Generac 0F9765MNL User Manual

0F9765MNL

3.0 liter

G A S

P.O. BOX 310 EAGLE WI 53119

Ford

Duratec

ENGINE

PARTS

MANUAL

PRINTED IN U.S.A.

Revision 0: 09/12/06

3.0L GAS ENGINE TABLE OF CONTENTS

QUICK REFERENCE GUIDE ................................................................................................................................... 1

SERVICE RECOMMENDATIONS ............................................................................................................................2

CYLINDER BLOCK & RELATED PARTS ................................................................................................................. 6

CYLINDER BLOCK & RELATED PARTS ................................................................................................................. 7

CYLINDER HEAD & RELATED PARTS ...................................................................................................................8

CYLINDER HEAD & RELATED PARTS ...................................................................................................................9

PISTON & CONNECTING ROD ............................................................................................................................. 10

TIMING COMPONENTS ........................................................................................................................................ 11

CRANKSHAFT & RELATED PARTS ...................................................................................................................... 12

CRANKSHAFT & RELATED PARTS ...................................................................................................................... 13

ENGINE COMMON PARTS ....................................................................................................................................14

LEGEND

“ A R ” A S R E Q U I R E D “ S T D ” S TA N D A R D S I Z E “ O. S .” O V E R S I Z E “ U . S .” U N D E R S I Z E “ N A ” N O T AVA I L A B L E

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.

3.0L GAS ENGINE QUICK REFERENCE GUIDE

DANGER

QUICK REFERENCE ENGINE PARTS

ENGINE SIZE: 3.0 Liter FUEL: Gas MAKE: Ford ENGINE P/N: 0F9765 MODEL: —

OIL CAPACITY: 1.0 gallons (w/filter) COOLANT CAPACITY: 4.0 gallons

scheduled maintenance kits

Description Part Number

Oil/Air NA – –

common reference parts

Description Part Number Special Notes

Oil Filter (Main) 0D5419 Fuel Filter NA Air Cleaner Element Check BOM V-Belt 0D3488N Serpentine Thermostat 075885 Thermostat Gasket 048665 Water Pump 0F9225 Starter Motor 0E9747 Spark Plug 0F97650226

additional reference parts

Alternator 0E9868A Ignition Coil 0F9228

User Notes

◆ 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:

Temperature Oil Grade (Recommended)

Above 75º F (24º C) SAE 30W

40º to 75º F (4.4º to 24º C) SAE 20W or 15W-40

10º to 40º F (-12º to 4.4º C) SAE 10W or 15W-40

Below 10º F (-12º C) SAE 5W-30 (Synthetic) or 5W-20

◆ 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.

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.

3.0L GAS ENGINE SERVICE RECOMMENDATIONS

8 kW - 35 kW Small Standby Generator Sets

Following is a recommended maintenance schedule for Generac small standby and residential generator sets from 8 kW to 35 kW in size, and applies to both diesel engine and gas engine driven units. 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 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 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.

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 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 approximately

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 4.0

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.

3.0L GAS ENGINE 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: _______________________________

PURCHASE DATE: ____________________ START-UP DATE: ____________________

APPLICATION: ____ Standby Power ____ Prime Power ____ Rental/Trailerized

NAME: ____________________________________ ADDRESS: _________________________________

SITE: _____________________________________

PHONE: ___________________________________

SIGNATURE: _______________________________

OWNER INFORMATION

GENERATOR & TRANSFER SWITCH INFORMATION

GENERATOR

MODEL NUMBER:___________________________ SERIAL NUMBER:___________________________

TRANSFER SWITCH

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.

3.0L GAS ENGINE SERVICE RECOMMENDATIONS

Maintenance Tasks Level 1 Level 2 Level 3 Level 4

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 ther-

mal protection level. Correct as

necessary.

5. Check the natural gas delivery

system on gas engine driven

units. Tighten connections as

necessary.

6. Check the diesel fuel supply

level for diesel engine driven

units. Fill as necessary.

7. Drain water and sediment from

the diesel fuel tank on diesel

engine driven units.

8. Drain water from the fuel line

water separator on diesel

engine driven units if the unit is

equipped with one.

9. Check the air inlets and outlets

for debris. Clean as necessary.

10. Check the battery electrolyte

level if accessible. Adjust as

necessary.

11. Check the battery posts,

cables, and charger for loose

connections, corrosion, and

proper operation. Correct as

necessary.

12. Check the unit wiring for loose

connections, corrosion, and

damage. Correct as necessary.

13. Check the engine accessory

drive belts for wear, weather

cracking, and damage. Replace

as necessary.

Recommended to

be done monthly/

10 hrs.

Task

Comp.

(Date-

Initials)

Required to be

done 3 months/

Break-in /30 hrs.

• • • •

• • •

• • • •

• • •

• • • •

Task

Comp.

(Date-

Initials)

Required to

be done Semi-

Annually/50 hrs.

Task

Comp.

(Date-

Initials)

Required to be done

Annually/ 100 hrs.

•

Task

Comp.

(Date-

Initials)

3.0L GAS ENGINE SERVICE RECOMMENDATIONS

Maintenance Tasks Level 1 Level 2 Level 3 Level 4

14. Visually inspect the unit look-

ing for leaks, wear or damage,

loose connections or compo-

nents, and corrosion. Correct

as necessary.

15. Test the engine and transfer

switch safety devices. Correct

and/or adjust as necessary.

16. 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 condi-

tions. Correct as necessary.

17. 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.

Recommended to

be done monthly/

10 hrs.

Task

Comp.

(Date-

Initials)

Required to be

done 3 months/

Break-in /30 hrs.

• • • •

• •

Task

Comp.

(Date-

Initials)

Required to

be done Semi-

Annually/50 hrs.

Task

Comp.

(Date-

Initials)

Required to be done

Annually/ 100 hrs.

•

Task

Comp.

(Date-

Initials)

18. Change the engine oil.

19. Replace the engine oil filter(s).

20. Replace the engine air filter(s).

21. Replace the engine fuel filter(s)

on diesel engine driven units

and re-prime the fuel system.

22. Check the engine spark plugs

on gas engine driven units.

Clean and re-gap orreplace as

necessary.

23. Perform a 5 minute no-load

operational run of the unit

looking for any post service

problems.

24. Return the unit to standby

setup for operation when

required.

•

• •

• • • •

3.0L GAS ENGINE CYLINDER BLOCK & RELATED PARTS

ITEM PART NUMBER DESCRIPTION QTY

ENGINE BLOCK

0F9765 SHORT BLOCK 1 REMAN ENGINE ASSY 1 6890 0F97650100 OILFILTER MOUNTING INSERT 1 W701501 0F97650101 DOWEL, TIMING CHAIN GUIDE 1

TIMING COVER

6019 0F97650102 FRONT TIMING COVER 1 6020 0F97650103 TIMING COVER GASKET, RH 1 6020 0F97650104 TIMING COVER GASKET, CENTER 1 6020 0F97650105 TIMING COVER GASKET, LH 1 6700 0F97650106 TIMING COVER SEAL 1 W701525 0F97650107 BOLT,M8 X 51MM POS.4,10,13,14,15 & 16 6 W701240 0F97650108 BOLT, M8 X 34MM POS.7 & 9 2 W701581 0F97650109 STUD M8 X 68MM X M8 X 2MM POS.2,3,5,6,8,11, &12 7 W701712 0F97650110 STUD M6 X 20 M8 X 47.5 POS. 1 1 W701228 0F97650111 DOWEL TIMING COVER TO BLOCK 2

PLUGS-CYLINDER BLOCK

6026 0F97650112 1/2" X 14 MM PIPE, RG & CENTER REAR OF BLOCK 2 6026 0F97650113 3/4" X 14MM PIPE RH & LH SIDE OF BLOCK 2 6026 0F97650114 3/8" X 18MM PIPE LH SIDE OF BLOCK 1 6026 0F97650115 19.35MM CUP LH SIDE OF BLOCK 1 6026 0F97650116 1 X 11.5MM PIPE RH & LH CYLINDER HEAD 2 6026 0F97650117 1/4" X 18 MM PIPE RH & LH CYLINDER HEAD 9 6391 0F97650118 DOWEL TRANY TO BLOCK 2

OIL PRESSURE SENDING UNIT

9278 0F97650119 OIL PRESSURE SENDING UNIT 1 6N071 0F97650120 OIL PRESSURE SENDING UNIT TO BLOCK ADAPTER 1

MAIN BOLTS

6345 0F97650121 HOLE # 1,2,3,4 &17 5 6345 0F97650122 HOLE # 13,14,15,& 16 4 6345 0F97650123 HOLE # 18,19,20,21,& 22 5 6345 0F97650124 HOLE #9,10,11 & 12 4 6345 0F97650125 HOLE #5,6,7,& 8 4

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