Generac Power Systems 1388490100 Owner's Manual

Engine: D5.0

Type: SD125

Model: 1388490100

INTRODUCTION

Thank you for purchasing this model of the standby
generator set product line by Generac Power Systems,
Inc..

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 the nearest 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 instructions 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.

The operator is responsible for proper and safe use
of the equipment. The manufacturer strongly recom­mends that the operator read this Owner's Manual
and thoroughly understand all instructions before
using this equipment. The manufacturer 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 an 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 an Authorized Service
Dealer for service aids and accessories.

Operating instructions presented in this manual
assume that the standby electric system has been
installed by an Authorized Service Dealer or other
competent, qualified contractor. Installation of this
equipment is not a “do-it-yourself” project.

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 infor-



mation 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.

HOW TO OBTAIN SERVICE 

When the generator requires servicing or repairs,
contact an Authorized Service Dealer for assistance.
Service technicians are factory-trained and are capa­ble of handling all service needs.

When contacting an Authorized Service Dealer 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 LABEL affixed to the unit.

AUTHORIZED SERVICE

DEALER LOCATION

To locate the nearest AUTHORIZED SERVICE

DEALER, please call this number:

1-800-333-1322

DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER

or visit the website at

www.generac.com.

8 Generac®Power Systems, Inc.

Section 1 – General Information

Generac Standby Generator Sets

ENGINE OIL RECOMMENDATIONS

The unit has been filled with 15W-40 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:

COOLANT

Use a mixture of half low silicate, ethylene glycol base
antifreeze and half soft water. Use only soft water and
only low silicate antifreeze. If desired, you may add a
high quality rust inhibitor to the recommended
coolant mixture. When adding coolant, always add
the recommended 50-50 mixture.

Do not remove the radiator pressure cap while
the engine is hot or serious burns from boiling
liquid or steam could result.

Ethylene 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
ethylene glycol base antifreeze, or chromium
hydroxide (“green slime”) will form and cause
overheating. Engines that have been operated
with a chromate base rust inhibitor must be
chemically cleaned before adding ethylene 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.

GEARBOX LUBRICATION

If your generator set is equipped with a gearbox
(Contact sales for availability.), the appropriate lubri­cation is SAE 90 gear lubrication.

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 #46622).

• Gaseous Fuel System: See Chapter 9 of Engine-

Generator Standby Electric Power Systems Installer’s
Guide and Reference Manual (part #46622).

GENERATOR AC LEAD CONNECTIONS

See “Voltage Codes” on Page 4. Your generator may be
rated at any one of several voltages, either single­phase or three-phase. 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.

Voltage codes apply to the type of stator assembly
installed on a particular generator.

FOUR-LEAD, SINGLE-PHASE STATOR

Four-lead generators are dual voltage coils or wind­ings (Figure 1.1). Units may be assigned any of the
following voltage codes:

• “A” units are rated 120/240 volts, single-phase,
60 Hertz.

• “M” units are rated 110/220 volts, single-phase,
50 Hertz.

Each stator winding in this case delivers a 110- or
120-volt AC output; connecting the two windings
series results in a 220- or 240-volt AC output.

The neutral line is formed by a junction of stator
leads 22 and 33. Thus, you may connect 120-volt (60
Hz) or 110-volt (50 Hz) loads across leads 11 and
neutral, or across leads 44 and neutral.

Figure 1.1 – Four-lead, Single-phase Stator

◆

◆

◆

!

◆

◆

Temperature Oil Grade (Recommended)

Above 86º F (30º C) SAE 40 or 15W-40

32º to 86º F (0º to 30º C) SAE 30 or 15W-40

Below 32º F (0º C) SAE 20 or 15W-40

All Seasons SAE 15W-40

DANGER

!

!

Section 5 – Warranty

Generac Standby Generator Sets

GENERAC POWER SYSTEMS’ STANDARD ONE-YEAR LIMITED WARRANTY

FOR STANDBY POWER SYSTEMS

NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES.

For a period of 1 (one) year or 1,500 (one thousand five hundred) hours of operation from the date of original sale, whichever
occurs first, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part which, upon examination,
inspection and testing by Generac or a Generac Authorized Warranty Service Facility, is found to be defective under normal use
and service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be
defective must be examined by the nearest Generac 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 generators used in “Standby” applications, as Generac has defined Standby, provided said generators have been
initially installed and inspected on-site by a Generac Authorized Service Dealer or branch thereof.

WARRANTY SCHEDULE

YEAR ONE – 100% (one hundred percent) coverage on mileage*, labor and parts listed:

• Engine – All components

• Alternator – All components

• Transfer System – All components

*Travel allowance is limited to 300 miles or 7.5 hours maximum, round trip, and applies only to permanently wired and
mounted units.

All warranty expense allowances are subject to the conditions defined in Generac’s Warranty Policies, Procedures and Flat
Rate Manual.

Units that have been resold are not covered under the Generac warranty, as this warranty is not transferable.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

• Costs of normal maintenance, adjustments, installation and start-up.

• Units sold, rated or used for “Prime Power” applications as Generac has defined Prime Power. Contact a Generac

Authorized Service Dealer for Prime Power definition and warranty.

• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation.

• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust,

fire, freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.

• Products that are modified or altered in a manner not authorized by Generac 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.

• Telephone, telegraph, teletype or other communication expenses.

• 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.

• Overnight freight costs for replacement part(s).

• Overtime labor.

• Starting batteries, fuses, light bulbs and engine fluids.

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC
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’S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT
SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE
A DIRECT RESULT OF GENERAC’S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or
consequential damages, so the above limitation may not apply to you. Purchaser/owner agrees to make no claims against
Generac 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. 21

1 055173 6 SCREW HHC M8

-

1.25 X 20 G10.9

2 022129 6 WASHER LOCK M8-5/16

33 042561 1 CLAMP HOSE #36 1.88

-

2.75

3 082130C 1 SENDER MAG P-U GOV. CONT. 54"

082130D 1 SENDER MAG P-U GOV. CONT. 72"
4 0G0724 1 FAN MACHINED 390 SAE ALTERATOR
5 0A3870 1 KEY SQ 3/8 X 1-9/16 STEEL
6 0A3009 1 HUB DRIVE
7 0A3877D 1 ROTOR 390 35KW GB BR BRLS

0A3878D 1 ROTOR 390 40KW GB BR BRLS

0A3879D 1 ROTOR 390 50KW GB BR BRLS

0A3880D 1 ROTOR 390 60KW GB BR BRLS

0A3881D 1 ROTOR 390 80KW GB BR BRLS

0A3882D 1 ROTOR 390 100KW GB BR BRLS

0A3883D 1 ROTOR 390 125KW GB BR BRLS

0A3877B 1 ROTOR 390 35KW GB 1P BRLS

0A3878B 1 ROTOR 390 40KW GB 1P BRLS

0A3879B 1 ROTOR 390 50KW GB 1P BRLS

0A3880B 1 ROTOR 390 60KW GB 1P BRLS

0A3881B 1 ROTOR 390 80KW GB 1P BRLS

0A3882B 1 ROTOR 390 100KW GB 1P BRLS

0A3883B 1 ROTOR 390 125KW GB 1P BRLS

0A3879G 1 ROTOR 390 50KW GB 3P LV BRLS

0A3880G 1 ROTOR 390 60KW GB 3P LV BRLS

0A3881G 1 ROTOR 390 80KW GB 3P LV BRLS
8 052624 1 BEARING
9 065477 4 SCREW HHC M14-2.0 X 150 G8.8

10 0A1633 4 WASHER 390 SAE ALT
11 020717D 1 STATOR 390 35KW BR BRLS

020718D 1 STATOR 390 40KW BR BRLS

020719D 1 STATOR 390 50KW BR BRLS

020720D 1 STATOR 390 60KW BR BRLS

020721D 1 STATOR 390 80KW BR BRLS

020722D 1 STATOR 390 100KW BR BRLS

020732D 1 STATOR 390 125KW BR BRLS

020717B 1 STATOR 390 35KW 1P BRLS

020718B 1 STATOR 390 40KW 1P BRLS

020719B 1 STATOR 390 50KW 1P BRLS

020720B 1 STATOR 390 60KW 1P BRLS

020721B 1 STATOR 390 80KW 1P BRLS

020722B 1 STATOR 390 100KW 1P BRLS

020732B 1 STATOR 390 125KW 1P BRLS

020717G 1 STATOR 390 35KW 3P LV BRLS

020718G 1 STATOR 390 40KW 3P LV BRLS

020719G 1 STATOR 390 50KW 3P LV BRLS

020720G 1 STATOR 390 60KW 3P LV BRLS

020721G 1 STATOR 390 80KW 3P LV BRLS

12 068113 1 BEARING CARRIER REAR
13 068115 1 CONTROL PANEL LOWER (SMALL)

091065 1 CONTROL PANEL LOWER (LARGE)

14 043123 4 WASHER LOCK M14
15 051779 4 NUT HEX M14-2 G8 YEL CHR
16 052259 2 WASHER FLAT M12
17 051769 3 WASHER LOCK M12
18 068406 2 SCREW HHC M12-1.75 X 60 G10.9
19 070274 1 KEY SQ 3/8 X 2-3/4 STEEL
20 087271 1 EXCITER (25-35KW)

087272 1 EXCITER (40-125KW)

21 068404 1 FIELD EXCITER (25-35KW)

068405 1 FIELD EXCITER (40-125KW)

22 092950 1 COLLAR SLIP FIT
24 068406 1 SCREW HHC M12-1.75 X 60 G10.9
25 090063 1 DIODE BRIDGE SUPPORT
26 090152 1 BRIDGE RECTIFIER ASSEMBLY
27 023365 1 WASHER SHAKEPROOF INT #8
28 033143 2 SCREW HHM #8-32 X 7/8
29 090064 1 END CAP ROTOR
30 083485 2 NUT PLATE
31 031980 2 TIE WRAP 11" WHITE

34 033212 2 SCREW HHC 5/16-18 X 1-1/4 G5
35 083549 1 SLEEVE RUBBER
36 022392 2 PIN DOWEL 1/2 X 1-1/4
37 044089 1 SCROLL ASSEMBLY
38 0A2337 2 FASTENER 1/4-20 X 5/8
39 022473 1 WASHER FLAT M6-1/4 ZINC
40 056326 8.4’ TRIM VINYL BLACK 1/8GPVV
41 022145 6 WASHER FLAT 5/16-M8 ZINC

1 0A6320 1 CONTROL PANEL BOTT OM
2 0A6324 1 CONTROL PANEL FRONT
3 0A6322 1 CONTROL PANEL RIGHT SIDE
4 0A6321 1 CONTROL PANEL LEFT SIDE
5 0E3550 1 CHASSIS, UNIVERSAL
6 0C8320 1 HARNESS E P NL. WAUK (W/FS)
7 SEE TABLE B 1 CIRCUIT BREAKER
8 044213 1 RESIST MISC 10RX12W

9 025192 1 RECTIFIER MSC 2A 600V 1N5062
10 SEE TABLE A 1 RESISTOR 2
11 055444 1 HEAT SINK
12 030468 1 WASHER STEP NYLON .20
13 049939 1 RECTIFIER MSC 12A 600V 1N1206R
14 039271 1 FITTING 90DEGREE 3/4
15 034616 1 FITTING STRAIGHT 3/4
16 0A3392 1 DECAL TERMIN AL STRIP
17 0C8229 1 DECAL E PNL TS#2 (W/FS)
18 0A6577 1 DECAL TERMIN AL STRIP TB3
19 0C2688 1 DECAL TERMIN AL STRIP TB4
20 048850 REF. BLOCK TERM 20A 5 X 6 X 1100V
22 061286 1 AUDIBLE ALARM
23 055089 1 CONN ELEC AMP M-N-L 15PLUG PNL
24 0E2693A 1 SWITCH MUSHRM HEAD/ARROWS 40MM
25 0E2693C 3 CONTACT BLOCK D5-3 X 01 W/2 1417
26 071361 1 POTENTIOMETER PNL 5K +/-10% 2.25W
27 050123 1 KNOB PLASTIC .25 SHAFT
28 055349 1 INSULATOR
29 0A4087 1 MASTER CONTROL BOX
30 0C8481 REF. BULB-PANEL LIGHT-12V

31 070082 1 LIGHT BLOCKER
32 032300 1 FUSE HOLDER
33 022676 1 FUSE 15A X AGC15
34 070054 1 AMMETER AC 0-50

35 070043 1 METER VOLT AC 0-300

36 070042 1 METER FREQUENCY 55-65HZ

37 061945 1 SWITCH 6A AMP/V SELECTOR
38 067680 1 ASSY VOLTAGE REGULATOR 60HZ

40 0A2275 1 DOOR-STOP RAM PANEL
41 0A2400A 1 TRUNKING 180MM
42 0A1441B 1 COVER PLATE AVR
43 0C1127 1 DECAL AVR COVER
44 0A1441C 1 COVER PLATE E-GOV
45 0A3394 1 DECAL E-GOV COVER
46 030809 1 GROMMET 11/16 X 1/8 X 7/16
47 028739 2 TIE WRAP 4" WHITE
48 0C2323 12 SCREW PHM SWAGE 6-3 2 X 5/8 Z/YC
49 036901 4 SCREW PPHM #6-32 X 3/8
50 022155 7 WASHER LOCK #6
51 036918 8 SCREW PPHM #8-32 X 1/2
52 022264 8 WASHER LOCK M4
53 038150 4 WASHER FLAT #8 ZINC
54 022471 4 NUT HEX #8-32 STEEL
55 033120 1 SCREW HHM 10-32 X 3/8
56 033121 13 SCREW HHM 10-32 X 1/2
58 0A2284 4 SCREW SWAGE 8-32 X 1/2 Z/YC

0E3703 REF. LIGHT PANEL WITH LUG

083288 REF. LIGHT 28VDC .17A MIN BAYNT MNT

070055 1 AMMETER AC 0-100
070056 1 AMMETER AC 0-150
070057 1 AMMETER AC 0-300
070058 1 AMMETER AC 0-400
070059 1 AMMETER AC 0-600
070060 1 AMMETER AC 0-800
075323 1 AMMETER AC 0-1000
075324 1 AMMETER AC 0-1600
075325 1 AMMETER AC 0-2000

070044 1 METER VOLT AC 0-600

070042A 1 METER FREQUENCY 240V 45-55HZ

092952 1 ASSY VOLTAGE REGULATOR 50HZ

59 022152 14 WASHER LOCK #10
60 023897 15 WASHER FLAT #10 ZINC
61 022158 2 NUT HEX #10-32 STEEL
62 074130 1 LUG DIS SN-PLG I-T 22-18 CU
63 036261 4 RIVET P OP .125 X .129-.133/#30
64 070370 2 WASHER MICA .203
65 023762 1 WASHER SHAKEPROOF EXT #10 STL
67 040479 4 MOUNT VIBR 1.0 X 1.0 X 1/4-20
68 022287 4 SCREW HHC 1/4-20 X 3/4 G5
69 022097 4 WASHER LOCK M6-1/4
70 022473 4 WASHER FLAT M6-1/4 ZINC
71 047246 4 WASHER FLAT 1/4 SPECIAL
72 0A2273 1 HINGE RAM PANEL
74 022188 2 NUT HEX #6-32 STEEL
75 0C2428 8 SCREW TAPTITE PH #6-32 X 1/2 ZYC

* 0A5705 1 FUSE 5A X LTTL215005 HLDRA4017 (NOT SHOWN)
78 057335 REF. BLOCK TERM 20A 20 X 6 X 1100V
79 0C4167 REF. BLOCK TERM 20A 14 X 6 X 1100V
80 055911 REF. BLOCK TERM 20A 12 X 6 X 1100V
81 0441140156 REF. WIRE ASSEMBLY
82 084717 1 ASSY TIME DELAY (13.3L GAS ONLY)
83 036908 1 SCREW PPHM #6-32 X 1-1/4 (13.3L GAS ONLY)
84 0C1229 1 DECAL WARNING
85 0E3783 1 DECAL WARNING REMOVE FUSE

1 * 020489 1 COVER FRONT
2 * 099458 2 DUCT TOP/BOTTOM

3 087871A 1 RADIATOR
4 022034B 1 HOSE REDUCER 2” x 1-3/4”
5 098186 1 VENTURI (40KW-80KW)

0A5096B 1 VENTURI CAC 26" (100KW)
0A5096C 1 VENTURI CAC 22" (125KW)

0A5096A 1 VENTURI (EMISSION)
6** 099710 1 GUARD LOWER FAN
7** 099715 1 GUARD FAN

8 0A5095A 1 SUPPORT SIDE LH (CAC)

0A5095B 1 SUPPORT SIDE RH (CAC)

098311 1 SUPPORT SIDE LH

098311A 1 SUPPORT SIDE RH

9 0A2770 1 TANK SURGE
10 099448 1 BRACKET SURGE TANK
11 046627 1 CAP RADIATOR
12 029032 1 HOSE 9/32 ID
13 058612 2 CLAMP HOSE #88 5.12 - 6.00
14 039253 2 SCREW HHC M8-1.25 X 20 G8.8
15 022145 2 WASHER FLAT M8-5/16 ZINC
16 0A7165 1 HOSE LOWER
17 0A2126 1 HOSE UPPER 5.0L
18 099667D 6 NUT SPRINGCLIP 3/8-16
27 042561 5 CLAMP HOSE #36 1.88 - 2.75
28 035685 1 CLAMP HOSE #28 1.32 - 2.25
29 052250 10’ TAPE FOAM 1 X 1

052250 14.5’ TAPE FOAM 1 X 1 (W/AFTERCOOLER)
30 035461 1 BARB STRAIGHT 3/8 X 1/4 X 1.72
31 040173 2 CLAMP HOSE #5.5 .62 - .62
32 047290 40” HOSE RES 3/8 SINGLE BRAID
33 036865 1 DRAINCOCK
34 052617 6 SCREW HHC M12-1.75 X 20 G8.8
35 049808 6 WASHER FLAT M12
36 029745 6 SCREW HHC 3/8-16 X 1 G5
37 040105 3” HOSE RES 2 3PLY RAD HOS
38 090283 1 CAP RADIATOR (7 PSI)
40 046526 6 WASHER LOCK M10
41 022131 12 WASHER FLAT M10-3/8 ZINC

42** 047411 4 SCREW HHC M6-1.0 X 16 G8.8
43** 022097 4 WASHER LOCK M6-1/4

44 052860 6 NUT HEX LOCK FLANGE M12-1.75
45 051756 6 SCREW HHC M10-1.5 X 20 G8.8

46** 022473 4 WASHER FLAT M6-1/4 ZINC

47 022237 6 WASHER LOCK 3/8
57 * 047411 12 SCREW HHC M6-1.0 X 16 G8.8
58 * 022097 12 WASHER LOCK M6-1/4
59 * 022473 12 WASHER FLAT M6-1/4 ZINC
60 040173 3 CLAMP HOSE #5.5 .62 - .62
61 029032 24” HOSE 9/32 ID
62 029032 30” HOSE 9/32 ID
63 035587 24” HOSE RES 1" CVR NEOPR SAE-20R3
64 057824 2 CLAMP HOSE #16 .87 - 1.50
65 022129 2 WASHER LOCK M8-5/16
66 049340 1 BARB ELBOW 3/8 X 1/4 X 1.04

67** 090388 12 SCREW TAP M6X12 YEL CHR

OIL COOLER COMPONENTS (GEARBOXES ONLY)

50 099251 1 COOLER OIL
51 047411 4 SCREW HHC M6-1.0 X 16 G8.8
52 022473 4 WASHER FLAT M6-1/4 ZINC
53 052857 4 NUT LOCK M6-1.0
54 056460 2 BARB ELBOW 5/8 X 1/2 X 1.21
55 057822 5 CLAMP HOSE #8 .53 - 1.00
56 065386 2 HOSE RES 5/8 -40/+300 SAE100RG 7' LONG

AFTER COOLER PARTS (100 & 125KW UNITS)

19 0A5260A 2 HOSE 3” DIA X 3” LONG
20 080773A 3” HOSE 3” DIA
21 086133E 6 CLAMP HI TORQUE 2.75 - 3.625
22 0D8150 1 CHARGE AIR COOLER ASSY 13TBS

0A5160 1 AFTERCOOLER (GEARBOX & EMISSION)
23 0A5098A 1 TUBE CAC
24 0A5097A 1 TUBE CAC
25 071296A 3” HOSE 2” DIA
26 086133C 2 CLAMP HI TORQUE 1.75 - 2.625
39 039253 6 SCREW HHC M8-1.25 X 20 G8.8
48 022129 6 WASHER LOCK M8-5/16
49 022145 6 WASHER FLAT M8-5/16 ZINC
68 0D3397 1 DECAL, CAUTION HOT SURFACES

*OPTIONAL STONE GUARD.
**FAN GUARD (KIT 0D9246), STANDARD, NOT USED
WITH OPTIONAL LEVEL ONE GUARDING.

1 095972 1 CASTING GEARBOX-ENG
2 0A1266 1 GEAR CASE MACHINED
3 095613 1 SEAL OIL
4 051756 2 SCREW HHC M10-1.5 X 20 G8.8
5 046526 44 WASHER LOCK M10
6 049814 4 SCREW HHC M10-1.5 X 25 G8.8
7 051735 8 SCREW HHC M10-1.5 X 70 G8.8
8 095973 1 GASKET GEARBOX ADPT

9 072879 1 SPACER .69 X 2.75 X .37 ST/ZNC
10 097557B 1 KEY 10 X 16 X 46
11 097785 1 GEAR OUTPUT 1.65:1

12 070263 2 SCREW HHC M16-2.0 X 35 G10.9
13 057019 2 BALL BRG 65 X 120 X 23
14 026847 1 BREATHER
15 097784 1 GEAR INP UT 1.65:1

16 095966 1 SHAFT 390 INPUT GEAR
17 095976 1 COLLAR HARDENED
18 095971 1 SEAL OIL
19 096777 1 SNAP RING INT 120MM X 3.0 KOREAN
20 057019S 1 BEARING #6213 SEALE D
22 096379 1 PLATE INTRNL BRG RET
23 048189 2 PIN DOWEL M8 X 24
24 095979 1 PLATE BEA RING THRST
25 021159 1 SPACER STRESSPROOF
26 097557A 1 KEY 10 X 16 X 40
27 057163 1 PLUG PIPE 3/8" MAGNETIC
28 070265 2 WASHER LOCK M16
29 099380 1 COVER,GEARBOX GUARD
30 020443 1 COUPLING INNER DRAWN
31 094666A 1 COUPLING OUTER MACHN
32 099828 8 DAMPER GB CPLR VIBRA
33 099828A 8 DAMPER GB CPLR VIBRA
34 026925 2 PLUG STD PIPE 3/8 STEEL SQ HD
35 097557C 1 KEY 10 X 16 X 50
36 038591 1 NIPPLE PIPE 3/8 NPT X 3-1/2
37 025066 1 COUPLING FULL 3/8-18
38 031578 6 SCREW HHC 3/8-16 X 1-1/2 G8
39 049814 10 SCREW HHC M10-1.5 X 25 G8.8
40 0A1786 5cc LOCTITE #8931 AA W/S
41 0A1788 1cc LOCTITE #25224 GASKT
44 045772 10 NUT HEX M10-1.5 G8 YEL CHR
45 052243 10 SCREW HHC M10-1.5 X 60 G8.8
46 057642 2 SCREW HHC M10-1.5 X 40 G10.9
47 0E3564 4 SCREW HHC M10-1.5 X 25 SEAL
48 027175 1.1 QT LUBE GREASE SAE #90 80W90 (NOT SHOWN)

095970 1 GEAR OUT 390-50H 37 T
095968 1 GEAR OUT 390-60H 35 T

095969 1 GEAR INPT 390-5 0 25T
095967 1 GEAR INPT 390-6 0 27T

1 092460 1 ENGINE 5.0L
2 095005 1 FLYWHEEL HSG.
3 097646 1 FLYWHEEL W/RING GEAR
4 095393 6 SCREW HHC 9/16-18 X 1.75 G8
5 095281 1 STARTER 12VDC
6 095008 1 ENGINE PLATE
7 098184 1 FAN COOLING 26” (NON-GB)

098185 1 FAN COOLING 22” (GB)
8 021082 1 ASSEMBLY 3" SPACER
9 0A3356 2 V-BELT 1/2 X 57 (50HZ NON-GB)

0A5747 2 V-BELT 1/2 X 58 (60HZ NON-GB & GB)

10 096693 1 ELBOW EXHAUST

020790 1 ELBOW 3.5" EXHAUST (GB)

11 096694 1 V-BAND CLAMP EXHAUST ELBOW

098458 1 V-BAND CLAMP EXHAUST (GB)

12 ** 095610 1 PLATE DAMPNER RETAIN

13 098856 1 BRACKET ENG MOUNT RH
14 098779 4 SCREW HHC 3/4-10 X 2-3/4 G5
15 045900 4 WASHER FLAT 3/4 ZINC
16 023171 6 WASHER LOCK 3/4
17 023170 4 NUT HEX 3/4-10 STEEL
18 096387 2 SCREW HHC 3/4-16 X 1-3/4 G5
19 096388 4 SCREW HHC M16-2.0 X 60 G8.8
20 022247 4 WASHER FLAT 5/8 ZINC
22 057822 8 CLAMP HOSE #8 .53 - 1.00
24 036287 4 SCREW HHC 5/16-24 X 4 G5
25 022129 10 WASHER LOCK M8-5/16
26 022145 8 WASHER FLAT 5/16 ZINC
27 058460 1 BARBED ELBOW 90 1/2 NPT X 5/8
28 030416 1 PIPE TEE 1/2 NPT
29 030985 1 NIPPLE CLOSE 1/2 X 1.125
30 049611 1 ELBOW REDUCING STREET 1/2 X 3/8
31 035606 1 SENSOR HI COOLANT SHUTDOWN
32 059981 2 SCREW HHC M10-1.5 X 30 G10.9
33 046526 3 WASHER LOCK M10
35 040173 4 CLAMP HOSE #5.5 .62 - .62
36 096765 1 OIL COOLER FILTER STYL
37 096771 1 UPPER INSERT OIL COOLER
38 096772 1 LOWER INSERT OIL COOLER
39 096701 1 FILTER OIL
40 098855 1 BRACKET ENG MOUNT LH
41 050967 2 HOSE 5/8 ID RIA 250F (3” LONG)
42 096776 1 INJECTION LINES
43 0A5950 1 PUMP INJECTION W/SOL (NON-GB 1800RPM)

097645A 1 PUMP INJECTION (2300 RPM-GB)
44 044831 1 SCREW HHC 3/8-16 X 3/4 G8
45 070265 4 WASHER LOCK M16
46 096759A 1 TUBE OIL COOLER RETURN
47 0D4557 1 LABEL, HOT TURBO 5.0L & 7.5L
48 035430 1 PIPE TEE 1/8 NPT
49 099856 1 FUEL RETURN
50 0A8584 1 SWITCH OIL PRESSURE
51 053666 1 SENDER OIL PRESURE
52 039558 1 NIPPLE PIPE 1/8 NPT X 1.75
53 055476 1 BUSHING REDUCER 3/8 TO 1/8 GAL
54 0A1344 1 KIT D.C ALTERNATOR (5.0L)
55 0A1349 1 PULLEY 2.75" DOUBLE (50HZ)

0A1350 1 PULLEY 3.5" DOUBLE (60 HZ)
58 053667 1 SENDER WATER TEMP
59 097474 2 BANJO ASSEMBLY M14-1.5
60 064416 1 SCREW HHC M10-1.5 X 45 G8.8
61 036865 1 DRAINCOCK 1/8
66 022511 4 SCREW HHC 3/8-16 X 1-1/4 G5
67 022237 7 WASHER LOCK 3/8

71 055934H 1 CLAMP VINYL .62 X .406 Z
72 029745 2 SCREW HHC 3/8-16 X 1 G5
74 096986 1 REDUCER RELIEF PIPE
75 096987 1 TUBE RELIEF VENT
76 096988 1 FITTING DUAL DRAIN
77 096860 1 ELBOW RELIEF PIPE
78 097659 1 GASKET TURBOCHARGER
79 099763 1 TURBOCHARGER 5L-100KW (NON GB)

095540 1 TURBOCHARGER 7.5L FORD (GB)

80 0E0713 3 SCREW HHC 5/16-24 X 1 G8 NZ

81 * 0A1370 8 WASHER FLAT M8 COPPER

(USED ON ITEM #49)
82 0A1371 1 WASHER FLAT M14 COPPER
83 096116 1 GASKET TURBO OUTLET
84 095958B 1 TUBE TURBO OUTLET 100KW (NON GB)

095958C 1 TUBE TURBO OUT 5L-125K (GB)
86 086133C 2 CLAMP HI TORQUE 1.75 - 2.625
87 071296A 1 HOSE 2" ID X 3.0" LG
88 086133E 2 CLAMP HI TORQUE 2.75 - 3.625
89 0A5260A 1 HOSE 3" ID X 3.0" LG
90 030795 1 SCREW HHC 5/16-18 X 1 G5
91 096859 1 GASKET TURBO INLET
92 095957B 1 TUBE TURBO INLET 100K (NON-GB)

095957C 1 TUBE TURBO INLET 5L-125 (GB)
93 0A1531 1 CONNECTOR 3/4 NPT-3/4-16
94 057829A 1 ADAPTOR M12-1.5 1/4 NPT
95 043790 1 BARBED ELBOW 90 3/8 NPT X 3/8
96 060616 1 ADAPTOR M14-1.5 1/8 NPT
97 099477 1 FITTING COMPRESSION 1/8 NPT 3/16
98 096704A 1 TUBE PREHEATER 5.0L
99 0A6344 1 BARBED ELBOW 90 1/8 NPT X 3/8

100 065317 1 FITTING OIL DRAIN M18-1.50
101 099616 1 SLEEVE 3/16 DIA TUBE
102 047290 1 HOSE 3/8 ID SINGLE BRAID (9”)
103 099615 1 COMP. NUT 3/8-24 3/16
105 052677 1 WASHER FLAT NYLON .50/.87/.06
106 054455 1 ADAPTOR OIL DRAIN 1/2-20
107 043124 1 NUT HEX JAM M14 X 1.5 G8
108 043123 1 WASHER LOCK M14
109 050967 1 HOSE 5/8 ID RIA 250F (30” LG)
110 0A1232 1 D.C. ALTERNATOR ASSEMBLY
111 0A3473A 1 BRACKET, ALTERNATOR
112 0A5610 1 BRACKET, TENSIONER
113 068407 1 SCREW HHC M12-1.75 X 90 G10.9
114 049808 2 WASHER FLAT M12
116 052860 1 NUT LOCK FL M12-1.75
117 033212 1 SCREW HHC 5/16-18 X 1-1/4 G5
118 022511 2 SCREW HHC 3/8-16 X 1-1/4 G5
119 022131 2 WASHER FLAT 3/8-M10 ZINC
120 064416 1 SCREW HHC M10-1.5 X 45 G8.8
121 046526 1 WASHER LOCK M10
122 0A5768 1 WASHER FLAT HEAVY DUTY
123 032421 1 SPACER .41 X .75 X .34 PWDR/ZNC
124 022131 4 WASHER FLAT 3/8-M10 ZINC
125 0A1532 1 CONNECTOR 1/2 NPT-7/8-14
126 * 0A3160 1 WASHER FLAT .265 ID X 1.34 OD (USED ON

ITEM #36)
127 057522 1 SENSOR COOLANT LEVEL
128 044117 2 BARBED STRAIGHT 3/8 NPT X 5/8

* NOT SHOWN
** USED ON GEAR BOX UNITS ONLY.

1 090625 1 AIR CLEANER 7 3/4 OD
2 0D3632 1 BRACKET AIR CLEANER
3 095310 3 SPACER .56 X 1.25 X 1.50 ST/ZNC
4 090624 1 MOUNTING CLAMP 7 3/4
5 022368 3 SCREW HHC 7/16-14 X 2-1/2 G5
6 022250 3 WASHER FLAT 7/16
7 022302 3 WASHER LOCK 7/16
8 049814 2 SCREW HHC M10-1.5 X 25

9 046526 2 WASHER LOCK M10
10 022131 2 WASHER FLAT M10-3/8 ZINC
11 045772 2 NUT HEX M10-1.5 G8 YEL CHR
12 057648 2 CLAMP HOSE #64 3.56 - 4.50
13 0D3631 1 TUBE AIR CLEANER 7.5L

0A5313 1 PIPE 101.6 OD X 106 (5.0L GB)
15 072448 1 HUMP REDUCER 4"-2 3/4"
16 039294 1 CLAMP HOSE #44 2.31 - 3.25

1 0C3594 14 ASSEMBLY M6 HINGE
3 0A3359 56 SCREW BHSC M6-1.0 X 16 SS
5 0C2522 (A) 7 DOOR SMALL STNDRD WELD
6 0C8399 (A) 1 CORNER POST LH REAR
7 0C8400 (A) 1 CORNER POST RH REAR
8 0C8397 (A) 1 CORNER POST LH FRONT
9 0C8398 (A) 1 CORNER POST RH FRONT

10 0C2548 (A) 1 REAR BRACE
11 0C2553 (A) 2 SIDE BRACE BOTTOM
12 0C2558 (A) 4 SIDE SUPPORT
13 0C2561 (A) 1 ROOF REAR WELD
14 0C2568 (A) 1 ROOF FRONT C GRP WLD
15 0C8393 (A) 1 FRONT BRACE TOP 5.0L

0C8394 (A) 1 FRONT BRACE TOP 7.5L
16 0C2633 7 PLATE STRIKER GEN 2000
17 0C6749 28 SCREW PPHM M4-0.7 X 12 SS
18 060069 7 PADDLE HANDLE LOCK
19 0C6748 28 NUT LOCK HEX M4-0.7 SS NYL INS
20 080490 28 WASHER FLAT #8 SS
21 087233 7 RIVET POP 3/16 X 1/4
22 0C7990 (A) 1 DUCT FRONT LH
23 0C7989 (A) 1 DUCT FRONT RH
24 0C8391 (A) 1 DUCT BOTTOM
25 0C7987 (A) 1 DUCT FRONT PANEL
26 0C7986 (A) 1 DUCT FRONT TOP/LH OUT
27 0C8395 (A) 1 FRONT BRACE BOTTOM 5.0L

0C8396 (A) 1 FRONT BRACE BOTTOM 7.5L
28 0C2634A 2 ASSEMBLY COVER ACCESS
29 0C2454 88 SCREW TH-FRM M6-1 X 16 N WA Z/JS
30 022129 2 WASHER LOCK M8-5/16
31 042907 2 SCREW HHC M8-1.25 X 16 G8.8
32 022473 24 WASHER FLAT 1/4 ZINC
33 022097 2 WASHER LOCK M6-1/4
34 022127 2 NUT HEX 1/4-20 STEEL
35 0A9881 68.88 FT GASKET DOOR RUBBER
36 0C3393 2 SCREW SHOULDER
38 0C3064 1 SEAL ROOF
39 0C8401 (A) 1 REAR BRACE TOP C GRP
40 042568 3 SCREW HHC M6-1.0 X 20 G8.8
41 077992 3 NUT LOCK FL M6-1.0 SSTL
42 0C3397 4 FASTENER RATCHET
43 066760 39-3/8” STRIP SEALANT 1/8 X 1
44 022145 2 WASHER FLAT 5/16 ZINC
46 0C8402 (A) 2 SIDE BRACE TOP C GRP

OPTIONAL COMPARTMENT MATERIALS:
ALL P/N’S WITH AN “A” SUFFIX
INDICATE ALUMINUM MATERIAL OPTION.

1 0C9653 1 MUFFLER 4 DIA INLET & 5 OUTLET
2 0C8757 1 PIPE / FLANGE WELDMENT
3 0A5215D 1 PIPE FLEX 4 DIA
4 0C2933 2 BRACKET MUFFLER MOUNTING
5 0C5665 4 CLAMP MUFFLER
6 0C9643 1 TUBE STRAIGHT 5 DIA
7 0C9647 1 TUBE ELBOW 4 DIA
8 065805 1 CAP RAIN 5 DIA

9 0C5668 1 BOLT U 5/16-18 X 5
10 055173 4 SCREW HHC M8-1.25 X 20 G10.9
11 022145 12 WASHER FLAT M8-5/16 ZINC
12 022129 4 WASHER LOCK M8-5/16
13 022131 8 WASHER FLAT M10-3/8 ZINC
14 046526 8 WASHER LOCK M10
15 0C8403 1 SHIELD HEAT
16 0C3433C 2 BAND CLAMP 4 DIA
17 051756 8 SCREW HHC M10-1.5 X 20 G8.8
18 0C2454 2 SCREW TH-FRM M6-1X16 N WA Z/JS
19 0C5737 2 BRACKET EXHAUST SHIELD
20 083468 1 BOLT U 3/8-16 X 4
21 098458 1 CLAMP EXHAUST V-BAND
22 051730 4 SCREW HHC M8-1.25 X 60 G8.8
23 049820 4 NUT LOCK HEX M8-1.25 NYL INS

24 * 0C8981 1 BLANKET EXHAUST

* NOTE: (ITEM NOT SHOWN) BLANKET USED TO COVER ITEMS 2, 3 & 16

GENERAC®POWER SYSTEMS, INC.

211 MURPHY DR. • P.O. BOX 310

EAGLE, WI 53119