Illustrated Parts List MODEL 076030-0 30,000 Watt Liquid Cooled Home Generator System Revision - Manual Part No. Rev. Date: 3/14/2011
Table Of Contents PRODUCT COMPONENTS Main Unit... 4 Alternator... 6 Control Panel... 7 Enclosure... 8 Engine - Impco 30L - Alternator... 9 Engine - Impco 30L - Crank Sensor... 10 Engine - Impco 30L - Distributor & Spark Plug Wires... 11 Engine - Impco 30L - Engine Control Module & Bracket... 12 Engine - Impco 30L - Engine Hangars... 13 Engine - Impco 30L - Engine Mounting Brackets... 14 Engine - Impco 30L - Fuel Control Valve & Brackets... 15 Engine - Impco 30L - Fuse Box & Bracket... 16 Engine - Impco 30L - Ignition Coil... 17 Engine - Impco 30L - Manifolds... 18 Engine - Impco 30L - Miscellaneous Engine... 19 Engine - Impco 30L - Oil Drain Tube... 20 Engine - Impco 30L - PCV Vent & Valve... 21 Engine - Impco 30L - Regulator... 22 Engine - Impco 30L - Starter... 23 Engine - Impco 30L - Thermostat & Housing... 24 Engine - Impco 30L - Took Kit & Accessories... 25 Engine - Impco 30L - Vacuum/Fuel Hoses... 26 Engine - Impco 30L - Venturi & Throttle Body... 27 Engine - Impco 30L - Water Port... 28 Engine - Impco 30L - Wire Harness/Fuses/Fuse Box Cover... 29 Torque Specification Chart... Inside Back Cover PAGES
Main Unit 312950 1 310345GS BASE 17 AA310518GS COUPLER 2 205623GS TRAY, Battery 18 312788GS VALVE, Ball 3 206119GS HEATER 19 312923GS HOSE, Fuel 4 312101GS EXHAUST 20 312398GS REDUCER 5 311972GS TUBE, Exhaust 21 206727GS ELBOW 6 205398GS 22 206598GS ELBOW 7 310600GS BRACKET, Muffler 23 205401GS 8 310582GS MUFFLER 24 186649GS 9 311354GS DIFFUSER 25 ----- * CAPSCREW, Hex Head, 1/4-20 x 3/4 10 205396GS 26 ----- * WASHER, Lock, 1/4-M6 11 205399GS 27 ----- * WASHER, Flat, 1/4 12 205226GS BOTTLE, Overflow 28 204653GS MOUNT, Vibration 13 205103GS CLAMP -- ----- * CAPSCREW, Hex Head, 1/2-13 x 30 14 204274GS FILTER, Air -- ----- * WASHER, 1/2 -- 207575GS FILTER, Cartridge -- ----- NUT, 1/2-13 15 207444GS ALTERNATOR 29 206985GS INSULATION 16 314110GS VALVE, Fuel * Items without part numbers are common fasteners and are available at your local hardware store. ** Contact Engine Manufacturer 4
Main Unit 312950 30 312906GS 31 B209900GS 32 314300GS 33 205392GS 34 314114GS 900 ----- -- 312898GS -- 312965GS -- 208538GS -- 206532GS -- 205206GS -- 198573GS -- 203374GS -- 208346GS -- 195642GS -- 205622GS TUBE BRACKET PANEL PANEL ** ENGINE MANUAL, Operator (Not Illustrated) MANUAL, Install (Not Illustrated), Spark (Not Illustrated) KIT, LED Remote (Not Illustrated) HOSE (Not Illustrated) FUSE (Not Illustrated) PAINT, Touch Up, Charcoal (Not Illustrated) PAINT, Touch Up, GE Silver (Not Illustrated), Rainproof (Not Illustrated) KIT, Hardware, Battery (Not Illustrated) -- 203417GS -- 208350GS -- 187315GS -- 6167 PAINT, Spray, Charcoal (Optional Accesso Not Included) PAINT, Spray, GE Silver (Optional Accessory, Not Included), Do Not Lift (Optional Accessory, N Included) KIT, Maintenance (Optional Accessory, No Included) * Items without part numbers are common fasteners and are available at your local hardware store. ** Contact Engine Manufacturer 5
Alternator 207444SV 1 ----- 2 ----- 3 ----- 4 208353GS 5 313280GS 6 313281GS 7 ----- 8 ----- 9 ----- 10 ----- 11 ----- 12 208220GS 13 ----- DISC, Coupling FAN ROTOR EXCITER, Rotor RECTIFIER ASSEMBLY RING BEARING HOUSING, Bell SCREEN HOUSING, Generator LIFTING EYE STATOR EXCITER, Stator COVER 6
Control Panel 312952 1 B209903GS 2 311350GS 3 B207515GS 4 186173GS 6 205395GS 7 198549GS 8 186582GS 9 208365GS 10 204519GS 11 209168GS 12 209856GS 13 192151GS 14 205110GS 15 198550GS 16 204530GS 17 B4986AGS 18 310656GS PANEL, Access CONTROL PANEL BOX, Control Panel BUSHING, Snap BUSHING, Snap TERMINAL INSULATION CIRCUIT BREAKER REGULATOR, Voltage FUSE?HOLDER FUSE LUG PLUG, Hole 19 B5082AGS 20 205392GS 21 205394GS 22 193297GS 23 192597GS 24 205393GS 25 B310533GS 26 198516GS 27 B209876GS 28 207242GS 29 209048GS 30 207241GS 31 B310469GS 32 205115GS -- 198573GS -- 312784GS COVER CONNECTOR, 10 Pin PANEL BRACKET FUSE (Not Illustrated) HARNESS, Wire (Not Illustrated) 7
Enclosure 312953 1 310345GS 2 186643GS 3 B4986AGS 4 312049GS 5 205368GS 6 207758GS 7 204700GS 8 AF310482GS 9 AF310477GS 10 205225GS 11 205126GS 12 205855GS 13 205853GS 14 314910GS 15 314900GS 16 207030GS 17 205851GS BASE ROOF SEAL SEAL KIT, Latch COVER PLATE, Cover HINGE BULKHEAD, Alternator RAIL, Support BULKHEAD, Engine DOOR RAIL, Support CORNER 18 313211GS 19 186049GS 20 207031GS 21 207032GS 22 B310486GS 23 207652GS 24 205398GS 25 197316GS 26 312708GS 27 312321GS -- 314566GS -- 314551GS 28 313210GS 29 B310532GS -- 207730GS HOSE, Radiator HANDLE RAIL, Support DOOR BRACKET KEY, Latch SEAL FAN RADIATOR CAP, Radiator VALVE, Drain HOSE, Radiator COVER SEAL (Cut to Fit) (Not Illustrated) 8
Engine - Impco 30L - Alternator 30LAlternator 1 314137GS 2 ----- 3 ----- 4 ----- 5 ----- 6 ----- 7 ----- 8 ----- 9 ----- 10 ----- 11 314138GS 12 ----- 13 ----- 14 ----- 15 ----- 16 ----- 17 ----- ALTERNATOR BRACKET-ALTERNATOR BOLT WASHER-LOCK WASHER-FLAT BRACKET-ALTERNATOR BOLT SPACER WASHER-FLAT NUT BELT-ALTERNATOR WASHER NUT BOLT PULLEY BOLT WASHER-LOCK 18 ----- BOLT 9
Engine - Impco 30L - Crank Sensor 30LCrank 1 314141GS CRANK SENSOR 10
Engine - Impco 30L - Distributor & Spark Plug Wires 30LDistrbtr 1 ----- 2 314144GS 3 314203GS 4 314148GS DISTRIBUTOR CAP, Distributor ROTOR MODULE SNESOR 11
Engine - Impco 30L - Engine Control Module & Bracket 30LCntrlMdl 1 ----- 2 ----- 3 ----- 4 ----- 5 ----- 6 ----- 7 ----- 8 ----- 9 ----- 10 ----- 11 ----- 12 314123GS SPACER SCREW WASHER WASHER-LOCK BOLT BRACKET NUT STUD SPACER STUD WASHERS ECM 12
Engine - Impco 30L - Engine Hangars 30LHngers 1 ----- 2 ----- 3 ----- 4 ----- 5 ----- BRACKET BOLT SPACER STRAP SCREW 13
Engine - Impco 30L - Engine Mounting Brackets 30LBrckts 1 ----- 2 ----- 3 ----- 4 ----- BOLT WASHER-LOCK BRACKET-MOUNT LH BRACKET-MOUNT RH 14
Engine - Impco 30L - Fuel Control Valve & Brackets 30LFuel 1 ----- 2 ----- 3 ----- 4 ----- 5 ----- 6 ----- 7 314111GS 8 ----- 9 ----- 10 ----- 11 ----- 12 ----- 13 ----- CLAMP WASHER WASHER-LOCK BOLT BRACKET BRACKET VALVE-REGULATOR NUT SCREW BRACKET NUT STUD BOLT 15
Engine - Impco 30L - Fuse Box & Bracket 30LFuse 1 ----- 2 ----- 3 ----- 4 ----- COVER SEAL SCREW BRACKET 16
Engine - Impco 30L - Ignition Coil 312593igntn 1 ----- 2 314101GS NUT COIL, Ignition 17
Engine - Impco 30L - Manifolds 30LManifold 1 ----- 2 ----- 3 ----- 4 ----- 5 ----- 6 ----- 7 ----- 8 ----- 9 ----- 10 ----- 11 ----- 12 ----- 13 ----- 14 ----- 15 ----- 16 ----- 17 ----- GASKET MANIFOLD-EXHAUST INTAKE-MANIFOLD FITTING FITTING STUD BOLT WASHER NUT WASHER SCREW SCREW SCREW SCREW WASHER WASHER SCREW 18 ----- 19 ----- 20 ----- 21 314107GS 22 ----- 23 ----- 24 ----- 25 314121GS 26 314122GS HEATSHIELD HEATSHIELD HEATSHIELD SENSOR-TMAP BRACKET BRACKET BRACKET GASKET SENSOR 18
Engine - Impco 30L - Miscellaneous Engine 30LMisc 1 6167 2 314124GS 3 ----- 4 314125GS 5 ----- 7 314126GS 8 ----- 9 ----- 10 ----- 11 ----- 12 ----- 13 ----- 14 ----- KIT-MAINTENANCE SENSOR PLUG SWITCH PLUG WIRE SET CAP CAP CLAMP CLAMP CONDUIT CONDUIT FITTING 19
Engine - Impco 30L - Oil Drain Tube 30LOilDrain 1 314127GS 2 314128GS 3 314129GS 4 314130GS 5 314131GS 6 314132GS 7 ----- 8 314133GS O-RING VALVE-DRAIN CLAMP HOSE CLAMP CAP HARDWARE-ENGINE ADAPTER 20
Engine - Impco 30L - PCV Vent & Valve 30LPCV 1 ----- 2 ----- 3 314143GS 4 ----- VENT, Elbow GROMMET PCV GROMMET 21
Engine - Impco 30L - Regulator 30LRegulator 1 314089GS 2 313916GS 3 314094GS 4 314095GS 5 314092GS FITTING FITTING FITTING REGULATOR, Voltage JET 22
Engine - Impco 30L - Starter 30LStarter 1 ----- 2 ----- 3 ----- 4 ----- 5 ----- 6 ----- 7 ----- 8 ----- 9 ----- 10 ----- 11 ----- 12 ----- 13 314140GS BOLT WASHER-LOCK WASHER-FLAT WASHER-LOCK NUT WASHER-LOCK NUT BRACKET-STARTER WASHER-FLAT WASHER-LOCK NUT BOLT STARTER-MOTOR 23
Engine - Impco 30L - Thermostat & Housing 30LThermo 1 ----- 2 ----- 3 314091GS 4 314093GS BOLT HOUSING, Thermostat GASKET THERMOSTAT 24
Engine - Impco 30L - Took Kit & Accessories 30LToolKit 1 100111 2 100112 3 ----- 4 ----- 5 ----- 6 ----- 7 ----- 8 ----- 9 ----- WIRE HARNESS ASM FITTING FITTING FITTING HOSE TEST KIT, Gauge TEST KIT, Gauge CASE, Plastic 25
Engine - Impco 30L - Vacuum/Fuel Hoses 30LVacum 1 314104GS 2 314103GS 3 314105GS 4 314106GS 5 ----- 6 ----- 7 ----- 8 ----- 9 ----- 10 314104GS 11 314108GS 12 ----- 13 314109GS 14 314102GS 15 ----- CLAMP HOSE HOSE HOSE PLUG PIPE PIPE FITTING ELBOW CLAMP HOSE ADAPTER HOSE CLAMP SWITCH 26
Engine - Impco 30L - Venturi & Throttle Body 30LThrttl 1 ----- 2 ----- 3 314086GS 4 313916GS 5 314089GS 6 314088GS 7 313927GS 8 314090GS 9 ----- 10 313921GS 11 313923GS 12 ----- 13 313922GS 14 314087GS SCREW WASHER VENTURI FITTING FITTING SCREW-SET ADAPTER SEAL THROTTLE BOTTLE GASKET ADAPTER SCREW GASKET PLUG 27
Engine - Impco 30L - Water Port 30LPort 1 314145GS 2 314146GS 3 314147GS 4 ----- 5 ----- ADAPTER CLIP, Retaining FITTING CLAMP CAP 28
Engine - Impco 30L - Wire Harness/Fuses/Fuse Box Cover 30LWire 1 ----- 2 314162GS 3 ----- 4 314142GS COVER FUSE HOLDER, Fuse HARNESS, Wire 29
Hardware Identification & Torque Specifications Torque Specification Chart FOR STANDARD METRIC MACHINE HARDWARE (Tolerance ± 20%) Torque Specification Chart FOR STANDARD MACHINE HARDWARE (Tolerance ± 20%) Property Class 5.6 Class 5.6 8.8 10.9 12.9 Class 8.8 Class 10.9 Class 12.9 Size Of in/lbs in/lbs in/lbs in/lbs Hardware ft/lbs Nm. ft/lbs Nm. ft/lbs Nm. ft/lbs Nm. M3 5.88.56 13.44 1.28 19.2 1.80 22.92 2.15 M4 13.44 1.28 30.72 2.90 43.44 4.10 52.56 4.95 M5 26.4 2.50 60.96 5.75 5.97 8.10 7.15 9.7 M6 44.64 4.3 7.3 9.9 10.3 14 12.1 16.5 M7 5.2 7.1 12.1 16.5 16.9 23 19.9 27 M8 7.7 10.5 17.7 24 25 34 29 40 M10 15 21 35 48 50 67 59 81 M12 26 36 61 83 86.2 117 103 140 M14 42 58 101 132 136 185 162 220 M16 64 88 147 200 210 285 250 340 M18 89 121 202 275 287 390 346 470 M20 126 171 290 390 405 550 486 660 M22 169 230 390 530 559 745 656 890 M24 217 295 497 375 708 960 840 1140 M27 320 435 733 995 1032 1400 1239 1680 M30 435 590 995 1350 1401 1900 1681 2280 M33 590 800 1349 1830 1902 2580 2278 3090 M36 759 1030 1740 2360 2441 3310 2935 3980 M39 988 1340 2249 3050 3163 4290 3798 5150 The guides and ruler furnished below are designed to help you select the appropriate hardware. 0 10 20 0 Inside Diameter (in) Nut, 1/2-16 1/4 1/2 3/4 1 30 40 1/4 1/2 3/4 50 60 Thread Diameter (mm) Body Diameter 2 Screw, 1/2-16 x 2 1/4 1/2 3/4 70 80 3 Body Diameter Nut, M8 Screw, M8-1.25 x 25 Thread Diameter (mm) Threads per inch Body Length Distance between threads (mm) Threads per inch 90 100 1/4 1/2 3/4 Body Length (mm) Body Length (in) 4 Hardware Grade No Marks SAE Grade 2 SAE Grade 5 SAE Grade 8 Size Of in/lbs in/lbs in/lbs Hardware ft/lbs Nm. ft/lbs Nm. ft/lbs Nm. 8-32 19 2.1 30 3.4 41 4.6 8-36 20 2.3 31 3.5 43 4.9 10-24 27 3.1 43 4.9 60 6.8 10-32 31 3.5 49 5.5 68 7.7 1/4-20 66 7.6 8 10.9 12 16.3 1/4-28 76 8.6 10 13.6 14 19.0 5/16-18 11 15.0 17 23.1 25 34.0 5/16-24 12 16.3 19 25.8 29 34.0 3/8-16 20 27.2 30 40.8 45 61.2 3/8-24 23 31.3 35 47.6 50 68.0 7/16-14 30 40.8 50 68.0 70 95.2 7/16-20 35 47.6 55 74.8 80 108.8 1/2-13 50 68.0 75 102.0 110 149.6 1/2-20 55 74.8 90 122.4 120 163.2 9/16-12 65 88.4 110 149.6 150 204.0 9/16-18 75 102.0 120 163.2 170 231.2 5/8-11 90 122.4 150 204.0 220 299.2 5/8-18 100 136 180 244.8 240 326.4 3/4-10 160 217.6 260 353.6 386 525.0 3/4-16 180 244.8 300 408.0 420 571.2 7/8-9 140 190.4 400 544.0 600 816.0 7/8-14 155 210.8 440 598.4 660 897.6 1-8 220 299.2 580 788.8 900 1,244.0 1-12 240 326.4 640 870.4 1,000 1,360.0 NOTES 1. These torque values are to be used for all hardware excluding: locknuts, self-tapping screws, thread forming screws, sheet metal screws and socket head setscrews. 2. Recommended seating torque values for locknuts: a. for prevailing torque locknuts - use 65% of grade 5 torques. b. for flange whizlock nuts and screws - use 135% of grade 5 torques. 3. Unless otherwise noted on assembly drawings, all torque values must meet this specification. Common Hardware Types Hex Head Capscrew Washer Standard Hardware Sizing When a washer or nut is identified as 1/2 (M8), this is the Nominal size, meaning the inside diameter is 1/2 inch (8mm metric thread diameter); if a second number is present it represents the threads per inch (distance between threads). Carriage Bolt Wrench & Fastener Size Guide Lockwasher Hex Nut When bolt or capscrew is identified as 1/2-16 x 2 (M8-1.25 x 50 ), this means the Nominal size, or body diameter is 1/2 inch (8mm metric thread diameter), the second number,16, represents the threads per inch, (1.25 thread diameter). The final number is the body length of the bolt or screw, 2 inches (50mm). 1/4 Bolt or Nut Wrench 7/16 M6 Bolt or Nut Wrench 10mm 5/16 Bolt or Nut Wrench 1/2 M8 Bolt or Nut Wrench 13mm 3/8 Bolt or Nut Wrench 9/16 M10 Bolt or Nut Wrench 17mm 7/16 Bolt or Nut Wrench (Bolt) 5/8 Wrench (Nut) 11/16 M12 Bolt or Nut Wrench 19mm 1/2 Bolt or Nut Wrench 3/4 M14 Bolt or Nut Wrench 22 mm
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