base Frame Drawing No. D2357-A 1 0D BASE FRAME WELDMENT 2 0D DOOR, SERVICE REAR 3 0C DOOR, SERVICE FRONT 4 0C SLIDE LATCH FLUSH VINYL TRIM -BLACK 180MM MM RUBBER TAPE 1/8 X ½" 7 0C GROMMET 1/8 X 13/ E 4 VIBRATION MOUNT 9 0C GASKET, CLEANOUT 10 0C PLATE, CLEANOUT HHCS M X WASHER, SPLIT LK- M WASHER, SPLIT LK -1/4-M6 42 Generac Power Systems, Inc HHCS M X C CARRIAGE BOLT 3/8-16 X 55MM 16 0A /8 SPECIAL LOCK WASHER 17 0C HEX NUT 3/8-16 BRASS HHCS M X NUT, HEX M C BLOCK, TERMINAL BATTERY POST 21 0C STUD 3/8-16 X 55MM WASHER 3/8 FLAT WASHER SPLIT LK -3/8 MM = MILLIMETRES
4 Enclosure Drawing No. 0D5059-B VIEW "A" A D ENCLOSURE PANEL RH 2 0C ENCLOSURE PANEL TOP 3 0C ENCLOSURE PANEL LH 4 0C ENCLOSURE PANEL FRONT 5 0C ENCLOSURE REAR PANEL 6 0C INSULATION, FRONT PANEL 7 0C INSULATION, LH SIDE PANEL 8 0C INSULATION, RH SIDE PANEL 9 0C INSULATION, TOP FRONT PANEL 10 0C INSULATION, TOP REAR PANEL 11 0C INSULATION, LIFTING LUG COVER 12 0C COVER, ACCESS LIFT 13 0C COVER, RADIATOR FILL 14 0C COVER, ACCESS ELECTRICAL 15 0C GASKET, ELECTRICAL ACCESS 16 0D WASHER, SELF LOCK 17 0A ¼ -20 X 5/8 W/WASHER 18 0C FRAME CONTROL PANEL - REFER TO DRAWING C C DECAL, BATTERY +/- 20 0C DECAL, RADIATOR CAP 21 0C DECAL, REMOTE 22 0C DECAL, COOLANT 23 0C DECAL, FUEL RETURN/SUPPLY 24 0C DECAL, OIL FILL / LEVEL 25 0C DECAL, LIFTING LUG 26 0C DECAL, MAX HOT / MIN COOLANT 27 0C DECAL, WARNING RV 28 0C SUPPORT, COOLANT TANK NUT, HEX M C7047A 1 FOAM, AIR DUCT FACE 31 0C7047B 1 FOAM, AIR DUCT SIDE 32 0D DECAL, UNIT WASHER, SPLIT LOCK ¼" - M DECAL, ENGINE DATA DECAL, CSA APPROVAL Generac Power Systems, Inc. 43
5 Cooling System Drawing No. D Generac Power Systems, Inc.
6 Cooling System Drawing No. D C Cover Plate, Scroll Weldment 2 0C Housing, Fan Scroll Weldment 3 0C Fan, Squirrel Cage 4 0C Shaft, Fan 5 0C Carrier, Bearing 6 0C Key, Square 3/16" x 3/16" x ½" 7 0C Pulley, Fan 4-7/8" 8 0C Bearing 2 Row Ball Fender Washer M Nut, Hex M mm LockWasher M Crimptite, ¼"-20 x 5/8" HHCS M x 10mm Washer, Split Lk ¼"- M HHCS M5-0.8 x 16mm Washer, Split Lk # Hex Nut M Nut, Hex M mm 19 0C Radiator 1.0L RV HHCS M x 12mm Washer ¼"-M6 22 0C Pulley, 3" Flat Flanged 23 0C Bracket, Rotary Tensioner HHCS M x 20mm Washer, Split Lk -M8 26 0C6549A 1 61" Green Belt 27 0C Filler Neck Assembly, Radiator Remote 28 0C Hose Tee 29 0C Coupling, Hose 30 0C Hose, Radiator Lower 31 0C Hose, Water Pump Lower 32 0C Hose, Top 33 0C Hose, Lower Intermediate A 8 Hose Clamp Hi Trq 1-3/4" Max Hose Clamp # mm Hose, ¾" SAE-20R M x 30mm HHCS M10 Lockwasher HHCS M x 16mm 40 0C mm Hose, 5/16" SAE-20R4 41 0C Hose Clamp 7/8" 3/8" HHCS M x 16mm 43 0C Cap, Coolant Fill 44 0C Tank, Coolant Overflow 45 0C mm Hose 5/16" SAE-20R K 1 Clamp, Vinyl Coated 1-5/8" 47 0C Cap, Radiator Pressure D 1 Clamp, Vinyl Coated 1-1/16" 49 0C Gasket, Radiator Base V 1 Clamp, Vinyl Coated 1-½" Nut, Hex M C Bracket, Support ½"-13 x 1-¾" HHCS 54 00C Tensioner ½"-13 Flange Nut mm = Millimeters Generac Power Systems, Inc. 45
7 Electrical Enclosure Assembly Drawing No. 0D5056-A D WELDMENT, ELECTRICAL ENCLOSURE TERMINAL BLOCK 4 POSITION ASSEMBLY, POTTED REGULATOR 4 0C RESISTOR 20R 5% 12W ASSEMBLY MARINE CONTROL BOARD RECTIFIER, BATTERY CHARGING CIRCUIT BREAKER 5 AMP A/R TAPE, GLASS INSULATED C 2 TAPTITE, M5-0.8 X TAPTITE, M5-0.8 X LOCKWASHER M NUT, HEX M PCB SUPPORT SNAP -IN 14 0C HHMS, #8-32 X 2.25" WASHER, FLAT M5 16 0D2021B 1 HARNESS 17 0C M4-0.7 X 16 HHCS TAPTITE 18 0C DECAL, CUSTOMER CONNECTION WASHER, FLAT #6 20 0C GASKET, ELECTRICAL ENCLOSURE 21 0D2021G* 1 WIRE ASSEMBLY # D2021F* 1 WIRE ASSEMBLY # D2021D* 1 DIODE ASSEMBLY 24 0D2021E* 1 WIRE ASSEMBLY # A ¼ SPECIAL LOCKWASHER WASHER, FLAT ¼-M WASHER, SPLIT LK ¼-M NUT, HEX M D 1 BUSHING, SNAP B 2 GROMMET HHCS, M4-0.7 X 16MM 32 0C GASKET, ELECTRICAL ENCLOSURE DIVIDER 33 0D HARNESS, AC OUTPUT A/R = AS REQUIRED * NOT SHOWN REFER TO WIRING DIAGRAM C Generac Power Systems, Inc.
8 Intake and Exhaust System Drawing No. D EXHAUST GASKET 2 0C CHAMBER AIR INTAKE 3 0C AIR FILTER 4 0C HOSE, AIR INLET 5 0C MUFFLER WELDMENT U BOLT & SADDLE C RAIL, ENGINE LH, WELDMENT 8 0C INSULATION, EXHAUST HOSE CLAMP # C OUTLET, EXHAUST FLEX 11 0C GASKET, EXHAUST OUTLET 12 0C PLATE, EXHAUST OUTLET HHCS M X WASHER, VIBRATION ISOLATOR WASHER, SPLIT LK -M NUT, HEX M CRIMPTITE, ¼"-20 X 5/8" 18 0C BRACKET, SUPPORT WASHER, FLAT - M HHCS M X HHCS M X HOSE CLAMP # HHCS M X HHCS M X FLAT WASHER, 5/16" MANIFOLD GASKET HORIZONTAL EXHAUST MANIFOLD Generac Power Systems, Inc. 47
9 Fuel and Electrical Systems Drawing No. 0D2363-A 1 0C6946A 1 Fuel Pump Assembly /8 NPT x 5/16 Barbed Straight Fitting B 2 Bulkhead Adaptor Fitting Washer, Split Lk- ¼ -M HHCS M x Relay Solenoid Nut, Hex M M 1 Clamp, Vinyl Coat 3/ Washer, Flat -M Hose Clamp A 1 1/8 NPT x 1/4 Barbed Straight Fitting 12 0C Hose Clamp 7/8 / 3/ HHCS M x C Hex Nut 3/8-16 Brass Washer Split Lk 3/ Boot, Battery Cable 48 Generac Power Systems, Inc A 3 Boot, Battery Cable 18 0C Grommet 3/8 I/D x 1 GD Hex Nut ¼ Cable, Battery Cable, Starter 22 0A HHCS, M6-1 x Resistor M Hose, 1/4 ID SAE-30R2 26 0C mm Hose, 5/16 ID SAE-30R7 27 0C mm Hose, 5/16 ID SAE-30/R7 28 0C Clamp, Fuel Pump 29 0D2021H 1 Wire Assy, #0 (PHC-SC) M = Meters mm = Millimeters
10 Customer Controls Assembly Drawing No. 0D5055-A 1 0D START / STOP SWITCH 2 0C COVER, ENGINE CONTROL BOX 3 0C HOUR METER FUSE HOLDER, SFE SWITCH, PUSHBUTTON SPST PPHMS M3-0.5 X LOCKWASHER M FUSE, SFE C DECAL 10 0C BOOT / NUT / PREHEAT SWITCH LOCKWASHER, M5 12 0C BOOT, CIRCUIT BREAKER (WITH 4 SEALING SCREWS) 13 0D2021A 1 HARNESS HEX NUT, M3 15 0C BOX, ENGINE CONTROL 16 0C FRAME, CONTROL PANEL 17 0D PLUG, OIL FILL 18 0C3971B 1 DIPSTICK ASSEMBLY 19 0C HOSE, DIPSTICK TUBE 20 0C HOSE, FILLER TUBE 21 0C HOSE CLAMP 7/8-3/ HOSE CLAMP SIZE # C M4-0.7 X 16 HHCS TAPTITE WASHER, FLAT # GROMMET 26 0C GASKET, ENGINE CONTROL BOX CIRCUIT BREAKER, 30A, 2 POLE NUT, HEX M PHMS M5-0.8 X FLATWASHER, # WASHER, SPLIT LOCK 1/4 -M6 Generac Power Systems, Inc. 49
11 1.0 Liter Diesel Camshaft Drawing No CAMSHAFT ASSEMBLY CAMSHAFT GEAR KEY GEAR SPACER BALL BEARING SLIDER PLATE TACHOMETER SHAFT BOLT BOLT GASKET NUT 50 Generac Power Systems, Inc.
12 1.0 Liter Diesel Cylinder Block Drawing No COMPLETE CYLINDER BLOCK EXPANSION PLUG EXPANSION PLUG EXPANSION PLUG EXPANSION PLUG EXPANSION PLUG PLUG PLUG IDLE GEAR SHAFT BUSHING BUSHING-STANDARD MM U.S. BUSHING MM U.S. BUSHING BALL BEARING EXPANSION PLUG BALL BEARING DOWEL PIN DOWEL PIN DOWEL PIN SPRING PIN STUD STUD STUD SNAP RING OIL SEAL DRAIN COCK CONNECTOR OIL FILTER TAPPET PUSH ROD RELIEF VALVE O-RING MM = MILLIMETER U.S. = UNDERSIZE Generac Power Systems, Inc. 51
13 1.0 Liter Diesel Cylinder Head Drawing No. D CYLINDER HEAD ASSEMBLY EXPANSION PLUG EXPANSION PLUG EXPANSION PLUG INTAKE VALVE EXHAUST VALVE VALVE GUIDE SEAL (EXHAUST) VALVE GUIDE SEAL (INTAKE) SPRING RETAINER KEY CAP CYLINDER HEAD GASKET, 1.2MM THICK CYLINDER HEAD GASKET, 1.3MM THICK BOLT BOLT LIFTING EYE BOLT TUBING BOLT 19 0A OIL SWITCH 20 0D THERMO-SWITCH GASKET WASHER ADAPTOR MM=MILLIMETER 52 Generac Power Systems, Inc.
14 1.0 Liter Diesel Crankshaft, Piston and Flywheel Drawing No B CRANKSHAFT ASSEMBLY CRANKSHAFT GEAR KEY DOWEL PIN SPRING PIN BEARING HOLDER ASSEMBLY BEARING HOLDER ASSEMBLY BEARING HOLDER ASSEMBLY BOLT DOWEL PIN STANDARD BEARING AR 0.25MM U.S. BEARING AR 0.50MM U.S. BEARING STANDARD BEARING AR 0.25MM U.S. BEARING AR 0.50MM U.S. BEARING THRUST WASHER BOLT BOLT STANDARD PISTON ASSEMBLY AR PISTON ASSEMBLY-0.5MM O.S AR PISTON ASSEMBLY-1.0MM O.S STANDARD PISTON RING SET AR PISTON RING SET-0.5MM O.S AR PISTON RING SET-1.0MM O.S PISTON PIN SNAP RING CONNECTING ROD ASSEMBLY BUSHING CONNECTING ROD BOLT NUT, CONNECTING ROD BOLT STANDARD BEARING AR BEARING-0.25MM U.S AR BEARING-0.50MM U.S PULLEY NUT U.S. - UNDERSIZE O.S. - OVERSIZE AR - AS REQUIRED MM - MILLIMETER Generac Power Systems, Inc. 53
15 1.0 Liter Diesel Oil Pump Drawing No IDLER GEAR ASSEMBLY SPRING THRUST WASHER ROTOR OIL PUMP COVER AR 0.10MM SHIM AR 0.15MM SHIM AR 0.20MM SHIM AR 0.50MM SHIM SPRING COLLAR SNAP RING FRONT PLATE GASKET BOLT AR - AS REQUIRED 54 Generac Power Systems, Inc.
16 1.0 Liter Diesel Rocker Arm Assembly Drawing No A ROCKER ARM ASSEMBLY (INCLUDES ALL COMPONENTS SHOWN BELOW) INTAKE ROCKER ARM EXHAUST ROCKER ARM NUT STUD ROCKER ARM BRACKET ROCKER ARM SHAFT SPRING SCREW SPRING,PIN NUT STUD Generac Power Systems, Inc. 55
17 1.0 Liter Diesel Injector Pump Drawing No C INJECTOR PUMP ASSEMBLY AR SHIM-0.2MM AR SHIM-0.3MM AR SHIM-0.5MM AR SHIM-1.0MM NUT BOLT GASKET INSERT CAP INJECTOR TUBING TUBING TUBING TUBING CLAMP BOLT GLOW PLUG CONNECTOR GASKET COVER (ALL MODELS EXCEPT & 04614) 0C TUBE, ENGINE OIL FILL (MODEL & 04614) BOLT SOLENOID WASHER WASHER SCREW AR - AS REQUIRED 56 Generac Power Systems, Inc.
18 1.0 Liter Diesel Fuel Supply Drawing No C FUEL FILTER SUPPORT FUEL FILTER 3 0C8008 AR HOSE, 5/16" SAE 30R7 4 0C MM HOSE, 5/16" SAE 30R HOSE CLAMP GASKET BANJO FITTING FUEL BLEED FITTING /8" NPT TEE (BRASS) /8" NPT X 3/16" 90 DEG. BARBED FITTING * 1/8" NPT X 3/16" BARBED STRAIGHT FITTING MM HOSE, 3/16" SAE 30R MM HOSE, 3/16" SAE 30R HOSE CLAMP FUEL BLEED FITTING FUEL BLEED GASKET HOLLOW BOLT BANJO FITTING A 1 1/8" NPT X 1/4" BARBED STRAIGHT FITTING (MODEL & 04614) * -QTY 1 (MODEL & 04614) AR - AS REQUIRED Generac Power Systems, Inc. 57
19 1.0 Liter Diesel Timing and Governor Drawing No B 58 Generac Power Systems, Inc.
20 1.0 Liter Diesel Timing and Governor Drawing No B HOUSING, TIMING GEAR SPRING PIN GASKET SPRING WASHER NUT STOP LEVER COVER GOVERNOR LEVER BOLT NUT SHAFT O-RING SNAP RING * BOLT BOLT OIL SEAL BOLT BOLT ARM SNAP RING O-RING GOVERNOR LEVER ASSEMBLY TENSION LEVER SNAP RING WASHER COTTER PIN SPRING SPRING ARM O-RING SNAP RING BRACKET BOLT BOLT SCREW HHC M6-1.0 X O-RING * O-RING * SPACER GASKET * HOLDER (OIL FILL) * O-RING * CAP * BOLT * NUT 48 0C BRACKET, FUEL FILTER (MODEL & 04614) SCREW HHC M X 60 G8.8 (MODEL & 04614) SCREW HHC M X 65 G8.8 (MODEL & 04614) NUT HEX M G8 (MODEL & 04614) WASHER LOCK M8-5/16 (MODEL & 04614) * NOT USED ON MODEL & Generac Power Systems, Inc. 59
21 1.0 Liter Diesel Engine Block Drawing No C OIL PAN BOLT 3 0D O-RING (MODELS & ONLY) DIPSTICK TUBE (ALL MODELS EXCEPT & 04614) 0C DIPSTICK TUBE (MODELS & ONLY) O-RING (ALL MODELS EXCEPT & 04614) BOLT DIPSTICK (ALL MODELS EXCEPT & 04614) ROCKER COVER GASKET ROCKER COVER OIL STOPPER SCREEN GASKET NUT CAP O-RING A 1 1/4" PIPE PLUG SQ. HD O-RING TUBING SUCTION FILTER GASKET 60 Generac Power Systems, Inc.
22 1.0 Liter Diesel Water Pump Drawing No WATER PUMP ASSEMBLY PLUG THERMOSTAT SPRING GASKET SET PLATE BOLT GASKET BOLT BOLT NUT PULLEY BOLT Generac Power Systems, Inc. 61
Appendix 4 Exploded Views and Parts Lists
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Section 10 Exploded Views and Parts Lists
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1 098671 1 ASSY ROTOR 10KW 098681 1 ASSY ROTOR 15KW 098675 1 ASSY ROTOR 20KW 098936 1 ASSY ROTOR 25KW 2 0A5336A 1 HOUSING BLOWER 3 0A1659 1 SCREEN AIR OUTLET 4 071912 4 SCREW PPHM M5-0.8 X 8 SS 5 049226
Section 7 Exploded Views and Parts Lists IMPACT-36 plus II Recreational Vehicle Generator Control Panel Drawing No. 0E7560
Control Panel Drawing No. 0E760 10 7 4 8 6 6 49 44 47 8 9 1 1 11 9 40 41 41 8 9 14 1 1 19 6 19 9 1 1 1 4 7 6 14 46 16 17 4 7 8 0 7 0 10 4 4 4 48 0 1 40 Generac Power Systems, Inc. Control Panel Drawing
Section 7 Exploded Views and Parts Lists. 40 Generac Power Systems, Inc.
Control Panel Drawing No. 0E7560 50 10 7 4 8 6 6 49 5 44 47 8 9 1 1 11 9 5 40 41 41 8 9 14 15 1 19 6 19 9 1 1 1 5 4 7 6 14 46 16 17 4 7 8 0 7 0 10 4 45 4 48 51 40 Generac Power Systems, Inc. Control Panel
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