Generac Doosan 22.0 Liter V12 Diesel 0F9438 Generator Engine Parts Manual Free download

Page 1


Oil/Fuel/Air

COMMON REFERENCE PARTS

OIL FILTER 0F94380204

FUEL FILTERS, SPIN ON TYPE, 0F94380348

PRE FUEL FILTER ELEMENT, PRIMARY 0432199804

FUEL FILTER ELEMENTS, ON INJECTION PUMP, 0432199934

FUEL HAND PRIMER PUMP P0F94380351

AIR CLEANER ELEMENT, STANDARD, 0F9050A

AIR CLEANER ELEMENT, HEAVY DUTY, 0C1993

MAGNETIC PICKUP SENSOR 0432199991

WATER PUMP 0F94380237

STARTER 0C46930475

ALTERNATOR 0F94380359

0F943800SM

0F94380ASM

OIL PRESSURE SWITCH 0432199916

TEMPERATURE SWITCH 0432199922

TEMPERATURE SENSOR 0432199919

THERMOSTAT SET THREE THERMOSTATS & SIX SEALS 0F94380235S HOSE, THERMOSTAT BYPASS HOSE 0F94380232

ROCKER COVER GASKET, HEAD COVER GASKET, 0F94380161

ROCKER CASE GASKET 0F94380164

FAN, ENGINE COOLING FAN, 0F94380244

INJECTOR ASSEMBLY, NOZZLE AND HOLDER, 0F94380316

FAN BELT SET 0F94380246

ALTERNATOR BELT SET 0F94380360

♦ 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

Above 75'1 F (242 C)

402 to 752 F (4.42 to 242 C)

102 to 402 F (-122 to 4.42 C)

Below 102 F (-122 C)

Coolant

Oil Grade (Recommended)

SAE30W

SAE 20W or 1SW-40

SAE 10W or 1SW-40

SAE SW-30 (Synthetic) or SW-20

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 des ired. 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.

www.HeavyEquipmentRestorationParts.com

Email: EngineParts@HeavyEquipmentRestorationParts.com alternate email: engineparts2@gmail.com

Phone: 269 673 1638

Text: 269 760 8652

I22.0L DIESEL ENGINE SERVICE RECOMMENDATIONS

500 kW to 2000 kW Standby Diesel Engine Driven Generator Sets

Following is a recommended maintenance schedule for Generac standby diesel engine driven generator sets from 500 kW to 2000 kW in size. The established intervals in the schedule are the maxtmum 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.

Peiformed 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 peiformed 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.

LtThe 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.

2 A wear-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.

Pe,jonned ONLY ONCE following thejtrst six months or the first 50 hours of operation after purchase of the unit and requires approximately 3.0 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.

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.

Peiformed 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 peiformed 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 knowledge to accomplish and should be performed only by an authorized Generac Sernice Dealer.

NOTE: Add 20% to all times for 12 cylinder or larger engines.

5 A comprehensive inspection of the generator set to insure it is properly serviced and ready to operate and carry the load when required, and to identify any potential problem areas.

Peiformed biannually or following each 250 hours of operation of the unit and requires approximately 8.0 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 peiformed only by an authorized Generac Service Dealer.

22.0L DIESEL ENGINE SERVICE RECOMMENDATIONS

Maintenance Tasks

1 Disable the unit from operating per the first page warning

2.Check the engine oil level. Adjust as necessary.

3. Ch ec k the engine coolant level.

Adjust as necessary

4 Check the engine coolant thermal protection level. Correct as

necessary

5 Ched< !he diesel fuel supply level. Fill as necessary

6.Drain water and sediment from the die sel fuel tank.

7.Drain water from the fueVwater separator if the unit is equ ipped

with one

B.Check the air inlets and outlets for debris Clean as necessary.

9 Check the battery electrolyte level and speci fic gravity if acces sible Adjust as neces -

sary.

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 neces-

sary

12.Check the engine ac:tessory drive belts for correct tension wear, weather cracking , and

damage Replace as necessary.

13. Check the engine valve clearance. Adjust as necessary.

14 Visually inspect the unit looking for leaks, wear or damage, loose connections or compo-

nents, and corrosion Correct as necessary

Maintenance Tasks

15.Test the engine and transfer switch safety devices. Correct

and/or adjust as necessary

t6.lnitiate 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

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 con-

nections or components, and abnormal operating conditions. Correct as necessa ry.

18. Perform an engine oil analysis (send a sample to a lab for results). Change the

engine oil and fi lters if the analysis resu lts indicate this is required

19.Change the engine oil.

20 Replace the engine oil filter(s)

21.Replace the engine fuel filler(s} on diesel engine driven units and re-prime the

fuel system.

22 Replace the engine air

filter(s)

23 Perform a 5 minute no-load operational run of the un it looking for any post service

problem s

24.Return the unit to standby setup for operation when c::::,

required

22.0L DIESEL ENGINE SERVICE RECOMMENDATIONS

Engine Parts contact

email: EngineParts@HeavyEquipmentRestorationParts.com

Alternate email: engineparts2@gmail.com

Website: www.Diesel-Generator-Engine-Parts.com

Related website: www.HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

22.0L DIESEL ENGINE

0F94380129

0F94380130

0F94380131

0F94380132

DESCRIPTION

SEPARATOR 0-RING

HOSE,RUBBER

HOSE,RUBBER

22.0L DIESEL ENGINE CRANKSHAFT I

DESCRIPTION

CRANKSHAFT ASY RING, WEAR (FRONT) PIN, PARALLEL GEAR, CRANKSHAFT RING, OIL THROWER DAMPER, VISCOUS BOLT, HEX M1 0X20 FLYWHEEL ASY FLYWHEEL GEAR, RING RlNG, WEAR (REAR) PIN, TAPER BOLT, FLYWHEEL HOUSING PULLEY, V-BELT DEVICE, TURNING BOLT, SOCKET HEAD M16X1 .5X75

0F94380153

0C27100413

0C27100400

0F94380154

0F94380157

0F94380158

0F94380159

0F94380160

0C46930146

0F94380161

0F94380162

0F94380163

0F94380164

0F94380165

0F94380166

CYLINDER HEAD ASY SCREW, PLUG M14X1 .5 RING, SEAL A14X20 BOLT, CYLINDER HEAD GASKET, CYLINDER HEAD COVER, CYLINDER HEAD COVER, CYLINDER HEAD PIN, DOWEL 6X10 HEX, BOLT ASY M8X28 GASKET, CYLINDER HEAD COVER COVER, INTERMEDIATE HEX, BOLT ASY M8X50 GASKET, INTERMEDIATE

PART NUMBER

0F94380200

0F94380201

0F94380202

0F94380203

0F94380204

OC46930270

OC46930271

OC46930272

0C27100323

0C27100310

DESCRIPTION

HEAD, OIL FILTER

ADAPTER, OIL PRESSURE SWITCH SCREW, PLUG M24X1 .5 RING, SEAL

CARTRIDGE ASSY GASKET, FILTER COVER

BOLT, HEX M10X125

BOLT, HEX M10X60

WASHER, SPRING A10 WASHER, PLAIN 10.5

DESCRIPTION

HOUSING, OIL COOLER

GASKET, OIL COOLER

BOLT, HEX M10X35

WASHER, WAVE

BOLT, SOCKET HEAD

WASHER

OIL COOLER ASY

GASKET

HEAD, OIL COOLER

GASKET, COVER HOUSING

BOLT, HEX M8X55

BOLT, HEX M8X16

WASHER, SPRING

SCREW, PLUG AM14X1 .5

RING, SEAL A14X20

BOLT, HEX MBXS0

BOLT, HEX MBX33

WASHER, SPRING

SCREW, PLUG

RING, SEAL 26X31 18

1010 0F94380211 1020 0F94380212

1030 0C46930314

1040 0C46930117 1050 0C46930118 1070 0F94380213

1080 0C46930317

1900 0C46390312

1910 0DB6900122

1920 0F94380214

1950 0C46930307

1960 0F94380215

DESCRIPTION PAN, OIL

GASKET, OIL PAN BOLT ASY MBX35

SCREW, PLUG

RING, SEAL A 1BX24 GUIDE TUBE ASY

GAUGE, OIL LEVEL

OIL DRAIN PUMP ASY

COCK, DRAIN

ADAPTER

RING, SEAL A26X32

SCREW, PLUG

Alternate

Website:

Related

DOOSAN DIESEL GENERATOR PARTS

Engine Parts contact

email: EngineParts@HeavyEquipmentRestorationParts.com

Alternate email: engineparts2@gmail.com

Website: www.Diesel-Generator-Engine-Parts.com

Related website: www.HeavyEquipmentRestorationParts.com Phone: 269 673 1638

DOOSAN DIESEL GENERATOR PARTS

22.0L DIESEL ENGINE

Alternate

22.0L DIESEL ENGINE COOLING FAN &

I22.0L DIESEL

22.0L DIESEL

22.0L DIESEL ENGINE TURBOCHARGER

Fuel

0432199952 Fuel filter assembly with hand primer pump, as shown in above picture

1 0432199960 Base, fuel filter base

filter element

0432199814 Cover, fuel filter

0432199803 Seal, fuel filter

0432199801 Retainer bolt, fuel filter

0432199811 Seal, fuel filter

DOOSAN DIESEL GENERATOR PARTS

ITEM 1010 1030 PART NUMBER OF94380325 OF94380326

DESCRIPTION

PIPE, FUEL INJECTION

PIPE, FUEL INJECTION

DOOSAN DIESEL GENERATOR PARTS

Engine Parts contact

email: EngineParts@HeavyEquipmentRestorationParts.com

Alternate email: engineparts2@gmail.com

Website: www.Diesel-Generator-Engine-Parts.com

Related website: www.HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

I 22.0L DIESEL ENGINE FUEL HOSE

0C46930477

0F94380364

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