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7.5 LITER
DIESEL
ENGINE
PARTS
MANUAL
P.O. BOX 8 WAUKESHA WI 53187
PRINTED IN U.S.A.
ISSUED: 03/01/02
0D9727
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7.5L DIESEL TABLE OF CONTENTS QUICK REFERENCE GUIDE .............................................................................................................................. 2 SERVICE RECOMMENDATIONS ........................................................................................................................ 4 CYLINDER HEAD ASSEMBLY ............................................................................................................................ 8 CYLINDER BLOCK ASSEMB
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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 REC- OMMENDED 50/50 MIXTURE. ENGINE OIL: USE A HIGH QUALITY DETERGENT OIL HAVING AAPI CLASSIFICA
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7.5L DIESEL QUICK REFERENCE GUIDE QUICK REFERENCE ENGINE PARTS PART NUMBER DESCRIPTION QTY 0D57030309 OIL FILTER 1 090625 AIR FILTER 1 0D57030353 FUEL FILTER 1 0D57030416 WATER PUMP 1 0D57030468 ALTERNATOR 1 0D57030463 STARTER 1 0D57030436 THERMOSTAT & GASKET KIT 1 0D57030424 ALTERNATOR BELT 1 0D57030106 ENGINE OVERHAUL GASKET KIT AR 3
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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 t
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7.5L DIESEL SERVICE RECOMMENDATIONS GENERAC POWER SYSTEMS, INC. RECOMMENDED SCHEDULED MAINTENANCE PROGRAM SERVICE WORK TO BE PERFORMED BY FACTORY-TRAINED PERSONNEL ONLY. DEALER INFORMATION OWNER INFORMATION NAME: NAME: ADDRESS: ACCOUNT #: ADDRESS: SITE: PHONE: PHONE: TECHNICIAN: SIGNATURE: SIGNATURE: PURCHASE DATE: START-UP DATE: APPLICATION: Standby Power Prime Power Rental/Trailerized GENERATOR & TRANSFER SWITCH INFORMATION GENERATOR TRANSFER SWITCH MODEL NUMBER: MODEL NUMBER: SERIAL NUMBER: S
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7.5L DIESEL SERVICE RECOMMENDATIONS Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom- Task Required Task Required Task Task mended Comp. to be done Comp. to 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. 3. Check the e
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7.5L DIESEL SERVICE RECOMMENDATIONS Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom- Task Required Task Required Task Task mended Comp. to be done Comp. to 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. 15. Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks, loose
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7.5L DIESEL — CYLINDER HEAD ASSEMBLY ITEM PART NUMBER DESCRIPTION QTY 01200A 0D57030100 CYLINDER HEAD ASSY 1 8
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7.5L DIESEL — CYLINDER BLOCK ASSEMBLY ITEM PART NUMBER DESCRIPTION QTY 01300A 0D57030101 CYLINDER BLOCK ASSY 1 9
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7.5L DIESEL — LINER AND PISTON KIT ITEM PART NUMBER DESCRIPTION QTY 01340 0D57030102 LINER AND PISTON KIT (SIZE 1) AR 0D57030103 LINER AND PISTON KIT (SIZE 2) AR 0D57030104 LINER AND PISTON KIT (SIZE 3) AR 10
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7.5L DIESEL — CRANKSHAFT ASSEMBLY ITEM PART NUMBER DESCRIPTION QTY 03000A 0D57030105 CRANKSHAFT ASSY 1 11
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7.5L DIESEL — ROCKER COVER AND BREATHER ITEM PART NUMBER DESCRIPTION QTY 01100 0D57030107 COVER, ROCKER 1 01110 0D57030108 GASKET, ROCKER COVER 1 01124 0D57030109 JOINT, ROCKER COVER BREATHER HOSE 1 01134 0D57030110 SEAL, ROCKER COVER BOLT 4 01182B 0D57030111 WASHER, ROCKER COVER 4 01198B 0D57030112 BOLT, ROCKER COVER 4 01951B 0D57030113 HOSE, ENGINE BREATHER 1 01978 0D57030114 BOLT, ENGINE BREATHER 3 01978C 0D57030115 BOLT, ENGINE BREATHER 2 01981B 0D57030116 STAY, ENGINE BREATHER 1 01981C 0D57
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7.5L DIESEL — CYLINDER HEAD ITEM PART NUMBER DESCRIPTION QTY 01210 0D57030122 GASKET, CYLINDER HEAD 1 01282C 0D57030123 STUD, CYLINDER HEAD 12 01287 0D57030124 PLUG, CYLINDER HEAD 6 01296C 0D57030125 CAP, CYLINDER HEAD 5 01296E 0D57030126 CAP, CYLINDER HEAD 18 01298B 0D57030127 BOLT, CYLINDER HEAD 20 01298C 0D57030128 BOLT, CYLINDER HEAD 6 01298E 0D57030129 BOLT, CYLINDER HEAD 6 03407 0D57030130 SEAT, EXHAUST VALVE 6 03411 0D57030131 SEAT, INLET VALVE 6 03460 0D57030132 GUIDE, INLET VALVE 6 0347
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7.5L DIESEL — CYLINDER BLOCK 14
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7.5L DIESEL — CYLINDER BLOCK ITEM PART NUMBER DESCRIPTION QTY 01305 0D57030134 CHECK VALVE 6 01307 0D57030135 COVER, CYLINDER BLOCK 1 01342 0D57030136 CYLINDER LINER (SIZE 1) AR 0D57030137 CYLINDER LINER (SIZE 2) AR 0D57030138 CYLINDER LINER (SIZE 3) AR 01361 0D57030139 OIL SEAL, CYLINDER BLOCK FR COVER 1 01381 0D57030140 OIL JET, CYLINDER BLOCK 6 01385M 0D57030141 PLUG, CYLINDER BLOCK 2 01385N 0D57030142 PLUG, CYLINDER BLOCK 3 01386M 0D57030143 SPRING PIN, CYLINDER BLOCK 6 01386N 0D57030144 SPR
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7.5L DIESEL — OIL PAN ASSEMBLY ITEM PART NUMBER DESCRIPTION QTY 01500 0D57030173 OIL PAN, ENGINE 1 01521 0D57030174 GASKET, ENGINE OIL PAN DRAIN PLUG 3 01597B 0D57030175 BOLT, ENGINE OIL PAN 35 01598 0D57030176 PLUG, ENGINE OIL PAN 1 01598C 0D57030177 PLUG, ENGINE OIL PAN 1 01598F 0D57030178 PLUG, ENGINE OIL PAN 1 01598G 0D57030179 PLUG, ENGINE OIL PAN 1 04911 0D57030475 GAUGE, OIL LEVEL 1 04912 0D57030476 GUIDE, OIL LEVEL GAUGE 1 04956 0A45310210 BOLT, OIL FILLER 1 04957 0D57030477 BUSHING, OIL
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7.5L DIESEL — ENGINE GASKET KIT ITEM PART NUMBER DESCRIPTION QTY 01070 0D57030106 ENGINE OVERHAUL GASKET KIT AR 17
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7.5L DIESEL — FLYWHEEL AND HOUSING 18
