Issuu

Generac generator engine parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com alternate email: engineparts2@gmail.com

www.Generac-Generator-Engine-Parts.com

Phone:

ENGINE SERVICE RECOMMENDATIONS

QUICK REFERENCE GUIDE

CYLINDER BLOCK/ HEAD / FRONT COVER

VALVE TRAIN AND COVER

CRANKSHAFT PISTONS

OIL PAN / PUMP

OIL FILTER

FUEL PUMP/ FILTER/ INJECTORS

WATER PUMP /THERMOSTAT/ HOUSING

INTAKE/ EXHAUST MANIFOLDS

INTAKE MANIFOLD HEATER

AIR CLEANER (40 / 50 KW NATURALLY ASPIRATED AND 60 / 80 KW TURBOCHARGED MODELS)

AIR CLEANER (100 AND 125 KW TURBOCHARGED AND AFTERCOOLED MODELS)

ENGINE FINISH PARTS (40 AND 50 KW NATURALLY ASPIRATED MODELS)

ENGINE FINISH PARTS (60 AND 80 KW TURBOCHARGED MODELS)

ENGINE FINISH PARTS (100 AND 125 KW TURBOCHARGED AND AFTERCOOLED MODELS)

The "Series-Two" 5.0 Liter Diesel #92460 has been utilized in the following model number units:

95A03883S

95A03900S

95A04377S

95A04447S

95A04511S

95A05199S

95A05200S

95A05201S

95A05202S

95A05203S

95A04576S 95A05204S

95A04991S 95A05205S.

95A04997S 95A05206S

95A05178S 95A05207S

95A05179S 95A05248S

95A05188S 95A05335S

95A05193S 95A05353S

95A05195S 95A05374S

95A05196S 95A05434S

95A05197S 95A05447S

95A05198S 95A05450S

And all "96A" and "97A" models.

For "95A" models not shown above, see publication PBS0000D for engine #96383 "Series-One" 5.0 Liter Diesel

l5.0L DIESEL ENGINE SERVICE RECOMMENDATIONS

SPECIFICATIONS:

CRANKCASE OIL CAPACITY:

COOLING SYSTEM CAPACITY:

RADIATOR:

RECOMMENDED FLUIDS

COOLANT:

USE A MIXTURE OF HALF LOW SILICATE, ETHYLENE GLYCOL BASE ANTI-FREEZE AND HALF SOFT WATER. COOLING SYSTEM CAPACITY IS ABOUT 4 U.S. GALLONS (15 LITERS). 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.

CAUTION: DO NOT USE ANY CHROMATE BASE RUST INHIBITOR WITH ETHYLENE GLYCOL BASE ANTI-FREEZE 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 ANTI-FREEZE. USING ANY HIGH SILICATE ANTI-FREEZE BOOSTERS OR ADDITIVES WILL ALSO CAUSE OVERHEATING. IT IS ALSO RECOMMENDED THAT NO SOLUBLE OIL INHIBITORS ARE USED FOR THIS EQUIPMENT.

ENGINE OIL:

USE A HIGH QUALITY DETERGENT OIL CLASSIFIED *FOR SERVICE SC, SD, SE, OR SF*.:DETERGENT OILS KEEP THE ENGINE CLEANER AND REDUCE CARBON DEPOSITS. USE OIL HAVING THE FOLLOWING VISCOSITY RATING BASED ON THE AMBIENT TEMPERATURE RANGE ANTICIPATED BEFORE THE NEXT OIL CHANGE.

!PERIODIC ENGINE MAINTAINANCE SCHEDULE

AFTER FIRST 50 HOURS OF OPERATION

CHANGE

EVERY SIX MONTHS

CHANGE ENGINE OIL AND FILTER

LUBRICATE ENGINE CONTROLS

SERVICE ENGINE AIR FILTER

SERVICE ENGINE FUEL FILTER

INSPECT FAN BELTS

CHECK ENGINE COOLANT LEVEL

INSPECT ENGINE COOLING SYSTEM HOSES

EVERY TWO YEARS

REPLACE ALL RUBBER HOSES

REPLACE ENGINE FAN BELTS

DRAIN, FLUSH AND REFILL COOLING SYSTEM

DIESEL

ENGINE TUNE-UP / ENGINE PARTS

AIR FILTER (40/50/60/80 KW) 90749

AIR FILTER (100 KW) 89216

AIR FILTER (125 KW) 90625

OIL FILTER CARTRIDGE 96701

FUEL FILTER ELEMENT 376-96383

PISTON KIT 132-92460

(INCL. RINGS, PIN, RETAINERS, AND SLEEVE)

PISTON RINGS (STD) 140-92460

PIN, PISTON 138-92460

RETAINER, PISTON PIN 139-92460

REAR MAIN OIL SEAL 109-96383

CRANKSHAFT MAIN BRG SET (STD) 172-96383

CRANKSHAFT THRUST BRG (STD) 178-96383

ROD BEARING SET (STD) 144-92460

V-BELT (2 REQ) 95280

THERMOSTAT 341-96383

TORQUE SPECIFICATIONS

CYLINDER HEAD BOLTS (FINAL STAGE)

FUEL INJECTORS

EXHAUST MANIFOLD BOLTS

INTAKE MANIFOLD BOLTS

CAMSHAFT GEAR BOLT

CAMSHAFT IDLER GEAR BOLT

FUEL INJ. PUMP GEAR BOLT

FRONT COVER BOLTS (5/16")

FRONT COVER BOLTS (3/8")

OIL PAN BOLTS

CONNECTING ROD CAP BOLTS

MAIN BEARING CAP BOLTS

REAR COVER PLATE BOLTS

OIL PUMP MOUNTING BOLTS

WATER PUMP MOUNTING BOLTS

336-96383 Thermostat bypass hose, water pump to thermostat 409-92460 Upper radiator hose tube assembly 411-92460 Lower radiator hose tube assembly 155-92460 Water pump

G099856 099856 99856 Fuel return line, connects to top of injectors, for four cylinder diesel, 221-96383 Valve cover gasket

Generac generator engine parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com alternate email: engineparts2@gmail.com

www.Generac-Generator-Engine-Parts.com

5.0L DIESEL CYLINDER BLOCK / HEAD /

l7.5L DIESEL CRANKSHAFT

LINER, MAIN BEARING, .030 U/S

LINER, MAIN BEARING, .040 U/S

j5.0L DIESEL OIL PAN / PUMP

jS.OL DIESEL FUEL PUMP/

5.0L DIESEL WATER

15.0L DIESEL INTAKE / EXHAUST MANIFOLDS.

5.0L DIESEL AIR CLEANER

10924601ENGINE5.0L

20950051FLYWHEELHSG. 30976461FLYWHEELW/RINGGEAR

40953936SCREWHHC9/16-18X1.75G8 50952811STARTER12VDC

60950081ENGINEPLATE

70981841FANCOOLING26(NON-GB)

0981851FANCOOLING22(GB) 80210821ASSEMBLY3"SPACER

90A33562V-BELT1/2X57(50HZNON-GB)

0A57472V-BELT1/2X58(60HZNON-GB&GB) 100966931ELBOWEXHAUST

0207901ELBOW3.5"EXHAUST(GB) 110966941V-BANDCLAMPEXHAUSTELBOW 0984581V-BANDCLAMPEXHAUST(GB) 12**0956101PLATEDAMPNERRETAIN 130988561BRACKETENGMOUNTRH 140987794SCREWHHC3/4-10X2-3/4G5 150459004WASHERFLAT3/4ZINC 160231716WASHERLOCK3/4 170231704NUTHEX3/4-10STEEL 180963872SCREWHHC3/4-16X1-3/4G5 190963884SCREWHHCM16-2.0X

INJECTIONW/SOL(NON-GB1800RPM) 097645A1PUMPINJECTION(2300RPM-GB) 440448311SCREWHHC3/8-16X3/4G8 450702654WASHERLOCKM16 46096759A1TUBEOILCOOLERRETURN

HOTTURBO5.0L&7.5L

TEE1/8NPT

RETURN

OILPRESSURE

PIPE1/8NPTX1.75

REDUCER3/8TO1/8GAL

D.CALTERNATOR(5.0L)

550A13491PULLEY2.75"DOUBLE(50HZ) 0A13501PULLEY3.5"DOUBLE(60HZ)

580536671SENDERWATERTEMP 590974742BANJO

71055934H1CLAMPVINYL.62X.406Z

720297452SCREWHHC3/8-16X1G5

740969861REDUCERRELIEFPIPE

750969871TUBERELIEFVENT

760969881FITTINGDUALDRAIN

770968601ELBOWRELIEFPIPE

780976591GASKETTURBOCHARGER

790997631TURBOCHARGER5L-100KW(NONGB) 0955401TURBOCHARGER7.5LFORD(GB)

800E07133SCREWHHC5/16-24X1G8NZ 81*0A13708WASHERFLATM8COPPER (USEDONITEM#49)

820A13711WASHERFLATM14COPPER 830961161GASKETTURBOOUTLET

84095958B1TUBETURBOOUTLET100KW(NONGB) 095958C1TUBETURBOOUT5L-125K(GB) 86086133C2CLAMPHITORQUE1.75-2.625

87071296A1HOSE2"IDX3.0"LG

88086133E2CLAMPHITORQUE2.75-3.625

890A5260A1HOSE3"IDX3.0"LG

900307951SCREWHHC5/16-18X1G5 910968591GASKETTURBOINLET

92095957B1TUBETURBOINLET100K(NON-GB) 095957C1TUBETURBOINLET5L-125(GB) 930A15311CONNECTOR3/4NPT-3/4-16 94057829A1ADAPTORM12-1.51/4NPT 950437901BARBEDELBOW903/8NPTX3/8 960606161ADAPTORM14-1.51/8NPT 970994771FITTINGCOMPRESSION1/8NPT3/16 98096704A1TUBEPREHEATER5.0L 990A63441BARBEDELBOW901/8NPTX3/8 1000653171FITTINGOILDRAINM18-1.50 1010996161SLEEVE3/16DIATUBE 1020472901HOSE3/8IDSINGLEBRAID(9) 1030996151COMP.NUT3/8-243/16 1050526771WASHERFLATNYLON.50/.87/.06 1060544551ADAPTOROILDRAIN1/2-20 1070431241NUTHEXJAMM14X1.5G8 1080431231WASHERLOCKM14 1090509671HOSE5/8IDRIA250F(30LG) 1100A12321D.C.ALTERNATORASSEMBLY 1110A3473A1BRACKET,ALTERNATOR 1120A56101BRACKET,TENSIONER 1130684071SCREWHHCM12-1.75X90G10.9 1140498082WASHERFLATM12 1160528601NUTLOCKFLM12-1.75 1170332121SCREWHHC5/16-18X1-1/4G5 1180225112SCREWHHC3/8-16X1-1/4G5 1190221312WASHERFLAT3/8-M10ZINC 1200644161SCREWHHCM10-1.5X45G8.8 1210465261WASHERLOCKM10 1220A57681WASHERFLATHEAVYDUTY 1230324211SPACER.41X.75X.34PWDR/ZNC 1240221314WASHERFLAT3/8-M10ZINC 1250A15321CONNECTOR1/2NPT-7/8-14 126*0A31601WASHERFLAT.265IDX1.34OD(USEDON ITEM#36) 1270575221SENSORCOOLANTLEVEL 1280441172BARBEDSTRAIGHT3/8NPTX5/8

*NOTSHOWN **USEDONGEARBOXUNITSONLY.

Generac Generator Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com

alternate email: EngineParts2@gmail.com www.Generac-Generator-Engine-Parts.com

Generac Generator Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com alternate email: EngineParts2@gmail.com www.Generac-Generator-Engine-Parts.com

10C359414ASSEMBLYM6HINGE

30A335956SCREWBHSCM6-1.0X16SS

0C2522(A)7DOORSMALLSTNDRDWELD

0C8399(A)1CORNERPOSTLHREAR

0C8400(A)1CORNERPOSTRHREAR

0C8397(A)1CORNERPOSTLHFRONT

0C8398(A)1CORNERPOSTRHFRONT

0C2548(A)1REARBRACE

0C2553(A)2SIDEBRACEBOTTOM 12

0C2558(A)4SIDESUPPORT

0C2561(A)1ROOFREARWELD

0C2568(A)1ROOFFRONTCGRPWLD 15

0C8393(A)1FRONTBRACETOP5.0L

0C8394(A)1FRONTBRACETOP7.5L

160C26337PLATESTRIKERGEN2000

170C674928SCREWPPHMM4-0.7X12SS

180600697PADDLEHANDLELOCK

19 0C674828NUTLOCKHEXM4-0.7SSNYLINS 20 08049028WASHERFLAT#8SS 210872337RIVETPOP3/16X1/4 22 0C7990(A)1DUCTFRONTLH 23 0C7989(A)1DUCTFRONTRH 24 0C8391(A)1DUCTBOTTOM

0C7987(A)1DUCTFRONTPANEL

0C7986(A)1DUCTFRONTTOP/LHOUT

0C8395(A)1FRONTBRACEBOTTOM5.0L

0C8396(A)1FRONTBRACEBOTTOM7.5L

28 0C2634A2ASSEMBLYCOVERACCESS 290C245488SCREWTH-FRMM6-1X16NWAZ/JS 300221292WASHERLOCKM8-5/16

310429072SCREWHHCM8-1.25X16G8.8

3202247324WASHERFLAT1/4ZINC

330220972WASHERLOCKM6-1/4

340221272NUTHEX1/4-20STEEL

350A988168.88FTGASKETDOORRUBBER

360C33932SCREWSHOULDER 380C30641SEALROOF

39 0C8401(A)1REARBRACETOPCGRP

400425683SCREWHHCM6-1.0X20G8.8

410779923NUTLOCKFLM6-1.0SSTL

420C33974FASTENERRATCHET

4306676039-3/8STRIPSEALANT1/8X1

440221452WASHERFLAT5/16ZINC

46 0C8402(A)2SIDEBRACETOPCGRP

OPTIONALCOMPARTMENTMATERIALS: ALLP/NSWITHANASUFFIX INDICATEALUMINUMMATERIALOPTION.

Generac Generator Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com alternate email: EngineParts2@gmail.com www.Generac-Generator-Engine-Parts.com

BRACKET, AIRCLEANER

CLAMP, U-BOLT&SADDLE3"

TUBE,AIRCLEANER

HEXHEADCAPSCREW

WASHER, FLAT

WASHER, LOCK CLAMP, HOSE#52

WASHER, LOCK HEXHEADCAPSCREW

WASHER, LOCK

WASHER, FLAT

5.0L DIESEL ENGINE FINISH PARTSj

5.0L DIESEL ENGINE FINISH PARTSI

5.0L DIESEL ENGINE FINISH PARTS!

INOTES Generac generator engine parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com alternate email: engineparts2@gmail.com

www.Generac-Generator-Engine-Parts.com

G099856 099856 99856 Fuel return line, connects to top of injectors, for four cylinder diesel, G096775 096775 96775 Fuel return line, connects to top of injectors, for six cylinder diesel