Generac Power Systems 0D9727 User's Manual
Contents
1. 03000A PART NUMBER DESCRIPTION 03000A 0D57030105 CRANKSHAFT ASSY 11 7 5L DIESEL ROCKER COVER AND 011988 04903A 01182B 01100 01134 019818 g3 01978C 01987 ITEM PART NUMBER DESCRIPTION QTY 01100 0D57030107 COVER ROCKER 01110 0D57030108 GASKET ROCKER COVER 01124 0D57030109 JOINT ROCKER COVER BREATHER HOSE 01134 0D57030110 SEAL ROCKER COVER BOLT 01182B 0D57030111 WASHER ROCKER COVER 01198B 0D57030112 BOLT ROCKER COVER 01951B 0D57030113 HOSE ENGINE BREATHER 01978 0D57030114 BOLT ENGINE BREATHER 019780 0D57030115 BOLT ENGINE BREATHER 01981B 0D57030116 STAY ENGINE BREATHER 019810 0D57030117 STAY ENGINE BREATHER 01981D 0D57030118 STAY ENGINE BREATHER 01987 0D57030119 CLIP ENGINE BREATHER 01988 0D57030120 CLAMP ENGINE BREATHER 04903A 0D57030121 CAP ASSY OIL FILLER CO gt WO 4 4 m 12 7 51 DIESEL CYLINDER HEAD 01298C 01296E 012988 03470 01282C ITEM PART NUMBER DESCRIPTION QTY 01210 0D57030122 GASKET CYLINDER HEAD 01282C 0D57030123 STUD CYLINDER HEAD 01287 0D57030124 PLUG CYLINDER HEAD 01296C 0D57030125 CAP CYLINDER HEAD 01296E 0D57030126 CAP CYLINDER HEAD 01298B 0D57030127 BOLT CYLINDER HEAD 01298C 0D57030128 BOLT CYLINDER HEAD 01298E 0D57030129 BOLT CYLINDER HEAD 03407 0D57030130 SEAT EXHAUST VALVE 03411 0D57030131 SEAT INLET VALVE 03460 0D57030132 GUIDE INLET VALVE 03470 0D57030133 GUIDE2. O 7 5 DIESEL ENGINE PARTS MANUAL 7 5L DIESEL TABLE OF CONTENTS QUICK REFERENCE GUIDE 1001 2 SERVICE RECOMMENDATIONS iahturi aidad eter tete neser ee vetet nie tn 4 CYLINDER HEAD ASSEMBLY u ee ne 8 CYLINDER BLOCK ASSEMBLY ll 9 LINER AND PISTON KIT 2 22 10 CRANKSHAFT ASSEMBLY astra 11 ROCKER COVER AND BREATHER 12 CYLINDER HEAD rs 13 CYLINDER BLOGK 14 SIM pedi 16 ENGINE GASKET viri iiien ee i 5 5 17 FLYWHEEL AND HOUSING 4 eene a 18 PISTON AND CONNECTING ROD 2 2 22 2 00 arre 20 GRANKSHAET dere Diete e 21 CAMSHAFT AND VALVE nes ie ee re en dj 22 TIMING GEAR E MN Rn 24 ATTACHING PARTS EE len 26 OIlL PUMP AND STRAINER gt aan dte 28 30 OIL COOLER ara dye eee Ga ie eres Peer dee ee a oe 31 OIL EINE Tu eee p UE RR Ek 32 FUEL 34 FUEL INJEGTION PUMP 5 iivet ee et De ED nenne 36 INJECTION PIPE mutant hri EE 38 INJECTION NOZZLE Ro t e D ete 40 FUEL RETURN HOSE pee ette n bonnet ar p iip 42 ENGINE MOUNTING AND SUPPORT aaa aaa aaa ann ananas neneve nese tere vere e 7 7 43 WATER PUMP AN
3. 0D57030198 0D57030199 0D57030200 0D57030201 0D57030202 0D57030203 0D57030204 0D57030141 0D57030174 RING GEAR FLYWHEEL OIL SEAL CRANKSHAFT RR COUPLING ASSY FLYWHEEL WASHER FLYWHEEL PIN FLYWHEEL BOLT FLYWHEEL BOLT FLYWHEEL PLUG TACHOMETER DRIVE GASKET SPEEDOMETER GEAR 19 1 a c gt 7 5L DIESEL PISTON AND CONNECTING ROD 030 10 PART NUMBER DESCRIPTION QTY 03006 0D57030205 BOLT CONNECTING ROD 03010A 0D57030206 CONNECTING ROD ASSY 03016 0D57030207 BUSHING CONNECTING ROD 03036 0D57030209 PIN PISTON 03037 0D57030210 PISTON SIZE A 0D57030211 PISTON SIZE B 03050 0D57030213 BEARING SET CONN ROD STD 0D57030214 BEARING SET CONN ROD U S 0 25 0D57030215 BEARING SET CONN ROD U S 0 50 0D57030216 BEARING SET CONN ROD U S 0 75 0D57030217 BEARING SET CONN ROD U S 1 00 03060 0D57030218 RING SET PISTON 03772 0D57030219 PIN CONNECTING ROD 03798 0D57030223 SNAP RING PISTON 20 7 5 DIESEL CRANKSHAFT 03788 03788C ITEM PART NUMBER DESCRIPTION QTY 03022 0D57030208 DAMPER CRANKSHAFT TORSIONAL 03047 0D57030212 PULLEY CRANKSHAFT 03775 0D57030220 BOLT TORSIONAL DAMPER 03787 0D57030221 BOLT PULLEY 03788 0D57030202 PIN CRANKSHAFT 03788B 0D57030222 PIN CRANKSHAFT 037880 0D57030147 PIN CRANKSHAFT 21 7 5L DIESEL CAMSHAFT AND VALVE 03277 6 0
4. 03107B 03295 e 0 03298C 0 03296 3 SER 478 03174 03298E 0 Hari 24 7 5L DIESEL TIMING GEAR ITEM PART NUMBER DESCRIPTION QTY 03026 0D57030254 GEAR CRANKSHAFT 03107B 0D57030255 BUSHING TIMING GEAR TRAIN 031070 0D57030256 BUSHING TIMING GEAR TRAIN 03133A 0D57030257 GEAR ASSY CAM IDLER 1ST 03134A 0D57030258 GEAR ASSY CAM IDLER 2ND 03136 0D57030259 GEAR CAMSHAFT 03156 0D57030260 SHAFT CAM IDLER 1ST GEAR 03157 0D57030261 SHAFT CAM IDLER 2ND GEAR 03174 0D57030262 THRUST WASHER TIMING GEAR TRAIN 03271 0D57030263 COLLAR TIMING GEAR TRAIN 03295 0D57030264 O RING TIMING GEAR TRAIN 03295B 0D57030265 O RING TIMING GEAR TRAIN 03296 0D57030266 NUT TIMING GEAR TRAIN 03297 0D57030227 KEY TIMING GEAR TRAIN 03298C 0D57030267 BOLT TIMING GEAR TRAIN 03298D 0D57030268 BOLT TIMING GEAR TRAIN 03298E 0D57030269 BOLT TIMING GEAR TRAIN 03298F 0D57030270 BOLT TIMING GEAR TRAIN nn 25 7 5L DIESEL ATTACHING PARTS gt 01399B k ZA YO 01385B E 013850 polte ty 01385C 3 ES MV g 01399B N FR 02251 REF 14 120 04298 HR 04298 04296 04296 94209 04296 26 7 5L DIESEL ATTACHING PARTS ITEM PART NUMBER DESCRIPTION QTY 01307D 0D57030271 COVER CYLINDER BLOCK 01385B 0D57030272 PLUG CYLINDER BLOCK 01385C 0D57030273 PLUG CYLINDER BLOCK 01385D 0D57030274 PLUG CYLINDER BLOCK 01392 0D57030275 JOINT CYLINDER BLOCK 01397 0D
5. Drain water and sediment from the diesel fuel tank Drain water from the fuel line water separator if the unit is equipped with one Check the air inlets and outlets for debris Clean as necessary Check the battery electrolyte level if accessible Adjust as necessary Check the battery posts cables and charger for loose connections corrosion and proper operation Correct as necessary Check the unit wiring for loose connections corrosion and damage Correct as necessary Check the engine accessory drive belts for wear weather cracking and damage Replace as necessary Visually inspect the unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary Test the engine and transfer switch safety devices Correct and or adjust as necessary Level 1 Level 2 Level 3 Level 4 Recom Task Required Task Required Task mended Comp be done Comp be done Comp Required to be done Date 3 months Date Semi Date to be done monthly Initials Break in Initials annually Initials Annually 10 hrs 30 hrs 50 hrs 100 hrs Task Comp Date Initials 7 5L DIESEL SERVICE RECOMMENDATIONS Maintenance Level 1 Level 2 Tasks Recom Task Required Task mended Comp lto be done Comp to be done Date 3 months Date monthly Initials Initials 10 hrs 30 hrs 15 Initiate an automatic start and tr
6. GASKET OIL STRAINER 041616 0057030299 GASKET OIL STRAINER 04161D 0D57030300 GASKET OIL STRAINER 04171 0D57030301 WASHER OIL STRAINER 04178B 0D57030228 BOLT OIL STRAINER 041780 0D57030302 BOLT OIL STRAINER 04178D 0D57030303 BOLT OIL STRAINER 04178F 0D57030304 BOLT OIL STRAINER BB a gt 29 7 5L DIESEL OIL FILTER 04100A 04121A 04182B 04181 04184 6 04192 04199B ITEM PART NUMBER DESCRIPTION QTY 04100A 0D57030305 OIL FILTER AND HEAD ASSY 04101 0D57030306 SWITCH OIL FILTER BY PASS 04121A 0D57030307 HEAD ASSEMBLY OIL FILTER 04143 0D57030308 VALVE OIL FILTER DRAIN 04150 0D57030309 OIL FILTER 04181 0D57030310 PLUG OIL FILTER INNER 04182B 0D57030311 O RING OIL FILTER INNER 04183 0D57030312 NUT OIL FILTER INNER 04184 0D57030313 GASKET OIL FILTER INNER 04184B 0D57030174 GASKET OIL FILTER INNER 04191 0D57030314 O RING OIL FILTER 04191B 0D57030315 O RING OIL FILTER 041916 0057030316 O RING OIL FILTER 04192 0D57030277 GASKET OIL FILTER 04199 0D57030285 BOLT OIL FILTER 04199B 0D57030317 BOLT OIL FILTER ca gt ca ca la la 2a 2a 30 7 51 DIESEL OIL COOLER 043004 O 04375 04379B 043 04379E 04322 o 04379B 04379E 04346 04379B 23 04338 LP N 043790 04379C 04385 54355 501393 04377 9 ITEM PART NUMBER DESCRIPTION QTY 0
7. x 1 G8 8NZ 059355 SCREW SHC M10 1 50 x 50 G12 9 0536210860 GROUND WIRE ASSY 051756 SCREW HHC M10 1 5 x 20 G8 8 025507 WASHER SHAKEPROOF EXT 7 16 STL 045771 NUT HEX M8 1 25 G8 YEL CHR 003936 GOVERNOR SI 0 K 3 gt gt on USED C PANEL ONLY 53 7 5L DIESEL ELECTRONIC GOVERNOR INJECTION PUMP THROTTLE ARM ITEM PART NUMBER DESCRIPTION QTY 067708 24V CCW 084753 LEVER ACTUATOR CLAMP 0D7657 STUD TH 1 4 28 x 15 1 2 G2 ZINC 084754 ROD END 1 4 28 038750 SCREW HHC M6 1 0 x 30 G8 8 049811 WASHER FLAT M6 022097 WASHER LOCK M6 1 4 049813 NUT HEX M6 x 1 0 G8 YEL CHR gt 54 7 5L DIESEL AIR CLEANER ITEM PART NUMBER DESCRIPTION QTY 090625 AIR CLEANER 7 3 4 090624 MOUNTING CLAMP 7 3 4 0D6749 INTAKE TUBE 4 OD x 10 LG 072448 HOSE RUBBER HUMP RDGR 4 2 3 4 0D6383 AIR CLEANER 086133G CLAMP HIGH TORQUE 3 75 4 625 086133D CLAMP HIGH TORQUE 2 25 3 125 049814 SCREW HHC M10 1 5 x 25 G8 8 022131 WASHER FLAT 3 8 M10 ZINC 045772 NUT HEX M10 1 5 G8 YEL CHR 046526 WASHER LOCK M10 62 BP 2 55 GENERAC POWER SYSTEMS ING
8. 2089E 12096 12099B PART NUMBER 0D57030446 0D57030447 0D57030448 0D57030449 0D57030450 0D57030451 120998 12043B DESCRIPTION MANIFOLD EXHAUST GASKET EXHAUST MANIFOLD INSULATOR EXHAUST MANIFOLD HEAT STUD EXHAUST MANIFOLD NUT EXHAUST MANIFOLD BOLT EXHAUST MANIFOLD 47 7 51 DIESEL TURBOCHARGER PART NUMBER DESCRIPTION 12500A 0D57030452 TURBOCHARGER ASSEMBLY 12779B 0D57030450 NUT T C 12784B 0D57030453 GASKET T C 48 7 51 DIESEL EXHAUST PIPE 13099C 12515 13010 13085 13085B 13099C 13321 PART NUMBER 0D57030454 0D57030455 0D57030456 0D57030457 0D57030458 0D57030459 13085B 13085 DESCRIPTION COUPLING TURBINE SIDE GASKET EXHAUST PIPE SEAL RING EXHAUST PIPE SEAL RING EXHAUST PIPE BOLT EXHAUST PIPE SUPPORT EXHAUST PIPE ELBOW 49 7 5L DIESEL STARTER 14195C ITEM PART NUMBER DESCRIPTION QTY 11607 0D57030460 WASHER INTAKE AIR HEATER 11610 0D57030461 HEATER INTAKE AIR 11631 0D57030462 PLATE INTAKE AIR HEATER CABLE EARTH 11682 0D57030363 NUT INTAKE SILENCER 14000A 0D57030463 STARTER ASSEMBLY 14191E 0D57030464 WASHER STARTER 14195C 0D57030465 NUT STARTER 14195E 0D57030466 NUT STARTER 14199B 0D57030467 BOLT STARTER 50 7 51 DIESEL ALTERNATOR SENA rl Do TA 14200A 14223 SS p 14799 147998 5 PART NUMBER DESCRIPTION QTY 14200A 0
9. 3264C 0326666 5 032668 033028 NO 2 e 03275 0 Q 03450 032648 amp 03405 032678 03417 B 03416 22 7 5L DIESEL CAMSHAFT AND VALVE ITEM PART NUMBER DESCRIPTION QTY 03100 0D57030224 CAMSHAFT 03146 0D57030225 PLATE CAMSHAFT THRUST 03172 0D57030226 TAPPET VALVE 03196 0D57030227 KEY CAMSHAFT 03198 0D57030228 BOLT CAMSHAFT 03264B 0D57030229 WASHER VALVE GEAR TRAIN 032640 0D57030230 WASHER VALVE GEAR TRAIN 03266B 0D57030231 SCREW VALVE GEAR TRAIN 03266C 0D57030232 SCREW VALVE GEAR TRAIN 03267B 0D57030233 SNAP RING VALVE GEAR TRAIN 03268B 0D57030234 PLUG VALVE GEAR TRAIN 03275 0D57030235 CAP VALVE GEAR TRAIN 03276 0D57030236 BUSHING VALVE GEAR TRAIN 03277 0D57030237 BOLT VALVE GEAR TRAIN 03299 0D57030238 NUT VALVE GEAR TRAIN 03300 0D57030239 SHAFT ROCKER ARM 03302B 0D57030240 BRACKET ROCKER SHAFT 033020 0D57030241 BRACKET ROCKER SHAFT 03302D 0D57030242 BRACKET ROCKER SHAFT 03302E 0D57030243 BRACKET ROCKER SHAFT 03316 0D57030244 PUSH ROD ROCKER ARM 03323 0D57030245 ROCKER ARM INLET amp EXHAUST VALVE 03356 0D57030246 SPRING ROCKER SHAFT 03405 0D57030247 RETAINER VALVE SPRING 03410 0D57030248 VALVE INTAKE 03416 0D57030249 SPRING VALVE INNER 03417 0D57030250 SPRING VALVE OUTER 03420 0D57030251 VALVE EXHAUST 03440 0D57030252 SEAL VALVE STEM 03450 0D57030253 LOCK VALVE SPRING RETAINER 23 7 5L DIESEL TIMING GEAR 03134A 03271
10. 4300A 0D57030318 OIL COOLER ASSEMBLY 04311A 0D57030319 COVER ASSEMBLY OIL COOLER 04322 0D57030320 ELEMENT ENGINE OIL COOLER 04334 0D57030321 GASKET ENGINE OIL COOLER COVER 04338 0D57030322 PLUG ENGINE OIL COOLER 04346 0D57030323 SPRING ENGINE OIL COOLER BY PASS VALVE 04353 0D57030324 VALVE ENGINE OIL COOLER BY PASS 04375 0D57030325 O RING ENGINE OIL COOLER 04377 0D57030326 NUT ENGINE OIL COOLER INNER 04379B 0D57030327 O RING ENGINE OIL COOLER INNER 04379C 0D57030328 O RING ENGINE OIL COOLER INNER 04379E 0D57030329 O RING ENGINE OIL COOLER INNER 04385 0D57030330 PLUG ENGINE OIL COOLER INNER 04399 0D57030331 BOLT ENGINE OIL COOLER GI gt gt cl 31 7 5L DIESEL OIL LINE 04998D E 049870 6 04998D 04379 04925C 04998E 04998D 04925B amp 049980 04gg6G Pe 04232 04973C 211 v YE 04997B 049960 8 04998D 42537 8 049970 32 7 5L DIESEL OIL LINE ITEM PART NUMBER DESCRIPTION QTY 04232 0D57030332 VALVE ENGINE OIL PRESSURE REGULATING 04925B 0D57030333 TUBE ENGINE OIL LINE 049256 0057030334 TUBE ENGINE OIL LINE 04973B 0D57030335 STAY ENGINE OIL LINE 04973 0D57030336 STAY ENGINE OIL LINE 04975 0D57030337 PROTECTOR ENGINE OIL LINE 04978 0D57030338 O RING ENGINE OIL LINE 04979 0D57030339 NUT ENGINE OIL LINE 04987B 0D57030340 JOINT ENGINE OIL LINE 04987D 0D57030341 JOINT ENGINE OIL LINE 04
11. 499 074980 38 7 5 DIESEL INJECTION PIPE ITEM PART NUMBER DESCRIPTION QTY 07429 0D57030394 TUBE FUEL INJECTION NO 4 0D57030395 TUBE FUEL INJECTION NO 5 0D57030396 TUBE FUEL INJECTION NO 3 0D57030397 TUBE FUEL INJECTION NO 6 0D57030398 TUBE FUEL INJECTION NO 2 0D57030399 TUBE FUEL INJECTION NO 1 07497 0D57030363 NUT FUEL INJECTION TUBE 07498B 0D57030407 CLAMP FUEL INJECTION TUBE 07498C 0D57030408 CLAMP FUEL INJECTION TUBE 07498H 0D57030409 CLAMP FUEL INJECTION TUBE 07498J 0D57030410 CLAMP FUEL INJECTION TUBE 07499 0D57030411 BOLT FUEL INJECTION TUBE ND 39 7 5L DIESEL INJECTION NOZZLE 07404 S 074060 ES 074930 D 07406B 07488B 074348 074328 07491 y 07420 07410 07493B 40 7 5L DIESEL INJECTION NOZZLE ITEM PART NUMBER DESCRIPTION QTY 07400A 0D57030384 NOZZLE AND HOLDER ASSY 07403 0D57030385 DUST SEAL NOZZLE HOLDER 07404 0D57030386 EYEBOLT FUEL INJECTION NOZZLE 07405 0D57030387 GASKET FUEL INJECTION NOZZLE 07406B 0D57030388 GASKET FUEL INJECTION NOZZLE INNER 07406G 0D57030389 GASKET FUEL INJECTION NOZZLE INNER 07406D 0D57030390 GASKET FUEL INJECTION NOZZLE INNER 07410A 0D57030391 HOLDER ASSY FUEL INJECTION NOZZLE 07414 0D57030392 JOINT FUEL INJECTION NOZZLE HOLDER 07420 0D57030393 NOZZLE FUEL INJECTION 07432B 0D57030400 PUSH ROD NOZZLE HOLDER 07434B 0D57030401 SPRING NOZ
12. 57030276 BOLT CYLINDER BLOCK 01399B 0D57030277 GASKET CYLINDER BLOCK 01399C 0D57030162 GASKET CYLINDER BLOCK 02200B 0D57030278 ENGINE HANGER 02200C 0D57030279 ENGINE HANGER 02251 0D57030280 GASKET ENGINE HANGER 02299B 0D57030281 BOLT ENGINE HANGER 04203 0D57030277 GASKET ENGINE OIL PRESSURE GAUGE 04296 0D57030282 PLUG ENGINE OIL PRESSURE GAUGE 04298 0D57030283 JOINT ENGINE OIL PRESSURE GAUGE 04298B 0D57030284 JOINT ENGINE OIL PRESSURE GAUGE 04299 0D57030285 BOLT ENGINE OIL PRESSURE GAUGE 3 gt 0200 27 7 5L DIESEL OIL PUMP AND STRAINER 04089 amp 04089 04000A 04037R 04037L 992785 04178F D 041616 E 04178B 27 041358 04161B 04178D 4 04171 4 041780 4 04174 04178F 0 lt lt 041788 04178F 28 7 5L DIESEL OIL PUMP AND STRAINER ITEM PART NUMBER DESCRIPTION QTY 04000A 0D57030288 OIL PUMP ASSEMBLY 04037L 0D57030289 SHIM ENGINE OIL PUMP CASE LH T 0 1 0D57030290 SHIM ENGINE OIL PUMP CASE LH T 0 2 04037R 0D57030291 SHIM ENGINE OIL PUMP CASE RH T 0 1 0D57030292 SHIM ENGINE OIL PUMP CASE RH T 0 2 04045 0D57030293 TUBE ENGINE OIL PUMP OUTLET 04089 0D57030294 PIN ENGINE OIL PUMP 04096B 0D57030193 BOLT ENGINE OIL PUMP 04096G 0D57030195 BOLT ENGINE OIL PUMP 04124 0D57030295 STRAINER ENGINE OIL PAN 04135B 0D57030296 STAY OIL STRAINER 041350 0D57030297 STAY OIL STRAINER 04161B 0D57030298
13. 994B 0D57030342 CLAMP ENGINE OIL LINE 04996D 0D57030344 EYEBOLT ENGINE OIL LINE 04996G 0D57030345 EYEBOLT ENGINE OIL LINE 04997B 0D57030346 BOLT ENGINE OIL LINE 049970 0D57030347 BOLT ENGINE OIL LINE 04997D 0D57030160 BOLT ENGINE OIL LINE 04997E 0D57030228 BOLT ENGINE OIL LINE 04998D 0D57030277 GASKET ENGINE OIL LINE 04998E 0D57030348 GASKET ENGINE OIL LINE 12537 0D57030349 GASKET T C OIL RETURN TUBE 12548 0D57030350 GASKET T C OIL RETURN PIPE TO CYL BLOCK 12617 0D57030351 TUBE OIL FEED 12621 0D57030352 TUBE T C OIL RETURN 24 3 p gt gt gt 33 7 5L DIESEL FUEL FILTER AND HOSE 05300A 05394C 05398 qy3 9 054968 05494 05488 0750 1N 34 7 5L DIESEL FUEL FILTER AND HOSE ITEM PART NUMBER DESCRIPTION QTY 05300 0D57030353 FUEL FILTER 05300A 0D57030354 FUEL FILTER ASSEMBLY 05302 0D57030355 BRACKET FUEL FILTER 05314 0D57030356 HEAD FUEL FILTER 05392 0D57030357 PLUG FUEL FILTER 05394G 0D57030358 GASKET FUEL FILTER 05398 0D57030359 EYEBOLT FUEL FILTER 05399 0D57030360 BOLT FUEL FILTER 05399 0D57030361 BOLT FUEL FILTER 8 x 20 0D57030362 BOLT FUEL FILTER 8 x 75 05488 0D57030363 NUT FUEL LINE 05491B 0D57030364 JOINT FUEL LINE 05494 0D57030365 CLAMP FUEL LINE 05496B 0D57030366 BOLT FUEL LINE 07501M 0D57030367 HOSE INJECTION PUMP FUEL FEED 07501N 0D57030368 HOSE
14. D FAN e estere 44 WATER PIPE AND THERMOSTAT 45 INTAKE MANIFOLD nase ee sie e ie dbe dd 46 EXHAUST MANIEOED prada ne don D ean 47 TURBOCHARGER eo ER ee ie d ee HE GR 48 EXHAUST PIPE ccoo cil TE ER 49 STARTER E 50 AETERNATOR 51 ENGINE GOMMON PART Sasi dun ide 52 ELECTRONIC GOVERNOR smi 54 AIR CLEANER a Ponte icti d Pe 55 AS REQUIRED STD STANDARD SIZE 0 5 OVERSIZE U S UNDERSIZE 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 USE THE MODEL NUMBER OF THE UNIT BEING SERVICED WHEN ORDERING FROM THIS MANUAL 7 5L DIESEL QUICK REFERENCE GUIDE SPECIFICATIONS CRANKCASE OIL CAPACITY 6 0 U S GALLONS 22 7 LITERS COOLING SYSTEM CAPACITY 11 2 U S GALLONS 42 4 LITERS RECOMMENDED FLUIDS COOLANT USE A 50 50 MIXTURE OF LOW SILICATE ETHYLENE GLYCOL BASE ANTI FREEZE AND SOFT WATER IF DESIRED A HIGH QUALITY RUST INHIBITOR MAY BE ADDED TO THE RECOMMENDED COOLANT MIXTURE WHEN ADDING COOLANT ALWAYS ADD THE OMMENDED 50 50 MIXTURE ENGINE
15. D57030468 ALTERNATOR ASSEMBLY 14216 0D57030469 BRAGE ALTERNATOR ADJUSTING 14223 0D57030470 BRAGKET ALTERNATOR MOUNTING 14384B 0D57030471 WASHER ALTERNATOR 14788B 0D57030472 NUT ALTERNATOR 14788C 0D57030466 NUT ALTERNATOR 14799B 0D57030160 BOLT ALTERNATOR 14799D 0D57030473 BOLT ALTERNATOR 14799E 0D57030474 BOLT ALTERNATOR I LA OWN E cas c 51 7 5L DIESEL ENGINE COMMON PARTS 52 7 5 DIESEL ENGINE COMMON PARTS ITEM PART NUMBER DESCRIPTION QTY 0D5703 7 5L MITSUBISHI ENGINE 0D5760 HOUSING FLYWHEEL ADAPTER MACH 7 5 021322 PLATE FLEX SAE 11 1 2 078417 FAN REWORK 30 0D6661 SPACER COOLING FAN 005341 INTAKE ADAPTER MACHINED 051698 SCREW HHC M8 1 25 x 75 G8 8 022145 WASHER FLAT 5 16 ZINC 0D8199 ENGINE MOUNT 022129 WASHER LOCK M8 5 16 051769 WASHER LOCK M12 053666 SENDER OIL PRESSURE 042574 ADAPTOR 1 8 NPTF TO 1 8 28 048584 SWITCH OIL PRESSURE 0D2168 OIL DRAIN M18 x 1 5 0D4739 WASHER FLAT M18 COPPER 1 5 THK 053667 SENDER WATER TEMPERATURE 065809 ADAPTOR WATER TEMP SENDER 035606 SENSOR HIGH COOLANT SHUTDOWN 0D2244M MAGNETIG PICKUP ASSY 3 8 24 MALE 0D2244F MAGNETIC PICKUP ASSY 3 8 24 FEMALE 068406 SCREW HHC M12 1 75 x 60 G10 9 045773 NUT HEX M12 1 75 G8 YEL CHR 049808 WASHER FLAT M12 046526 WASHER LOCK M10 071623 SCREW SHC M10 1 50 x 55 G12 9 022131 WASHER FLAT 3 8 M10 ZINC 059981 SCREW HHC M10 1 5 x 30 G10 9 0D8427 WASHER LOCK M10 RIBBED 043097 SCREW SHC 3 8 16
16. DEALER INFORMATION OWNER INFORMATION SIGNATURE SIGNATURE PURCHASE DATE START UP DATE APPLICATION Standby Power Prime Power Rental Trailerized GENERATOR amp TRANSFER SWITCH INFORMATION GENERATOR TRANSFER SWITCH MODEL NUMBER LL MODEL NUMBER SERIAL NUMBER LLL 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 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 7 5L DIESEL SERVICE RECOMMENDATIONS 10 11 12 13 14 Maintenance Tasks Disable the unit from operating per the first page warning Check the engine oil level Adjust as necessary Check the engine coolant level Adjust as necessary Check the engine coolant thermal protection level Correct as necessary Check the diesel fuel supply level Fill as necessary
17. EXHAUST VALVE 13 7 5L DIESEL CYLINDER BLOCK 01386 01396C 01396B 01395K 01395N 01399N 01385M Ny AN 01361 01397 87 S APPLICABLE SIZE SYMBOLS CYLINDER CYLINDER PISTON LINER 04395NB t 3 1 SE 01396E Q 01395BB 01396D gt Ey 01381 01395J 01399N amp 01305 01397K 01387K 043654 7 51 DIESEL CYLINDER BLOCK ITEM PART NUMBER 01305 0D57030134 01307 0D57030135 01342 0D57030136 0D57030137 0D57030138 01361 0D57030139 01381 0D57030140 01385M 0D57030141 01385N 0D57030142 01386M 0D57030143 01386N 0D57030144 01387H 0D57030145 01387K 0D57030146 01387M 0D57030147 01395BB 0D57030148 01395H 0D57030149 01395J 0D57030150 01395K 0D57030151 01395M 0D57030152 01395N 0D57030153 01395NB 0D57030154 01396B 0D57030155 013960 0D57030156 01396D 0D57030157 01396E 0D57030158 01397J 0D57030159 01397K 0D57030160 01397N 0D57030161 01399N 0D57030162 DESCRIPTION CHECK VALVE COVER CYLINDER BLOCK CYLINDER LINER SIZE 1 CYLINDER LINER SIZE 2 CYLINDER LINER SIZE 3 OIL SEAL CYLINDER BLOCK FR COVER OIL JET CYLINDER BLOCK PLUG CYLINDER BLOCK PLUG CYLINDER BLOCK SPRING PIN CYLINDER BLOCK SPRING PIN CYLINDER BLOCK PIN CYLINDER BLOCK PIN CYLINDER BLOCK PIN CYLINDER BLOCK CAP CYLINDER BLOCK CAP CYLINDER BLOCK CAP CYLINDER BLOCK CAP CYLINDER BLOCK CAP CYLINDER BLOCK CAP CYLINDER BLOCK CAP C
18. INJECTION PUMP FUEL FEED a a 0 4 ND DH 35 7 5L DIESEL FUEL INJECTION PUMP amp 07332 07347 073398 amp 07000A 3 pe 07347 PART NUMBER DESCRIPTION QTY 07000A 0D57030369 PUMP ASSY FUEL INJECTION 07022 0D57030371 DISG INJECTION PUMP DRIVING 07236 0D57030372 LEVER INJECTION PUMP GOVERNOR 07307 0D57030277 GASKET INJECTION PUMP FUEL FEED PUMP 07329 0D57030373 WASHER INJECTION PUMP 07332D 0D57030376 STAY INJECTION PUMP BODY 07332E 0D57030377 STAY INJECTION PUMP BODY 07338 0D57030379 O RING INJECTION PUMP 07339B 0D57030326 NUT INJECTION PUMP 07342 0D57030380 HOSE INJECTION PUMP 07346 0D57030381 EYEBOLT INJECTION PUMP 07347 0D57030160 BOLT INJECTION PUMP 07347B 0D57030382 BOLT INJECTION PUMP B 4 44 pp 36 7 51 DIESEL FUEL INJECTION PUMP 07347BB 07347CB 07339BB 07347DB ITEM PART NUMBER DESCRIPTION QTY 07013A 0D57030370 CASE ASSY INJECTION PUMP DRIVE 07331B 0D57030374 STUD INJECTION PUMP 073316 0057030375 STUD INJECTION PUMP 07338B 0D57030378 O RING INJECTION PUMP 07339BB 0D57030326 NUT INJECTION PUMP 07347BB 0D57030191 BOLT INJECTION PUMP 07347CB 0D57030383 BOLT INJECTION PUMP 07347DB 0D57030285 BOLT INJECTION PUMP NM 4 37 7 5L DIESEL INJECTION PIPE amp 07497 499 07498 12 SO 074988 we 074988 07
19. OIL USE A HIGH QUALITY DETERGENT OIL HAVING AAPI CLASSIFICATION FOR SERVICE OR CD THE SAE VISCOSITY RATING OF THE OIL SHOULD BE CAREFULLY SELECTED BASED ON THE PREVAILING AMBIENT TEMPERATURE RANGE ANTICIPATED BEFORE THE NEXT OIL CHANGE RECOMMENDED SAE VISCOSITY GRADES ARE AS FOLLOWS TEMPERATURE RECOMMENDED OIL GRADE ABOVE 90 F 32 F TO 90 F 12 F TO 32 F 7 5L DIESEL QUICK REFERENCE GUIDE PART NUMBER DESCRIPTION 0D57030309 OIL FILTER 090625 AIR FILTER 0D57030353 FUEL FILTER 0D57030416 WATER PUMP 0D57030468 ALTERNATOR 0D57030463 STARTER 0D57030436 THERMOSTAT amp GASKET KIT 0D57030424 ALTERNATOR BELT 0D57030106 ENGINE OVERHAUL GASKET KIT l l cl c gt JJ 7 5L DIESEL SERVICE RECOMMENDATIONS 40 KW 400 KW STANDBY DIESEL ENGINE DRIVEN GENERATOR SETS Following is a recommended maintenance schedule for Generac standby diesel engine driven generator sets from 40 kW to 400 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 fre quently 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
20. UNIT WATER PUMP SHAFT 10044 0D57030427 SHAFT WATER PUMP 10051 0D57030428 THRUST WASHER WATER PUMP INNER 10078 0D57030429 NIPPLE WATER PUMP INNER 100888 0057030302 BOLT WATER PUMP 100886 0057030331 BOLT WATER 10096B 0D57030430 SPAGER WATER PUMP INNER 10098 0D57030431 SNAP RING WATER PUMP INNER 10134 0D57030432 HOSE THERMOSTAT WATER BY PASS 10175 0D57030433 CLAMP THERMOSTAT 10592 0D57030160 BOLT COOLING FAN 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 2 1 1 1 2 4 44 7 5L DIESEL WATER PIPE AND THERMOSTAT 101778 10106 DEM 10115 10898B 3 10110 PNC 10122 THERMOSTAT ITEM PART NUMBER DESCRIPTION QTY 10100A 0D57030434 CASE ASSY THERMOSTAT 10106 0D57030435 COVER THERMOSTAT CASE 10110 0D57030436 THERMOSTAT KIT 10115 0D57030280 GASKET THERMOSTAT CASE TO CYL HEAD 10122 0D57030437 GASKET THERMOSTAT COVER 10177B 0D57030438 BOLT THERMOSTAT 10177E 0D57030439 BOLT THERMOSTAT 10177F 0D57030440 BOLT THERMOSTAT 10898 0D57030441 PLUG WATER TEMPERATURE GAUGE 1 1 1 1 1 3 2 2 2 45 7 5L DIESEL INTAKE MANIFOLD 11442C 11424E 11424B PART NUMBER DESCRIPTION 11400 0D57030442 MANIFOLD INTAKE 11424 0D57030443 BOLT INTAKE MANIFOLD 11424B 0D57030304 BOLT INTAKE MANIFOLD 11424E 0D57030444 BOLT INTAKE MANIFOLD 11442C 0D57030445 STUD INTAKE MANIFOLD 46 7 5L DIESEL EXHAUST MANIFOLD 12000 12010 12043B 1
21. YLINDER BLOCK BUSHING CYLINDER BLOCK BUSHING CYLINDER BLOCK BUSHING CYLINDER BLOCK BUSHING CYLINDER BLOCK BOLT CYLINDER BLOCK BOLT CYLINDER BLOCK BOLT CYLINDER BLOCK GASKET CYLINDER BLOCK a gt KO 03033 0D57030163 OIL SLINGER CRANKSHAFT FR 03040 0D57030164 BEARING SET CRANKSHAFT STD 0D57030165 BEARING SET CRANKSHAFT U S 0 25 0D57030166 BEARING SET CRANKSHAFT U S 0 50 0D57030167 BEARING SET CRANKSHAFT U S 0 75 0D57030168 BEARING SET CRANKSHAFT U S 1 00 03044 0D57030169 PLATE CRANKSHAFT THRUST STD 0D57030170 PLATE CRANKSHAFT THRUST O S 0 15 0D57030171 PLATE CRANKSHAFT THRUST O S 0 30 0D57030172 PLATE CRANKSHAFT THRUST O S 0 45 15 7 5L DIESEL OIL PAN ASSEMBLY 01598C 01521 601521 015978 01598F 01598 PART NUMBER DESCRIPTION 01500 0D57030173 OIL PAN ENGINE 01521 0D57030174 GASKET ENGINE OIL PAN DRAIN PLUG 01597B 0D57030175 BOLT ENGINE OIL PAN 01598 0D57030176 PLUG ENGINE OIL PAN 015980 0D57030177 PLUG ENGINE OIL PAN 01598F 0D57030178 PLUG ENGINE OIL PAN 01598G 0D57030179 PLUG ENGINE OIL PAN 04911 0D57030475 GAUGE OIL LEVEL 04912 0D57030476 GUIDE OIL LEVEL GAUGE 04956 0445310210 BOLT OIL FILLER 04957 0D57030477 BUSHING OIL FILLER a a a 2 co 16 7 5L DIESEL ENGINE GASKET KIT The part number of engine overhaul gasket kit is that of the kit used fo
22. ZLE HOLDER 07488B 0D57030402 SCREW FUEL INJECTION NOZZLE 07491 0D57030403 PIN FUEL INJECTION NOZZLE 07493B 0D57030404 NUT FUEL INJECTION NOZZLE 07493C 0D57030405 NUT FUEL INJECTION NOZZLE 07494 0D57030406 BOLT FUEL INJECTION NOZZLE 41 7 5L DIESEL FUEL RETURN HOSE 57 26 07511 05467 3 05473 7 PART NUMBER DESCRIPTION 05467 0D57030412 STAY FUEL RETURN LINE 05473 0D57030413 CLIP FUEL RETURN LINE 05477 0D57030114 BOLT FUEL RETURN LINE 07511 0D57030414 TUBE INJECTION PUMP FUEL RETURN 07512 0D57030415 TUBE FUEL INJECTION NOZZLE FUEL RETURN 42 7 5 DIESEL ENGINE MOUNTING AND SUPPORT PART NUMBER DESCRIPTION 02101 0D57030286 BRACKET FLYWHEEL HOUSING ENG MOUNTING 02880 0D57030287 BOLT ENGINE RR MOUNTING 43 7 51 DIESEL WATER PUMP AND FAN 10088B 10000A ga 10088 10010 PNC 10001B 10001 10021 10025 10043 10044 ITEM PART NUMBER DESCRIPTION QTY 10000A 0D57030416 WATER PUMP ASSEMBLY 100018 0D57030417 BEARING WATER PUMP 10001 0D57030418 BEARING WATER PUMP 10010 0D57030419 WATER PUMP KIT 10012 0D57030420 CASE WATER PUMP 10016 0D57030421 FLANGE WATER PUMP PULLEY DRIVE 10021 0D57030422 GASKET WATER PUMP 10025 0D57030423 IMPELLER WATER PUMP 10040 0D57030424 BELT ALTERNATOR 10041 0D57030425 PULLEY WATER PUMP 10043 0D57030426 SEAL
23. ansfer of the unit to site load and exercise it for at least 1 hour looking for leaks loose connections or 5 and abnormal operating conditions Correct as necessary 16 Start and exercise the unit at full rated load use load bank if the site load is not enough for at least 2 hours looking for leaks loose connections or 5 and abnormal operating conditions Correct as necessary 17 Change the engine oil 18 Replace the engine oi filter s Ere 2 Replace the engine air filter s 2 2 N Level 3 Level 4 Required Task Task to be donej Comp Required Comp Semi Date be donej Date annually Initials Annually Initials 50 hrs 100 hrs Replace the engine fuel filter s and re prime the fuel system Perform 5 minute operational run of the unit looking for any post service problems Return the unit to standby Se Je required 7 5L DIESEL CYLINDER HEAD ASSEMBLY 01200A PART NUMBER DESCRIPTION 01200A 0D57030100 CYLINDER HEAD ASSY 7 5L DIESEL CYLINDER BLOCK ASSEMBLY 01300A PART NUMBER DESCRIPTION 01300A 0D57030101 CYLINDER BLOCK ASSY 7 5L DIESEL LINER AND PISTON KIT PART NUMBER DESCRIPTION 01340 0D57030102 LINER AND PISTON KIT SIZE 1 0D57030103 LINER AND PISTON KIT SIZE 2 0D57030104 LINER AND PISTON KIT SIZE 3 10 7 5L DIESEL CRANKSHAFT ASSEMBLY
24. 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 Disable the generator set from starting and or connecting to the load by setting the 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 The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condi ion 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 2 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 the first three months or the first 30 hours of operation after purchase of the unit and
25. nr the standard engine Please note that if the engine is provided with equipment other than the standard one there is a kit component shortage or overage PART NUMBER DESCRIPTION 01070 0D57030106 ENGINE OVERHAUL GASKET KIT 17 7 5L DIESEL FLYWHEEL AND HOUSING 02185 02100A 021920 03080 02179B 02191 921926 LO D 02192 02192 NN 021858 02178C OF 81984 18 7 51 DIESEL FLYWHEEL AND HOUSING ITEM 01395 02100A 02116 02122 02124 02178C 02179 02179B 02183 02185 02185B 02188 02191 02192 02192B PART NUMBER 0D57030180 0D57030181 0D57030174 0D57030182 0D57030183 0D57030184 0D57030185 0D57030186 0D57030187 0D57030188 0D57030178 0D57030189 0D57030190 0D57030191 0D57030192 DESCRIPTION CAP CYLINDER BLOCK HOUSING ASSY FLYWHEEL GASKET FLYWHEEL HOUSING PLATE CYLINDER BLOCK RR POINTER FLYWHEEL HOUSING ENG TIMING WASHER FLYWHEEL HOUSING STUD FLYWHEEL HOUSING STUD FLYWHEEL HOUSING SCREW FLYWHEEL HOUSING PLUG FLYWHEEL HOUSING PLUG FLYWHEEL HOUSING NUT FLYWHEEL HOUSING CAP FLYWHEEL HOUSING BOLT FLYWHEEL HOUSING BOLT FLYWHEEL HOUSING 021926 0057030193 BOLT FLYWHEEL HOUSING 10 50 0D57030194 BOLT FLYWHEEL HOUSING 10 x 55 0D57030195 BOLT FLYWHEEL HOUSING 10 x 65 03030A 0D57030196 FLYWHEEL ASSEMBLY 03034 0D57030197 OIL SLINGER CRANKSHAFT RR 03057 03080 03764A 03794 03796 03797 03797B 81976 81984
26. 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 which require special tools equipment and or knowl edge to accomplish and should be performed only by an authorized Generac Service Dealer 4 A 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 7 5L DIESEL SERVICE RECOMMENDATIONS GENERAC POWER SYSTEMS INC RECOMMENDED SCHEDULED MAINTENANCE PROGRAM SERVICE WORK TO BE PERFORMED BY FACTORY TRAINED PERSONNEL ONLY
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