0D9727
7.5LITER
DIESEL
ENGINE
PARTS
MANUAL
P.O. BOX 8 WAUKESHA WI 53187
PRINTED IN U.S.A.
ISSUED: 03/01/02
7.5L DIESEL TABLE OF CONTENTS
1
LEGEND
“AR” AS REQUIRED
(STD) STANDARD SIZE
“O.S.” 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.
QUICK REFERENCE GUIDE .............................................................................................................................. 2
SERVICE RECOMMENDATIONS ........................................................................................................................ 4
CYLINDER HEAD ASSEMBLY ............................................................................................................................ 8
CYLINDER BLOCK ASSEMBLY .......................................................................................................................... 9
LINER AND PISTON KIT .................................................................................................................................... 10
CRANKSHAFT ASSEMBLY ................................................................................................................................ 11
ROCKER COVER AND BREATHER .................................................................................................................. 12
CYLINDER HEAD .............................................................................................................................................. 13
CYLINDER BLOCK ............................................................................................................................................ 14
OIL PAN ASSEMBLY .......................................................................................................................................... 16
ENGINE GASKET KIT ........................................................................................................................................ 17
FLYWHEEL AND HOUSING .............................................................................................................................. 18
PISTON AND CONNECTING ROD .................................................................................................................... 20
CRANKSHAFT .................................................................................................................................................... 21
CAMSHAFT AND VALVE .................................................................................................................................... 22
TIMING GEAR .................................................................................................................................................... 24
ATTACHING PARTS ............................................................................................................................................ 26
OIL PUMP AND STRAINER .............................................................................................................................. 28
OIL FILTER ........................................................................................................................................................ 30
OIL COOLER ...................................................................................................................................................... 31
OIL LINE ............................................................................................................................................................ 32
FUEL FILTER AND HOSE .................................................................................................................................. 34
FUEL INJECTION PUMP .................................................................................................................................. 36
INJECTION PIPE ................................................................................................................................................ 38
INJECTION NOZZLE .......................................................................................................................................... 40
FUEL RETURN HOSE ........................................................................................................................................ 42
ENGINE MOUNTING AND SUPPORT .............................................................................................................. 43
WATER PUMP AND FAN .................................................................................................................................... 44
WATER PIPE AND THERMOSTAT .................................................................................................................... 45
INTAKE MANIFOLD ............................................................................................................................................ 46
EXHAUST MANIFOLD ........................................................................................................................................ 47
TURBOCHARGER .............................................................................................................................................. 48
EXHAUST PIPE .................................................................................................................................................. 49
STARTER ............................................................................................................................................................ 50
ALTERNATOR .................................................................................................................................................... 51
ENGINE COMMON PARTS ................................................................................................................................ 52
ELECTRONIC GOVERNOR .............................................................................................................................. 54
AIR CLEANER .................................................................................................................................................... 55
7.5L DIESEL QUICK REFERENCE GUIDE
2
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 CLASSIFICATION “FOR SERVICE CC 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
SAE 40
SAE 30
SAE 20
3
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
7.5L DIESEL QUICK REFERENCE GUIDE
QUICK REFERENCE ENGINE PARTS
4
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 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 prevent 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 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 ONL
Y ONCE
following the 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 knowledge 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 approximately 1.5 man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge 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 knowledge 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.
5
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
NAME:
ACCOUNT #:
ADDRESS:
PHONE:
TECHNICIAN:
SIGNATURE:
OWNER INFORMA
TION
NAME:
ADDRESS:
SITE:
PHONE:
SIGNATURE:
PURCHASE DATE: START-UP DATE:
APPLICATION: Standby Power Prime Power Rental/Trailerized
GENERATOR & TRANSFER SWITCH INFORMATION
GENERA
TOR
MODEL NUMBER:
SERIAL NUMBER:
TRANSFER SWITCH
MODEL 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 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 condition 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
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 engine coolant
level. Adjust as necessary.
4. Check the engine coolant
thermal protection level.
Correct as necessary.
5. Check the diesel fuel
supply level. Fill as
necessary.
6. Drain water and sediment
from the diesel fuel tank.
7. Drain water from the fuel
line water separator if the
unit is equipped with one.
8. Check the air inlets and
outlets for debris. Clean as
necessary.
9. Check the battery
electrolyte level if
accessible. Adjust as
necessary.
10. Check the battery posts,
cables, and charger for
loose connections,
corrosion, and proper
operation. Correct as
necessary.
11. Check the unit wiring for
loose connections,
corrosion, and damage.
Correct as necessary.
12. Check the engine
accessory drive belts for
wear, weather cracking,
and damage. Replace as
necessary.
13. Visually inspect the unit
looking for leaks, wear or
damage, loose connections
or components, and
corrosion. Correct as
necessary.
14. Test the engine and
transfer switch safety
devices. Correct and/or
adjust as necessary.
7
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 connections or
components, and abnormal
operating conditions.
Correct as necessary.
16. 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.
17. Change the engine oil.
18. Replace the engine oi
filter(s).
19. Replace the engine fuel
filter(s) and re-prime the
fuel system.
20. Replace the engine air
filter(s).
21. Perform a 5 minute no-load
operational run of the unit
looking for any post service
problems.
22. Return the unit to standby
setup for operation when
required.
7.5L DIESEL — CYLINDER HEAD ASSEMBLY
8
ITEM PART NUMBER DESCRIPTION QTY
01200A 0D57030100 CYLINDER HEAD ASSY 1
7.5L DIESEL — CYLINDER BLOCK ASSEMBLY
9
ITEM PART NUMBER DESCRIPTION QTY
01300A 0D57030101 CYLINDER BLOCK ASSY 1
7.5L DIESEL — LINER AND PISTON KIT
10
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
7.5L DIESEL — CRANKSHAFT ASSEMBLY
11
ITEM PART NUMBER DESCRIPTION QTY
03000A 0D57030105 CRANKSHAFT ASSY 1
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 0D57030117 STAY, ENGINE BREATHER 1
01981D 0D57030118 STAY, ENGINE BREATHER 1
01987 0D57030119 CLIP, ENGINE BREATHER 3
01988 0D57030120 CLAMP, ENGINE BREATHER 1
04903A 0D57030121 CAP ASSY, OIL FILLER 1
12
7.5L DIESEL — ROCKER COVER AND BREATHER137.5L 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
03470 0D57030133 GUIDE, EXHAUST VALVE 6
14
7.5L DIESEL — CYLINDER BLOCK
7.5L DIESEL — CYLINDER BLOCK
15
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 SPRING PIN, CYLINDER BLOCK 2
01387H 0D57030145 PIN, CYLINDER BLOCK 1
01387K 0D57030146 PIN, CYLINDER BLOCK 1
01387M 0D57030147 PIN, CYLINDER BLOCK 2
01395BB 0D57030148 CAP, CYLINDER BLOCK 1
01395H 0D57030149 CAP, CYLINDER BLOCK 5
01395J 0D57030150 CAP, CYLINDER BLOCK 1
01395K 0D57030151 CAP, CYLINDER BLOCK 1
01395M 0D57030152 CAP, CYLINDER BLOCK 1
01395N 0D57030153 CAP, CYLINDER BLOCK 1
01395NB 0D57030154 CAP, CYLINDER BLOCK 9
01396B 0D57030155 BUSHING, CYLINDER BLOCK 1
01396C 0D57030156 BUSHING, CYLINDER BLOCK 1
01396D 0D57030157 BUSHING, CYLINDER BLOCK 1
01396E 0D57030158 BUSHING, CYLINDER BLOCK 1
01397J 0D57030159 BOLT, CYLINDER BLOCK 5
01397K 0D57030160 BOLT, CYLINDER BLOCK 5
01397N 0D57030161 BOLT, CYLINDER BLOCK 14
01399N 0D57030162 GASKET, CYLINDER BLOCK 2
03033 0D57030163 OIL SLINGER, CRANKSHAFT, FR 1
03040 0D57030164 BEARING SET, CRANKSHAFT STD 1
0D57030165 BEARING SET, CRANKSHAFT U/S 0.25 AR
0D57030166 BEARING SET, CRANKSHAFT U/S 0.50 AR
0D57030167 BEARING SET, CRANKSHAFT U/S 0.75 AR
0D57030168 BEARING SET, CRANKSHAFT U/S 1.00 AR
03044 0D57030169 PLATE, CRANKSHAFT THRUST STD 3
0D57030170 PLATE, CRANKSHAFT THRUST O/S 0.15 AR
0D57030171 PLATE, CRANKSHAFT THRUST O/S 0.30 AR
0D57030172 PLATE, CRANKSHAFT THRUST O/S 0.45 AR
7.5L DIESEL — OIL PAN ASSEMBLY
16
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 FILLER 1
7.5L DIESEL — ENGINE GASKET KIT
17
ITEM PART NUMBER DESCRIPTION QTY
01070 0D57030106 ENGINE OVERHAUL GASKET KIT AR
18
7.5L DIESEL — FLYWHEEL AND HOUSING
7.5L DIESEL — FLYWHEEL AND HOUSING
19
ITEM PART NUMBER DESCRIPTION QTY
01395 0D57030180 CAP, CYLINDER BLOCK 1
02100A 0D57030181 HOUSING ASSY, FLYWHEEL 1
02116 0D57030174 GASKET, FLYWHEEL HOUSING 1
02122 0D57030182 PLATE, CYLINDER BLOCK, RR 1
02124 0D57030183 POINTER, FLYWHEEL HOUSING ENG TIMING 1
02178C 0D57030184 WASHER, FLYWHEEL HOUSING 12
02179 0D57030185 STUD, FLYWHEEL HOUSING 12
02179B 0D57030186 STUD, FLYWHEEL HOUSING 1
02183 0D57030187 SCREW, FLYWHEEL HOUSING 1
02185 0D57030188 PLUG, FLYWHEEL HOUSING 1
02185B 0D57030178 PLUG, FLYWHEEL HOUSING 1
02188 0D57030189 NUT, FLYWHEEL HOUSING 12
02191 0D57030190 CAP, FLYWHEEL HOUSING 1
02192 0D57030191 BOLT, FLYWHEEL HOUSING 8
02192B 0D57030192 BOLT, FLYWHEEL HOUSING 5
02192C 0D57030193 BOLT, FLYWHEEL HOUSING 10 x 50 1
0D57030194 BOLT, FLYWHEEL HOUSING 10 x 55 5
0D57030195 BOLT, FLYWHEEL HOUSING 10 x 65 1
03030A 0D57030196 FLYWHEEL ASSEMBLY 1
03034 0D57030197 OIL SLINGER, CRANKSHAFT, RR 1
03057 0D57030198 RING GEAR, FLYWHEEL 1
03080 0D57030199 OIL SEAL, CRANKSHAFT, RR 1
03764A 0D57030200 COUPLING ASSY, FLYWHEEL 1
03794 0D57030201 WASHER, FLYWHEEL 1
03796 0D57030202 PIN, FLYWHEEL 1
03797 0D57030203 BOLT, FLYWHEEL 6
03797B 0D57030204 BOLT, FLYWHEEL 6
81976 0D57030141 PLUG, TACHOMETER DRIVE 1
81984 0D57030174 GASKET, SPEEDOMETER GEAR 1
ITEM PART NUMBER DESCRIPTION QTY
03006 0D57030205 BOLT, CONNECTING ROD 12
03010A 0D57030206 CONNECTING ROD ASSY 6
03016 0D57030207 BUSHING, CONNECTING ROD 6
03036 0D57030209 PIN, PISTON 6
03037 0D57030210 PISTON SIZE A AR
0D57030211 PISTON SIZE B AR
03050 0D57030213 BEARING SET, CONN ROD STD 6
0D57030214 BEARING SET, CONN ROD U/S 0.25 AR
0D57030215 BEARING SET, CONN ROD U/S 0.50 AR
0D57030216 BEARING SET, CONN ROD U/S 0.75 AR
0D57030217 BEARING SET, CONN ROD U/S 1.00 AR
03060 0D57030218 RING SET, PISTON 6
03772 0D57030219 PIN, CONNECTING ROD 12
03798 0D57030223 SNAP RING, PISTON 12
20
7.5L DIESEL — PISTON AND CONNECTING ROD217.5L DIESEL — CRANKSHAFT
ITEM PART NUMBER DESCRIPTION QTY
03022 0D57030208 DAMPER, CRANKSHAFT TORSIONAL 1
03047 0D57030212 PULLEY, CRANKSHAFT 1
03775 0D57030220 BOLT, TORSIONAL DAMPER 8
03787 0D57030221 BOLT, CRANKSHAFT PULLEY 6
03788 0D57030202 PIN, CRANKSHAFT 1
03788B 0D57030222 PIN, CRANKSHAFT 1
03788C 0D57030147 PIN, CRANKSHAFT 1
22
7.5L DIESEL — CAMSHAFT AND VALVE
7.5L DIESEL — CAMSHAFT AND VALVE
23
ITEM PART NUMBER DESCRIPTION QTY
03100 0D57030224 CAMSHAFT 1
03146 0D57030225 PLATE, CAMSHAFT THRUST 1
03172 0D57030226 TAPPET, VALVE 12
03196 0D57030227 KEY, CAMSHAFT 1
03198 0D57030228 BOLT, CAMSHAFT 2
03264B 0D57030229 WASHER, VALVE GEAR TRAIN 2
03264C 0D57030230 WASHER, VALVE GEAR TRAIN 6
03266B 0D57030231 SCREW, VALVE GEAR TRAIN 12
03266C 0D57030232 SCREW, VALVE GEAR TRAIN 1
03267B 0D57030233 SNAP RING, VALVE GEAR TRAIN 2
03268B 0D57030234 PLUG, VALVE GEAR TRAIN 2
03275 0D57030235 CAP, VALVE GEAR TRAIN 12
03276 0D57030236 BUSHING, VALVE GEAR TRAIN 12
03277 0D57030237 BOLT, VALVE GEAR TRAIN 6
03299 0D57030238 NUT, VALVE GEAR TRAIN 12
03300 0D57030239 SHAFT, ROCKER ARM 1
03302B 0D57030240 BRACKET, ROCKER SHAFT 1
03302C 0D57030241 BRACKET, ROCKER SHAFT 3
03302D 0D57030242 BRACKET, ROCKER SHAFT 1
03302E 0D57030243 BRACKET, ROCKER SHAFT 1
03316 0D57030244 PUSH ROD, ROCKER ARM 12
03323 0D57030245 ROCKER ARM, INLET & EXHAUST VALVE 12
03356 0D57030246 SPRING, ROCKER SHAFT 5
03405 0D57030247 RETAINER, VALVE SPRING 12
03410 0D57030248 VALVE, INTAKE 6
03416 0D57030249 SPRING, VALVE, INNER 12
03417 0D57030250 SPRING, VALVE, OUTER 12
03420 0D57030251 VALVE, EXHAUST 6
03440 0D57030252 SEAL, VALVE STEM 12
03450 0D57030253 LOCK, VALVE SPRING RETAINER 24
24
7.5L DIESEL — TIMING GEAR
7.5L DIESEL — TIMING GEAR
25
ITEM PART NUMBER DESCRIPTION QTY
03026 0D57030254 GEAR, CRANKSHAFT 1
03107B 0D57030255 BUSHING, TIMING GEAR TRAIN 1
03107C 0D57030256 BUSHING, TIMING GEAR TRAIN 1
03133A 0D57030257 GEAR ASSY, CAM IDLER 1ST 1
03134A 0D57030258 GEAR ASSY, CAM IDLER 2ND 1
03136 0D57030259 GEAR, CAMSHAFT 1
03156 0D57030260 SHAFT, CAM IDLER 1ST GEAR 1
03157 0D57030261 SHAFT, CAM IDLER 2ND GEAR 1
03174 0D57030262 THRUST WASHER, TIMING GEAR TRAIN 1
03271 0D57030263 COLLAR, TIMING GEAR TRAIN 1
03295 0D57030264 O-RING, TIMING GEAR TRAIN 1
03295B 0D57030265 O-RING, TIMING GEAR TRAIN 1
03296 0D57030266 NUT, TIMING GEAR TRAIN 1
03297 0D57030227 KEY, TIMING GEAR TRAIN 1
03298C 0D57030267 BOLT, TIMING GEAR TRAIN 1
03298D 0D57030268 BOLT, TIMING GEAR TRAIN 1
03298E 0D57030269 BOLT, TIMING GEAR TRAIN 1
03298F 0D57030270 BOLT, TIMING GEAR TRAIN 4
26
7.5L DIESEL — ATTACHING PARTS
7.5L DIESEL — ATTACHING PARTS
27
ITEM PART NUMBER DESCRIPTION QTY
01307D 0D57030271 COVER, CYLINDER BLOCK 1
01385B 0D57030272 PLUG, CYLINDER BLOCK 1
01385C 0D57030273 PLUG, CYLINDER BLOCK 1
01385D 0D57030274 PLUG, CYLINDER BLOCK 1
01392 0D57030275 JOINT, CYLINDER BLOCK 1
01397 0D57030276 BOLT, CYLINDER BLOCK 20
01399B 0D57030277 GASKET, CYLINDER BLOCK 2
01399C 0D57030162 GASKET, CYLINDER BLOCK 1
02200B 0D57030278 ENGINE HANGER 1
02200C 0D57030279 ENGINE HANGER 1
02251 0D57030280 GASKET, ENGINE HANGER 2
02299B 0D57030281 BOLT, ENGINE HANGER 4
04203 0D57030277 GASKET, ENGINE OIL PRESSURE GAUGE 1
04296 0D57030282 PLUG, ENGINE OIL PRESSURE GAUGE 4
04298 0D57030283 JOINT, ENGINE OIL PRESSURE GAUGE 1
04298B 0D57030284 JOINT, ENGINE OIL PRESSURE GAUGE 1
04299 0D57030285 BOLT, ENGINE OIL PRESSURE GAUGE 2
28
7.5L DIESEL — OIL PUMP AND STRAINER
7.5L DIESEL — OIL PUMP AND STRAINER
29
ITEM PART NUMBER DESCRIPTION QTY
04000A 0D57030288 OIL PUMP ASSEMBLY 1
04037L 0D57030289 SHIM, ENGINE OIL PUMP CASE, LH, T=0.1 AR
0D57030290 SHIM, ENGINE OIL PUMP CASE, LH, T=0.2 AR
04037R 0D57030291 SHIM, ENGINE OIL PUMP CASE, RH, T=0.1 AR
0D57030292 SHIM, ENGINE OIL PUMP CASE, RH, T=0.2 AR
04045 0D57030293 TUBE, ENGINE OIL PUMP OUTLET 1
04089 0D57030294 PIN, ENGINE OIL PUMP 2
04096B 0D57030193 BOLT, ENGINE OIL PUMP 1
04096C 0D57030195 BOLT, ENGINE OIL PUMP 2
04124 0D57030295 STRAINER, ENGINE OIL PAN 1
04135B 0D57030296 STAY, OIL STRAINER 1
04135C 0D57030297 STAY, OIL STRAINER 1
04161B 0D57030298 GASKET, OIL STRAINER 1
04161C 0D57030299 GASKET, OIL STRAINER 1
04161D 0D57030300 GASKET, OIL STRAINER 1
04171 0D57030301 WASHER, OIL STRAINER 4
04178B 0D57030228 BOLT, OIL STRAINER 4
04178C 0D57030302 BOLT, OIL STRAINER 1
04178D 0D57030303 BOLT, OIL STRAINER 1
04178F 0D57030304 BOLT, OIL STRAINER 6
ITEM PART NUMBER DESCRIPTION QTY
04100A 0D57030305 OIL FILTER AND HEAD ASSY 1 04101 0D57030306 SWITCH, OIL FILTER BY-PASS 1 04121A 0D57030307 HEAD ASSEMBLY, OIL FILTER 1 04143 0D57030308 VALVE, OIL FILTER DRAIN 1 04150 0D57030309 OIL FILTER 1 04181 0D57030310 PLUG, OIL FILTER INNER 1 04182B 0D57030311 O-RING, OIL FILTER INNER 1 04183 0D57030312 NUT, OIL FILTER INNER 1 04184 0D57030313 GASKET, OIL FILTER INNER 1 04184B 0D57030174 GASKET, OIL FILTER INNER 1 04191 0D57030314 O-RING, OIL FILTER 1 04191B 0D57030315 O-RING, OIL FILTER 1 04191C 0D57030316 O-RING, OIL FILTER 1 04192 0D57030277 GASKET, OIL FILTER 1 04199 0D57030285 BOLT, OIL FILTER 2 04199B 0D57030317 BOLT, OIL FILTER 1
30
7.5L DIESEL — OIL FILTER
31
7.5L DIESEL — OIL COOLER
ITEM PART NUMBER DESCRIPTION QTY
04300A 0D57030318 OIL COOLER ASSEMBLY 1
04311A 0D57030319 COVER ASSEMBLY, OIL COOLER 1
04322 0D57030320 ELEMENT, ENGINE OIL COOLER 1
04334 0D57030321 GASKET, ENGINE OIL COOLER COVER 1
04338 0D57030322 PLUG, ENGINE OIL COOLER 1
04346 0D57030323 SPRING, ENGINE OIL COOLER BY-PASS VALVE 1
04353 0D57030324 VALVE, ENGINE OIL COOLER BY-PASS 1
04375 0D57030325 O-RING, ENGINE OIL COOLER 3
04377 0D57030326 NUT, ENGINE OIL COOLER INNER 4
04379B 0D57030327 O-RING, ENGINE OIL COOLER INNER 5
04379C 0D57030328 O-RING, ENGINE OIL COOLER INNER 3
04379E 0D57030329 O-RING, ENGINE OIL COOLER INNER 2
04385 0D57030330 PLUG, ENGINE OIL COOLER INNER 3
04399 0D57030331 BOLT, ENGINE OIL COOLER 23
32
7.5L DIESEL — OIL LINE
7.5L DIESEL — OIL LINE
33
ITEM PART NUMBER DESCRIPTION QTY
04232 0D57030332 VALVE, ENGINE OIL PRESSURE REGULATING 1
04925B 0D57030333 TUBE, ENGINE OIL LINE 1
04925C 0D57030334 TUBE, ENGINE OIL LINE 1
04973B 0D57030335 STAY, ENGINE OIL LINE 1
04973C 0D57030336 STAY, ENGINE OIL LINE 2
04975 0D57030337 PROTECTOR, ENGINE OIL LINE 2
04978 0D57030338 O-RING, ENGINE OIL LINE 1
04979 0D57030339 NUT, ENGINE OIL LINE 1
04987B 0D57030340 JOINT, ENGINE OIL LINE 1
04987D 0D57030341 JOINT, ENGINE OIL LINE 1
04994B 0D57030342 CLAMP, ENGINE OIL LINE 2
04996D 0D57030344 EYEBOLT, ENGINE OIL LINE 1
04996G 0D57030345 EYEBOLT, ENGINE OIL LINE 1
04997B 0D57030346 BOLT, ENGINE OIL LINE 4
04997C 0D57030347 BOLT, ENGINE OIL LINE 2
04997D 0D57030160 BOLT, ENGINE OIL LINE 2
04997E 0D57030228 BOLT, ENGINE OIL LINE 2
04998D 0D57030277 GASKET, ENGINE OIL LINE 9
04998E 0D57030348 GASKET, ENGINE OIL LINE 1
12537 0D57030349 GASKET, T/C OIL RETURN TUBE 1
12548 0D57030350 GASKET, T/C OIL RETURN PIPE TO CYL BLOCK 1
12617 0D57030351 TUBE, T/C OIL FEED 1
12621 0D57030352 TUBE, T/C OIL RETURN 1
34
7.5L DIESEL — FUEL FILTER AND HOSE
7.5L DIESEL — FUEL FILTER AND HOSE
35
ITEM PART NUMBER DESCRIPTION QTY
05300 0D57030353 FUEL FILTER 1
05300A 0D57030354 FUEL FILTER ASSEMBLY 1
05302 0D57030355 BRACKET, FUEL FILTER 1
05314 0D57030356 HEAD, FUEL FILTER 1
05392 0D57030357 PLUG, FUEL FILTER 1
05394C 0D57030358 GASKET, FUEL FILTER 4
05398 0D57030359 EYEBOLT, FUEL FILTER 2
05399 0D57030360 BOLT, FUEL FILTER 2
05399C 0D57030361 BOLT, FUEL FILTER 8 x 20 1
0D57030362 BOLT, FUEL FILTER 8 x 75 3
05488 0D57030363 NUT, FUEL LINE 1
05491B 0D57030364 JOINT, FUEL LINE 1
05494 0D57030365 CLAMP, FUEL LINE 2
05496B 0D57030366 BOLT, FUEL LINE 1
07501M 0D57030367 HOSE, INJECTION PUMP FUEL FEED 1
07501N 0D57030368 HOSE, INJECTION PUMP FUEL FEED 1
36
7.5L DIESEL — FUEL INJECTION PUMP
ITEM PART NUMBER DESCRIPTION QTY
07000A 0D57030369 PUMP ASSY, FUEL INJECTION 1
07022 0D57030371 DISC, INJECTION PUMP DRIVING 1
07236 0D57030372 LEVER, INJECTION PUMP GOVERNOR 1
07307 0D57030277 GASKET, INJECTION PUMP FUEL FEED PUMP 2
07329 0D57030373 WASHER, INJECTION PUMP 2
07332D 0D57030376 STAY, INJECTION PUMP BODY 1
07332E 0D57030377 STAY, INJECTION PUMP BODY 1
07338C 0D57030379 O-RING, INJECTION PUMP 1
07339B 0D57030326 NUT, INJECTION PUMP 5
07342 0D57030380 HOSE, INJECTION PUMP 1
07346 0D57030381 EYEBOLT, INJECTION PUMP 1
07347 0D57030160 BOLT, INJECTION PUMP 4
07347B 0D57030382 BOLT, INJECTION PUMP 2
7.5L DIESEL — FUEL INJECTION PUMP
37
ITEM PART NUMBER DESCRIPTION QTY
07013A 0D57030370 CASE ASSY, INJECTION PUMP DRIVE 1
07331B 0D57030374 STUD, INJECTION PUMP 2
07331C 0D57030375 STUD, INJECTION PUMP 4
07338B 0D57030378 O-RING, INJECTION PUMP 1
07339BB 0D57030326 NUT, INJECTION PUMP 2
07347BB 0D57030191 BOLT, INJECTION PUMP 1
07347CB 0D57030383 BOLT, INJECTION PUMP 1
07347DB 0D57030285 BOLT, INJECTION PUMP 2
38
7.5L DIESEL — INJECTION PIPE
7.5L DIESEL — INJECTION PIPE
39
ITEM PART NUMBER DESCRIPTION QTY
07429 0D57030394 TUBE, FUEL INJECTION NO. 4 1
0D57030395 TUBE, FUEL INJECTION NO. 5 1
0D57030396 TUBE, FUEL INJECTION NO. 3 1
0D57030397 TUBE, FUEL INJECTION NO. 6 1
0D57030398 TUBE, FUEL INJECTION NO. 2 1
0D57030399 TUBE, FUEL INJECTION NO. 1 1
07497 0D57030363 NUT, FUEL INJECTION TUBE 1
07498B 0D57030407 CLAMP, FUEL INJECTION TUBE 3
07498C 0D57030408 CLAMP, FUEL INJECTION TUBE 1
07498H 0D57030409 CLAMP, FUEL INJECTION TUBE 2
07498J 0D57030410 CLAMP, FUEL INJECTION TUBE 2
07499 0D57030411 BOLT, FUEL INJECTION TUBE 5
40
7.5L DIESEL — INJECTION NOZZLE
7.5L DIESEL — INJECTION NOZZLE
41
ITEM PART NUMBER DESCRIPTION QTY
07400A 0D57030384 NOZZLE AND HOLDER ASSY 6
07403 0D57030385 DUST SEAL, NOZZLE HOLDER 6
07404 0D57030386 EYEBOLT, FUEL INJECTION NOZZLE 6
07405 0D57030387 GASKET, FUEL INJECTION NOZZLE 6
07406B 0D57030388 GASKET, FUEL INJECTION NOZZLE INNER 6
07406C 0D57030389 GASKET, FUEL INJECTION NOZZLE INNER 6
07406D 0D57030390 GASKET, FUEL INJECTION NOZZLE INNER 12
07410A 0D57030391 HOLDER ASSY, FUEL INJECTION NOZZLE 6
07414 0D57030392 JOINT, FUEL INJECTION NOZZLE HOLDER 6
07420 0D57030393 NOZZLE, FUEL INJECTION 6
07432B 0D57030400 PUSH ROD, NOZZLE HOLDER 6
07434B 0D57030401 SPRING, NOZZLE HOLDER 6
07488B 0D57030402 SCREW, FUEL INJECTION NOZZLE 6
07491 0D57030403 PIN, FUEL INJECTION NOZZLE 12
07493B 0D57030404 NUT, FUEL INJECTION NOZZLE 6
07493C 0D57030405 NUT, FUEL INJECTION NOZZLE 6
07494 0D57030406 BOLT, FUEL INJECTION NOZZLE 12
7.5L DIESEL — FUEL RETURN HOSE
42
ITEM PART NUMBER DESCRIPTION QTY
05467 0D57030412 STAY, FUEL RETURN LINE 1
05473 0D57030413 CLIP, FUEL RETURN LINE 1
05477 0D57030114 BOLT, FUEL RETURN LINE 1
07511 0D57030414 TUBE, INJECTION PUMP FUEL RETURN 1
07512 0D57030415 TUBE, FUEL INJECTION NOZZLE FUEL RETURN 1
7.5L DIESEL — ENGINE MOUNTING AND SUPPORT
43
ITEM PART NUMBER DESCRIPTION QTY
02101 0D57030286 BRACKET, FLYWHEEL HOUSING ENG MOUNTING 2
02880 0D57030287 BOLT, ENGINE RR MOUNTING 8
ITEM PART NUMBER DESCRIPTION QTY
10000A 0D57030416 WATER PUMP ASSEMBLY 1
10001B 0D57030417 BEARING, WATER PUMP 1
10001C 0D57030418 BEARING, WATER PUMP 1
10010 0D57030419 WATER PUMP KIT 1
10012 0D57030420 CASE, WATER PUMP 1
10016 0D57030421 FLANGE, WATER PUMP PULLEY DRIVE 1
10021 0D57030422 GASKET, WATER PUMP 1
10025 0D57030423 IMPELLER, WATER PUMP 1
10040 0D57030424 BELT, ALTERNATOR 1
10041 0D57030425 PULLEY, WATER PUMP 1
10043 0D57030426 SEAL UNIT, WATER PUMP SHAFT 1
10044 0D57030427 SHAFT, WATER PUMP 1
10051 0D57030428 THRUST WASHER, WATER PUMP INNER 1
10078 0D57030429 NIPPLE, WATER PUMP INNER 1
10088B 0D57030302 BOLT, WATER PUMP 5
10088C 0D57030331 BOLT, WATER PUMP 2
10096B 0D57030430 SPACER, WATER PUMP INNER 1
10098C 0D57030431 SNAP RING, WATER PUMP INNER 1
10134 0D57030432 HOSE, THERMOSTAT WATER BY-PASS 1
10175 0D57030433 CLAMP, THERMOSTAT 2
10592 0D57030160 BOLT, COOLING FAN 4
44
7.5L DIESEL — WATER PUMP AND FAN
45
7.5L DIESEL — WATER PIPE AND THERMOSTAT
ITEM PART NUMBER DESCRIPTION QTY
10100A 0D57030434 CASE ASSY, THERMOSTAT 1
10106 0D57030435 COVER, THERMOSTAT CASE 1
10110 0D57030436 THERMOSTAT KIT 1
10115 0D57030280 GASKET, THERMOSTAT CASE TO CYL HEAD 1
10122 0D57030437 GASKET, THERMOSTAT COVER 1
10177B 0D57030438 BOLT, THERMOSTAT 3
10177E 0D57030439 BOLT, THERMOSTAT 2
10177F 0D57030440 BOLT, THERMOSTAT 2
10898B 0D57030441 PLUG, WATER TEMPERATURE GAUGE 2
7.5L DIESEL — INTAKE MANIFOLD
46
ITEM PART NUMBER DESCRIPTION QTY
11400 0D57030442 MANIFOLD, INTAKE 1
11424 0D57030443 BOLT, INTAKE MANIFOLD 12
11424B 0D57030304 BOLT, INTAKE MANIFOLD 3
11424E 0D57030444 BOLT, INTAKE MANIFOLD 2
11442C 0D57030445 STUD, INTAKE MANIFOLD 1
7.5L DIESEL — EXHAUST MANIFOLD
47
ITEM PART NUMBER DESCRIPTION QTY
12000 0D57030446 MANIFOLD, EXHAUST 1
12010 0D57030447 GASKET, EXHAUST MANIFOLD 6
12043B 0D57030448 INSULATOR, EXHAUST MANIFOLD HEAT 1
12089E 0D57030449 STUD, EXHAUST MANIFOLD 4
12096 0D57030450 NUT, EXHAUST MANIFOLD 12
12099B 0D57030451 BOLT, EXHAUST MANIFOLD 5
7.5L DIESEL — TURBOCHARGER
48
ITEM PART NUMBER DESCRIPTION QTY
12500A 0D57030452 TURBOCHARGER ASSEMBLY 1
12779B 0D57030450 NUT, T/C 4
12784B 0D57030453 GASKET, T/C 1
7.5L DIESEL — EXHAUST PIPE
49
ITEM PART NUMBER DESCRIPTION QTY
12515 0D57030454 COUPLING, T/C TURBINE SIDE 1
13010 0D57030455 GASKET, EXHAUST PIPE 1
13085 0D57030456 SEAL RING, EXHAUST PIPE 1
13085B 0D57030457 SEAL RING, EXHAUST PIPE 1
13099C 0D57030458 BOLT, EXHAUST PIPE 4
13321 0D57030459 SUPPORT, EXHAUST PIPE ELBOW 1
50
ITEM PART NUMBER DESCRIPTION QTY
11607 0D57030460 WASHER, INTAKE AIR HEATER 1
11610 0D57030461 HEATER, INTAKE AIR 1
11631 0D57030462 PLATE, INTAKE AIR HEATER CABLE EARTH 1
11682 0D57030363 NUT, INTAKE SILENCER 2
14000A 0D57030463 STARTER ASSEMBLY 1
14191E 0D57030464 WASHER, STARTER 1
14195C 0D57030465 NUT, STARTER 1
14195E 0D57030466 NUT, STARTER 2
14199B 0D57030467 BOLT, STARTER 1
7.5L DIESEL — STARTER
7.5L DIESEL — ALTERNATOR
51
ITEM PART NUMBER DESCRIPTION QTY
14200A 0D57030468 ALTERNATOR ASSEMBLY 1
14216 0D57030469 BRACE, ALTERNATOR ADJUSTING 1
14223 0D57030470 BRACKET, ALTERNATOR MOUNTING 1
14384B 0D57030471 WASHER, ALTERNATOR 1
14788B 0D57030472 NUT, ALTERNATOR 1
14788C 0D57030466 NUT, ALTERNATOR 1
14799B 0D57030160 BOLT, ALTERNATOR 2
14799D 0D57030473 BOLT, ALTERNATOR 1
14799E 0D57030474 BOLT, ALTERNATOR 1
52
7.5L DIESEL — ENGINE COMMON PARTS
7.5L DIESEL — ENGINE COMMON PARTS
53
ITEM PART NUMBER DESCRIPTION QTY
1 0D5703 7.5L MITSUBISHI ENGINE 1
2 0D5760 HOUSING, FLYWHEEL ADAPTER MACH 7.5 1
3 021322 PLATE, FLEX SAE 11-1/2 5
4 078417 FAN REWORK 30” 1
5 0D6661 SPACER, COOLING FAN 1
6 0D5341 INTAKE ADAPTER, MACHINED 1
7 051698 SCREW HHC M8-1.25 x 75 G8.8 2
8 022145 WASHER FLAT 5/16 ZINC 2
9 0D8199 ENGINE MOUNT 2
10 022129 WASHER LOCK M8-5/16 2
11 051769 WASHER LOCK M12 16
12 053666 SENDER OIL PRESSURE 1
13 042574 ADAPTOR 1/8 NPTF TO 1/8-28 2
14* 0A8584 SWITCH, OIL PRESSURE 1
15 0D2168 OIL DRAIN M18 x 1.5 1
16 0D4739 WASHER FLAT M18 COPPER 1.5 THK 1
17 053667 SENDER, WATER TEMPERATURE 1
18 065809 ADAPTOR, WATER TEMP SENDER 1
19 035606 SENSOR, HIGH COOLANT SHUTDOWN 1
20 0D2244M MAGNETIC PICKUP ASSY (3/8-24 MALE) 1
21 0D2244F MAGNETIC PICKUP ASSY (3/8-24 FEMALE) 1
22 068406 SCREW HHC M12-1.75 x 60 G10.9 12
23 045773 NUT HEX M12-1.75 G8 YEL CHR 8
24 049808 WASHER FLAT M12 8
25 046526 WASHER LOCK M10 22
26 071623 SCREW SHC M10-1.50 x 55 G12.9 4
27 022131 WASHER FLAT 3/8-M10 ZINC 18
28 059981 SCREW HHC M10-1.5 x 30 G10.9 6
29 0D8427 WASHER LOCK M10 RIBBED 8
30 043097 SCREW SHC 3/8-16 x 1 G8.8NZ 8
31 059355 SCREW SHC M10-1.50 x 50 G12.9 12
32 0536210860 GROUND WIRE ASSY 1
33 051756 SCREW HHC M10-1.5 x 20 G8.8 10
34 025507 WASHER SHAKEPROOF EXT 7/16 STL 2
35 045771 NUT HEX M8-1.25 G8 YEL CHR 2
36 0D3936 BRACKET, GOVERNOR 1
* USED FOR C-PANEL ONLY
54
ITEM PART NUMBER DESCRIPTION QTY
1 067708 ACTUATOR 24V CCW 1
2 084753 LEVER ACTUATOR CLAMP 1
3 0D7657 STUD TH 1/4-28 x 15-1/2 G2 ZINC 1
4 084754 ROD, END, BRG 1/4”-28 2
5 038750 SCREW HHC M6-1.0 x 30 G8.8 6
6 049811 WASHER FLAT M6 8
7 022097 WASHER LOCK M6-1/4 6
8 049813 NUT HEX M6 x 1.0 G8 YEL CHR 8
7.5L DIESEL — ELECTRONIC GOVERNOR
7.5L DIESEL — AIR CLEANER
55
ITEM PART NUMBER DESCRIPTION QTY
1 090625 AIR CLEANER 7 3/4 1
2 090624 MOUNTING CLAMP 7 3/4 1
3 0D6749 INTAKE TUBE 4” OD x 10 LG 1
4 072448 HOSE RUBBER HUMP RDCR 4-2-3/4 1
5 0D6383 BRACKET AIR CLEANER 1
6 086133G CLAMP HIGH TORQUE 3.75-4.625 2
7 086133D CLAMP HIGH TORQUE 2.25-3.125 1
8 049814 SCREW HHC M10-1.5 x 25 G8.8 2
9 022131 WASHER FLAT 3/8-M10 ZINC 4
10 045772 NUT HEX M10-1.5 G8 YEL CHR 2
11 046526 WASHER LOCK M10 2
Notes
Notes
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