POWER SYSTEMS, INC. Owner s Manual. Standby Generator. Models: & This manual should remain with the unit.

Transcription

1 POWER SYSTEMS, INC. Owner s Manual Standby Generator Models: 8- & 8- This manual should remain with the unit.

2 INTRODUCTION Thank you for purchasing this model of the standby generator set product line by Generac Power Systems. Every effort was expended to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written. However, the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any time without prior notice. READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood, contact Generac or the nearest Generac Authorized Service Dealer for starting, operating and servicing procedures. Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert personnel to special instruction about a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows: DANGER After this heading, read instructions that, if not strictly complied with, will result in personal injury or property damage. After this heading, read instructions that, if not strictly complied with, may result in personal injury or property damage. After this heading, read instructions that, if not strictly complied with, could result in damage to equipment and/or property. NOTE: After this heading, read explanatory statements that require special emphasis. These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the service are essential to preventing accidents. Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of information each indicates is as follows: This symbol points out important safety information that, if not followed, could endanger personal! safety and/or property of others. This symbol points out potential explosion hazard. This symbol points out potential fire hazard. This symbol points out potential electrical shock hazard. The operator is responsible for proper and safe use of the equipment. Generac strongly recommends that the operator read this Owner's Manual and thoroughly understand all instructions before using this equipment. Generac also strongly recommends instructing other users to properly start and operate the unit. This prepares them if they need to operate the equipment in an emergency. OPERATION AND MAINTENANCE It is the operator's responsibility to perform all safety checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment checked periodically by a Generac Authorized Service Dealer. Normal maintenance service and replacement of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service. Proper maintenance and care of the generator ensure a minimum number of problems and keep operating expenses at a minimum. See a Generac Authorized Service Dealer for service aids and accessories. Operating instructions presented in this manual assume that the standby electric system has been installed by a Generac Authorized Service Dealer or other competent, qualified contractor. Installation of this equipment is not a do-it-yourself project. HOW TO OBTAIN SERVICE When the generator requires servicing or repairs, simply contact a Generac Authorized Service Dealer for assistance. Service technicians are factory-trained and are capable of handling all service needs. When contacting a Generac Authorized Service Dealer or the factory about parts and service, always supply the complete model number of the unit as given on the front cover of this manual or on the DATA CARD affixed to the unit. AUTHORIZED SERVICE DEALER LOCATION To locate the nearest GENERAC AUTHORIZED SERVICE DEALER, please call this number: DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER. Generac Power Systems, Inc.

3 Table of Contents Introduction...Inside Front Cover Read This Manual Thoroughly...IFC Operation and Maintenance...IFC How to Obtain Service...IFC Authorized Service Dealer Locator Number...IFC Safety Rules... Section General Information.... IDENTIFICATION RECORD..... Data Plate.... EQUIPMENT DESCRIPTION..... Standard Generator Features....3 ENGINE PROTECTIVE DEVICES High Coolant Temperature Switch Low Coolant Level Sensor Low Oil Pressure Switch Low Fuel Pressure Switch Overspeed Shutdown Overcrank Shutdown RPM Sensor Loss Shutdown...5. DC FUSE FUEL SYSTEM Fuel Requirements Diesel Fuel System...5. SPECIFICATIONS Generator Engine Engine Oil Recommendations..... Coolant Fuel System Requirements and Recommendations....7 GENERATOR AC LEAD CONNECTIONS Four-lead, Single-phase Stator....8 GENERATOR AND LOAD COMPATIBILITY....9 STARTING AIDS Engine Coolant Heaters Battery Chargers...7 Section Installation...7. STANDBY GENERATOR INSTALLATION NFPA Standards Other Published Standards...8. BASIC STANDBY ELECTRIC SYSTEM EMERGENCY CIRCUIT ISOLATION METHOD...8. TOTAL CIRCUIT ISOLATION METHOD GROUNDING THE GENERATOR...9. GENERATOR AC NEUTRAL CONNECTIONS TRANSFER SWITCH START SIGNAL CONNECTIONS BATTERY INSTALLATION Vented Batteries....9 PREPARATION BEFORE START-UP Prior to Initial Start-up Start-up Inspection... Section 3 Operation GENERATOR CONTROL AND OPERATION OPERATING UNIT WITH MANUAL TRANSFER SWITCH Engine Start-up and Transfer Retransfer and Shutdown OPERATING UNIT WITH AUTOMATIC TRANSFER SWITCH... Section Maintenance...3. SERVICE SCHEDULE Authorized Operator Maintenance Functions..3.. Authorized Service Technician Maintenance Functions...3. PERIODIC MAINTENANCE Test Standby Generator System Operation and Components..... Inspect Battery Battery Replacement..... Check Fluids Inspect Exhaust System..... Inspect/Test Fuel Supply System REPAIR PARTS How to Order Parts...5 Section 5 Installation Diagram... Section Electrical Data...8 Section 7 Exploded Views and Parts Lists...8 Section 8 Notes...9 Section 9 Warranty...5 Generac Power Systems, Inc.

4 Important Safety Instructions! Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner s Manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions. Generac cannot possibly anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit are, therefore, not all-inclusive. If using a procedure, work method or operating technique that Generac does not specifically recommend, satisfy yourself that it is safe for others. Also make sure the procedure, work method or operating technique choosen does not render the generator unsafe.!! SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries.!!! WARNING:! The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.! WARNING:! This product contains or emits chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. DANGER Despite the safe design of this generator, operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to install, operate or maintain this equipment. Potentially lethal voltages are generated by these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator. Parts of the generator are rotating and/or hot during operation. Exercise care near running generators. Generac Power Systems, Inc.! GENERAL HAZARDS For safety reasons, Generac recommends that this equipment be installed, serviced and repaired by a Generac Authorized Service Dealer or other competent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations. The operator also must comply with all such codes, standards and regulations. Installation, operation, servicing and repair of this (and related) equipment must always 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 Administration (OSHA) has established. Also, ensure that the generator is installed, operated and serviced in accordance with the manufacturer s instructions and recommendations. Following installation, do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes, standards, laws and regulations. The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. For that reason, adequate ventilation must be provided. Exhaust gases must be piped safely away from any building or enclosure that houses the generator to an area where people, animals, etc., will not be harmed. This exhaust system must be installed properly, in strict compliance with applicable codes and standards. Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating. Adequate, unobstructed flow of cooling and ventilating air is critical in any room or building housing the generator to prevent buildup of explosive gases and to ensure correct generator operation. Do not alter the installation or permit even partial blockage of ventilation provisions, as this can seriously affect safe operation of the generator. Keep the area around the generator clean and uncluttered. Remove any materials that could become hazardous. When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued.!!

5 Important Safety Instructions Inspect the generator regularly, and promptly repair or replace all worn, damaged or defective parts using only factory-approved parts. Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start-up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or ( ) first. Reconnect that cable last. Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc. ELECTRICAL HAZARDS All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous voltages to the transfer switch as well as the standby generator. Avoid contact with bare wires, terminals, connections, etc., on the generator as well as the transfer switch, if applicable. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce shock hazard. Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT. If people must stand on metal or concrete while installing, operating, servicing, adjusting or repairing this equipment, place insulative mats over a dry wooden platform. Work on the equipment only while standing on such insulative mats. The National Electrical Code (NEC), Article 5 requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground and/or grounding rods. This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator set or by static electricity. Never disconnect the ground wire. Wire gauge sizes of electrical wiring, cables and cord sets must be adequate to handle the maximum electrical current (ampacity) to which they will be subjected. Before installing or servicing this (and related) equipment, make sure that all power voltage supplies are positively turned off at their source. Failure to do so will result in hazardous and possibly fatal electrical shock. Connecting this unit to an electrical system normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distribution system when the generator is operating. Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy. Generators installed with an automatic transfer switch will crank and start automatically when normal (utility) source voltage is removed or is below an acceptable preset level. To prevent such automatic start-up and possible injury to personnel, disable the generator s automatic start circuit (battery cables, etc.) before working on or around the unit. Then, place a Do Not Operate tag on the generator control panel and on the transfer switch. In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help. Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving components causing injury. FIRE HAZARDS Keep a fire extinguisher near the generator at all times. Do NOT use any carbon tetra-chloride type extinguisher. Its fumes are toxic, and the liquid can deteriorate wiring insulation. Keep the extinguisher properly charged and be familiar with its use. If there are any questions pertaining to fire extinguishers, consult the local fire department. EXPLOSION HAZARDS Properly ventilate any room or building housing the generator to prevent build-up of explosive gas. Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result. Keep the area surrounding the generator clean and free from debris. Generac generator sets may operate using one of several types of fuels. All fuel types are potentially FLAMMABLE and/or EXPLOSIVE and should be handled with care. Comply with all laws regulating the storage and handling of fuels. Inspect the unit s fuel system frequently and correct any leaks immediately. Fuel supply lines must be properly installed, purged and leak tested according to applicable fuel-gas codes before placing this equipment into service. Diesel fuels are highly FLAMMABLE. Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE. Natural gas is lighter than air, and LP gas is heavier than air; install leak detectors accordingly. Generac Power Systems, Inc. 3

6 Section General Information. IDENTIFICATION RECORD.. DATA PLATE Every generator set has a metal DATA PLATE that contains important information pertinent to the generator. The data plate, which can be found attached to the generator s lower connection box, lists the unit s serial number and its rated voltage, amps, wattage capacity, phase, frequency, rpm, power factor, etc.... Generator Model Number This number is the key to numerous engineering and manufacturing details pertaining to your unit. Always supply this number when requesting service, ordering parts or seeking information.... Groups and Assembly Numbers The data card lists the groups and corresponding assembly numbers for each unit. The assembly numbers refer to exploded view drawing numbers that are applicable to your specific generator model. These drawings are located in the back half of this manual.. EQUIPMENT DESCRIPTION This equipment is a revolving field, alternating current generator set. The generator was designed to supply electrical power for the operation of compatible electrical loads when the UTILITY power supply is not available or has dropped to an unacceptable level. The generator s revolving field is directly connected to and driven by an engine by means of flexible discs. Generators with a four-pole rotor are driven at rated speeds of,8 rpm to supply a frequency of Hz. Refer to the data plate on your specific generator or to the data card affixed to the unit for rated AC voltage, wattage, amperage, number of phases, etc... STANDARD GENERATOR FEATURES This generator incorporates the following generator features: The rotor insulation system is Class H rated, and the stator insulation is Class H rated as defined by NEMA MG-. and NEMA MG-.5. The generator is self-ventilated and drip-proof constructed. The voltage waveform deviation, total harmonic content of the AC waveform and telephone influence factor have been evaluated and are acceptable according to NEMA MG-. All prototype tested models have passed three-phase symmetrical short circuit test to ensure system protection and reliability..3 ENGINE PROTECTIVE DEVICES The standby generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant temperature, oil pressure or rpm. For that reason, the engine has several devices designed to protect it against potentially damaging conditions by automatically shutting down the unit when the oil pressure is too low, the coolant temperature is too high, the coolant level is too low, or the engine is running too fast. NOTE: Engine protective switches and sensors are mentioned here for the reader s convenience. Also refer to the applicable control panel manual for additional automatic engine shutdown information..3. HIGH COOLANT TEMPERATURE SWITCH This normally open (N.O.) switch closes to automatically shut down the engine if the engine coolant temperature rises above a safe level..3. LOW COOLANT LEVEL SENSOR Should the engine coolant level drop below the level of the high coolant temperature switch, it is possible for the engine to overheat without automatic shutdown. To prevent such overheating, the engine has a low coolant level sensor. If the level of engine coolant drops below the level of the low coolant level sensor, the engine automatically shuts down..3.3 LOW OIL PRESSURE SWITCH This normally closed (N.C.) switch is held open by engine oil pressure during operation. If oil pressure drops below a safe level, the switch contacts close, automatically shutting down the engine..3. LOW FUEL PRESSURE SWITCH This normally closed (N.C.) switch is held open by fuel pressure during operation. If fuel pressure drops below a safe level, the switch contacts close, automatically shutting down the engine..3.5 OVERSPEED SHUTDOWN A speed circuit controls engine cranking, start-up, operation and shutdown. Engine speed signals are delivered to the circuit board whenever the unit is running. Should the engine overspeed above a safe, preset value, the circuit board initiates an automatic engine shutdown. Generac Power Systems, Inc.

7 Section General Information.3. OVERCRANK SHUTDOWN After a prespecified duration of cranking, this function ends the cranking if the engine has failed to start..3.7 RPM SENSOR LOSS SHUTDOWN If the speed signal to the control panel is lost, engine shutdown will occur.. DC FUSE This clearly labeled fuse is located on the front panel of the control system. It protects the panel wiring and components from damaging overload. Always remove this fuse before commencing work on the generator. The unit will not start or crank if the fuse is blown. Replace the fuse with one of the same size, type, and rating. Generac normally uses an AGC fuse rated at 5 amps..5 FUEL SYSTEM.5. FUEL REQUIREMENTS NOTE: It is the responsibility of the installer to make sure that only the correct recommended fuel is supplied to the generator fuel system. Thereafter, the owner/operator must make certain that only the proper fuel is supplied. For further information on the various types of fuel systems, refer to Engine-Generator Standby Electric Power Systems Installer s Guide and Reference Manual (part #)..5. DIESEL FUEL SYSTEM Diesel fuel is supplied to the generator set from a base-mounted fuel tank. Diesel fuels are less volatile than gaseous fuels, however, careless installation can lead to safety hazards and/or serious problems with engine/generator performance and reliability. NOTE: Appropriate care should be taken in applications where extremely low ambient temperatures are possible to ensure the temperature of the diesel fuel is not allowed to fall below levels where gelling could occur.. SPECIFICATIONS.. GENERATOR Refer to the data plate on your particular generator for rated watts, amperes, frequency, voltage, phase and other pertinent information... ENGINE General: Cylinders and Arrangement... in-line Displacement...3. L (8.5 in 3 ) Bore...95 mm (3.7 in.) Stroke...5 mm (. in.) Compression Ratio...-to- Number of Main Bearings...5 Type of Main Bearing Caps...Cast Iron Aspiration...Turbocharged (T) Governed Engine Speed...8 rpm Type of Valve Lifters...Solid Cylinder Head...Cast Iron with Overhead Valve Pistons... - Aluminum Alloy Crankshaft...Forged Steel Number of Flywheel Teeth...38 Engine Lubrication System: Type of Oil Pump...Gear Driven Oil Filter...Full Flow, Cartridge Crankcase Oil Capacity... L (.3 U.S. quarts) Fuel System: Type of Fuel...#D Fuel (Min Cetane #) Consumption:* Rated Freq. 5% Load 5% Load 75% Load % Load Hz.8... *Given in: gal/h Cooling System: Type...Pressurized, Closed Recovery Coolant Capacity System... L (.8 U.S. gals.) Engine...5 L (. U.S. gals.) Coolant Flow Per Minute...9 L ( U.S. gals.) Heat Rejection to Coolant...7,5 Btu/h Cooling Fan...Pusher Type Diameter of Fan...57 mm (8 in.) Cooling Airflow Required...,33 cfm Recommended Coolant...See Coolant on Page 8 Combustion Airflow Required... cfm Exhaust System: Exhaust Flow at Rated Output...3 cfm Exhaust Outlet Size... in. Exhaust Temperature at Rated Output...( C) 8 F Generac Power Systems, Inc. 5

8 Section General Information Engine Electrical System: DC Alternator Output... amps at volts Starter Motor...-volt DC Recommended Battery...One -volt, 9 Ah, 7 F Ground Polarity...Negative ( )..3 ENGINE OIL RECOMMENDATIONS The unit has been filled with 5W- engine oil at the factory. Use a high-quality detergent oil classified For Service CC, SD, SE or SF. Detergent oils keep the engine cleaner and reduce carbon deposits. Use oil having the following SAE viscosity rating, based on the ambient temperature range anticipated before the next oil change: Temperature Oil Grade (Recommended) Above 8º F (7º C) SAE 3W or 5W- 3º to 8º F (-º to 7º C) SAE W- or 5W- Below 3º F (º C) SAE W or 5W-.. COOLANT Use a mixture of half Propylene glycol base antifreeze and half soft water. Use only soft water and Propylene glycol antifreeze. When adding coolant, always add the recommended 5-5 mixture.!!! DANGER Do not remove the radiator pressure cap while the engine is hot or serious burns from boiling liquid or steam could result. Propylene glycol base antifreeze is poisonous. Do not use your mouth to siphon coolant from the radiator, recovery bottle or any container. Wash your hands thoroughly after handling. Never store used antifreeze in an open container 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 propylene glycol base antifreeze. Using any high silicate antifreeze boosters or additives also will cause overheating. We also recommend that you DO NOT use any soluble oil inhibitor for this equipment...5 FUEL SYSTEM REQUIREMENTS AND RECOMMENDATIONS Diesel Fuel System: See Chapter 8 of Engine- Generator Standby Electric Power Systems Installer s Guide and Reference Manual (part #). Generac Power Systems, Inc..7 GENERATOR AC LEAD CONNECTIONS The electrical wires in the unit s AC connection (lower) panel should be installed according to the number of leads and the voltage/phase required for your application. If there is any question regarding lead connection, refer to the wiring diagrams at the back of this manual..7. FOUR-LEAD, SINGLE-PHASE STATOR Four-lead generators are dual voltage coils or windings (Figure.). Units may be assigned the following voltage code: A units are rated / volts, single-phase, Hertz. Each stator winding in this case delivers a -volt AC output; connecting the two windings series results in a -volt AC output. The neutral line is formed by a junction of stator leads and 33. Thus, you may connect -volt loads across leads and neutral, or across leads and neutral. Figure. Four-lead, Single-phase Stator.8 GENERATOR AND LOAD COMPATIBILITY The generator must be fully compatible with the rated voltage, phase and frequency of the connected electrical loads. The generator, connected electrical devices, or both, can be damaged if voltage, phase and frequency are not compatible. NOTE: This manual assumes that the standby generator has been properly selected, installed and interconnected by a competent, qualified electrician or installation contractor. Once the installation is complete, you must not do anything that may result in noncompatibility between the generator and connected electrical loads.

9 Section Installation.9 STARTING AIDS This standby generator is equipped with the following starting aids that serve to provide quicker, easier starts under varying climactic conditions. Figure.3 Typical Dual-rate Battery Charger This generator has been mounted with an engine coolant heater and a battery charger. These aids are powered by a normal (utility) power source during nonoperating periods..9. ENGINE COOLANT HEATERS This unit is equipped with an engine coolant (block) heater (Figure.), it is powered by a circuit normally fed by the utility power supply. The heater acts to heat the engine coolant when the unit is not operating. This action keeps the engine warm even in cold weather, thus helping ensure quicker starts. Heated coolant in the engine rises continuously drawing cold coolant into the heater, thus making certain of a constant flow of warm coolant through the engine. Figure. Typical Engine Coolant Heater OUTPUT. STANDBY GENERATOR INSTALLATION DANGER Connecting this generator to an electrical system normally supplied by an electric utility shall be by means of a transfer switch (such as the Generac GTS type transfer switch), so as to isolate the electric system from the utility distribution system when the generator is operating. Failure to isolate the electric system by these means will result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy..9. BATTERY CHARGERS All UL units will be fitted with a V or V, amp charger. This charger is similar to the one shown in Figure Dual-rate Battery Charger This SCR-controlled, fully automatic battery charger has a panel-mounted DC ammeter and voltmeter, fused input and output circuits, and an automatic current limiter design. The unit is equipped with automatic float and equalize control and uses an SCR to maintain proper charge voltage. This type of system precisely monitors the charge rate (Figure.3 ). The charger is rated at amps DC. If an open bottom is used, the engine-generator is to be installed over non-combustible materials and should be located such that combustible materials are not capable of accumulating under the generator set. Only qualified, competent installation contractors or electricians thoroughly familiar with applicable codes, standards and regulations should install this standby electric power system. The installation must comply strictly with all codes, standards and regulations pertaining to the installation. This genset must be installed on a level surface. The base frame must be level within two () inches all around.! After the system has been installed, you must not do anything that might render the installation in noncompliance with such codes, standards and regulations. Generac Power Systems, Inc. 7

10 Section Installation NOTE: For more information about the installation of a standby system, you can order Engine-Generator Standby Electric Power Systems Installer s Guide and Reference Manual (part #) from your Generac Authorized Service Dealer... NFPA STANDARDS The following published standards booklets pertaining to standby electric systems are available form the National Fire Protection Association (NFPA), Batterymarch Park, Quincy, MA 9: NFPA No. 37, STATIONARY COMBUSTION ENGINES AND GAS TURBINES. NFPA No. 7A, ESSENTIAL ELECTRICAL SYS- TEMS FOR HEALTH CARE FACILITIES. NFPA No., STANDARD TYPES OF BUILDING CONSTRUCTION NFPA No. 8, GUIDE FOR EXPLOSION VENTING NFPA No. 7, NATIONAL ELECTRICAL CODE. NFPA No. 3, FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE. NFPA No., INSTALLATION, MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS... OTHER PUBLISHED STANDARDS In addition to NFPA standards, the following information pertaining to the installation and use of standby electric systems is available: Article X, NATIONAL BUILDING CODE, available from the American Insurance Association, 85 John Street, New York, N.Y. 38. AGRICULTURAL WIRING HANDBOOK, obtainable from the Food and Energy Council, 99 University Avenue, Columbia, MO, 5. ASAE EP-3., INSTALLATION AND MAINTE- NANCE OF FARM STANDBY ELECTRIC POWER, available from the American Society of Agricultural Engineers, 95 Niles Road, St. Joseph, MI 985. A5., AMERICAN NATIONAL STANDARD FOR CHIMNEYS, FIREPLACES AND VENTING SYS- TEMS, available from the American National Standard Institute, 3 Broadway, New York, N.Y. 8.. BASIC STANDBY ELECTRIC SYSTEM Figure. shows a schematic diagram of a basic standby electric system. Both the UTILITY power supply and the STANDBY (generator) output are connected to an approved transfer switch. The transfer switch is required by electrical code and serves the following functions: Permits the LOAD circuits to be connected to only one power supply at a time. Prevents electrical backfeed between the generator and the UTILITY power circuits. Figure. Basic Standby Electric System Notice that both the STANDBY and the UTILITY power supplies to the transfer switch are protected against overload by a main line circuit breaker. NOTE: Generac recommends the use of a Generac power systems GTS type transfer switch in conjunction with this generator..3 EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator. If the generator is powering only critical loads, within the wattage/amperage capacity, during utility power outages, you might consider using the emergency circuit isolation method. Critical electrical loads are grouped together and wired into a separate Emergency Distribution Panel. Load circuits powered by that panel are within the wattage/amperage capacity of the generator set. When this method is used, it is difficult to overload the generator. The transfer switch must meet the following requirements: It must have an ampere rating equal to the total amperage rating of the emergency distribution panel circuit. Have it installed between the building s main distribution panel and the emergency distribution panel. 8 Generac Power Systems, Inc.

11 Section Installation. TOTAL CIRCUIT ISOLATION METHOD When a generator capable of powering all electrical loads in the circuit is to be installed, you may use the Total Circuit Isolation Method. It is possible for the generator to be overloaded when this isolation method is employed. The following apply to the transfer switch in this type of system. Ampere rating of the transfer switch must equal the ampere rating of the normal incoming utility service. The transfer switch is installed between the utility service entrance and the building distribution panel..5 GROUNDING THE GENERATOR The National Electrical Code requires the frame and external electrically conductive parts of this equipment to be properly connected to an approved earth ground and/or grounding rods. For that purpose, a GROUND LUG (Figure.) is provided on the generator mounting base. Consult a qualified electrician for grounding requirements in your area. Grounding procedures must meet local regulations. DANGER Do not connect the ground wire to any pipe that carries a flammable or explosive substance FIRE or an EXPLOSION may result. Proper grounding helps protect personnel against electrical shock in the event of a ground fault condition in the generator or in connected electrical devices. In addition, grounding helps dissipate static electricity that often builds up in ungrounded devices. Figure. Generator Grounding Lug (typical). GENERATOR AC NEUTRAL CONNECTIONS Generac uses an UNGROUNDED AC neutral. Grounding is recommended only at the main service entrance. If the neutral wire is grounded and one of the phase loads becomes grounded, the excessive current opens the load circuit breaker or collapses the generator field. The actual result depends on the electrical characteristics of the particular installed generator..7 TRANSFER SWITCH START SIGNAL CONNECTIONS If your generator is to be installed with an automatic transfer switch, such as a Generac GTS-type switch, it will be necessary to connect the two-wire start control system. Connect the two-wire start signal from the automatic transfer switch to the automatic start connection, which is located in the upper right hand corner of the AC connection panel (see Figure.3). Match wires 78 and 83 in the transfer switch to 78 and 83 on the terminal strip in the connection box. The conductors for the two-wire start circuit must be in their own conduit. Figure.3 Start Signal Connections.8 BATTERY INSTALLATION! DANGER Standby generators installed with automatic transfer switches will crank and start automatically when normal (utility) source voltage is removed or is below an acceptable preset level. To prevent such automatic start-up and possible injury to personnel, do not connect battery cables until you are certain that normal source voltage at the transfer switch is correct and you are ready to place the system into operation. Generac Power Systems, Inc. 9

12 Section Installation!! Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing tools or equipment near the battery. Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If you spill the fluid, flush the affected area immediately with clear water. Do not dispose of the battery in a fire. The battery is capable of exploding. Do not open or mutilate the battery. Released electrolyte can be toxic and harmful to the skin and eyes. The battery represents a risk of high short circuit current. When working on the battery, always remove watches, rings or other metal objects, and only use tools that have insulated handles..8. VENTED BATTERIES The electrolyte is a dilute sulfuric acid that is! harmful to the skin and eyes. It 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, Where electrolyte contacts the eyes, flush thoroughly and immediately with water and seek medical attention, and Spilled electrolyte is to be washed down with an acid-neutralizing agent. A common practice is to use a solution of one pound (5 grams) bicarbonate of soda to one gallon ( liters) of water. The bicarbonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried. Lead acid batteries present a risk of fire because they generate hydrogen gas. The following procedure are to be followed: DO NOT SMOKE when near batteries, DO NOT cause flame or spark in battery area, and Discharge static electricity from body before touching batteries by first touching a grounded metal surface. Servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries. For recommended batteries, see Specifications. All batteries must be at percent state-of-charge before they are installed on the generator. When using maintenance-free batteries, it is not necessary to check the specific gravity or electrolyte level. Have these procedures performed at the intervals specified in Section, Maintenance. A negative ground system is used. Battery connections are shown on the wiring diagrams. Make sure all batteries are correctly connected and terminals are tight. Observe battery polarity when connecting batteries to the generator set. NOTE: Damage will result if the battery connections are made in reverse..9 PREPARATION BEFORE START-UP The instructions in this section assume that the standby generator has been properly installed, serviced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor. Be sure to read the Safety Rules on Pages and 3, as well as all other safety information in this manual, before attempting to operate this (and related) equipment..9. PRIOR TO INITIAL START-UP Prior to initially starting the generator, it must! be properly prepared for use. Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids (oil, coolant, fuel, etc.) may result in an engine failure. Before starting the generator for the first time, the installer must complete the following procedures. For follow-up maintenance information and/or service intervals, please refer to Section, Maintenance, and the Service Schedule on Page 7. Generac Power Systems, Inc.

13 Section Installation.9.. Transfer Switch If this generator is used to supply power to any electrical system normally powered by an electric utility, the National Electrical Code requires that a transfer switch be installed. The transfer switch prevents electrical backfeed between two different electrical systems. (For additional information, see the applicable transfer switch manual for this unit.) The transfer switch, as well as the generator and other standby components, must be properly located and mounted in strict compliance with applicable codes, standards and regulations..9.. Fuel System Make sure the fuel supply system to the generator (a) delivers the correct fuel at the correct pressure and (b) is properly purged and leak tested according to code. No fuel leakage is permitted. See Specifications (Page 7) for more information. If the unit has been idle for a long period of time, or if the fuel lines or system components have been removed and reinstalled, the fuel system may require bleeding to remove air from the system. Air in the fuel system causes hard starting and rough operation. All fuel system lines must be installed and must be tight. A loose line may show no sign of leakage, but may draw air into the system. Use a suitable container to catch the fuel that will spill during system bleeding process. Clean up all spilled fuel after bleeding Generator Set Lubrication Check the engine crankcase oil level before operating and add oil to the proper level the dipstick FULL mark. Never operate the engine with the oil level below the dipstick ADD mark. See Specifications (Page 7) and Engine Oil Recommendations (Page 8). NOTE: This engine is shipped from the manufacturer with 5W- oil. This oil should be changed after 3 hours of operation. The engine is equipped with a mechanical governor. Make sure the governor is properly lubricated with clean engine oil.!.9.. Engine Coolant Have the engine cooling system properly filled with the recommended coolant mixture. Check the system for leaks and other problems. See Specifications (Page 7) and Coolant (Page 8) Belt Tension Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals. Belt tension is correct when a force of approximately pounds ( kg), applied midway between pulleys, deflects the belt about 3/8- to 5/8- inch ( to mm)..9.. Electrical System Make sure the generator is properly connected to an approved earth ground. Make sure the generator battery is fully charged, properly installed and interconnected, and ready for use. Check to ensure that there are no loose electrical connections. Restrain any loose wires to keep them clear of any moving generator set components Rodent Protection Make sure the four 3-inch diameter cap plugs (part # A8785) are properly installed in the tie-down holes in the side rails of the unit s base frame (Figure.). The cap plugs are shipped in a plastic bag located in the lower connection box. These plugs are needed to prevent rodents from accessing the interior of the generator set. On acoustic units, cap plugs also are needed to stay within noise specification limits. Figure. Base Frame Cap Plugs.9. START-UP INSPECTION A standard three-part form titled Start-up Inspection for Standby Power Systems (part # 7377) should be completed by the installation technician or engineer. As stated on the form, inspections are to be accomplished only by factory-trained personnel. The installer should complete the form and disseminate copies as follows: White copy: Mail to Generac Warranty Department, P.O. Box 8, Waukesha, WI Pink Copy: For service file of installing dealer. Yellow Copy: For the customer s records. Generac Power Systems, Inc.

14 Section Maintenance 3. GENERATOR CONTROL AND OPERATION Refer to the appropriate control panel operator s manual for this unit. 3.3 OPERATING UNIT WITH AUTOMATIC TRANSFER SWITCH If your generator has been installed along with an automatic transfer switch, such as a Generac GTStype switch, the engine may be started and stopped automatically or manually. NOTE: Refer to the applicable manual for your transfer switch and to Transfer Switch Start Signal Connections (Page 3). In addition, please note the dangers under Engine Start-up and Transfer.. SERVICE SCHEDULE.. AUTHORIZED OPERATOR MAINTENANCE FUNCTIONS... Every Month or Hours (whichever comes first) Test standby generator system. Inspect battery (batteries) and cables. Check engine oil level. Check gearbox oil level (if so equipped). Check engine coolant level. Check generator ground connections. Test/inspect starting aids.... Every Three Months or Every Hours (whichever comes first) Inspect and test fuel system and connections. Inspect exhaust system. Inspect/test fuel supply system... AUTHORIZED SERVICE TECHNICIAN MAINTENANCE FUNCTIONS... After First 3 Hours of Operation Inspect wiring. Change engine crankcase oil and oil filter. Inspect engine fan belts. Inspect battery (batteries) and cables.... Every Six Months or Every Hours (whichever comes first) Change engine oil and filter. Lubricate engine controls. Service engine air cleaner. Service engine fuel filter. Inspect AC generator. Test engine safety controls. Inspect fan belts. Check engine coolant level. Inspect engine cooling system hoses. Check optional starting aids. Check battery (batteries). Check engine compression. Check electrical connections. Check/test annunciator panel. Perform operational test....3 Annually or Every Hours (whichever comes first) Check engine valve clearance. Test fuel injection nozzles. Test injection timing. Inspect all wiring. Test engine starter operation. Drain water from fuel tank. Retorque fan bolts. Drain and refill gearbox (If so equipped, contact sales for availability.)... Every Two Years Replace all rubber hoses. Replace engine fan belts. Inspect the Standby Generator System. Drain, flush, refill cooling system....5 Every, Operating Hours Inspect engine DC alternator. Inspect engine starter. Retorque engine mounting brackets. Remove/test fuel injection pump. Remove/test cooling system thermostat.... As Required Bleed engine fuel system. Generac Power Systems, Inc.

15 Section Maintenance. PERIODIC MAINTENANCE A rigorous program of scheduled periodic maintenance should be established and maintained. Such a program, if adhered to diligently, will provide added assurance that your power system functions properly when it is needed. Keeping a Maintenance Log is highly recommended. Such a log should be a continuous record of repairs, parts replacements, gauge and instrument readings during operational tests, etc. Generac recommends that a Customer Maintenance Inspection Agreement be established between the user of this equipment and the installing Generac Authorized Service Dealer. Under this agreement, (Part No. 533), a Generac Authorized Service Technician performs prestart and engine running tests and checks at six-month and one-year intervals. Ask your Generac Authorized Service Dealer (or consult the factory) about this agreement. The tasks listed in the Service Schedule (Page 7) cover the minimum recommended maintenance requirements for this equipment. Note that many of the tests and checks listed in the schedule are to be performed only by a Generac Authorized Service Technician. Fluid capacities and recommendations, as well as other applicable specifications, are listed in Specifications (Page 7)... TEST STANDBY GENERATOR SYSTEM OPERATION AND COMPONENTS An authorized operator should test the operation of the standby generator system and inspect its components monthly (or hours). This should include inspecting the transfer switch for evidence of arcing, and pitted or burned contacts; inspecting wiring and grounding connections (see Grounding the Generator, Page 3); and ensuring that starting devices are operational. During this operational test, all instrument and gauge readings should be recorded in a Maintenance Log. The transfer system also should be tested at this time; the engine should be run at least 3 minutes and any discrepancies corrected immediately. Every six months (or hours), a Generac Authorized Service Technician should perform a system operational test.!!.. INSPECT BATTERY DANGER Standby generators installed with automatic transfer switches will crank and start automatically when normal (utility) source voltage is removed or is below an acceptable preset level. To prevent such automatic start-up and possible injury to personnel, do not connect battery cables until you are certain that normal source voltage at the transfer switch is correct and you are ready to place the system into operation. Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing tools or equipment near the battery. Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If you spill the fluid, flush the affected area immediately with clear water. Do not dispose of the battery in a fire. The battery is capable of exploding. Do not open or mutilate the battery. Released! electrolyte can be toxic and harmful to the skin and eyes. The battery represents a risk of high short circuit current. When working on the battery, always remove watches, rings or other metal objects, and only use tools that have insulated handles. An authorized operator should inspect the engine battery system monthly (or hours). At this time, the battery fluid level should be checked and distilled water added if needed. Battery cables and connections also should be inspected for cleanliness and corrosion. Once every six months (or hours), a Generac Authorized Service Technician should inspect the battery system. At this time the battery condition and state of charge should be checked using a battery hydrometer. The battery should be recharge or replaced as required. Generac Power Systems, Inc. 3

16 Section Maintenance..3 BATTERY REPLACEMENT When replacing batteries, use the same number and the following type batteries. Generac P/N BCI Group No. CCA 585 7F deg. F NOTE: The BCI number should be located directly on the battery. For more information, see Specifications... CHECK FLUIDS An authorized operator should check the levels of engine oil, and engine coolant monthly (or hours). The oil level should be maintained between the FULL and ADD marks on the engine dipstick. Recommended fluids are listed on page 8 of this manual...5 INSPECT EXHAUST SYSTEM Every three months (or hours), an authorized operator should inspect the entire exhaust system. Abnormal noise levels heard during each operational test may indicate a defective exhaust pipe or muffler. Any defective or leaking component should be repaired or replaced immediately by a Generac Authorized Service Technician... INSPECT/TEST FUEL SUPPLY SYSTEM Every three months (or hours), an authorized operator should inspect and test the fuel supply system, as well as all fuel system connections. All connections must be tight and in good condition. A loose fuel system line may show no signs of leakage, but may draw air into the system causing rough operation and starting difficulties. Any defective or leaking component should be repaired or replaced immediately by a Generac Authorized Service Technician..3 REPAIR PARTS The latter portion of this manual consist of exploded views, parts lists and electrical data pertaining to this generator set. The parts lists consist of (a) an item number, (b) a part number, (c) the quantity required, and (d) a description of the part. The item number corresponds to an identical number on the exploded view drawing..3. HOW TO ORDER PARTS To order a replacement part, locate the part in the applicable exploded view. Contact your Generac Authorized Service Dealer (call to locate one in your area) and provide the following information: The generator model number. The generator identification code, which indicates the specific generator assembly for each unit. The part number and corresponding description from the applicable parts list in this manual. The applicable exploded view Group letter (A-H) and drawing number (five-digit number), which can be found on the exploded view drawing. NOTE: In most cases, you can obtain repair parts by providing your Generac Authorized Service Dealer with the data card information and a description of the required part. If you are unable to locate either the data card or the construction document, simply describe the part you need and provide your unit s model number. This number can be found on the metal DATA PLATE attached to the generator s lower connection box. Generac Power Systems, Inc.

17 Section 5 Installation Installation Diagram Drawing No. E595 Generac Power Systems, Inc. 5

18 Section Electrical Data Wiring Diagram - E Panel Drawing No. D378V-B N M 5 5 L B C E F 5 K B D P 3/8 V V V H F SOC LPC T 53 5/ CLEAR BLACK 79 9 TB U /8 9 S5 /9 /9 3/8 9 /9 / /8 5/ 5/ 5/ BLACK/85+ CLEAR/85- BARE 3 BAT GND (-) PRG RLY NO PRG RLY NC PRG RLY COM BAT GND (-) DC FUSED (+) (5/) PRG RLY COM PRG RLY NO PRG RLY NC PRG RLY 3 COM PRG RLY 3 NO PRG RLY 3 NC FUEL + 59 FUEL- 59 CA / /8 78 /9 7 /9 83 /9 5/ 5/ R R R3 R R5 R R7 R8 R /9 TB 5/ 5/ / 5/ C ALT W/L A A3 A A MLCB SW 7 PRG INPT GND PRG INPT GND B/C FAIL GEN POWER LINE POWER PRG INPT PRG INPT 7 MLCB RUPT TANK TB PRE-HEAT RUPT TANK EC TB WIRE COLOR LEGEND WHITE RED NEUTRAL NON-FUSED DC,,R5,59,3,9,8 ORANGE FUSED DC,5,9, BROWN CONTROL 5,5A,57-59,7,89,78,83,S-3,59 BLUE SIGNAL/SENSING,9,5,A-8,R-9 S5,S,,5 BLACK AC/MISC YELLOW UNIT STATUS 8,9,85,5,59, 55,53,57,575,589 AVR = AUTOMATIC VOLTAGE REGULATOR CB = AVR CIRCUIT BREAKER CA = REMOTE ANNUNCIATOR D = FIELD BOOST DIODE D = C/A EXCITER DIODE EC = ENGINE CONNECTOR [ENGINE] EC = ENGINE CONNECTOR [ENGINE] EC3 = ENGINE CONNECTOR [BASETANK] FA = FILTER ASS. [LOW FUEL PRES SWH] LPC = LOWER PANEL CONNECTOR R = FIELD BOOST RESISTOR R = C/A EXCITER RESISTOR TB = TERMINAL BLOCK [ POS.] TB = TERMINAL BLOCK [ POS.] TB3 = TERMINAL BLOCK [ POS.] TB = TERMINAL BLOCK [8 POS.] CB D LEGEND 5/ 5/ /9 /9 9 R 5 FUNCTION 9 D /9 AVR 3 WIRE #'s 89 3/8 CABLE 5/ 5/ /9 89 S T X NOT USED S3 S S5 Generac Power Systems, Inc.

19 Section Electrical Data Wiring Diagram - E Panel Drawing No. D378V-B ES MC R5 /9 A 5 /9 3/8 5/ S 5 3/8 5/ F VR S 5A 89 5A A R5 A A A3 A A5 A A7 A R PRG INPT PRG INPT 3 PRG INPT 5 PRG INPT 7 GND FUEL LVL OIL TEMP COOL TEMP SPD SNSR + REMOTE STRT SPR INPT FUEL SNDR - SNDR RLY N/C SNDR RLY N/O SNDR RLY COM PRG RLY 3 NC PRG RLY 3 NO PRG RLY 3 COM PRG RLY NC PRG RLY NO PRG RLY COM PRG RLY NC PRG RLY NO PRG RLY COM PRE-HEAT N/O PRE-HEAT COM STARTER SOL FUEL SOL ALT LINE ALT LINE BAT - BAT + 8 S S5 55 5/ R8 R R R 5 5A A 55 AA 5/ S5 S 3/8 CABLE 5/ 5/ /9 89 /9 PFG /9 L 5/ FERRITE BEADS 5/ S5 S5 S S WIRE COLOR LEGEND RED ORANGE BROWN BLUE BLACK YELLOW FUNCTION NEUTRAL NON-FUSED DC FUSED DC CONTROL SIGNAL/SENSING AC/MISC UNIT STATUS 59 WIRE #'s,,r5,59,3,9,8,5,9, 5,5A,57-59,7,89,78,83,S-3,59,9,5,A-8,R-9 S5,S,,5 8,9,85,5,59, 55,53,57,575,589 S3 S S S S S S5 S5 S5 LEGEND AA = AUDIBLE ALARM AM = AMMETER ES = EMERGENCY STOP SWITCH F = 5 AMP AGC TYPE FUSE HZ = FREQUENCY METER L = PANEL LAMP MC = E-PANEL CONTROL ASSEMBLY PFG = PANEL FRONT GROUND STUD SW = VOLT/AMMETER SWITCH VM = VOLT METER VR = VOLTS TRIM POTENTIOMETER SW 8 7 S S S S5 S5 S5 HZ VM 5 7 AM Generac Power Systems, Inc. 7

20 Section Electrical Data Wiring Schematic - E Panel Drawing No. D379V-A LOWER PANEL CONNECTOR MLCB OPEN 589 BC-R BC-S GROUND RETURN CT COMMON BC-A L CT 57 L CT L3 CT BC-N BC-O 58 BC-P 59 L VOLTS L VOLTS L3 VOLTS BC-K BC-L S BC-M S3 -WIRE START SIGNAL AVR SENSING AVR POWER EXCITER FIELD BC-J 78 BC-B 83 BC-H S5 BC-G S BC-F BC-C FIELD BOOST ALTERNATOR EXCITATION D R D R AUTOMATIC VOLTAGE REGULATOR (AVR) FIELD POWER SENSING 3 5 CB VR 8 9 VM SW AM CHARGE ALT. W/L CONN. 9 AUX. FUSED DC SUPPLY 5 POSITIVE DC FROM BATTERY 3 POSITIVE DC FROM BATTERY 3 GROUND FROM ENGINE GROUND FROM ENGINE FUEL SOLENOID STARTER SOLENOID 5 PRE-HEAT SOLENOID 5 COOLANT TEMP. SENSOR 8 OIL PRESSURE SENSOR OIL TEMP. SENSOR FUEL LEVEL SENSOR FUEL SENDER + FUEL SENDER - COOLANT LEVEL DETECTOR MAGNETIC RPM SENSOR SHIELD BC3- TB-5 BC3- BC3- BC3-7 BC3-9 BC3-3 BC3- BC-9 BC-8 BC- BC-7 BC- BC- BC- BC- F 5A L ES-3 ES- ES- AA CON- CON- CON3- CON3- CON3- CON3-3 CON3- CON- CON-5 CON- CON- CON-3 CON- CON-7 CON-8 CON-9 CON- CON3-5 HZ S S5 CON- CON- CON- 'E' PANEL CONTROL BOX MC DSUB-3 DSUB- DSUB-5 DSUB- DSUB- CON- CON- CON-3 CON- CON-5 CON- CON-7 CON-8 CON-9 CON- CON3-5 CON3- CON3-7 CON3-8 CON3-9 CON3- CON3- CON3- CON3-3 BC-5 BC- BC- BC- BC-3 COM N/O N/C COM N/O N/C COM N/O N/C A 5 A A3 A A5 A7 A8 57 R R R3 R R5 R R7 R8 R9 PROG. INPUT BATT CHRG FAIL PROG. INPUT GEN. POWER PROG. INPUT 3 LINE POWER LOW FUEL PRESSURE # PROG. INPUT 5 GEN. FLUID BASIN # 7 PROG. INPUT 7 MLCB OPEN PROG. INPUT 8 RUPT. TANK GROUND RETURN GROUND RETURN PROG. RELAY PROG. RELAY PROG. RELAY 3 TB-8 TB-7 TB- RS3 (DSR) RS3 (Rx)/RS85+ RS3 (Tx)/RS85- RS3 (DTR) COMMON 8 Generac Power Systems, Inc.

21 Section Electrical Data Wiring Schematic - E Panel Drawing No. D379V-A CODE AA AM AVR CB D D ES ES-3 HZ L MC R R SW VM VR XXX-X P/N: 8 VARIOUS VARIOUS A 98C 7 7A C88 7 A87 VARIOUS VOLTMETER -3V 7 VOLTMETER -V 8 VOLTMETER -75V 73 REFERENCE DESCRIPTION AUDIBLE ALARM AMMETER AUTOMATIC VOLTAGE REGULATOR 5Hz AUTOMATIC VOLTAGE REGULATOR Hz AVR CIRCUIT BREAKER FIELD BOOST DIODE CHARGE ALT EXCITER DIODE EMERGENCY STOP BUTTON NORMALLY CLOSED CONTACTS FREQUENCY METER 5Hz FREQUENCY METER Hz PANEL LAMP V PANEL LAMP V E-PANEL CONTROLLER ASSEMBLY FIELD BOOST RESISTOR CHARGE ALT EXCITER RESISTOR VOLT/AMMETER SWITCH VOLTS TRIM POTENTIOMETER E-PANEL CONNECTOR TERMINATIONS WIRE COLOR LEGEND WHITE RED ORANGE BROWN BLUE BLACK YELLOW FUNCTION NEUTRAL NON-FUSED DC FUSED DC CONTROL SIGNAL/SENSING AC/MISC UNIT STATUS WIRE #'s,,r5,59,3,9,8,5,9, 5,5A,57-59,7,89,78,83,S-3,9,5,A-8,R-9 S5,S,,5 8,9,85,5,59,55 53,57,575,589 Generac Power Systems, Inc. 9

22 K Section Electrical Data Wiring Diagram - Battery Charger Drawing No. D8 TS TS3 A TS7 TS TS F COVER GND GND TS7 COVER GND GENERAC POWER SYSTEMS D K ASSY # 7 REV_G PCB K CHASSIS TB GND AC NEUT GND GND TB GND D98-T LEGEND 3 F AC HOT AC HOT L AC NEUT AM - DC AMMETER, -5A F - FUSE, 5V, A (V) OR 7A (V) F - FUSE, 3V, A GND - GROUND POST L - LAMP, PANEL PCB - CIRCUIT BOARD ASSY, 7C (V) OR 7A (V) TB - TERM BOARD, AC INPUT TB - TERM BOARD, DC OUTPUT VM - VOLTMETER,-5V(V) OR -3V(V) Generac Power Systems, Inc. 3B 3B F TB AM 89-T + - 3A 3 VM 3 + POS NEG 3 35

23 Section Electrical Data Electrical Schematic - Battery Charger Drawing No. D8 A/7A 5V SLOW-BLOW 3A AM A 3B TB-3 F F A TS5 3 AC HOT L PCB VM + - "POWER ON" TB- TS3 TS 35 AC NEUT F AMP 3V -5V -3V TB- GND GND TS TS7 LEGEND AM - DC AMMETER, -5A F - FUSE, 5V, A (V) OR 7A (V) FUSE 3V A F - FUSE, 3V, A GND - GROUND POST L - LAMP, PANEL PCB - CIRCUIT BOARD ASSY, 7C (V) OR 7A (V) TERM BOARD AC INPUT TB - TERM BOARD, AC INPUT TB - TERM BOARD, DC OUTPUT VM - VOLTMETER,-5V(V) OR -3V(V) TB- TB- TB-3 TB- Generac Power Systems, Inc.

24 Section Electrical Data Wiring Diagram - 3.L Engine Drawing No. E5A Generac Power Systems, Inc.

25 Section Electrical Data Electrical Schematic - 3.L Engine Drawing No. EA Generac Power Systems, Inc. 3

26 Section 7 Exploded Views and Parts Lists Mounting Base Drawing No. C37-H 5 7 * * ENGINE MOUNTING FOOT 3 3* 5* TO RADIATOR DRAIN 9 8 REAR BLOCK TO FUEL FILTER 3 To Fuel MOUNTING BASE * TO STARTER TO OIL PAN 3 5 5* Generac Power Systems, Inc.

27 Section 7 Exploded Views and Parts Lists Mounting Base Drawing No. C37-H ITEM PART NO. QTY. DESCRIPTION C3 MOUNTING BASE 3.L HA KIA 39 ALTERNATOR C MOUNTING BASE 3.L HA KIA " ALTERNATOR 58 NUT FLANGED HEX M DAMPENER VIBRATION BLUE 557 SPACER.9 X. X.87 PWDR/ZNC 5 55 DAMPENER VIBRATION WASHER FLAT M SCREW HHC M-.75 X 8 G PLUG STD PIPE / STEEL SQ HD 8 BARB STRAIGHT 5/8 X / X CLAMP HOSE # " HOSE RES 5/8 TYP 3 SNGL 7 BARB STRAIGHT 5/8 X 3/8 X ADAPTER OIL DRAIN M-.5 X 3/8 NPT 73A 3 PLUG STD PIPE / STEEL SQ HD 9 35 BARB STRAIGHT 3/8 X / X CLAMP HOSE # HOSE RES 3/8 SINGLE BRAID 93 BARB ELBOW 3/8 X / X " HOSE RES 5/ TYP SNGL 33 3" HOSE / ID SAE 3R7 5 7 SCREW HHC M-. X G WASHER FLAT M-/ ZINC 7 55 LUG SLDLSS #-#8 X 7/ CU 8 85 WASHER SHAKEPROOF EXT / STL 9 97 WASHER LOCK M-/ NUT HEX M -. G8 YEL CHR SCREW HHC M-.5 X G WASHER LOCK / CABLE GROUDING / X / X WASHER NYLON K CABLE BATT BLACK # X AA CABLE BATT RED # X NUT HEX M8-.5 G8 YEL CHR 38 9 WASHER LOCK M8-5/ 39 5 WASHER FLAT M8-5/ ZINC 78 WASHER SHAKEPROOF EXT 5/ STL 37 SCREW HHC M8-.5 X 5 G8.8 7 WASHER LOCK M EXT 3 * A8785 PLUG BUTTON 3" DIA * C5 SCREW TH-FRM M- X N WA Z/JS 5 * C3 5 PLATE VARMINT * 793 WASHER FLAT.8 ID X. OD BATTERY VDC 9-AH 7F (OPTIONAL) 8 9 HOLD DOWN BATTERY HOLD DOWN BATTERY 5 A SCREW HHC M8-.5 X FTHD NUT LOCK FL M NUT LOCK HEX M8-.5 NYL INSRT BOOT BATTERY CABLE * ITEMS 3- ARE PART OF KIT C739 (VARMINT GUARDING) Generac Power Systems, Inc. 5

28 BASE FRAME STATES FOAM IS ON NEAR SIDE STATES FOAM IS ON FAR SIDE Typical of all duct components & that require insulation. Secure as shown Section 7 Exploded Views and Parts Lists Compartment Drawing No. C-G Generac Power Systems, Inc.

29 Section 7 Exploded Views and Parts Lists Compartment Drawing No. C-G ITEM PART NO. QTY. DESCRIPTION C359 8 ASSEMBLY, M HINGE 3 A SCREW BHSC M-. X SS A33 3 SHAKEPROOF, INT. M S.S SCREW HHC M8-.5 X G8.8 9 WASHER LOCK M8-5/ 7 C5 (A) DUCT, FRONT L.H. 8 C (A) DUCT, FRONT R.H. 9 C (A) DUCT, BOTTOM C7 (A) DUCT, FRONT PANEL C7 (A) DUCT, FRONT TOP C5 M-. x TRD. FORM W/WASHER C57 (A) CORNER POST, L.H. REAR 5 C58 (A) CORNER POST, R.H. REAR C535 (A) CORNER POST, L.H. FRONT 7 C53 (A) CORNER POST, R.H. FRONT 8 C8 (A) REAR PANEL, SOUND 9 C55 (A) SIDE BRACE, TOP & BOTTOM C555 (A) SIDE SUPPORT C38 (A) ROOF C (A) FRONT BRACE, BOTTOM (.L) C57 (A) FRONT BRACE, BOTTOM (3.L D ONLY) 3 C (A) FRONT BRACE, TOP (.L) C5 (A) FRONT BRACE, TOP (3.L D ONLY) C33 STRIKER PLATE 5 C3A ACCESS COVER ASSEMBLY 7 97 WASHER LOCK M-/ WASHER FLAT M-/ ZINC 9 C79 3 SCREW PPHC M x SS 3 9 PADDLE HANDLE LOCK 3 C78 NUT LOCK HEX M-.7 SS NYL INS WASHER FLAT #8 SS RIVET POP.875 X.9-.9/# 35 C3 (A) DUCT, REAR L.H. 3 C (A) DUCT, REAR R.H. 37 C (A) DUCT, REAR PANEL 38 A FT. DOOR GASKET, RUBBER 39 C5 (A) DUCT, REAR TOP C375R INSULATION, FRONT DUCT ITEM PART NO. QTY. DESCRIPTION A535A 8 SELF ADHESIVE HANGER 3/" 3 C375S INSULATION, DUCT BOTTOM C375J INSULATION, DUCT FRONT PANEL 5 C375M INSULATION, REAR DUCT R.H. C375N INSULATION, REAR DUCT L.H. 7 C375L INSULATION, DUCT REAR PANEL 8 C375K INSULATION, REAR DUCT TOP 9 C375A INSULATION, ROOF TOP 5 C357K INSULATION, DOOR 5 C357L INSULATION, DOOR 53 C375F INSULATION, FRONT CORNER POST 5 C375E INSULATION, FRONT CORNER POST 55 C375V INSULATION, TOP & BOTTOM SIDE BRACE 5 C375D INSULATION, SIDE SUPPORT 57 C375G INSULATION, FRONT TOP BRACE 58 C375H INSULATION, REAR PANEL 59 C375C INSULATION, REAR CORNER POSTS, SECT. # C375B INSULATION, REAR CORNER POSTS, SECT. # WASHER, SELF LOCKING DOME 7 NUT HEX /- STEEL C3393 SHOULDER SCREW 5 C3 (A) COVER, EXHAUST HOLE C375 INSULATION, FRONT ROOF TOP 7 C5 (A) DOOR, SMALL SOUND 75 C375U INSULATION, FRONT DUCT R.H. & L.H. 7 C375T INSULATION, REAR DUCT R.H. & L.H. 77 C77 STANDOFF M x AL 78 C35 COVER, LATCH ACOUSTIC 8 C535 (A) VARMIT BLOCKOFF PLATE /" SEALANT STRIP /8" x " WASHER LOCK 8-M SS 8 5 WASHER FLAT M8-5/ ZINC OPTIONAL COMPARTMENT MATERIALS:ALL P/N'S WITH AN "A" SUF- FIXINDICATE ALUMINUM MATERIAL OPTION. Generac Power Systems, Inc. 7

30 Section 7 Exploded Views and Parts Lists Tank Drawing No. E55 8 Generac Power Systems, Inc.

31 Section 7 Exploded Views and Parts Lists Tank Drawing No. E55 ITEM PART NO. QTY. DESCRIPTION E58 TANK A GRP DW 3 GAL VERIZON 55 SCREW HHC M-.75 X 3 G WASHER FLAT M 58 NUT LOCKING M E5 COVER STUB-UP A GRP VERIZON 59 WASHER FLAT.3 ID X. OD SCREW HHC M8-.5 X G DETECTOR ALARM FUEL LEAK CLAMP HOSE # B FUEL DIP PIPE 538MM INLET & RETURN 737 VALVE CHECK 3/8 NPT * E57 LABEL EMERGENCY RELIEF VENTING BARBED STR 3/8 NPT MALE X 5/ D73 FUEL LEVEL GAUGE KIT ELECTRICAL- FT (TO INCLUDE ITEMS A, B, C & D) A D7B ELECTRICAL FUEL GAUGE- FT (IN KIT D73) B D8 PLATE ADAPTOR (IN KIT D73) C SCREW SHC M8-.5 X G.9 (IN KIT D73) D 979 SCREW SHC M-. X 5 G.9 (IN KIT D73) E E35 GASKET ROCHESTER FUEL LEVEL GAUGE F E35 GASKET ADAPTER PLATE 5 A9 CAP FUEL FILL D7 NECK FUEL FILL (STANDARD-") PLUG STD PIPE.5" NPT STEEL SQ HD 8 ** 78 VENT OEM " NPT 9 A738 NIPPLE PIPE NPT X 3.5 BL IRON ** 7989J 3" NPT EMRG. PRES. VENT 95V DETECTOR ALARM FUEL LEAK W/CON E37 LABEL DIESEL FUEL ONLY 3 8 LABEL DATA GENERAC 83 LABEL DATA UL (DOUBLE WALL) 5 * A78 LABEL FUEL RETURN * A77 LABEL FUEL SUPPLY 7 * A7 LABEL FUEL FILL 8 * A5 LABEL FUEL LEVEL 9 * A79 LABEL VENT 3 * 8 LABEL EMERG. VENTING 3 * A8 LABEL LEAK DETECTOR 3 E58 LABEL 3 GALLON CAPACITY 33 * 8V LABEL STICKER WARNING 3 E7 VALVE FUSIBLE LINK SHUT-OFF 3/ COUPLING FULL 3/ ELBOW 9D STREET 3" 37 D5 BARBED STR 3/8 NPT MALE X / * UL LABEL KIT P/N E5 ** PARTS ARE LOCATED IN LOOSE VENTS KIT P/N E59 Generac Power Systems, Inc. 9

32 Section 7 Exploded Views and Parts Lists Generator Drawing No. E55 TO ENGINE FLYWHEEL TO ENGINE FLYWHEEL HOUS 7 9 NOTE: THREAD IN SENSOR (8) UNTIL CONTACT IS MADE WITH RING GEAR, THEN BACK OFF / TO 3/ TURN AND TIGHTEN NUT. CAUTION: DO NOT ROTATE ENGINE DURING THIS ADJUSTMENT. 3 TIE-WRAPS & SLEEVE (I/N:) IN PLACE 3 ROTOR LEADS 37 HUB DETAIL SCROLL DETAIL 55 STATOR LEADS Generac Power Systems, Inc.

33 Section 7 Exploded Views and Parts Lists Generator Drawing No. E55 ITEM PART NO. QTY. DESCRIPTION 578 SCREW HHC M-.75 X 5 G WASHER LOCK M 3 A89 ASSEMBLY SCROLL 39 SAE 7 SCREW HHC 3/8- X -3/ G5 5 A8 FLEX PLATE SAE (REF.) 3953 SCREW HHC M8-.5 X G WASHER LOCK M8-5/ 8 83D ASSEMBLY MAG PICKUP 7" (REF.) 9 C8 ASSEMBLY FAN W/PRESS DISC.75 X 3 * A SCREW HHC M-. X 5 G8.8 * A WASHER FLAT.88 ID X 3.5 OD * A38 KEY SQ 3/8 X -/ STEEL 3 * 9 COUPLER 39 SAE 88B ROTOR 39 /3P BRUSHLESS 5 * 5 BEARING BALL SEALED A558 SCREW HHC M-. X G8.8 7 A33 WASHER 39 SAE ALT. 8 79B STATOR 39 AP SAE 9 3 WASHER FLAT 3/8-M ZINC 37 WASHER LOCK 3/8 5 SCREW HHC 3/8- X -/ G5 83 CARRIER REAR BRG 5" 3 85 LOWER PANEL 5 (SMALL) (REF.) 95 LOWER PANEL 39MM (LARGE) (REF.) 33 WASHER LOCK M NUT HEX M-. G8 YEL CHR 559 WASHER FLAT M 7 73 WASHER FLAT /-M ZINC SCREW HHC M-.75 X G KEY SQ 3/8 X -3/ STEEL ITEM PART NO. QTY. DESCRIPTION ASSEMBLY EXCITER.5" STACK 3 8 EXCITER FIELD.5" STACK COLLAR SLIP FIT 39 MM 33 5 CLAMP VINYL.3 X.3 Z 3 A SCREW SWAGE /- X / Z/YC BRIDGE SUPPORT DIODE 5" 3 95 ASSEMBLY BRIDGE RECTIFIER WASHER SHAKEPROOF INT # SCREW HHM #8-3 X 7/ CAP END ROTOR 39MM 3333 SCREW HHM #8-3 X 3/8 398 TIE WRAP UL. X. NATL (BLACK) 8739A TIE WRAP 3.9" X." BLACK UL 3 85D TIE WRAP UL 7.7 X.35 BLACK HT L SLEEVING UL #.33 ID SLEEVE RUBBER 39 PIN DOWEL / X -/ KIT A89 PARTS 7 A9 SHROUD ALT SHEET METAL 8 A97 SCREEN SHROUD SAE 9 A9 BRKT TENSIONER SAE SCROLL FT. TRIM VINYL BLACK /8 GP 7" 5 97 WASHER LOCK M-/ 5 73 WASHER FLAT /-M ZINC SCREW HHC M-. X 5 G SCREW HHC M-. X G A SCREW SWAGE /- X / Z/YC * ROTOR REPLACEMENT PARTS Generac Power Systems, Inc. 3

34 Section 7 Exploded Views and Parts Lists Radiator Drawing No. E5-A 3 TO "B" ROUTE CORD INTO TO "A" 9 TO "C" BATTERY CHARGER RADIATOR DRAIN 3 7 RIGHT RAIL MOUNTING BASE 3 "A" BLOCK HEATER INTO ENGINE 33 COOLANT ACCESS (RIGHT SIDE, FRONT OF ENGINE) LOWER RADIATOR HOSE 35 LOWER RADIATOR HOSE TO OIL COOLER TURBO CHARGED TO UPPER RADIATOR CONNECTION Overflow Drain TURBO CHARGED "B" 3 TO OIL COOLER (ROUTE UNDER 3 39 TO COOLANT DRAIN PORT (RIGHT SIDE, REAR OF ENGINE) Generac Power Systems, Inc.

35 Section 7 Exploded Views and Parts Lists Radiator Drawing No. E5-A ITEM PART NO. QTY. DESCRIPTION C389 RADIATOR FIN 3 LHA (UNITS 5KW & ABOVE) C37 RADIATOR SIDE SUPPORT 3.L HA 3 C38 VENTURI 3.L HA A8583A ADAPTOR M-. X 3/8 NPT SCREW HHC M-. X G BRACKET COOLANT RECOVERY TANK TANK COOLANT RECOVERY 8 C3775 HOSE LOWER RADIATOR 3.L HA 9 C388 HOSE UPPER RADIATOR 3.L HA 55 SCREW HHTT /- X CZ 97 5 WASHER LOCK M-/ 73 WASHER FLAT / ZINC NUT HEX M X. G8 YEL CHR 98 SCREW HHC M-.5 X 5 G WASHER LOCK 3/8 3 8 WASHER FLAT 3/8-M ZINC NUT HEX M-.5 G8 YEL CHR A 3 TIE WRAP 3.9" X." BLACK UL 9 55 TAPE FOAM X X 7-/" 3585 CLAMP HOSE # C 3 CLAMP HOSE BAND / 93 HOSE 9/3 ID (3" LONG) 3 93 HOSE 9/3 ID (3" LONG) 3337 SPACER. X.75 X.5 STL/ZNC 5 7 CAP RADIATOR 898A HEATER ENG W V 7 87 BRACKET HEATER W/WELDNUTS 8 7 SCREW HHC M-. X G WASHER LOCK M-/ 3 73 WASHER FLAT /-M ZINC NUT HEX M X. G8 YEL CHR HOSE CONN T BARBED STR 3/8 NPT X 5/ CLAMP HOSE # CLAMP HOSE # HOSE COOL 5/8 ID R (33" LONG) HOSE COOL 5/8 ID R (" LONG) BARBED STR / NPT X 5/8 39 E7 MANIFOLD / NPT X PORTS 9 NIPPLE PIPE / NPT X -/ 833B CLAMP HI TORQUE C8359 GUARD CSA TOP/R 3LHA 3 C83 GUARD CSA BOT/L 3LHA C83 GUARD CSA LO BK 3LHA 5 C83 GUARD CSA ALT 3LHA C833 GUARD CSA FRNT 3LHA SCREW CRIMPTITE /- X 5/ C CLAMP VINYL.5 X. Z 9 53 TRIM VINYL BLACK /8 GP 8" 5 53 TRIM VINYL BLACK /8 GP 7" Generac Power Systems, Inc. 33

36 Section 7 Exploded Views and Parts Lists Muffler Drawing No. E557-A ITEM PART NO. QTY. DESCRIPTION MUFFLER NPT BXU 3 MUFFLR STRAP IN DIA ELBOW 9D NPT 599 NIPPLE TOE NPT X 9 BLK IRON SCREW HHC M8-.5 X G NUT LOCK FL M H FLEX EXH " X " RAIN CAP.37 I.D. 9 E597 BLANKET MUFFLER 3.L VERIZON 3 Generac Power Systems, Inc.

37 Section 7 Exploded Views and Parts Lists Turbo Drawing No. E REMOVE FACTORY LIFTING EYE REMOVE & REPLACE FACTORY BOLTS TO OIL PAN REMOVE & REPLACE FACTORY BOLTS 9 EXHAUST MANIFOLD GASKET /8" NPT CROSS ON OIL PUMP REMOVE FACTORY STUDS ITEM PART NO. QTY. DESCRIPTION 75A ASSY TURBO 3.LHA KIA A5 INDICATOR FILTER MINDR G CON TURBO. X.9 9 ELBOW /8" NPT x /"- x 37 DEG. 5 9B OIL SUPPLY LINE 5 CLAMP HOSE # SCREW HHC M8-.5 X G LOCK WASHER, 5/"-M8 9 C35 8 SCREW SHC 3/8- X 3/ G8.8 NZ 358 ADAPTER UPPER TURBOCHARGER C59 ADAPTER LOWER TURBOCHARGER C58 TUBE TURBO INTK 3LHA 3 7 GASKET TURBOCHARGER C37 OIL RETURN TUBE 5 97 LOCK WASHER /-M 7 SCREW HHC M-. X G CLAMP HOSE SIZE: # REDUCER COUPLING, RED RUBBER " TO -3/" ITEM PART NO. QTY. DESCRIPTION ELBOW RUBBER 9.5 ID 5 CLAMP, HOSE SIZE: #3 578 CLAMP HOSE SIZE: #8 98 REDUCER, RUBBER 5/8" TO /" CLAMP HOSE # D3 LABEL HOT TURBO.L UL 5 C95 BRACKET, AIR CLEANER 575 SCREW HHC M-.5 X G FLAT WASHER 5/8-M 8 5 LOCK WASHER 5/8-M NUT HEX M-.5 G8 YEL CHR STRAP AIR CLEANER 3 C37 AIR CLEANER 3.L HA CLAMP HOSE # CLAMP HOSE # E53 TUBE INTAKE W/ /8" NPT VERIZON Generac Power Systems, Inc. 35

38 Section 7 Exploded Views and Parts Lists Circuit Breaker Drawing No. E53 BOTTOM OF CONTROL PANEL 5 8 ALT. LEADS & 3 SENSING WIRE FD 3 POLE (V) (5-5A) ALT. LEADS & SENSING WIRE FD FRAME 3 POLE AMPERAGE RATING 5-A 5-A DESCRIPTION: LINE SIDE LOAD SIDE CABLE SCREW TORQUE 8 IN/LBS 75 IN/LBS WIRE SIZE RANGE (-) UP TO #/-5kcmil (-)#3/-5kcmil (Cu) (-) #/-5kcmil (Al) 5 NOTE: ALWAYS REPLACE PLASTIC TERMINAL COVERS. DO NOT OPERATE GENERATOR WITHOUT ALL TERMINAL COVERS IN PLACE. 3 Generac Power Systems, Inc.

39 Section 7 Exploded Views and Parts Lists Circuit Breaker Drawing No. E53 ITEM PART NO. QTY. DESCRIPTION 85 PANEL LOWER (39 BOX) 87 COVER LOWER PANEL BLANK 3 73 WASHER FLAT / 97 WASHER LOCK M-/ SCREW HHC /- X 3/ G5 7 NUT HEX /- 7 38N BUSHING SNAP 8 D3388 DECAL REMOTE START CONNECTION 9 87 REF BLOCK TERMINAL -CKT 985 WASHER FLAT # WASHER LOCK M C SCREW TAPTITE PH M-.7 X ZYC 3 8 COVER LOWER PANEL 5" REF. BATTERY CHARGER 5 REF. ASSY. CONTROL PANEL D557 CB 5A 3P V S FD LL 7 D589 PLATE CB MOUNT S (FD) 39S RELAY SOLENOID VDC PANEL MOUNT 9 73 WASHER FLAT / ZINC 97 WASHER LOCK M-/ 87 SCREW HHC /- X 3/ G TRANSFORMER CURRENT-5/5 3 5 WASHER FLAT M8-5/ ZINC 9 WASHER LOCK M8-5/ 5 59 NUT HEX 5/-8 STEEL SCREW HHC 5/-8 X 3/ G5 7 D593 COVER CB TERMINALS S (FD 3P) 8 97 / WASHER LOCK M-/ / SCREW HHC /- X 3/ G5 3 7 NUT HEX /- STEEL 3 73 WASHER FLAT / ZINC 3 83 SCREW SHC /- X.5 G8.8 NZ WASHER LOCK 3/ SCREW SHC 3/8- X 3/ G5 35 D5A NEUTRAL BLOCK 39/5-75A JUNCTION BLOCK 3/ WASHER LOCK # SCREW PHM #-3 X 5/8 CAD WASHER LOCK 3/8 NUT HEX 3/8- STEEL 5 WASHER FLAT 5/ ZINC 9 WASHER LOCK M8-5/ NUT HEX M8-.5 G8 YEL CHR Generac Power Systems, Inc. 37

40 Section 7 Exploded Views and Parts Lists Engine Parts Drawing No. E53-A REMOVE & REPLACE FROM FUEL PUMP ASSEMBLY REMOVE AND REPLACE FROM ENGINE TO TURBO OIL SUPPLY TO RADIATOR HOSE FITTING TO UPPER RADIATOR 35 CONNECTION OF ENGINE Generac Power Systems, Inc.

41 Section 7 Exploded Views and Parts Lists Engine Parts Drawing No. E53-A ITEM PART NO. QTY. DESCRIPTION C9 ENGINE KIA 3.L KIA C97L FOOT LH ENGINE MOUNTING C97R FOOT RH ENGINE MOUNTING (NOT SHOWN) 3 3 WASHER LOCK 7/ 35 NUT HEX 7/- STEEL 5 C3 FAN SPACER 3L HA 95 FAN COOLING 8" DIA. 7 C889 SCREW SH 5/- X.5 G8.8 NZ 8 5 WASHER FLAT M8-5/ ZINC 9 9 WASHER LOCK M8-5/ 3953 SCREW HHC M8-.5 X C97 FLYWHEEL MACHINED 3L HA NIPPLE CLOSE /8 NPT 3 58 PIPE CROSS /8 NPT (C OPTION ONLY) 353 PIPE TEE /8 NPT (D & E OPTION) 53 SENDER OIL PRESSURE 5 A858 SWITCH OIL PRESSURE (C OPTION ONLY) C9 PIN SPRING.MM X 3MM WASHER FLAT M-3/8 ZINC WASHER LOCK 3/ SCREW SHC M-.5 X C98 SCREW SHC M-.5 X 5 G.9 C99 ADAPTER FLYWHEEL 3L HA 55 NUT HEX M-.5 3 C397 BRACKET FUEL FILTER 3L HA CLAMP HOSE # HOSE RES 5/ TYP SNGL ("LONG) 9 C3759 ADAPTER THERMOSTAT 3L HA PLUG STD PIPE 3/8 COUNTERSUNK 3 35 SENSOR HI COOLANT SHUTDOWN SENDER WATER TEMP 33 E5 ASSYEMBLY WATER LEVEL SENSOR C/E PL WASHER FLAT M-/ ZINC WASHER LOCK M-/ SCREW HHC M-. X 5 38 A8 FLEX PLATE SCREW SHC M-.5 X 5 C589 ADAPTER OIL COOLER 3LHA (M X.5) 975 OIL COOLER FILTER STYLE 5 WASHER FLAT 7/ CLAMP HOSE # HOSE RES 5/8 -/+3 SAERG (" LONG) HOSE RES 5/8 -/+3 SAERG (38" LONG) 975 GASKET EXHAUST MANIFOLD 7 C9 GASKET THERMOSTAT 8 97 FILTER OIL 9 93 SCREW HHC M-.5 X 3 5 DM ASSY MAGPICKUP (3/8- MALE) 5 E97 HARNESS, ENGINE 3LHA (NOT SHOWN) 5 57 ADAPTOR /8 NPTF TO / RELAY SOLENOID VDC PNL MNT (NOT SHOWN) WASHER FLAT MM ID X 8MM OD 55 E538B ADAPTER BANJO FITTING LW FL PR 5 E59 SNUBBER BRASS /8" NPT 57 E53A ADAPTER BANJO BOLT LOW FUEL PR Generac Power Systems, Inc. 39

42 Section 7 Exploded Views and Parts Lists Control Panel Drawing No. E558 Generac Power Systems, Inc.

43 Section 7 Exploded Views and Parts Lists Control Panel Drawing No. E558 ITEM PART NO. QTY. DESCRIPTION E38 PANEL,BACK & BOTTOM E-PNL VRZN E379 E-PANEL FRONT, W/ SILK SCREEN 3 E383 PANEL RH SIDE, E-PNL VERIZON E38 PANEL LH SIDE, E-PNL VERIZON 5 E355 CHASSIS, UNIVERSAL D38 HARNESS E-PANEL W/SEALED CONS 7 3 RES R 5% W 8 59 RECTIFIER MSC A V N WASHER MICA.3 37 WASHER SHAKEPROOF EXT # STL 55 HEATSINK 3.3L 38 WASHER STEP NYLON RECTIFIER MSC A V NR A339 DECAL TERMINAL BLOCK 5 C89 DCL-E PNL TS# (W/FS) A577 DECAL T STRIP 3 E PNL 7 D353 DECAL T STRIP TB W/SEALED CON 8 D97 HINGE CONTINUOUS 9 C9 DECAL CUST CONN BOX E93A SWITCH MUSHRM HEAD/ARROWS MM E93C 3 CONTACT BLOCK D5-3 X W/ 7 33 HOLDER FUSE 3 7 FUSE 5A X AGC INSULATOR 5 73 POT 5K %.5W PNL 53 KNOB PLASTIC.5 SHAFT 7 8 SOUNALERT BUZZER 8 95 SWITCH SELECTOR A AMP/V 9 A87 MASTER CTRL BOX E-PNL 3 E373 LIGHT PANEL WITH LUG 3 C88 BULB-PANEL LIGHT-V 8388 LIGHT 8VDC.7A MIN BAYNT MNT 3 78 BLOCKER LIGHT 33 A75 DOOR-STOP RAM PANEL 3 E779 ASSY, GOVERNOR CONTROLLER TIE WRAP 3.9" X." NAT'L UL 3 AA TRUNKING 8MM 37 E83 ASSY LOW FUEL PRES FILTER 3.9L 38 E385 COVER PLATE,VOLTAGE REG.VERIZN 39 C7 DECAL AVR COVER E38 COVER PLATE,ELECT.GOVENOR VRZN A339 DECAL ELEC GOVERNOR A575 REF. FUSE 5A X LTTL55 (NOT SHOWN) 3 D33 CBL ASSY-RS85 E PNL W/SEALED D37 DECAL COVER DEUTSCH (RECT) ITEM PART NO. QTY. DESCRIPTION 5 D37 DECAL COVER DEUTSCH (RECT) (ELECTRONIC GOVERNOR HARNESS IF EQUIPPED) C5 CONN DEUTSCH GASKET 8/POS DT 5 55 WASHER LOCK # 5 C8 SCREW TAPTITE PH -3X/ Z/YC 5 C33 SCREW TAPTITE PH -3X5/8 ZYC 53 7 NUT HEX #8-3 STEEL 5 8 WASHER LOCK M WASHER FLAT #8 ZINC SCREW PPHM #8-3 X / 57 A8 SCREW SWAGE 8-3 X / Z/YC NUT HEX #-3 STEEL 59 5 WASHER LOCK # WASHER FLAT # ZINC 9 SCREW TAPTITE #-3 X 3/8 BP 33 SCREW HHC #-3 X 3/ SCREW HHM #-3 X 5/8 57 SCREW HHC /- X / G WASHER LOCK M-/ 73 WASHER FLAT / ZINC 7 79 VIB MNT. X. X / RIVET POP.5 X.375 AL 9 C83 WASHER LOCK HDPDEUTSCH 7 C8 NUT, HDP DEUTSCH ADDITIONAL PARTS (BASE TANK UNITS) 75 D33 HARNESS BASETANK FOR E-PANEL 7 C5 CONN DEUTSCH GASKET 8/ POS DT PANEL SPECIAL PARTS BRACKET RESISTOR MNTNG FOR 5W 8 SEE TABLE A RESISTOR # 8 SEE TABLE B FIELD CIRCUIT BREAKER 83 SEE TABLE C AMMETER 8 SEE TABLE D VOLTMETER AC 85 7 METER FREQUENCY 55-5HZ 7A FREQUENCY METER V 5-55HZ 8 78 ASSY VOLTAGE REGULATOR HZ 995 ASSY VOLTAGE REGULATOR 5HZ SCREW HHTT M5-.8 X BP SCREW HHM #-3 X SCREW PPHM M-.7 X 9 E3 SUB-PLATE, E-PANEL VERIZON 9 A3 SCREW SWAGE -3 X Z/YC SPACER.9 X.3 X.5 PL Generac Power Systems, Inc.

44 Section 7 Exploded Views and Parts Lists Exhaust (Model 8-) Drawing No. E " Dia. Clamp Assembly Engine To Compartment 8 5 Front ITEM PART NO. QTY. DESCRIPTION 87 BOLT U 3/8- X. 37 WASHER LOCK 3/8 3 NUT HEX 3/8- STEEL 599A CAP RAIN.5 /.9 5 C9 TUBE, STRAIGHT 'A' GROUP C95 MUFFLER,-/"INLET/OUTLET 7 CA MUFLR,.5"BAND CLAMP 8 C BRACKET, MUFFLER MTG 9 A55B PIPE FLEX.5" C7 BRKT, EXHAUST SHIELD C35 SHIELD, A-GRP HEAT ITEM PART NO. QTY. DESCRIPTION C5 SCREW TH-FRM M-X N WA Z/JS 3 C333A CLAMP BAND WASHER LOCK M8-5/ 5 5 WASHER FLAT 5/ ZINC SCREW HHC M8-.5 X G SCREW HHC M8-.5 X G8.8 9 C9 TUBE ELBOW 9 DEG C58 TUBE TURBO EXHAUST C57 GASKET TURBO EXHAUST E59 BLANKET,EXHAUST 3.L VERIZON Generac Power Systems, Inc.

45 Section 7 Exploded Views and Parts Lists Air Duct Drawing No. E ITEM PART NO. QTY. DESCRIPTION A98 BRACKET AIR DUCT TOP/BOTTOM A98 BRACKET AIR DUCT RH SIDE 3 A983 BRACKET AIR DUCT LH SIDE 3 SCREW HHC /- X G WASHER LOCK M-/ 73 8 WASHER FLAT / ZINC 7 55 SCREW HHTT /- X CZ Generac Power Systems, Inc. 3

46 Section 7 Exploded Views and Parts Lists Electronic Governor Drawing No. E88-A TO CONTROLLER (BLACK / WHITE STRIPE & WHITE) FACTORY THROTTLE CONTROL ARM TO FLYWHEEL HOUSING CHASSIS INSIDE CONTROL PANEL TO CONTROLLER (PURPLE WIRES) 5 7.±. [3±/"] ITEM PART NO. QTY. DESCRIPTION E77 ASSY, LINEAR ACTUATOR C37 BRACKET, ACTUATOR 3 C97 THROTTLE CONTROL ARM 7 3 SCREW, HHC M-. x WASHER, FLAT-M x 7. x WASHER, LOCK-M x NUT, HEX M-. x SCREW, PHM #-3 x 3/ CAD WASHER, FLAT M5 x 5.5 X.7 5 WASHER, LOCK #-M 58 NUT, HEX #-3 STEEL ITEM PART NO. QTY. DESCRIPTION 33 STUD, #-3 x.75 F THR ZNC BALL JOINT, PLASTICS #-3 E779 ASSY, GOVERNOR CONTROLLER 5 C737 BRACKET, ACTUATOR 5757 SCREW,HHC M x. x CLEVIS, #-3 8 DM ASSY MAGPICKUP(3/8- MALE) SCREW HHTT M5-.8 X BP E97G HARNESS, ENGINE 3LHA EGOV (NOT SHOWN) 9 SCREW HHTT #8-3 X 3/8 CZ Generac Power Systems, Inc.

47 Section 8 Notes Generac Power Systems, Inc. 5

48 Section 8 Notes Generac Power Systems, Inc.

49 Section 8 Notes Generac Power Systems, Inc. 7

50 Section 9 Warranty NOTE: This Emission Control Warranty Statement applies only to mobile (trailerized) non-road diesel engine powered generators (model year ) as follows: The EPA portion of this statement pertains to this product; The CARB portion of this statement pertains to this product only IF the generator size is () 5 kw or below OR () 3 kw or greater. CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT 8 Generac Power Systems, Inc. YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control System Warranty on your new non-road diesel engine.* New non-road diesel engines must be designed, built and equipped to meet stringent anti-smog standards for the state of California and the federal government. Generac will warrant the emission control system on your non-road diesel engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modification or improper maintenance of your non-road diesel engine. Your emission control system may include such parts as the fuel injection system and the air induction system. Also included may be hoses, belts, connectors and other emission-related assemblies. Generac will repair your non-road diesel engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur. MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE: Emission control systems on 99 and later model year non-road diesel engines are warranted for five years, or 3, hours of use, whichever occurs first. In the absence of an hourmeter, the said coverage is five years. If, during said warranty period, any emission-related component or system on your engine is found to be defective in materials or workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Facility. PURCHASER S/OWNER S WARRANTY RESPONSIBILITIES: As the non-road diesel engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance of your non-road diesel engine. However, Generac cannot deny warranty solely due to lack of receipts or for your failure to ensure the completion of all scheduled maintenance. As the non-road diesel engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or responsibility if your non-road diesel engine, or a part/component thereof, has failed due to abuse, neglect, improper maintenance or unapproved modifications., or the use of counterfeit and/or grey market parts not made, supplied or approved by Generac. Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with federal or California emission requirements. You are responsible for contacting a Generac Authorized Warranty Service Facility as soon as a problem occurs. The warranty repairs should be completed in a reasonable amount of time, not to exceed 3 days. Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility. To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number: IMPORTANT NOTE: This Warranty statement explains your rights and obligations under the Emission Control System Warranty (ECS Warranty), which is provided to you by Generac pursuant to federal and California law. See also the Generac Limited Warranties for Generac Power Systems, Inc., which is enclosed herewith on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission control system of your new non-road diesel engine. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac describe important rights and obligations with respect to your new non-road diesel engine. Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service, evidence must be presented showing the date of sale to the original purchaser/owner. If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the following address: ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS, INC. MURPHY DRIVE EAGLE, WI 539 Part

51 Section 9 Warranty EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS Warranty) for 99 and later model year non-road diesel engines: (a) Applicability: This warranty shall apply to 99 and later model year non-road diesel engines. The ECS Warranty shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for months, or 3, hours of use, thereafter, whichever occurs first. (b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new non-road diesel engine or equipment, and to each subsequent purchaser/owner, that each non-road diesel engine is () Designed, built and equipped so as to conform with all applicable regulations adopted by the EPA and CARB pursuant to their respective authority, and () Free from defects in materials and workmanship, which, at any time during the ECS Warranty Period, may cause a warranted emission-related part to fail to be identical in all material respects to the part as described in the engine manufacturer s application for certification. (c) The ECS Warranty pertains only to emissions-related parts on your non-road diesel engine, as follows: () Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac according to Subsection () below. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period. () Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period. (3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection () below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part. () Repair and replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner by a Generac Authorized Warranty Service Facility. (5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsible for diagnostic costs if the repair is deemed warrantable. () Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emissions-related part covered by the ECS Warranty. (7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emissions-related parts sufficient to meet the expected demand for such emission-related parts. (8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS warranty maintenance or repairs and will be provided without charge to the owner. Such use will not reduce Generac s ECS Warranty obligations. (9) Unapproved, add-on, modified, counterfeit and/or grey market parts may not be used to modify or repair a Generac non-road diesel engine. Such use voids this ECS warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for failures of any warranted parts of a Generac non-road diesel engine caused by the use of such an unapproved, add-on, modified, counterfeit and/or grey market part. EMISSION RELATED PARTS INCLUDE THE FOLLOWING: ) Fuel Metering System: a) Fuel injection system ) Air Induction System: a) Intake manifold and gasket b) Turbocharger systems (if so equipped) c) Charge air cooling systems (if so equipped) 3) Exhaust System: a) Exhaust manifold and gasket (turbocharged engines only) b) Catalytic converter (if so equipped) ) Miscellaneous Items used in above systems: a) Hoses, connectors, assemblies, clamps, fittings, tubing, sealing gaskets or devices, and mounting hardware *Generac non-road diesel engine types covered by this warranty statement include the following: ) Standby Generator Part Generac Power Systems, Inc. 9

52 Section 9 Warranty GENERAC POWER SYSTEMS STANDARD TWO-YEAR LIMITED WARRANTY FOR STANDBY POWER SYSTEMS NOTE: ALL UNITS MUST HAVE A STARTUP INSPECTION PERFORMED BY AN AUTHORIZED GENERAC DEALER. For a period of (two) years or, (two thousand) hours of operation from the date of sale, which ever occurs first, Generac Power Systems, Inc. will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or a Generac Power Systems Authorized Warranty Service Facility, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be returned to, and examined by the nearest Generac Power Systems Authorized Warranty Service Facility. All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to Generac Power Systems Generators used in "Standby" applications, as Generac Power Systems, Inc. have defined Standby, provided said generator has been initially installed and inspected on-site by a Generac Power Systems Authorized Service Dealer or branch thereof. A scheduled maintenance agreement with a local Authorized Generac Power Systems Dealer is highly recommended to verify adequate service has been performed on the unit throughout the warranty period. Limited to, and available only on Liquid-cooled units. WARRANTY SCHEDULE YEAR ONE % (one hundred percent) coverage on mileage*, labor, and parts listed. ALL COMPONENTS YEAR TWO % (one hundred percent) coverage on parts listed. ALL COMPONENTS *PARTS ONLY *Travel allowance is limited to 3 miles maximum, or 7.5 hours maximum (per occurrence), round trip, to the nearest authorized Generac Service Facility, and only applies to permanently wired and mounted units. A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a Non - Generac Power Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the genset, no warranty coverage shall apply. All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty, Policies, and Procedures Flat Rate Manual. Units that have been resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable. GEAR BOX EQUIPPED UNITS Limited Gearbox Coverage YEARS ONE THROUGH FIVE Parts and labor coverage on gearbox and components. YEARS SIX THROUGH TEN Parts only coverage on gearbox and components. THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:. Any unit built/manufactured prior to January,.. Unit enclosure is only covered against rust or corrosion the first year of the warranty provision. 3. Costs of normal maintenance i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up.. Use of Non-Generac replacement part(s) will void the warranty in its entirety. 5. Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze.. Units sold, rated or used for "Prime Power", "Trailer Mounted" or "Rental Unit" applications as Generac Power Systems have defined Prime Power, Trailer Mounted or Rental Unit. Contact a Generac Power Systems Distributor for Prime Power, Trailer Mounted or Rental Unit definition and warranty. 7. Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing. 8. Failures caused by any external cause or act of God such as collision, fire, theft, freezing, vandalism, riot or wars, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado, hurricane, terrorist acts or nuclear holocaust. 9. Products that are modified or altered in a manner not authorized by Generac Power Systems in writing.. 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).. Failure due to misapplication, misrepresentation, or bi-fuel conversion.. Telephone, telegraph, teletype or other communication expenses. 3. Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty period.. Rental equipment used while warranty repairs are being performed i.e. rental generators, cranes, etc.. 5. Overtime labor or more than one person performing repairs.. Any and all expenses incurred investigating performance complaints unless defective Generac materials and or workmanship were the direct cause of the problem. 7. *Engine coolant heaters (block-heaters), heater controls and circulating pumps after the first year. 8. *Starting batteries, fuses, light bulbs, engine fluids, and overnight freight cost for replacement part(s). THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC POWER SYSTEMS MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to you. Purchaser/owner agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gives you specific legal rights. You also may have other rights that vary from state to state. GENERAC POWER SYSTEMS, INC. P.O. BOX 8 WAUKESHA, WI 5387 PH: () 5-8 FAX: () 5-85 Bulletin 9SBY / Printed in USA. Part No. E78 Revision (3//3) Printed in U.S.A.

53 BOTTOM OF CONTROL PANEL 5 8 ALT. LEADS & 3 SENSING WIRE FD 3 POLE (V) (5-5A) ALT. LEADS & SENSING WIRE FD FRAME 3 POLE AMPERAGE RATING 5-A 5-A DESCRIPTION: LINE SIDE LOAD SIDE CABLE SCREW TORQUE 8 IN/LBS 75 IN/LBS WIRE SIZE RANGE (-) UP TO #/-5kcmil (-)#3/-5kcmil (Cu) (-) #/-5kcmil (Al) 5 NOTE: ALWAYS REPLACE PLASTIC TERMINAL COVERS. DO NOT OPERATE GENERATOR WITHOUT ALL TERMINAL COVERS IN PLACE.

54 85 PANEL LOWER (39 BOX) 87 COVER LOWER PANEL BLANK 3 73 WASHER FLAT / 97 WASHER LOCK M-/ SCREW HHC /- X 3/ G5 7 NUT HEX /- 7 38N BUSHING SNAP 8 D3388 DECAL REMOTE START CONNECTION 9 87 REF BLOCK TERMINAL -CKT 985 WASHER FLAT # WASHER LOCK M C SCREW TAPTITE PH M-.7 X ZYC 3 8 COVER LOWER PANEL 5 REF. BATTERY CHARGER 5 REF. ASSY. CONTROL PANEL D557 CB 5A 3P V S FD LL 7 D589 PLATE CB MOUNT S (FD) 39S RELAY SOLENOID VDC PANEL MOUNT 9 73 WASHER FLAT / ZINC 97 WASHER LOCK M-/ 87 SCREW HHC /- X 3/ G TRANSFORMER CURRENT-5/5 3 5 WASHER FLAT M8-5/ ZINC 9 WASHER LOCK M8-5/ 5 59 NUT HEX 5/-8 STEEL SCREW HHC 5/-8 X 3/ G5 7 D593 COVER CB TERMINALS S (FD 3P) 8 97 / WASHER LOCK M-/ / SCREW HHC /- X 3/ G5 3 7 NUT HEX /- STEEL 3 73 WASHER FLAT / ZINC 3 83 SCREW SHC /- X.5 G8.8 NZ WASHER LOCK 3/ SCREW SHC 3/8- X 3/ G5 35 D5A NEUTRAL BLOCK 39/5-75A JUNCTION BLOCK 3/ WASHER LOCK # SCREW PHM #-3 X 5/8 CAD WASHER LOCK 3/8 NUT HEX 3/8- STEEL 5 WASHER FLAT 5/ ZINC 9 WASHER LOCK M8-5/ NUT HEX M8-.5 G8 YEL CHR

55 8 TO ENGINE FLYWHEEL SCROLL DETAIL 55 7 TO ENGINE FLYWHEEL HOUS NOTE: THREAD IN SENSOR (8) UNTIL CONTACT IS MADE WITH RING GEAR, THEN BACK OFF / TO 3/ TURN AND TIGHTEN NUT. CAUTION: DO NOT ROTATE ENGINE DURING THIS ADJUSTMENT. 3 5 STATOR LEADS 3 TIE-WRAPS & SLEEVE (I/N:) IN PLACE 3 37 ROTOR LEADS HUB DETAIL 3

56 578 SCREW HHC M-.75 X 5 G WASHER LOCK M 3 A89 ASSEMBLY SCROLL 39 SAE 7 SCREW HHC 3/8- X -3/ G5 5 A8 FLEX PLATE SAE (REF.) 3953 SCREW HHC M8-.5 X G WASHER LOCK M8-5/ 8 83D ASSEMBLY MAG PICKUP 7" (REF.) 9 C8 ASSEMBLY FAN W/PRESS DISC.75 X 3 * A SCREW HHC M-. X 5 G8.8 * A WASHER FLAT.88 ID X 3.5 OD * A38 KEY SQ 3/8 X -/ STEEL 3 * 9 COUPLER 39 SAE 88B ROTOR 39 /3P BRUSHLESS 5 * 5 BEARING BALL SEALED A558 SCREW HHC M-. X G8.8 7 A33 WASHER 39 SAE ALT. 8 79B STATOR 39 AP SAE 9 3 WASHER FLAT 3/8-M ZINC 37 WASHER LOCK 3/8 5 SCREW HHC 3/8- X -/ G5 83 CARRIER REAR BRG 5" 3 85 LOWER PANEL 5 (SMALL) (REF.) 95 LOWER PANEL 39MM (LARGE) (REF.) 33 WASHER LOCK M NUT HEX M-. G8 YEL CHR 559 WASHER FLAT M 7 73 WASHER FLAT /-M ZINC SCREW HHC M-.75 X G KEY SQ 3/8 X -3/ STEEL ASSEMBLY EXCITER.5 STACK 3 8 EXCITER FIELD.5 STACK COLLAR SLIP FIT 39 MM 33 5 CLAMP VINYL.3 X.3 Z 3 A SCREW SWAGE /- X / Z/YC BRIDGE SUPPORT DIODE 5" 3 95 ASSEMBLY BRIDGE RECTIFIER WASHER SHAKEPROOF INT # SCREW HHM #8-3 X 7/ CAP END ROTOR 39MM 3333 SCREW HHM #8-3 X 3/8 398 TIE WRAP UL. X. NATL (BLACK) 8739A TIE WRAP 3.9" X." BLACK UL 3 85D TIE WRAP UL 7.7 X.35 BLACK HT L SLEEVING UL #.33 ID SLEEVE RUBBER 39 PIN DOWEL / X -/ KIT A89 PARTS 7 A9 SHROUD ALT SHEET METAL 8 A97 SCREEN SHROUD SAE 9 A9 BRKT TENSIONER SAE SCROLL FT. TRIM VINYL BLACK /8 GP 7" 5 97 WASHER LOCK M-/ 5 73 WASHER FLAT /-M ZINC SCREW HHC M-. X 5 G SCREW HHC M-. X G A SCREW SWAGE /- X / Z/YC * ROTOR REPLACEMENT PARTS

57

58 E38 PANEL,BACK & BOTTOM E-PNL VRZN E379 E-PANEL FRONT, W/ SILK SCREEN 3 E383 PANEL RH SIDE, E-PNL VERIZON E38 PANEL LH SIDE, E-PNL VERIZON 5 E355 CHASSIS, UNIVERSAL D38 HARNESS E-PANEL W/SEALED CONS 7 3 RES R 5% W 8 59 RECTIFIER MSC A V N WASHER MICA.3 37 WASHER SHAKEPROOF EXT # STL 55 HEATSINK 3.3L 38 WASHER STEP NYLON RECTIFIER MSC A V NR A339 DECAL TERMINAL BLOCK 5 C89 DCL-E PNL TS# (W/FS) A577 DECAL T STRIP 3 E PNL 7 D353 DECAL T STRIP TB W/SEALED CON 8 D97 HINGE CONTINUOUS 9 C9 DECAL CUST CONN BOX E93A SWITCH MUSHRM HEAD/ARROWS MM E93C 3 CONTACT BLOCK D5-3 X W/ 7 33 HOLDER FUSE 3 7 FUSE 5A X AGC INSULATOR 5 73 POT 5K %.5W PNL 53 KNOB PLASTIC.5 SHAFT 7 8 SOUNALERT BUZZER 8 95 SWITCH SELECTOR A AMP/V 9 A87 MASTER CTRL BOX E-PNL 3 E373 LIGHT PANEL WITH LUG 3 C88 BULB-PANEL LIGHT-V 8388 LIGHT 8VDC.7A MIN BAYNT MNT 3 78 BLOCKER LIGHT 33 A75 DOOR-STOP RAM PANEL 3 E779 ASSY, GOVERNOR CONTROLLER TIE WRAP 3.9" X." NAT'L UL 3 AA TRUNKING 8MM 37 E83 ASSY LOW FUEL PRES FILTER 3.9L 38 E385 COVER PLATE,VOLTAGE REG.VERIZN 39 C7 DECAL AVR COVER E38 COVER PLATE,ELECT.GOVENOR VRZN A339 DECAL ELEC GOVERNOR A575 REF. FUSE 5A X LTTL55 (NOT SHOWN) 3 D33 CBL ASSY-RS85 E PNL W/SEALED D37 DECAL COVER DEUTSCH (RECT) 5 D37 DECAL COVER DEUTSCH (RECT) (ELECTRONIC GOVERNOR HARNESS IF EQUIPPED) C5 CONN DEUTSCH GASKET 8/POS DT 5 55 WASHER LOCK # 5 C8 SCREW TAPTITE PH -3X/ Z/YC 5 C33 SCREW TAPTITE PH -3X5/8 ZYC 53 7 NUT HEX #8-3 STEEL 5 8 WASHER LOCK M WASHER FLAT #8 ZINC SCREW PPHM #8-3 X / 57 A8 SCREW SWAGE 8-3 X / Z/YC NUT HEX #-3 STEEL 59 5 WASHER LOCK # WASHER FLAT # ZINC 9 SCREW TAPTITE #-3 X 3/8 BP 33 SCREW HHC #-3 X 3/ SCREW HHM #-3 X 5/8 57 SCREW HHC /- X / G WASHER LOCK M-/ 73 WASHER FLAT / ZINC 7 79 VIB MNT. X. X / RIVET POP.5 X.375 AL 9 C83 WASHER LOCK HDPDEUTSCH 7 C8 NUT, HDP DEUTSCH ADDITIONAL PARTS (BASE TANK UNITS) 75 D33 HARNESS BASETANK FOR E-PANEL 7 C5 CONN DEUTSCH GASKET 8/ POS DT PANEL SPECIAL PARTS BRACKET RESISTOR MNTNG FOR 5W 8 SEE RESISTOR # TABLE A 8 SEE FIELD CIRCUIT BREAKER TABLE B 83 SEE AMMETER TABLE C 8 SEE VOLTMETER AC TABLE D 85 7 METER FREQUENCY 55-5HZ 7A FREQUENCY METER V 5-55HZ 8 78 ASSY VOLTAGE REGULATOR HZ 995 ASSY VOLTAGE REGULATOR 5HZ SCREW HHTT M5-.8 X BP SCREW HHM #-3 X SCREW PPHM M-.7 X 9 E3 SUB-PLATE, E-PANEL VERIZON 9 A3 SCREW SWAGE -3 X Z/YC SPACER.9 X.3 X.5 PL

59 * MOUNTING FOOT ENGINE 3 * 3* 5* BASE MOUNTING 5 7 3* BLOCK 9 REAR 8 TO RADIATOR 9 DRAIN 3 TO FUEL FILTER To Fuel TO OIL 5 3 TO STARTER PAN 5*

60 C3 MOUNTING BASE 3.L HA KIA 39 ALTERNATOR C MOUNTING BASE 3.L HA KIA ALTERNATOR 58 NUT FLANGED HEX M DAMPENER VIBRATION BLUE 557 SPACER.9 X. X.87 PWDR/ZNC 5 55 DAMPENER VIBRATION WASHER FLAT M SCREW HHC M-.75 X 8 G PLUG STD PIPE / STEEL SQ HD 8 BARB STRAIGHT 5/8 X / X CLAMP HOSE # HOSE RES 5/8 TYP 3 SNGL 7 BARB STRAIGHT 5/8 X 3/8 X ADAPTER OIL DRAIN M-.5 X 3/8 NPT 73A 3 PLUG STD PIPE / STEEL SQ HD 9 35 BARB STRAIGHT 3/8 X / X CLAMP HOSE # HOSE RES 3/8 SINGLE BRAID 93 BARB ELBOW 3/8 X / X HOSE RES 5/ TYP SNGL 33 3 HOSE / ID SAE 3R7 5 7 SCREW HHC M-. X G WASHER FLAT M-/ ZINC 7 55 LUG SLDLSS #-#8 X 7/ CU 8 85 WASHER SHAKEPROOF EXT / STL 9 97 WASHER LOCK M-/ NUT HEX M -. G8 YEL CHR SCREW HHC M-.5 X G WASHER LOCK / CABLE GROUDING / X / X WASHER NYLON K CABLE BATT BLACK # X AA CABLE BATT RED # X NUT HEX M8-.5 G8 YEL CHR 38 9 WASHER LOCK M8-5/ 39 5 WASHER FLAT M8-5/ ZINC 78 WASHER SHAKEPROOF EXT 5/ STL 37 SCREW HHC M8-.5 X 5 G8.8 7 WASHER LOCK M EXT 3 * A8785 PLUG BUTTON 3" DIA * C5 SCREW TH-FRM M- X N WA Z/JS 5 * C3 5 PLATE VARMINT * 793 WASHER FLAT.8 ID X. OD BATTERY VDC 9-AH 7F (OPTIONAL) 8 9 HOLD DOWN BATTERY HOLD DOWN BATTERY 5 A SCREW HHC M8-.5 X FTHD NUT LOCK FL M NUT LOCK HEX M8-.5 NYL INSRT BOOT BATTERY CABLE * ITEMS 3- ARE PART OF KIT C739 (VARMINT GUARDING)

61

62 A98 BRACKET AIR DUCT TOP/BOTTOM A98 BRACKET AIR DUCT RH SIDE 3 A983 BRACKET AIR DUCT LH SIDE 3 SCREW HHC /- X G WASHER LOCK M-/ 73 8 WASHER FLAT / ZINC 7 55 SCREW HHTT /- X CZ

63

64 E58 TANK A GRP DW 3 GAL VERIZON C789 8 SCREW HHC M-.75 X 3 SS FT WASHER FLAT / SS NUT HEX M-.75 G8 SS 5 E5 COVER STUB-UP A GRP VERIZON 59 WASHER FLAT.3 ID X. OD SCREW HHC M8-.5 X G CLAMP HOSE # B FUEL DIP PIPE 538MM 737 VALVE CHECK 3/8 NPT * E57 LABEL EMERGENCY RELIEF VENTING BARBED STR 3/8 NPT MALE X 5/ G87 FUEL LEVEL GAUGE KIT ELECTRICAL- FT (TO INCLUDE ITEMS A, B, C & D) A G8B FUEL LEVEL GAUGE (IN KIT G87) B D8 PLATE ADAPTOR (IN KIT G87) C SCREW SHC M8-.5 X G.9 (IN KIT G87) D 979 SCREW SHC M-. X 5 G.9 (IN KIT G87) E E35 GASKET ROCHESTER FUEL LEVEL GAUGE F E35 GASKET ADAPTER PLATE 5 A9 CAP FUEL FILL D7 NECK FUEL FILL (STANDARD- ) 8 ** 78 VENT OEM NPT 9 A738 NIPPLE PIPE NPT X 3.5 BL IRON ** 7989J 3" NPT EMRG. PRES. VENT 95V DETECTOR ALARM FUEL LEAK W/CON E37 LABEL DIESEL FUEL ONLY 3 8 LABEL DATA GENERAC 83 LABEL DATA UL (DOUBLE WALL) 5 * A78 LABEL FUEL RETURN * A77 LABEL FUEL SUPPLY 7 * A7 LABEL FUEL FILL 8 * A5 LABEL FUEL LEVEL 9 * A79 LABEL VENT 3 * 8 LABEL EMERG. VENTING 3 * A8 LABEL LEAK DETECTOR 3 E58 LABEL 3 GALLON CAPACITY 33 * 8V LABEL STICKER WARNING 3 E7 VALVE FUSIBLE LINK SHUT-OFF 3/ WASHER LOCK / SS * UL LABEL KIT P/N E5 ** PARTS ARE LOCATED IN LOOSE VENTS KIT P/N E59

65 TO "B" TO "C" ROUTE CORD INTO BATTERY CHARGER RIGHT RAIL MOUNTING BASE TO "A" RADIATOR DRAIN TO UPPER RADIATOR CONNECTION BLOCK HEATER INTO ENGINE 3 "A" 5 3 TURBO CHARGED Overflow Drain 7 33 COOLANT ACCESS (RIGHT SIDE, FRONT OF ENGINE) LOWER RADIATOR HOSE 35 TO OIL COOLER LOWER RADIATOR HOSE TO OIL COOLER (ROUTE UNDER 3 "B" 3 39 TO COOLANT DRAIN PORT (RIGHT SIDE, REAR OF ENGINE) TURBO CHARGED

66 C389 RADIATOR FIN 3 LHA (UNITS 5KW & ABOVE) C37 RADIATOR SIDE SUPPORT 3.L HA 3 C38 VENTURI 3.L HA A8583A ADAPTOR M-. X 3/8 NPT SCREW HHC M-. X G BRACKET COOLANT RECOVERY TANK TANK COOLANT RECOVERY 8 C3775 HOSE LOWER RADIATOR 3.L HA 9 C388 HOSE UPPER RADIATOR 3.L HA 55 SCREW HHTT /- X CZ 97 5 WASHER LOCK M-/ 73 WASHER FLAT / ZINC NUT HEX M X. G8 YEL CHR 98 SCREW HHC M-.5 X 5 G WASHER LOCK 3/8 3 8 WASHER FLAT 3/8-M ZINC NUT HEX M-.5 G8 YEL CHR A 3 TIE WRAP 3.9" X." BLACK UL 9 55 TAPE FOAM X X 7-/ 3585 CLAMP HOSE # C 3 CLAMP HOSE BAND / 93 HOSE 9/3 ID (3 LONG) 3 93 HOSE 9/3 ID (3 LONG) 3337 SPACER. X.75 X.5 STL/ZNC 5 7 CAP RADIATOR 898A HEATER ENG W V 7 87 BRACKET HEATER W/WELDNUTS 8 7 SCREW HHC M-. X G WASHER LOCK M-/ 3 73 WASHER FLAT /-M ZINC NUT HEX M X. G8 YEL CHR HOSE CONN T BARBED STR 3/8 NPT X 5/ CLAMP HOSE # CLAMP HOSE # HOSE COOL 5/8 ID R (33 LONG) HOSE COOL 5/8 ID R ( LONG) BARBED STR / NPT X 5/8 39 E7 MANIFOLD / NPT X PORTS 9 NIPPLE PIPE / NPT X -/ 833B CLAMP HI TORQUE C8359 GUARD CSA TOP/R 3LHA 3 C83 GUARD CSA BOT/L 3LHA C83 GUARD CSA LO BK 3LHA 5 C83 GUARD CSA ALT 3LHA C833 GUARD CSA FRNT 3LHA SCREW CRIMPTITE /- X 5/ C CLAMP VINYL.5 X. Z 9 53 TRIM VINYL BLACK /8 GP 8" 5 53 TRIM VINYL BLACK /8 GP 7"

67 TO CONTROLLER (BLACK / WHITE STRIPE & WHITE) FACTORY THROTTLE CONTROL ARM TO FLYWHEEL HOUSING CHASSIS INSIDE CONTROL PANEL TO CONTROLLER (PURPLE WIRES) 5 7.±. [3±/"]

68 E77 ASSY, LINEAR ACTUATOR C37 BRACKET, ACTUATOR 3 C97 THROTTLE CONTROL ARM 7 3 SCREW, HHC M-. x WASHER, FLAT-M x 7. x WASHER, LOCK-M x NUT, HEX M-. x SCREW, PHM #-3 x 3/ CAD WASHER, FLAT M5 x 5.5 X.7 5 WASHER, LOCK #-M 58 NUT, HEX #-3 STEEL 33 STUD, #-3 x.75 F THR ZNC BALL JOINT, PLASTICS #-3 E779 ASSY, GOVERNOR CONTROLLER 5 C737 BRACKET, ACTUATOR 5757 SCREW,HHC M x. x CLEVIS, #-3 8 DM ASSY MAGPICKUP(3/8- MALE) SCREW HHTT M5-.8 X BP E97G HARNESS, ENGINE 3LHA EGOV (NOT SHOWN) 9 SCREW HHTT #8-3 X 3/8 CZ

69 TO UPPER RADIATOR CONNECTION REMOVE & REPLACE FROM FUEL PUMP ASSEMBLY REMOVE AND REPLACE FROM ENGINE 3 5 TO TURBO OIL SUPPLY TO RADIATOR 3 HOSE FITTING 5 OF ENGINE

70 C9 ENGINE KIA 3.L KIA C97L FOOT LH ENGINE MOUNTING C97R FOOT RH ENGINE MOUNTING (NOT SHOWN) 3 3 WASHER LOCK 7/ 35 NUT HEX 7/- STEEL 5 C3 FAN SPACER 3L HA 95 FAN COOLING 8 DIA. 7 C889 SCREW SH 5/- X.5 G8.8 NZ 8 5 WASHER FLAT M8-5/ ZINC 9 9 WASHER LOCK M8-5/ 3953 SCREW HHC M8-.5 X C97 FLYWHEEL MACHINED 3L HA NIPPLE CLOSE /8 NPT 3 58 PIPE CROSS /8 NPT (C OPTION ONLY) 353 PIPE TEE /8 NPT (D & E OPTION) 53 SENDER OIL PRESSURE 5 A858 SWITCH OIL PRESSURE (C OPTION ONLY) C9 PIN SPRING.MM X 3MM WASHER FLAT M-3/8 ZINC WASHER LOCK 3/ SCREW SHC M-.5 X C98 SCREW SHC M-.5 X 5 G.9 C99 ADAPTER FLYWHEEL 3L HA 55 NUT HEX M-.5 3 C397 BRACKET FUEL FILTER 3L HA CLAMP HOSE # HOSE RES 5/ TYP SNGL ( LONG) 9 C3759 ADAPTER THERMOSTAT 3L HA PLUG STD PIPE 3/8 COUNTERSUNK 3 35 SENSOR HI COOLANT SHUTDOWN SENDER WATER TEMP 33 E5 ASSYEMBLY WATER LEVEL SENSOR C/E PL WASHER FLAT M-/ ZINC WASHER LOCK M-/ SCREW HHC M-. X 5 38 A8 FLEX PLATE SCREW SHC M-.5 X 5 C589 ADAPTER OIL COOLER 3LHA (M X.5) 975 OIL COOLER FILTER STYLE 5 WASHER FLAT 7/ CLAMP HOSE # HOSE RES 5/8 -/+3 SAERG ( LONG) HOSE RES 5/8 -/+3 SAERG (38 LONG) 975 GASKET EXHAUST MANIFOLD 7 C9 GASKET THERMOSTAT 8 97 FILTER OIL 9 93 SCREW HHC M-.5 X 3 5 DM ASSY MAGPICKUP (3/8- MALE) 5 E97 HARNESS, ENGINE 3LHA (NOT SHOWN) 5 57 ADAPTOR /8 NPTF TO / RELAY SOLENOID VDC PNL MNT (NOT SHOWN) WASHER FLAT MM ID X 8MM OD 55 E538B ADAPTER BANJO FITTING LW FL PR 5 E59 SNUBBER BRASS /8" NPT 57 E53A ADAPTER BANJO BOLT LOW FUEL PR

71 3 REMOVE FACTORY LIFTING EYE REMOVE & REPLACE FACTORY BOLTS TO 3 ENGINE TO OIL PAN 9 EXHAUST MANIFOLD 5 /8" NPT OIL PUMP CROSS ON 8 REMOVE & REPLACE FACTORY BOLTS 9 GASKET REMOVE FACTORY STUDS 35 REMOVE & REPLACE FACTORY NUTS & WASHERS 7

72 75A ASSY TURBO 3.LHA KIA A5 INDICATOR FILTER MINDR G CON TURBO. X.9 9 ELBOW /8 NPT x / - x 37 DEG. 5 9B OIL SUPPLY LINE 5 CLAMP HOSE # SCREW HHC M8-.5 X G LOCK WASHER, 5/ -M8 9 C35 8 SCREW SHC 3/8- X 3/ G8.8 NZ 358 ADAPTER UPPER TURBOCHARGER C59 ADAPTER LOWER TURBOCHARGER C58 TUBE TURBO INTK 3LHA 3 7 GASKET TURBOCHARGER C37 OIL RETURN TUBE 5 97 LOCK WASHER /-M 7 SCREW HHC M-. X G CLAMP HOSE SIZE: # REDUCER COUPLING RED RUBBER TO -3/ ELBOW RUBBER 9.5 ID 5 CLAMP HOSE SIZE: #3 578 CLAMP HOSE SIZE: #8 98 REDUCER, RUBBER 5/8 TO / CLAMP HOSE # D3 LABEL HOT TURBO.L UL 5 C95 BRACKET, AIR CLEANER 575 SCREW HHC M-.5 X G FLAT WASHER 5/8-M 8 5 LOCK WASHER 5/8-M NUT HEX M-.5 G8 YEL CHR STRAP AIR CLEANER 3 C37 AIR CLEANER 3.L HA CLAMP HOSE # CLAMP HOSE # E53 TUBE INTAKE W/ /8" NPT VERIZON 35 E58 HEAT SHIELD TURBO 3.L KIA

73

74 C359 8 ASSEMBLY, M HINGE 3 A SCREW BHSC M-. X SS A33 3 SHAKEPROOF, INT. M S.S SCREW HHC M8-.5 X G8.8 9 WASHER LOCK M8-5/ 7 C5 (A) DUCT, FRONT L.H. 8 C (A) DUCT, FRONT R.H. 9 C (A) DUCT, BOTTOM C7 (A) DUCT, FRONT PANEL C7A DUCT,FRONT TOP RH AL C5 M-. x TRD. FORM W/WASHER C57 (A) CORNER POST, L.H. REAR 5 C58 (A) CORNER POST, R.H. REAR C535 (A) CORNER POST, L.H. FRONT 7 C53 (A) CORNER POST, R.H. FRONT 8 C8 (A) REAR PANEL, SOUND 9 C55 (A) SIDE BRACE, TOP & BOTTOM C555 (A) SIDE SUPPORT C38 (A) ROOF C (A) FRONT BRACE, BOTTOM (.L) C57 (A) FRONT BRACE, BOTTOM (3.L D ONLY) 3 C (A) FRONT BRACE, TOP (.L) C5 (A) FRONT BRACE, TOP (3.L D ONLY) C33 STRIKER PLATE 5 C3A ACCESS COVER ASSEMBLY 7 97 WASHER LOCK M-/ WASHER FLAT M-/ ZINC 9 C79 SCREW PPHC M x SS 3 9 PADDLE HANDLE LOCK 3 C78 NUT LOCK HEX M-.7 SS NYL INS WASHER FLAT #8 SS RIVET POP.875 X.9-.9/# 35 C3 (A) DUCT, REAR L.H. 3 C (A) DUCT, REAR R.H. 37 C (A) DUCT, REAR PANEL 38 A FT. DOOR GASKET, RUBBER 39 C5 (A) DUCT, REAR TOP C375R INSULATION, FRONT DUCT A535A 8 SELF ADHESIVE HANGER 3/ 3 C375S INSULATION, DUCT BOTTOM C375J INSULATION, DUCT FRONT PANEL 5 C375M INSULATION, REAR DUCT R.H. C375N INSULATION, REAR DUCT L.H. 7 C375L INSULATION, DUCT REAR PANEL 8 C375K INSULATION, REAR DUCT TOP 9 C375A INSULATION, ROOF TOP 5* C357K INSULATION, DOOR 5* C357L INSULATION, DOOR 53 C375F INSULATION, FRONT CORNER POST 5 C375E INSULATION, FRONT CORNER POST 55 C375V INSULATION, TOP & BOTTOM SIDE BRACE 5 C375D INSULATION, SIDE SUPPORT 57 C375G INSULATION, FRONT TOP BRACE 58 C375H INSULATION, REAR PANEL 59 C375C INSULATION, REAR CORNER POSTS, SECT. # C375B INSULATION, REAR CORNER POSTS, SECT. # WASHER, SELF LOCKING DOME 7 NUT HEX /- STEEL C3393 SHOULDER SCREW 5 C3 (A) COVER, EXHAUST HOLE C375 INSULATION, FRONT ROOF TOP 7 F733** DOOR SMALL, ACO C5A* DOOR,SM ACO WELD AL 75 C375U INSULATION, FRONT DUCT R.H. & L.H. 7 C375T INSULATION, REAR DUCT R.H. & L.H. 77* C77 STANDOFF M x AL 78* C35 COVER, LATCH ACOUSTIC 8 C535 (A) VARMIT BLOCKOFF PLATE / SEALANT STRIP /8 x 83* 7837 WASHER LOCK 8-M SS 8 5 WASHER FLAT M8-5/ ZINC 85** C357AD INSULATION, SMALL DOOR 8* 89 WASHER FLAT #8 SS 87* C79 SCREW PPHM M-.7 X SS OPTIONAL COMPARTMENT MATERIALS: ALL P/N S WITH AN A SUFFIX INDICATE ALUMINUM MATERIAL OPTION. * USED ON ALUMINUM ENCLOSURES ONLY. ** USED ON STAINLESS STEEL ENCLOSURES ONLY.

75

76 59937 MUFFLER NPT BXU 3 MUFFLR STRAP IN DIA ELBOW 9D NPT 599 NIPPLE TOE NPT X 9 BLK IRON SCREW HHC M8-.5 X G NUT LOCK FL M H FLEX EXH " X " RAIN CAP.37 I.D. 9 E597 BLANKET MUFFLER 3.L VERIZON

77 " Dia. Clamp Assembly Engine To Compartment 8 5 Front