Generac Power Systems 0E6478 User's Manual
Contents
1. 6 81 7 U S qts Oil Grade Recommended SAE 30W 15W 40 SAE 20W 20 15W 40 SAE 10W or 0 Temperature Above 80 F 27 C 30 to 80 F 1 to 27 C Below 32 F 0 C 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 recom mended 50 50 mixture Cooling System CCoolant Capacity 23 7 6 3 0 5 gals ENGINE 12 3 L 3 3 U S gals A A A DIG A 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 caution 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 glycol2. Disable the generator set from starting and or connecting to load by setting control panel Auto Off Manual switch to the OFF position Remove control panel fuse Turn off the battery charger Remove the negative battery cable The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condi tion from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to insure the unit is returned to standby setup for normal oper ation when required 2 A break in service inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed ONLY ONCE following first three months or the first 30 hours of operation after purchase of the unit and requires approximately 2 5 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowl edge to accomplish and should be performed only by an authorized Generac Service Dealer 3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed semi annually or following each 50 hours of operation of the unit and requires approximate ly 1 5 man hours per unit to complete This inspection contains some maintenance tasks
3. FORD ENGINE PARTS MANUAL P O BOX 310 EAGLE WI 53119 PRINTED IN U S A Revision 0 08 29 03 6 8L GAS TABLE OF CONTENTS QUICK REFERENCE GUIDE gt 2 SERVICE RECOMMENDATIONS 3 ENGINE LOWER u Rasa A 8 ENGINE UPPER cuina h 12 ENGINE FRONT lata 14 COOLING SYSTEM 16 INTAKE AND IGNITION SYSTEM men Bee Eaua 18 ENGINE COMMON PARTS LEFT HAND SIDE DIRECT DRIVE 5 20 LEFT HAND SIDE GEAR BOX UNITS 22 RIGHT HAND SIDE DIRECT DRIVE UNITS OPEN SET NO ENCLOSURE 24 RIGHT HAND SIDE DIRECT DRIVE UNITS CLOSED SET W ENCLOSURE 26 RIGHT HAND SIDE GEAR BOX UNITS OPEN SET ENCLOSURE 28 RIGHT HAND SIDE GEAR BOX UNITS CLOSED SET W ENCLOSURE 30 LEGEND AR AS REQUIRED STD STANDARD SIZE 5 OVERSIZE U S UNDERSIZE NA NOT AVAILABLE NOTICE THE INFORMATION IN THIS MANUAL IS KNOWN TO BE ACCURATE AS OF THE DATE OF RELEASE SHOWN ON THE COVER HOWEVER ENGINEERING CHANGES CAN OCCUR WITHOUT NOTICE TO OBTAIN THE PROPER PARTS PLEASE BE SURE TO
4. 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 6 8L GAS SERVICE RECOMMENDATIONS 35 KW 200 KW STANDBY GAS ENGINE DRIVEN GENERATOR SETS Following is a recommended maintenance schedule for Generac standby gas engine driven generator sets from 35 kW to 200 kW in size The established intervals in the schedule are the maximum recommended when the unit is used in an average service application They will need to be decreased performed more frequently if the unit is used in a severe application Use the unit hour meter or calendar time whichever occurs first from the previous maintenance interval to determine the next required maintenance interval Service Maintenance Interval Information The various service maintenance intervals are designated by interval numbers as follows 1 An early inspection of the generator set to insure it is ready to operate when required and to identify any potential problem areas Performed monthly or following each 10 hours of operation of the unit and requires approximately 5 man hours per unit to complete This inspection may be performed by the end user providing the following safety steps are taken to pre vent the engine from starting automatically without warning To prevent injury perform the following steps in the order indicated before starting any maintenance
5. 0 8 X 12 ZNC 0C9748 PLUG M18 1 50 60 N BAB 02 RO 02 02 4 fa N N 31 POWER SYSTEMS INC
6. 070008 WASHER FLAT M8 SS 0A7387 SCREW HHC M10 1 5 X 40 G10 9 046526 WASHER LOCK M10 022131 WASHER FLAT 3 8 M10 ZINC 0D5417 SCREW 10 1 0 25 G10 9 057822 CLAMP HOSE 8 53 1 00 047290 HOSE 3 8 ID SINGLE BRAID 15 047411 SCREW 6 1 0 X 16 8 0D6742 VALVE PCV FORD 6 8L 0D2244M ASSEMBLY MAGPICKUP 3 8 24 MALE 052647 SCREW SHC 10 1 5 X 25 G12 9 035606 SENSOR HI COOLANT SHUTDOWN 077996 CAP HOSE 055934M CLAMP VINYL 75 X 343 Z 0D6575D DEUTSCH MOUNTING CLIP F DT S 0D9423 BRACKET MAG PICKUP CONNECTORS 0D9913 SCREW SHC 8 1 25 35 SS 052648 SCREW SHC 10 1 5 X 20 G12 9 091526 SCREW PPHM M5 0 8 X 12 ZNC 051716 NUT HEX M5 0 8 G8 YEL CHR 049813 NUT HEX M6 X 1 0 G8 YEL CHR 087599 PLUG PLASTIC 3 8 NPT 00 N gt 5 N AS 4 27 6 8L GAS ENGINE COMMON PARTS GEAR Box OPEN SET NO ENCLOSURE 61490 DONIM VIG T AOI 6 YV39 3015 SLYVA ON MAIA CACO 571 000 2 0 28 6 8L GAS ENGINE COMMON PARTS GEAR Box UNITS OPEN SET NO ENCLOSURE PART NUMBER DESCRIPTION 0D3454 6 8L FORD V 10 0D5418 STARTER MOTOR FORD V 10 ENGINE 0D4162 MANIFLD BLK COOLANT TEM
7. N806155 TDS ER 4 HE 1 43970 2 TNE ESS 0 1 6333 ___ 0806201 N806183 602644 6345 6626 6622 0806158 FRONT SUPPLIED WITH 6010 W701605 10 6 8L GAS ENGINE LOWER 6622 6626 6675 6710 6731 6840 6884 6890 87836 N620482 N806155 N806156 N806180 N806183 N605904 W701605 W704787 PART NUMBER 0D34540147 0D34540148 0D34540150 0D34540151 0D5419 0D34540154 0D34540155 0D34540156 0D34540187 0D34540158 0D34540305 0D34540159 0D34540160 0D34540161 0D34540162 0D34540163 0D34540164 DESCRIPTION SCREEN amp COVER ASY OIL PUMP SEAL SCREEN amp COVER ASSY PAN ASY ENGINE OIL GASKET OIL PAN FILTER ASY OIL GASKET OIL FILTER ADAPTOR ADAPTER OIL FILTER INSERT OIL FILTER MOUNTING PLUG PIPE 1 8 275 HEX NUT ADTR REAR ENG STUD M10X1 5 SCREW amp WASHER M6 X 1 0 X 27 5 BOLT ADPTR ENG M8X1 25X41 HEX SPACER SCRN amp CVR M8X1 25X37 9 BOLT OIL PUMP M6X1 0X42 5 HEX BOLT SCRN amp CVR SPACR 8 1 25 19 BOLT amp WASHER M8X30 HEX FLANGE STUD ADAPTOR REAR TO ENGINE 11 6 8L GAS ENGINE UPPER 68284 6250 AGSF 22F M1 808897 SUPPLIED WITH 6049 N808777 6C267 N 12 9 E 00288 4 a 6057 6505 6507 e gt 12 6 8L GAS ENGINE UPPER 6A008 6026C 6026BA 6026K 6049 6049 6051 6051 6057 605
8. USE THE MODEL NUMBER OF THE UNIT BEING SERVICED WHEN ORDERING FROM THIS MANUAL 6 8L GAS QUICK REFERENCE GUIDE QUICK REFERENCE ENGINE PARTS PART NUMBER DESCRIPTION QTY 0D5419 FILTER ASY OIL 0034540114 PISTON RING SET STD 2 PISTONS 0D34540115 PISTON RING SET 020 50MM O S 0D34540203 CAP OIL FILLER 0D34540123 SLINGER CRANKSHAFT OIL REAR 0D34540126 SEAL CRANKSHAFT REAR 0D34540213 CHAIN TIMING 0D34540232 PUMP ASY amp SEAL WATER 0D34540233 SEAL WATER PUMP 0D34540235 SEAL THERMOSTAT O RING 0D34540238 THERMOSTAT ASSY WATER 0D34540249 COIL amp BOOT ASY IGNITION 0D34540186 SPARK PLUG PLATINUM 044 GAP 2 003488 BELT SERPENTINE 67 5 DIRECT DRIVE 0D3488A BELT SERPENTINE 70 GEAR BOX 0A1232 D C ALTERNATOR ASSY 0D5418 STARTER MOTOR FORD V 10 ENGINE 0A8584 SWITCH OIL PRESSURE 053667 SENDER WATER TEMP 053666 SENDER OIL PRESSURE sah poe 6 8L GAS SERVICE RECOMMENDATIONS ENGINE OIL RECOMMENDATIONS The unit has been filled with break in engine oil at the factory Use a high quality detergent oil classified For Service CC SD SE or SE Detergent oils keep the engine cleaner and reduce carbon deposits Use oil hav ing the following SAE viscosity rating based on the ambient temperature range anticipated before the next oil change Engine Lubrication System Crankcase Oil
9. control panel Auto Off Manual switch to the OFF position Remove the control panel fuse Turn off the battery charger Remove the negative battery cable NOTE The battery charger must be turned off BEFORE removing the battery cable to prevent an over current con dition from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to insure the unit is returned to standby setup for normal operation when required 6 8L GAS SERVICE RECOMMENDATIONS Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task Task mended Comp done Comp be done Comp Required Comp to be done Date 3 months Date Semi Date to be done Date monthly Initials Break in Initials annually Initials Annually Initials 10 hrs 30 hrs 50 hrs 100 hrs 1 Disable the unit from operating per the first page warning 2 Check the engine oil level Adjust as necessary level Adjust as necessary 4 Check the engine coolant Correct as necessary 5 Check the natural gas sees connections as necessary 6 Check the air inlets and as necessary 7 Check the battery electrolyte level if accessible Adjust as necessary 8 Check the battery posts cables and charger for loose connections corrosion and proper operation Correct as necessary 9 Check the unit wir
10. 0 20 68 8 022129 WASHER LOCK 6 022142 SCREW HHC 5 16 18 X 3 4 G5 039253 SCREW 8 1 25 20 G8 8 022145 WASHER FLAT 5 16 ZINC 057796 GROMMET 0A5737B SPACER DC ALT 25LG 0D3507 ALTERNATOR PULLEY 84 O D 022237 WASHER LOCK 3 8 022131 WASHER FLAT 3 8 M10 ZINC 0D3784 HARNESS 6 8L ENGINE E PANEL NOT SHOWN 0D3784A HARNESS ENGINE 6 8L C PANEL NOT SHOWN 049814 SCREW M10 1 5 X 25 8 0D7801 WIRE HARNESS 6 8L IGN SYSTEM NOT SHOWN 032300 HOLDER FUSE 086310 FUSE 2A AGC2 028578 FUSE 10A X AGC10 034125 VIB MNT 5 X 62 X 10 32 033121 SCREW HHC 10 32 X 1 2 022152 WASHER LOCK 10 023897 WASHER FLAT 10 ZINC 0D8031 DECAL GOVERNOR 10 AMP 0D8032 DECAL COIL 10 AMP 0D8033 DECAL PCB 2 AMP 0D8027 BOLT WATER PUMP PULLEY 0D8025 BOLT GROOVED IDLER PULLEY 0D8026 BOLT BELT TENSIONER 0D8030 TENSIONER ENG AUTOMATIC BELT 0D8029 PULLEY ENGINE WATER PUMP 0D8028 PULLEY GROOVED ENGINE IDLER 0D8450 BRACKET TERMINAL BLOCK 048766 BLOCK TERM 20 2 6 1100V 049815 SCREW 5 0 8 X 16 68 8 049226 WASHER LOCK M5 051713 WASHER FLAT M5 051716 NUT HEX M5 0 8 G8 YEL CHR 0D8991 MODULE COVER 0D8614 COVER FUSE PANEL 055934B CLAMP VINYL 1 X 281 2 029107 GROMMET 7 8 X 3 16 X 5 8 0E5333 SCREW 5 0 8 X 8 ZINC 0D6575D DEUTSCH MOUNTING CLIP F DT S 043146 SCREW HHC M6 1 0 X 10 G8 8 091526 SCREW 5 0 8 X 12 ZNC 058441 SCREW CRIMPTITE 1 4 20 X 3 8 035578 NIPPLE CLOSE 1 8 NPT 035430
11. 60MM 0D5417 SCREW HHC M10 1 0 X 25 G10 9 057822 CLAMP HOSE 8 53 1 00 047290 HOSE 3 8 ID SINGLE BRAID 15 052625 SCREW SHC M10 1 5 X 35 G12 9 0D6575D DEUTSCH MOUNTING CLIP F DT S 0D9423 BRACKET MAG PICKUP CONNECTORS 009913 SCREW SHC 8 1 25 X 35 SS 091526 SCREW 5 0 8 12 ZNC 049813 HEX 6 1 0 G8 YEL CHR 051716 NUT 5 0 8 G8 YEL CHR 00 N NNANMGZAMWAAHAAANMNNNNNAWADWAAWWNWANABAAAAAAA AA oO 29 6 8L GAS ENGINE COMMON PARTS RH GEAR Box UNITS CLOSED SET W ENCLOSURE 017 916900 XO 9 3015 SLYYd NOWWOO 3 3 T JO HOVA 0103111 HX 3015 HA OL 0 1 8 988 4 07 30 6 8L GAS ENGINE COMMON PARTS GEAR UNITS CLOSED SET W ENCLOSURE PART NUMBER DESCRIPTION 0D3454 6 8L FORD V 10 0D5418 STARTER MOTOR FORD V 10 ENGINE 0D4162 MANIFLD BLK COOLANT TEMP amp LEVEL 0D4312 BRACKET MANIFOLD BLOCK 050968 HOSE 3 4 ID SAE 20R3 3 047290 HOSE 3 8 ID SINGLE BRAID 247 0 0561 ASSEMBLY WATER LEVEL SENSOR 053667 SENDER WATER TEMP 0C3433A CLAMP BAND 2 5 0D2696 ADAPTOR THROTTLE BODY 0D2698 GASKET ADAPTOR THROTTLE BODY 057823 CLAMP HOSE 10 56 1 06 049120 BARBED EL 90 1 2 NPT X 3 4 049340 BARBED EL 90 1 4 NPT X 3 8 007649 CLAMP HOSE 38 87 049821 SCREW SHC 8 1 25 X 30 G12 9 022129 WASHER LOCK 8 5 16 043146 SCREW 6 1 0 X 10 8 055816 SCREW HHC M6 1 0 X 70 G8 8 0220
12. 7 6065 6L293 N808777 6C501 6505 6507 6510 6513 6514 6518 6564 6571 AGSF 22F M1 87836 6250 6250 6256 6256 6265 6278 6A303 6A304 6A31 1 6582 6582 6584 NOT SHOWN 6766 6279 N808897 0 4 6C266 6 267 6 272 0034540108 0034540166 0034540104 0034540167 0034540168 0034540169 0034540170 0034540171 0034540172 0034540173 0034540174 0034540175 0034540176 0034540177 0034540178 0034540179 0034540180 0034540181 0034540182 0034540183 0034540184 0034540185 0034540186 0034540187 0034540188 0034540189 0034540190 0034540191 0034540192 0034540193 0034540194 0034540195 0034540196 0034540199 0034540200 0034540202 0034540203 0034540204 DESCRIPTION PIN DOWEL CYL HEAD 16 0X19 0 PLUG CYL HD PRESS RELIEF PLUG 38 3MM CUP STAINLESS STEEL PLUG CYL HD MAIN OIL GALLERY CYL HD RH W O VLV W INSRTS GDS CYL HD LH W O VLVS W INSRTS GDS GASKET CYLINDER HEAD RH GASKET CYLINDER HEAD LH INSERT VALVE SEAT INTAKE INSERT VALVE SEAT EXHAUST BOLT CYL HD HEX FLANGE HEAD BOLT CAM CAPS M6X1 0X42 5 HXFL BOLT CAP BALANCE SHAFT ADJUSTER ASSY VALVE LASH VALVE EXHAUST VALVE INTAKE GUIDE INT amp EXH VALVE STD SPRING VALVE RETAINER VALVE SPRING KEY VALVE SPRING ARM VALVE ROCKER SEAL VALVE STEM SPARK PLUG PLATINUM 044 GAP PLUG PIPE 1 8 275 HEX CAMSHAFT RH CAMSHAFT LH SPROCKET CAMSHAFT RH SPROCKET CAMSHAFT LH SPACER CAMSHAFT SPROCKET RH WASHE
13. 8 0 X 18 25 TIMING COVER TUBE ASSY HEATER WATER PIN DOWELL SOLID 8 0 X 45 5 PIN DOWELL CYL HEAD 16 0 X 19 0 PISTON amp PIN ASSY STD PINSTON amp PIN ASSY 0 25MM 8 PISTON amp PIN ASSY 0 50MM 5 PIN PISTON RETAINER PISTON PIN PISTON RING SET STD 2 PISTONS PISTON RING SET 020 50MM O S ROD CONNECTING BUSHING CONNECTING ROD BEARING CONNECTING ROD BRG CONN ROD 020 50MM U S BOLT CONNECTING ROD RETAINER CRANKSHAFT OIL SEAL CRANKSHAFT ASSY SLINGER CRANKSHAFT OIL REAR KEY WOODRUFF 4 76 X 49 PIN FLYWHL 16 0X25 0 HOLLOWDWL PIN DOWEL 8 0 X 18 25 TIMING COVER SEAL CRANKSHAFT REAR SCREW amp WASHER M6 X 1 0 X 27 5 BRG CRKSFT MAIN UPR STD GRD 2 BRG CRKSFT MAIN UPR STD GRD 1 BRG CRKSFT MAIN UPR STD GRD 3 BRG CRKSFT MAIN UPR 25MM U S BRG CRKSFT THRUST UPPER STD BRG CRKSFT MAIN UPR STD 1 GD2 BRG CRKSFT MN UPR STD 1 GRD1 BRG CRKSFT MN UPR STD 1 GRD3 BRG CRKSH MN UPR STD 1 25 U S BRG CRKSFT MAIN LWR GRADE 2 BRG CRKSFT MAIN LWR GRADE 1 BRG CRKSFT MAIN LWR GRADE 3 BRG CRKSFT MN LWR 25MM U S WASHER CRKSHFT THRUST LOWER STUDBOLT CRKCS MAIN BRG CAP M8 X 1 25 M10 X 1 5 X 126 BOLT CRKSHFT MAIN BEARING CAP M10 X 1 5 X 94 5 HEX HEAD NOTE Do not re use removed bolts when replacing bearings 0D34540144 0D34540145 0D34540146 BOLT CRKSFT MAIN BEARING CAP 9 X 1 25 X 53 HEX HEAD DOWEL MAIN BRG CAP TO BLOCK PUMP ASSY OIL 6 8L GAS ENGINE LOWER 6397 D 6397 4
14. 97 WASHER LOCK 6 1 4 045757 SCREW 6 1 0 25 G8 8 022473 WASHER FLAT 1 4 ZINC 049226 WASHER LOCK M5 052618 SCREW 5 0 8 X 12 8 051713 WASHER FLAT 5 0D3808 EXH MANIFOLD MACH 6 8L V 10 0D4255 GASKET EXHAUST MANIFOLD 070010 SCREW 8 1 25 X 35 55 G8 8 006686 ASSEMBLY 6 8L G BOX FLYWHEEL 0D3803 FLYWHEEL HOUSING MACH 6 8L V10 0D3805 COVER FLYWHEEL MACH 6 8L V 10 021113 PLATE DAMPNER RETNR 0A6765 RING GASKET 2 5DIA 0D3166 PIPE R H EXHAUST MANIFOLD 0A5215B PIPE FLEX 2 5 0D3159 FLANGE EXHAUST 0D3196 PIPE R H MUFFLER INLET 0D3160 PIPE L H EXHAUST MANIFOLD 0D3195 PIPE L H MUFFLER INLET 0D5623 HEAT SHIELD EXHAUST 0D2608 SCREW HHC 5 16 18 X 1 2 SS 070006 WASHER LOCK 8 SS 070008 WASHER FLAT M8 SS 0A7387 SCREW HHC M10 1 5 X 40 G10 9 046526 WASHER LOCK M10 0C9730 THROTTLE BODY PWR FLO 60 0D5417 SCREW HHC M10 1 0 X 25 G10 9 NOT SHOWN 057822 CLAMP HOSE 8 53 1 00 047290 HOSE 3 8 ID SINGLE BRAID 15 047411 SCREW 6 1 0 X 16 8 0D6742 VALVE PCV FORD 6 8L 0D2244M ASSY MAGPICKUP 3 8 24 MALE 052647 SCREW SHC M10 1 5 X 25 G12 9 0C9785 POWER FLOW 50 amp 60 ADAPTOR 022131 WASHER FLAT 3 8 M10 ZINC 077996 CAP HOSE 055934M CLAMP VINYL 75 X 343 Z 052625 SCREW SHC M10 1 5 X 35 G12 9 0D9913 SCREW SHC 8 1 25 X 35 SS 0D6575D DEUTSCH MOUNTING CLIP F DT S 0D9423 BRACKET MAG PICKUP CONNECTORS 051716 NUT HEX M5 0 8 G8 YEL CHR 049813 NUT HEX M6 X 1 0 G8 YEL CHR 091526 SCREW PPHM M5
15. ASHER FLAT 1 4 ZINC 042568 SCREW 6 1 0 20 68 8 022129 WASHER LOCK 8 5 16 022131 WASHER FLAT 3 8 M10 ZINC 039253 SCREW 8 1 25 X 20 G8 8 022145 WASHER FLAT 5 16 ZINC 057796 GROMMET 0A5737B SPACER DC ALT 25LG 0D3507A ALTERNATOR PULLEY 140 O D 0D1744 6 8L IGN CONTROL SCH ASSY 007801 WIRE HARNESS 6 8L GEAR BOX SHOWN 032300 HOLDER FUSE 086310 FUSE 2A X AGC2 028578 FUSE 10A X AGC10 034125 VIB MNT 5 X 62 X 10 32 033121 SCREW HHC 10 32 X 1 2 022152 WASHER LOCK 10 023897 WASHER FLAT 10 ZINC 0D8991 MODULE COVER 0D8032 DECAL COIL 10 AMP 0D8033 DECAL PCB 2 AMP 0D8025 BOLT GROOVED IDLER PULLEY 0D8026 BOLT BELT TENSIONER 0D8027 BOLT WATER PUMP PULLEY 0D8028 PULLEY GROOVED ENGINE IDLER 0D8030 TENSIONER ENG AUTOMATIC BELT 0D8029 PULLEY ENGINE WATER PUMP 0D8614 COVER FUSE PANEL 055934B CLAMP VINYL 1 281 2 029107 GROMMET 7 8 X 3 16 X 5 8 0E5333 SCREW 5 0 8 X 8 ZINC 0D6575D DEUTSCH MOUNTING CLIP F DT S 043146 SCREW HHC M6 1 0 X 10 G8 8 091526 SCREW PPHM 5 0 8 X 12 ZNC 051713 WASHER FLAT M5 049226 WASHER LOCK M5 051716 NUT HEX M5 0 8 G8 YEL CHR 058441 SCREW CRIMPTITE 1 4 20 X 3 8 049815 SCREW 5 0 8 X 16 68 8 048766 BLOCK TERM 20 2 X 6 X 1100V 0D8450 BRACKET TERMINAL BLOCK 035578 NIPPLE CLOSE 1 8 NPT 035430 PIPE TEE 1 8 NPT 0A8584 SWITCH OIL PRESSURE HOBBS 056739 RELAY SOLENOID 12VDC PNL MNT NOT SHOWN 074908 SCREW 5 0 8 X 10 BP 00 0
16. ASKET EXHAUST MANIFOLD 070010 SCREW 8 1 25 X 35 SS G8 8 006344 ASSEMBLY 6 8L FLYWHEEL DIRECT 0D3803 FLYWHEEL HOUSING MACH 6 8L V10 0D3805 COVER FLYWHEEL MACH 6 8L V 10 0A8240 FLEX PLATE SAE10 2 2 002608 SCREW 5 16 18 1 2 SSTL 070006 WASHER LOCK 8 SSTL 070008 WASHER FLAT M8 SS 046526 WASHER LOCK M10 022131 WASHER FLAT 3 8 10 ZINC 0D5417 SCREW HHC 10 1 0 25 G10 9 057822 CLAMP HOSE 8 53 1 00 083982 HOSE 3 8 ID 100R6 OIL LINE 047411 SCREW 6 1 0 X 16 G8 8 0D6742 VALVE PCV FORD 6 8L 0D2244M ASSY MAG PICKUP 3 8 24 MALE 052647 SCREW SHC 10 1 5 25 G12 9 035606 SENSOR HI COOLANT SHUTDOWN 087599 PLUG PLASTIC 3 8 NPT 077996 CAP HOSE 055934M CLAMP VINYL 75 343 2 0D5623 HEAT SHIELD EXHAUST 0065750 DEUTSCH MOUNTING CLIP F DT S 009423 BRACKET MAG PICKUP CONNECTORS 009913 SCREW SHC 8 1 25 X 35 SS 052648 SCREW SHC 10 1 5 20 G12 9 049813 NUT HEX 6 X 1 0 G8 YEL CHR 051716 NUT HEX 5 0 8 G8 YEL CHR 091526 SCREW PPHM 5 0 8 X 12 ZNC 600 O O U N N N N ORAR 00 N HHH 25 6 8L GAS ENGINE COMMON PARTS DIRECT DRIVE UNITS CLOSED SET W ENCLOSURE GROUP D TO MUFFLER ENGINE COMMON PARTS SIDE DD EXPLODED VIEW DRAWING 0D6209 RADIATOR 15 14 PAGE OF 2 5 5 58 2 E 55 26 6 8L GAS ENGINE COMMON
17. N SYSTEM 18 6 8L GAS INTAKE amp IGNITION SYSTEM PART NUMBER DESCRIPTION 9424 0D34540245 MANIFOLD ASY INTAKE UPPER 9424 0D34540246 MANIFOLD INTAKE LOWER 9439 0D34540247 GASKET INT MNFLD TO CYL HEAD 18599 0D34540304 TUBE INT MAN HEATER INLET N806156 0D34540159 BOLT M8 X 1 25 X 43MM 12029 0D34540249 COIL amp BOOT ASY IGNITION W706175 0D34540252 BOLT COIL ON PLUG M5 X 25 HEX 19 6 8L GAS ENGINE COMMON PARTS DIRECT DRIVE UNITS 0 5900 ONIM VAGA 730 1 0 67 1 6 1231013015 51874 2 3 NHIA NOILdO 12 40 NVA 0 300 1HOdANS 01 qasn SS3NHVH 89180001008 OL qasn 0 20 6 8L GAS ENGINE COMMON PARTS DIRECT DRIVE UNITS PART NUMBER DESCRIPTION 0D3293A FAN COOLING 22 DIA KYSOR 0D2149 SPACER FAN 6 8L 0D2843 BRKT LWR ALT 6 8L 0D2844 BRKT UPR ALT 6 8L 0D5419 OIL FILTER FORD V 10 ENGINE 0D7055 DIPSTICK TUBE FORD 6 8L 0D3488 BELT SERPENTINE 67 5 DIRECT DRIVE 057795 CONNECTOR C C VENT 0A6283 HOSE PREFORMED BLOCK HEATER 046526 WASHER LOCK M10 0D1744 6 8L IGN CONTROL SCH ASSY 0A1232 D C ALTERNATOR ASSY 031678 SCREW HHC 3 8 16 X 3 3 4 G5 022241 NUT HEX 3 8 16 STEEL 055476 BUSHING REDUCER 3 8 TO 1 8 GAL 053666 SENDER OIL PRESSURE 006658 DIPSTICK 6 8L FORD 047411 SCREW 6 1 0 16 68 8 022097 WASHER LOCK 6 1 4 022473 WASHER FLAT 1 4 ZINC 042568 SCREW 6 1
18. P amp LEVEL 0D4312 BRACKET MANIFOLD BLOCK 050968 HOSE 3 4 ID SAE 20R3 3 047290 HOSE 3 8 ID SINGLE BRAID 24 0 0561 ASSEMBLY WATER LEVEL SENSOR 053667 SENDER WATER TEMP 055934M CLAMP VINYL 75 X 343 Z 0D2696 ADAPTOR THROTTLE BODY 0D2698 GASKET ADAPTOR THROTTLE BODY 057823 CLAMP HOSE 10 56 1 06 049120 BARBED EL 90 1 2 NPT X 3 4 049340 BARBED EL 90 1 4 NPT X 3 8 007649 CLAMP HOSE 38 87 049821 SCREW SHC M8 1 25 X 30 G12 9 022129 WASHER LOCK M8 5 16 043146 SCREW M6 1 0 X 10 G8 8 055816 SCREW 6 1 0 X 70 G8 8 022097 WASHER LOCK M6 1 4 045757 SCREW 6 1 0 X 25 G8 8 022473 WASHER FLAT 1 4 ZINC 049226 WASHER LOCK M5 052618 SCREW HHC M5 0 8 X 12 G8 8 051713 WASHER FLAT 5 0D3808 EXH MANIFOLD MACH 6 8L V 10 0D4255 GASKET EXHAUST MANIFOLD 070010 SCREW 8 1 25 X 35 55 G8 8 006686 ASSEMBLY 6 8L G BOX FLYWHEEL 0D3803 FLYWHEEL HOUSING MACH 6 8L V10 0D3805 COVER FLYWHEEL MACH 6 8L V 10 021113 PLATE DAMPNER RETNR 077996 CAP HOSE 022131 WASHER FLAT 3 8 M10 ZINC 0C9785 GASKET POWER FLOW 50 amp 60 ADAPTOR 052647 SCREW SHC M10 1 5 X 25 G12 9 0D2244M ASSY MAGPICKUP 3 8 24 MALE 006742 VALVE PCV FORD 6 8L 047411 SCREW 6 1 0 X 16 8 0D5623 HEAT SHIELD EXHAUST 002608 SCREW 5 16 18 1 2 SSTL 070006 WASHER LOCK 8 SSTL 070008 WASHER FLAT 8 SS 049541 SCREW 10 1 5 35 68 8 NOT SHOWN 046526 WASHER LOCK M10 0C9730 PWR FLO 60 ACTUATOR POWERFLOW
19. PARTS DIRECT DRIVE UNITS CLOSED SET W ENCLOSURE PART NUMBER DESCRIPTION 0D3454 6 8L FORD V 10 0D5418 STARTER MOTOR FORD V 10 ENGINE 0D4162 MANIFLD BLK COOLANT TEMP amp LEVEL 0D4312 BRACKET MANIFOLD BLOCK 050968 HOSE 3 4 ID SAE 20R3 3 047290 HOSE 3 8 ID SINGLE BRAID 24 0 0561 ASSEMBLY WATER LEVEL SENSOR 053667 SENDER WATER TEMP 0C3433A CLAMP BAND 2 5 0D2696 ADAPTOR THROTTLE BODY 0D2698 GASKET ADAPTOR THROTTLE BODY 057823 CLAMP HOSE 10 56 1 06 049120 BARBED EL 90 1 2 NPT X 3 4 049340 BARBED EL 90 1 4 NPT X 3 8 007649 CLAMP HOSE 38 87 049821 SCREW SHC M8 1 25 X 30 G12 9 022129 WASHER LOCK M8 5 16 043146 SCREW M6 1 0 X 10 G8 8 055816 SCREW 6 1 0 X 70 G8 8 022097 WASHER LOCK M6 1 4 045757 SCREW 6 1 0 X 25 G8 8 022473 WASHER FLAT 1 4 ZINC 049226 WASHER LOCK M5 052618 SCREW HHC M5 0 8 X 12 G8 8 051713 WASHER FLAT 5 0D3808 EXH MANIFOLD MACH 6 8L V 10 0D4255 GASKET EXHAUST MANIFOLD 070010 SCREW 8 1 25 X 35 G8 8 0D6344 ASSEMBLY 6 8L FLYWHEEL DIRECT 0D3803 FLYWHEEL HOUSING MACH 6 8L 0 0D3805 COVER FLYWHEEL MACH 6 8L V 10 0A8240 FLEX PLATE SAE10 2 2 0A6765 RING GASKET 2 5 DIA 0D3649 TUBE R H EXHAUST MANIFOLD 0A5215B PIPE FLEX 2 5 0D3159 FLANGE EXHAUST 0D3651 TUBE R H EXHAUST MUFFLER INLET 0D3648 TUBE L H EXHAUST MANIFOLD 0D3650 TUBE L H EXHAUST MUFFLER INLET 0D5623 HEAT SHIELD EXHAUST 0D2608 SCREW HHC 5 16 18 X 1 2 SSTL 070006 WASHER LOCK M8 SSTL
20. PIPE TEE 1 8 NPT 0A8584 SWITCH OIL PRESSURE HOBBS 056739 RELAY SOLENOID 12VDC PNL MNT NOT SHOWN 074908 SCREW 5 0 8 X 10 BP 00 N AAA PEG ON 21 6 8L GAS ENGINE COMMON PARTS LH GEAR Box UNITS 116900 6 0 01 6 9 3015 SLYYd MATA 9 81b6 d 110 08 NVA 01 5310 04 1 OL 7 OL 68 01 R LS ur 55 22 6 8L GAS ENGINE COMMON PARTS GEAR Box UNITS PART NUMBER DESCRIPTION 049814 SCREW HHC M10 1 5 X 25 G8 8 0D3784 HARNESS 6 8L ENGINE E PANEL NOT SHOWN 0D2843 BRKT LOWER ALT 6 8L 0D2844 BRKT UPPER ALT 6 8L 0D5419 OIL FILTER FORD V 10 ENGINE 0D7055 DIPSTICK TUBE FORD 6 8L 0D3488A BELT SERPENTINE 70 GEAR BOX 057795 CONNECTOR C C VENT 0 6283 HOSE PREFORMED BLOCK HEATER 046526 WASHER LOCK M10 022237 WASHER LOCK 3 8 0A1232 D C ALTERNATOR ASSY 031678 SCREW HHC 3 8 16 X 3 3 4 G5 022241 NUT HEX 3 8 16 STEEL 055476 BUSHING REDUCER 3 8 TO 1 8 GAL 053666 SENDER OIL PRESSURE 006658 DIPSTICK 6 8L FORD 047411 SCREW 6 1 0 X 16 68 8 022097 WASHER LOCK 6 1 4 022473 W
21. Q Q 02 02 2 02 2 23 6 8L GAS ENGINE COMMON PARTS DIRECT DRIVE UNITS OPEN SET ENCLOSURE ENGINE COMMON PARTS RH SIDE DD gt A 5 A m REVISION G 0001 E 24 6 8L GAS ENGINE COMMON PARTS DIRECT DRIVE UNITS OPEN SET NO ENCLOSURE PART NUMBER DESCRIPTION 0D3454 6 8L FORD V 10 0D5418 STARTER MOTOR FORD V 10 ENGINE 0D4162 MANIFLD BLK COOLANT TEMP amp LEVEL 004312 BRACKET MANIFOLD BLOCK 050968 HOSE 3 4 ID SAE 20R3 083982 HOSE 3 8 ID 100R6 OIL LINE 0 0561 ASSEMBLY WATER LEVEL SENSOR 053667 SENDER WATER TEMP 002696 ADAPTOR THROTTLE BODY 002698 GASKET ADAPTOR THROTTLE BODY 057823 CLAMP HOSE 10 56 1 06 049120 BARBED EL 90 1 2 NPT X 3 4 049340 BARBED EL 90 1 4 NPT X 3 8 0 7649 CLAMP HOSE 38 7 049821 SCREW SHC 8 1 25 X 30 G12 9 022129 WASHER LOCK 8 5 16 043146 SCREW 6 1 0 X 10 G8 8 055816 SCREW 6 1 0 70 G8 8 022097 WASHER LOCK 6 1 4 045757 SCREW 6 1 0 X 25 G8 8 022473 WASHER FLAT 1 4 ZINC 049226 WASHER LOCK M5 052618 SCREW 5 0 8 X 12 G8 8 051713 WASHER FLAT M5 0D3808 EXH MANIFOLD MACH 6 8L V 10 0D4255 G
22. R CAMSHAFT FLAT HARDENED GEAR BALANCE SHFT ON CAMSHFT GEAR BAL SHFT DRV ON BAL SHF SHAFT amp GEAR ASY BALANCE CVR amp GASKET ASY ROCKER ARM RH CVR amp GASKET ASY ROCKER ARM LH GASKET ROCKER COVER USE SEALANT SILICONE GASKET amp SEALANT CAP OIL FILLER BOLT CAMSHFT SPROCKET HEX NOT SERVICED PART OF CYLINDER HEAD SUPPLIED WITH CYLINDER HEAD ITEM 6049 SUPPLIED WITH CYLINDER HEAD ITEM 6049 SUPPLIED WITH CYLINDER HEAD ITEM 6049 SUPPLIED WITH CYLINDER HEAD ITEM 6049 SUPPLIED WITH CYLINDER HEAD ITEM 6049 13 OSS 6 8L GAS ENGINE FRONT N806155 66315 68288 806155 806177 08529 6 255 6L266 DA N606543 N606527 14 6 8L GAS ENGINE FRONT PART NUMBER 6019 6020 6020 6020 6K255 6M256 6L266 CA 6L266 DA 6268 6M274 6K297 6306 6700 12A227 N605892 N606527 N606543 N806177 N808140 N808142 N808529 6312 6A340 6378 6B288 6C315 N806155 0D34540205 0D34540206 0D34540207 0D34540208 0D34540209 0D34540210 0D3454021 1 0D34540212 0D34540213 0D34540214 0D34540215 0D34540216 0D34540217 0D34540218 0D34540219 0D34540220 0D34540221 0D34540222 0D34540223 0D34540224 0D34540225 0D34540226 0D34540227 0D34540228 0D34540230 0D34540231 0D34540305 DESCRIPTION COVER amp GASKETS ASSY FRONT GASKET COVER LH GASKET COVER CENTER GASKET COVER RH ARM TIMING CHAIN TENSIONER RH GUIDE TIMING CHAIN RH TENSIONER TIMING CHAIN LH TENSIONER
23. TIMING CHAIN RH CHAIN TIMING ARM TIMING CHAIN TENSIONER LH GUIDE TIMING CHAIN LH SPROCKET CRANKSHAFT SEAL CRANKSHAFT FRONT RING IGN PULSE CRKSHFT SENSOR BOLT TIMING CHAIN GUIDES BOLT TIMING CHAIN GUIDE LH HEX BOLT TIMING CHAIN TENSIONERS BOLT FRONT CVR M8X1 25X53 HEX STUD amp WASHER FRONT COVER SCREW amp WASHER FRONT COVER STUD FRONT CVR M10X1 5X103 DAMPER ASSY CRANKSHAFT BOLT CRANKSHAFT DAMPER WASHER CRKSHFT DAMPER FLAT HRD SENSOR ASSY CAMSHAFT POSITION SENSOR ASSY CRANKSHAFT SCREW amp WASHER M6 X 1 0 X 27 5 15 Py AH GQ Na 6 8L GAS COOLING SYSTEM 811415 NR Se GF FR pS ESTAN I AS 3187 ERA w r Ms 8501 808794 16 6 8L GAS COOLING SYSTEM PART NUMBER 8501 8507 N808794 8255 8555 8575 8592 18599 18663 N806178 N811415 0D34540232 0D34540233 0D34540234 0D34540235 0D34540236 0D34540238 0D34540239 0D34540241 0D34540242 0D34540243 0D34540244 DESCRIPTION PUMP ASY amp SEAL WATER SEAL WATER PUMP BOLT amp WASHER WATER PUMP SEAL THERMOSTAT O RING TUBE WATER THERMOSTAT ASSY WATER CONNECTION ASY WATER OUTLET TUBE INT MNFLD HEATER INLET TUBE WATER HEATER BOLT THERMOSTAT OUTLET CONNECT STUD HEATER TUBE HEX 17 2 N 6 8L GAS INTAKE amp IGNITIO
24. ine spark T or replace as necessary Perform a 5 minute no load operational run of the unit looking for any post service problems 20 Return the unit to standby Zee T required N 5 1 6 8L GAS ENGINE LOWER 806155 1 6333 N806201 __ N806183 602644 SUPPLIED WITH 6010 6 8L GAS ENGINE LOWER PART NUMBER 6010 6026AA 6026A 6026A 6026BA 6397D 8555 N806040 6A008 6108 6108 6108 6135 6140 6148 6148 6200 6207 6211 6214 6K301 6303 6310 N806201 6397A 6397D 6701 N806155 6333 6333 6333 6333 6A341 6333 6333 6333 6333 6A338 6A338 6A338 6A338 6K302 6345 BA 6345 AA 6345 AA 6A346 6600 0D34540100 0D34540101 0D34540102 0D34540103 0D34540104 0D34540105 0D34540106 0D34540107 0D34540108 0D34540109 0D34540110 0034540111 0034540112 0034540113 0034540114 0034540115 0034540116 0034540117 0034540118 0034540119 0034540120 0034540121 0034540122 0034540123 0034540124 0034540125 0034540105 0034540126 0034540305 0034540127 0034540128 0034540129 0034540130 0034540131 0034540132 0034540133 0034540134 0034540135 0034540136 0034540137 0034540138 0034540139 0034540140 0034540142 0034540143 DESCRIPTION CYL BLOCK LESS CRKSHFT PISTONS PLUG 1 75 STAINLESS STEEL CUP 4 EA LEFT RIGHT 2 REAR PLUG CL BLK FRT 13 84MM PLUG CYL BLK REAR 3 8 18X 425 PLUG 38 3MM CUP STAINLESS STEEL PIN DOWEL
25. ing for loose connections corrosion and damage Correct as necessary 10 Check the engine accessory drive belts for wear weather cracking and damage Replace as necessary 11 Visually inspect the unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary 12 Test the engine and transfer switch safety devices Correct and or adjust as necessary 6 8L GAS SERVICE RECOMMENDATIONS Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task Task mended Comp be done Comp be done Comp Required Comp to be done Date 3 months Date Semi Date 10 done Date monthly Initials Break in Initials annually Initials Annually Initials 10 hrs 30 hrs 50 hrs 100 hrs 13 Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 14 Start and exercise the unit at full rated load use a load bank if the site load is not enough for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 15 Change the engine oil lt 16 Replace the engine oi 20 17 the engine air 11111 Check the eng
26. which require special tools equipment and or knowl edge to accomplish and should be performed only by an authorized Generac Service Dealer 4 mid level inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed annually or following each 100 hours of operation of the unit and requires approximately 5 0 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowl edge to accomplish and should be performed only by an authorized Generac Service Dealer NOTE Add 20 to all times for 8 cylinder or larger engines 6 8L GAS SERVICE RECOMMENDATIONS GENERAC POWER SYSTEMS INC RECOMMENDED SCHEDULED MAINTENANCE PROGRAM SERVICE WORK TO BE PERFORMED BY FACTORY TRAINED PERSONNEL ONLY DEALER INFORMATION OWNER INFORMATION SIGNATURE SIGNATURE PURCHASE DAE START UP DATE APPLICATION Standby Power Rental Trailerized GENERATOR amp TRANSFER SWITCH INFORMATION GENERATOR TRANSFER SWITCH MODEL NUMBER _ MODEL NUMBER SERIAL NUMBER SERIAL NUMBER HOUR METER READING at Completion of the Inspection WARNING To prevent injury perform the following steps in the order indicated before starting any maintenance Disable the generator set from starting and or connecting to the load by setting the
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