Generac 0E6478 User Manual
0E6478
6.8LITER
GAS
ENGINE
PARTS
MANUAL
P.O. BOX 310 EAGLE WI 53119
PRINTED IN U.S.A.
Revision 0: 08/29/03
FORD
6.8L GAS TABLE OF CONTENTS
1
LEGEND
“AR” AS REQUIRED
“STD” STANDARD SIZE
“O.S.” 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 USE THE MODEL
NUMBER OF THE UNIT BEING SERVICED WHEN ORDERING FROM THIS MANUAL.
QUICK REFERENCE GUIDE .............................................................................................................................. 2
SERVICE RECOMMENDATIONS ........................................................................................................................ 3
ENGINE LOWER .................................................................................................................................................. 8
ENGINE UPPER ................................................................................................................................................ 12
ENGINE FRONT.................................................................................................................................................. 14
COOLING SYSTEM ............................................................................................................................................ 16
INTAKE AND IGNITION SYSTEM ...................................................................................................................... 18
ENGINE COMMON PARTS:
LEFT HAND SIDE (DIRECT DRIVE UNITS) .............................................................................................. 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 - NO ENCLOSURE) ............................................ 28
RIGHT HAND SIDE (GEAR BOX UNITS, CLOSED SET - W/ ENCLOSURE) .......................................... 30
6.8L GAS QUICK REFERENCE GUIDE
QUICK REFERENCE ENGINE PARTS
2
PART NUMBER DESCRIPTION QTY
0D5419 FILTER ASY. - OIL 1
0D34540114 PISTON RING SET STD (2 PISTONS) 5
0D34540115 PISTON RING SET .020"/.50MM O/S 5 AR
0D34540203 CAP - OIL FILLER 1
0D34540123 SLINGER-CRANKSHAFT OIL REAR 1
0D34540126 SEAL-CRANKSHAFT REAR 1
0D34540213 CHAIN-TIMING 2
0D34540232 PUMP ASY & SEAL-WATER 1
0D34540233 SEAL-WATER PUMP 1
0D34540235 SEAL-THERMOSTAT (O-RING) 1
0D34540238 THERMOSTAT ASSY-WATER 1
0D34540249 COIL & BOOT ASY-IGNITION 10
0D34540186 SPARK PLUG (PLATINUM) .044 GAP 10
0D3488 BELT SERPENTINE 67.5” (DIRECT DRIVE) 1
0D3488A BELT SERPENTINE 70” (GEAR BOX) 1
0A1232 D.C. ALTERNATOR ASSY 1
0D5418 STARTER MOTOR FORD V-10 ENGINE 1
0A8584 SWITCH OIL PRESSURE 1
053667 SENDER WATER TEMP 1
053666 SENDER OIL PRESSURE 1
3
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 SF.” Detergent oils keep the
engine cleaner and reduce carbon deposits. Use oil having the following SAE viscosity rating, based on the
ambient temperature range anticipated before the next
oil change:
Engine Lubrication System:
Crankcase Oil Capacity..............................................6.8 L (7 U.S. qts.)
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 recommended 50-50 mixture.
Cooling System:
CCoolant Capacity
System..............................................................23.7 L (6.3 U.S. gals.)
Engine ..............................................................12.3 L (3.3 U.S. gals.)
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.
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 glycol
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.
!
◆
◆
Temperature Oil Grade (Recommended)
Above 80º F (27º C) SAE 30W or 15W-40
30º to 80º F (-1º to 27º C) SAE 20W-20 or 15W-40
Below 32º F (0º C) SAE 10W or 15W-40
6.8L GAS SERVICE RECOMMENDATIONS
DANGER
!
!
4
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 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 batter
y charger m
ust 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 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.
6.8L GAS SERVICE RECOMMENDATIONS
5
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.
!
!
6.8L GAS SERVICE RECOMMENDATIONS
6
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 natural gas
delivery system. Tighten
connections as necessary.
6. Check the air inlets and
outlets for debris. Clean
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 wiring 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
7
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.
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.
16. Replace the engine oi
filter(s).
17. Replace the engine air
filter(s).
18. Check the engine spark
plugs. Clean and re-gap
or replace as necessary.
19. Perform a 5 minute no-load
operational run of the unit
looking for any post service
problems.
20. Return the unit to standby
setup for operation when
required.
6.8L GAS SERVICE RECOMMENDATIONS
8
6.8L GAS ENGINE LOWER
9
ITEM PART NUMBER DESCRIPTION QTY
6010 0D34540100 CYL BLOCK LESS CRKSHFT,PISTONS 1
6026AA 0D34540101 PLUG 1.75" STAINLESS STEEL CUP 10
(4 EA. LEFT/RIGHT, 2 REAR)
6026A 0D34540102 PLUG-CL BLK FRT 13.84MM 2
6026A 0D34540103 PLUG-CYL BLK REAR 3/8-18X.425 2
6026BA 0D34540104 PLUG-38.3MM CUP STAINLESS STEEL 2
6397D 0D34540105 PIN-DOWEL 8.0 X 18.25 TIMING COVER 2
8555 0D34540106 TUBE ASSY - HEATER WATER 1
N806040 0D34540107 PIN-DOWELL (SOLID) 8.0 X 45.5 2
6A008 0D34540108 PIN-DOWELL, CYL HEAD 16.0 X 19.0 4
6108 0D34540109 PISTON & PIN ASSY - STD 10
6108 0D34540110 PINSTON & PIN ASSY 0.25MM O.S. AR
6108 0D34540111 PISTON & PIN ASSY 0.50MM O.S. AR
6135 0D34540112 PIN - PISTON 10
6140 0D34540113 RETAINER - PISTON PIN 20
6148 0D34540114 PISTON RING SET STD (2 PISTONS) 5
6148 0D34540115 PISTON RING SET .020"/.50MM O.S. 5 AR
6200 0D34540116 ROD-CONNECTING 10
6207 0D34540117 BUSHING-CONNECTING ROD 10
6211 0D34540118 BEARING-CONNECTING ROD 20
0D34540119 BRG-CONN ROD .020"/50MM U.S. AR
6214 0D34540120 BOLT-CONNECTING ROD 20
6K301 0D34540121 RETAINER-CRANKSHAFT OIL SEAL 1
6303 0D34540122 CRANKSHAFT ASSY 1
6310 0D34540123 SLINGER-CRANKSHAFT OIL REAR 1
N806201 0D34540124 KEY-WOODRUFF 4.76 X 49 1
6397A 0D34540125 PIN-FLYWHL 16.0X25.0 HOLLOWDWL 2
6397D 0D34540105 PIN-DOWEL 8.0 X 18.25 TIMING COVER 2
6701 0D34540126 SEAL-CRANKSHAFT REAR 1
N806155 0D34540305 SCREW & WASHER M6 X 1.0 X 27.5 6
6333 0D34540127 BRG-CRKSFT MAIN UPR STD (GRD 2) 5
6333 0D34540128 BRG-CRKSFT MAIN UPR STD (GRD 1) 5 AR
6333 0D34540129 BRG-CRKSFT MAIN UPR STD (GRD 3) 5 AR
6333 0D34540130 BRG-CRKSFT MAIN UPR .25MM U.S. 5 AR
6A341 0D34540131 BRG-CRKSFT THRUST UPPER STD 2
6333 0D34540132 BRG-CRKSFT MAIN UPR STD #1 GD2 1
6333 0D34540133 BRG-CRKSFT MN UPR STD #1 (GRD1) 1 AR
6333 0D34540134 BRG-CRKSFT MN UPR STD #1 (GRD3) 1 AR
6333 0D34540135 BRG-CRKSH MN UPR STD#1 .25MM U.S. 1 AR
6A338 0D34540136 BRG-CRKSFT MAIN LWR (GRADE 2) 6
6A338 0D34540137 BRG-CRKSFT MAIN LWR (GRADE 1) 6 AR
6A338 0D34540138 BRG-CRKSFT MAIN LWR (GRADE 3) 6 AR
6A338 0D34540139 BRG-CRKSFT MN LWR .25MM U.S. 6 AR
6K302 0D34540140 WASHER-CRKSHFT THRUST LOWER 1
6345-BA 0D34540142 STUDBOLT-CRKCS MAIN BRG CAP 1
M8 X 1.25 + M10 X 1.5 X 126
6345-AA 0D34540143 BOLT-CRKSHFT MAIN BEARING CAP 11
M10 X 1.5 X 94.5 HEX HEAD
(NOTE: Do not re-use removed bolts when replacing bearings!)
6345-AA 0D34540144 BOLT-CRKSFT MAIN BEARING CAP 12
M9 X 1.25 X 53 HEX HEAD
6A346 0D34540145 DOWEL-MAIN BRG CAP TO BLOCK 12
6600 0D34540146 PUMP ASSY-OIL 1
6.8L GAS ENGINE LOWER
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