TP-6594 - Atlantis Marine Power
Contents
1. 6210 9 3 8 16 Spiralock X 465 21 1 4 20 x 5 00 X 129 15 1 2 13 x 75 X 6210 10 3 8 24 Spiralock X 465 25 1 4 28 x 38 X 129 17 1 2 13 x 1 00 X 6210 11 7 16 14 Spiralock X 465 20 1 4 28 x 1 00 X 129 18 1 2 13 x 1 25 X 6210 12 1 2 13 Spiralock L 129 19 1 2 13 x 1 50 X 6210 15 7 16 20 Spiralock X 12 99 SE 129 20 1 2 13 x 1 75 X 6210 14 1 2 20 Spiralock X 125 23 5 16 18 x 62 X 125 3 5 16 18x 75 X 129 21 1 2 13 x 2 00 X 129 22 1 2 13 x 2 25 X 85 3 5 8 11 Standard 25 31 2 je 8x ze X 129 23 1 2 13 x 2 50 X 88 12 3 4 10 Standard 1299 3 16 18 x 1 X 129 24 1 2 13 x 2 75 X 89 2 1 2 20 Standard X 125 24 5 16 18 x 1 25 X 129 25 1 2 13 x 3 00 X 125 34 5 16 18 x 1 50 125 25 5 16 18 1 75 129 27 1 2 13 x 3 50 129 29 1 2 13 x 4 00 Washers X 125 26 5 16 18 x 2 00 X 129 30 1 2 13 x 4 50 230578 5 16 18 x 2 25 463 9 1 213 x 5 50 Bolt X 125 29 5 16 18 x 2 50 i Part No ID OD Thick Screw 125 27 5 16 18x 2 75 129 44 1 2 13x 6 00 X 125 28 5 16 18 x 3 00 X 129 51 1 2 20 x 75 X 25 46 125 250 022 4 X 125 32 5 16 18 x 5 00 X 129 52 1 2 20 x 1 50 X 25 48 188 438 049 8 X 125 35 5 16 18 x 5 50 25 36 219 500 049 10 X 125 36 5 16 18 x 6 00 X 6021 3 5 8 11 x 1 00 X 25 40 281 625 065 1 4 125 40 5 16 18 6 50 SE 2 E 25 85 344 687 065 5 16 E di x1 25 37 406 812 065 3 8 X 125 43 5 16 24 x 1 75 X 6021 1 5 8 11 x 1 75 5 2 25 34 469 922 065 7 16 X 125 44 5 16 24 x 2 50 273049 5 8 11 x 2 00 OR2. Qty Var Item Part No Description 1 1 X 309 11 Clamp hose 3 4 2 2 GM54739 Hose molded breather 1 3 GM24212 Arrestor flame 1 4 25 73 Washer plain 266 ID x 1 OD 2 5 X 50 13 Screw machine 2 6 M7985A 05100 20 Screw pan head machine 4 7 M125A 05 80 Washer plain 4 8 GM53162 Duct air intake 1 9 GM58016 Foam accoustic 1 10 GM58015 Panel air intake 1 11 GM53163 Cover air intake duct 1 12 X 50 13 Screw machine 6 18 X 25 36 Washer plain 219 ID x 5 in OD 4 14 GM23496 Screw thread forming 4 18 GM58156 C 6594 101 TP 6594 2 14 6594 2 14 Group 103 Fuel System GM58157 C 6594 103 Qty Var Item Part No Description 1 1 GM53090 Line fuel 1 2 GM59106 Module fuel pump 1 3 267987 Filter fuel 1 4 in NPT 1 4 X 447 7 Elbow male tube 90 deg vibra seal 1 5 GM59012 Line fuel 1 6 X 296 1 Fitting half union 1 7 M933 06025 60 Screw hex cap 5 8 GM59107 Pump assembly fuel 1 9 X 211 14 Elbow street 1 10 GM58847 Bracket fuel pump 1 19 Group 104 Cooling System 21 2224 O Des AS p d gt J i Y A us E 1 7 U E AS an AUC P NY E gt Y Si N 41 y A A e 12 gt 112 GERS L Ec Ry KJ SNE Si e Y 9 b 27222 6 7 N IN GM58158 M 6594_104 20 TP 6594 2 14 6594 2 14 Group
3. 28 ACCESSOM S er een 29 Appendix A Glossary of Abbreviations 33 Appendix B Common Hardware Application Guidelines 35 Appendix C General Torque Specifications 36 Appendix D Common Hardware Identification 37 Appendix E Common Hardware List 38 Introduction This manual lists service replacement parts for 5EKD AEFKD 10EKD 8EFKD generator sets Information in this publication represents data available at the time of print Kohler Co reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever This manual includes the following main sections Table of Contents Lists the sections of the manual Introduction and other information sections Contains introductory material about part numbers illustrations and hardware Index Lists the generator set specs and groups Group Parts Lists Listthe part numbers of parts in the groups Kit Sections List modules and accessories and their parts Appendices Include Abbreviations Common Hardware Application Guidelines General Torque Specifications Common Hardware Identification and Common Hardware List x in 004 002 Numbering System Significance This manual uses the following numbering systems Specification Number A six digit number with a PA prefix The Specification Number Index does not show the prefix Spec numbers br
4. 25 26 531 1 062 095 1 2 X 125 30 5 16 24 x 75 X 6021 5 5 8 11 x 2 25 25 15 656 1 312 095 5 8 X 125 39 5 16 24 x 2 00 X 6021 6 5 8 11 x 2 50 X 25 29 812 1 469 134 3 4 X 125 38 5 16 24 x 2 75 X 6021 7 5 8 11 x 2 75 X 25 127 1 062 2 000 134 1 X 6021 12 5 8 11 x 3 75 X 6238 2 3 8 16 x 62 X 6021 11 5 8 11 x 4 50 6238 10 3 8 16 75 6021 10 5 8 1 x 6 00 X 6238 3 3 8 16 x 88 95617 BESS X 6238 11 3 8 16 x 1 00 X 6021 9 5 8 18 x 2 50 X 6238 4 3 8 16 x 1 25 X 6238 5 3 8 16 x 1 50 X 6239 1 3 4 10 x 1 00 X 6238 1 3 8 16 x 1 75 X 6239 8 3 4 10 x 1 25 X 6238 6 3 8 16 x 2 00 X 6239 2 3 4 10 x 1 50 X 6238 17 3 8 16 2 25 X 6239 3 3 4 10 x 2 00 X 6238 7 3 8 16 x 2 50 X 6239 4 3 4 10 x 2 50 X 6238 8 3 8 16 x 2 75 X 6239 5 3 4 10 x 3 00 X 6238 9 3 8 16 x 3 00 X 6239 6 3 4 10 x 3 50 X 6238 19 3 8 16 3 25 X 792 1 1 8x 2 25 6238 20 3 8 16 3 75 X 792 8 1 8 x 5 00 X 6238 13 3 8 16 x 4 50 X 6238 18 3 8 16 x 5 50 X 6238 25 3 8 16 x 6 50 38 Appendix TP 6594 2 14 Hex head bolts are hardness grade 8 8 unless noted Part No Hex Head Bolts Partial Thread M931 05055 60 M931 06040 60 M931 06055 60 M931 06060 60 M931 06060 SS M931 06070 60 M931 06070 SS M931 06075 60 M931 06090 60 M931 06145 60 M931 06150 60 M931 08035 60 M931 08040 60 M931 08045 60 M931 08050 60 M931 08055 60 M931 08055 82 M931 08060 60 M931 08070 60 M931 08070 82 M931 08075 60 M931 08080 60 M931 08090 60 M931 08095 60
5. Accessories Qty Description Part No Circuit Breaker 18 A 1P Instructions installation Screw RHM Breaker circuit 18 A Plate cover Decal notice Guard circuit breaker Circuit Breaker 27 A 1P Instructions installation Screw RHM Breaker circuit 27 A Plate cover Decal notice Guard circuit breaker Circuit Breaker 85 1P Instructions installation Screw RHM Breaker circuit 85 A Plate cover Decal notice Guard circuit breaker Circuit Breaker 70A 1P Instructions installation Screw RHM Breaker circuit 85 A Plate cover Decal notice Guard circuit breaker Circuit Breaker 35A 2P Instructions installation Screw RHM Breaker circuit 33 A Decal notice Guard circuit breaker LH Guara circuit breaker RH Circuit Breaker 42A 2P Instructions installation Screw RHM Breaker circuit 42 A Decal notice Guard circuit breaker LH Guard circuit breaker RH Circuit Breaker 35A 1P Instructions installation Screw RHM Breaker circuit 35 A Plate cover Decal notice Guard circuit breaker Aa a VI Aaa a yo E ao a er eat A Sch ve pu 2 PA 359617 TT 875 49 25 X 506 68 229183 246242 GM48893 PA 359618 TT 875 49 25 X 506 58 229183 246242 GM48893 GM59907 KP1 TT 875 X 49 25 X 506 70 229183 246242 GM48893 GM59907 KP2 TT 875 49 25 X 506 48 229183 246242 GM48893 GM59907 KP3 TT 875 49 25 X 506 39 2
6. 23 24 393 53 S Kit Oil Pump Assembly 1 24 24 381 04 S Pick up Oil 1 25 2415301 S O ring Oil Pick up 1 26 24 153 08 S O ring 1 27 5205002 S Oil Filter 1 28 24 136 01 Nipple Oil Filter 1 29 25086 17 S Screw 1 30 24 086 17 5 Screw Flg M8x1 25x45 9 31 25 099 27 5 Switch Pressure 1 TP 6594 2 14 Group 3 Lubrication Before engine serial number 4112200011 TP 6594 2 14 Qty Var Item Part No Description 43 1 41153 01 S O ring 1 2 52 050 02 S Filter oil 1 3 25 099 27 S Switch oil pressure 1 Items not shown GM79149 Tube oil fill service kit for 24 123 24 1 25 038 07 Dipstick assembly Group 4 Valve Covers After engine serial number 4112200001 CRANKCASE Var Var Item Part No Description 41 Item Part No Description 41 6 66 096 11 S Kit Rocker Cover 2 20 25 445 02 S Strap lifting 2 7 66 041 09 S Gasket Valve Cover 2 23 24 755 66 S Kit Valve Train 4 8 12 755 03 S Kit retainer 4 24 25 351 10 S Kit hydraulic valve lifter 4 9 25 173 28 S Cap valve spring 4 25 24 411 05 S Rod Push 4 10 24 089 02 S Spring valve 4 27 66 318 02 S Kit cylinder head 2 1 11 235011 S Retainer spring 4 28 66 13901 5 Plug pipe 2 12 24 100 10 S Nut flg m8x1 25 8 29 25 186 01 S Arm Rocker 4 13 220534 S Washer flat 5 16 8 30 24 599 02 S Pivot Rocker Arm 4 14 66 032 05 S Seal valve stem 4 37 25 086 84 S Screw
7. Flg M6x1 0x55 2 15 66 318 01 S Kit cylinder head 1 1 38 24 402 03 S Reed breather 1 16 66 841 02 S Kit cylinder head gasket 39 66 018 04 S Retainer reed 1 includes 220534 S 24 041 49 40 M 545010 S Screw flg thd frm M5 x 8 x 10 1 24 100 10 S 66 041 05 S 2 41 24 050 11 S Filter breather 1 17 66 072 03 S Stud 8 42 24 033 01 S Kit Breather Assembly 1 18 24 017 01 S Valve intake std 2 43 24 041 67 S Gasket breather 1 18 24 017 02 S Valve intake 25 2 44 24 096 130 S Kit breather cover 1 19 24 016 01 S Valve exhaust std 2 45 25139 60 S Plug Ctsk Pipe 1 8 1 19 24 016 02 S Valve exhaust 25 2 46 25086 396 S Screw Thread Forming 4 M 640034 S Screw Flg M6x1 0x34 not shown 4 25 086 124 S Screw Flg M6x1 0x25 not shown 4 10 TP 6594 2 14 Group 4 Valve Covers Before engine serial number 4112200011 Qty Var Item Part No Description 34 1 66086 07 S Screw rocker arm pivot 4 2 M 651080 S Screw flg M6 x 1 0 x 80 2 3 25086 84 S Screw flg M6 x 1 0 x 55 2 4 66041 09 S Gasket valve cover 2 5 25086 124 S Screw flg M6 x 1 0 x 25 4 6 66 096 11 S Kit rocker cover includes 66 041 09 S 2 7 66 139 01 5 Plug pipe 2 8 24411 05 S Rod push 4 9 25 18601 5 Arm rocker 4 10 24 599 02 S Pivot rocker arm 4 TP 6594 2 14 11 Group 5 Ignition Item Part No Description 33 1 24 025 23 S Flywheel 1 2 25 155 41 S Connector 1 3 M 5
8. M931 08100 60 M931 08110 60 M931 08120 60 M931 08130 60 M931 08140 60 M931 08150 60 M931 08200 60 M931 10040 82 M931 10040 60 M931 10045 60 M931 10050 60 M931 10050 82 M931 10055 60 M931 10060 60 M931 10065 60 M931 10070 60 M931 10080 60 M931 10080 82 M931 10090 60 M931 10090 82 M931 10100 60 M931 10110 60 M931 10120 60 M931 10130 60 M931 10140 60 M931 10180 60 M931 10235 60 M931 10260 60 M960 10330 60 M931 12045 60 M960 12050 60 M960 12050 82 M931 12050 60 M931 12050 82 M931 12055 60 M931 12060 60 M931 12060 82 M931 12065 60 M931 12075 60 M931 12080 60 M931 12090 60 M931 12100 60 M931 12110 60 This metric hex bolt s hardness is grade 10 9 TP 6594 2 14 Dimensions M5 0 80 x 55 M6 1 00 x 40 M6 1 00 x 55 M6 1 00 x 60 M6 1 00 x 60 M6 1 00 x 70 M6 1 00 x 70 M6 1 00 x 75 M6 1 00 x 90 M6 1 00 x 145 M6 1 00 x 150 M8 1 25 x 35 M8 1 25 x 40 M8 1 25 x 45 M8 1 25 x 50 M8 1 25 x 55 M8 1 25 x 55 M8 1 25 x 60 M8 1 25 x 70 M8 1 25 x 70 M8 1 25 x 75 M8 1 25 x 80 M8 1 25 x 90 M8 1 25 x 95 M8 1 25 x 100 M8 1 25 x 110 M8 1 25 x 120 M8 1 25 x 130 8 1 25 x 140 M8 1 25 x 150 M8 1 25 x 200 M10 1 25 x 40 M10 1 50 x 40 M10 1 50 x 45 M10 1 50 x 50 M10 1 25 x 50 M10 1 50 x 55 M10 1 50 x 60 M10 1 50 x 65 M10 1 50 x 70 M10 1 50 x 80 M10 1 25 x 80 M10 1 50 x 90 M10 1 50 x 90 M10 1 50 x 100 M10 1 50 x 110 M10 1 50 x 120 M10 1 50 x 130 M10 1 50 x 140 M10 1 50 x 180 M10 1 50 x 235 M10
9. 1 39 GM90436 Switch flow 1 40 312 42 Hose 63 ID 1 21 Group 105 Engine Item 51 Engine Harness is Not Shown 6594 105 22 6594 2 14 Group 105 Engine Qty Qty Var Var Item Part No Description 1 Item Part No Description 1 1 X 651 32 Hose rubber 375 in ID 1 26 M931 08080 60 Screw hex cap 2 2 M933 06016 60 Screw hex cap M6 x 16mm 6 27 GM86399 Motor starter 12 V 1 3 M125A 06 80 Washer plain 16 28 M933 08016 60 Screw hex cap 1 4 X 6084 1 Clip J 1 29 X 22 16 Washer lock 326 ID x 883 in 1 5 X 426 9 Clamp hose 25 70 in 1 30 X 22 12 Washer lock 262 ID x 743 in 2 6 359653 Valve oil drain 3 8 18 NPT 1 31 GM53193 Bracket ignition coil Ih 1 7 GM66090 Bushing adapter 1 32 66041 05 S Gasket intake manifold 1 8 GM39601 Sensor coolant temperature 1 33 M933 06040 60 Screw hex cap 1 9 M933 06025 60 Screw hex cap 3 34 M931 06075 60 Screw hex cap 2 10 GM58727 Eye lifting 1 35 M931 06060 60 Screw hex cap 1 11 M933 05020 60 Screw hex cap 1 36 GM53181 Bracket crank position sensor 1 12 M125A 05 80 Washer plain 3 37 M7500D 05010 85 Screw metric thread forming 3 13 GM39604 Sensor TMAP 1 38 25 403 21 S Regulator rectifier 1 16 PS LH690 0018 Engine assy Kohler LH690 1 39 GM55325 Guard flywheel 1 17 2543507 Solenoid starter 1 40 X 25 124 Washer plain 266 ID x 1 in OD 3 18 X 22 5 Washer lock 326 ID
10. 21 24 017 01 S Valve intake std 2 21 24017 02 5 Valve intake 25 2 22 Crankcase not serviced 1 23 52 139 09 5 Plug cup 1 24 66 032 07 5 Seal camshaft 1 25 24 032 19 5 Seal oil helix lip 1 26 66 100 01 S Nut 1 27 66 431 03 5 Sleeve 1 28 52 139 02 S Plug hd pipe 3 8 2 29 24 380 16 5 Pin locating 2 30 24 067 24 S Connecting rod std 2 30 24 067 25 S Connecting rod 25 2 31 66 009 13 S Closure plate assembly includes 24 153 08 S 24 393 51 5 25 032 06 5 25 139 60 5 631005 M 645025 S 1 32 25 032 06 S Seal oil 1 33 24 153 08 S O ring 1 34 M 631005 S Washer flat 6 mm 2 35 M 645025 S Screw flg thd frm M6 x 1 0 x 25 2 36 24 393 51 S Kit oil pump assembly includes 24 153 01 S 24 381 04 S 1 37 24 15301 5 O ring oil pick up 1 38 24 381 04 S Pick up oil 1 39 24 13601 5 Nipple oil filter 1 40 25 139 60 5 Plug ctsk pipe 1 8 1 41 24 086 17 S Screw flg m8x1 25x45 10 42 66014 50 S Crankshaft assembly includes 52 139 09 S 1 43 52 139 09 S Plug cup 1 44 24 874 42 S Kit piston w ring set std includes 24 108 18 S 24 018 01 S qty 2 2 44 24 874 43 5 Kit piston w ring set 08 includes 24 108 19 S 24 018 01 S qty 2 2 44 24 874 44 S Kit piston w ring set 25 includes 24 108 20 S 24 018 01 S qty 2 2 44 24 874 45 S Kit piston w ring set 50 includes 24 108 21 S 24 018 01 S qty 2 2 45 24 108 18 S Ring set piston std 1 45 24
11. Decal notice 1 19 GM58163 Decal fuse panel 1 20 X 6276 1 Logo Kohler 1 21 344486 Decal CE 1 22 GM66934 Decal Emissions 1 23 GM71479 Decal Warning Explosion 1 TP 6594 2 14 23 Group 109 Skid and Mounting Qty Var Part No Description 1 1 X 101 13 Nut hex elastic stop 3 8 16 2 2 X 25 37 Washer plain 406 ID x 812 in OD 2 3 GM40264 Support engine 1 4 X 6210 2 Nut flange spiralock 1 4 20 1 5 X 22 11 Washer lock 262 ID x 469 OD 2 6 LK 0606 1515 Lead 1 7 X 22 12 Washer lock 262 ID x 743 in OD 2 8 GM40263 Tray drip 1 9 X 6210 7 Nut flange spiralock 5 16 18 8 10 M933 08020 60 Screw hex cap 4 11 X 25 85 Washer plain 344 ID x 687 in OD 8 12 GM31230 Mount anti vibration 4 13 M982 08 80 Nut hex elastic stop 8mm 4 14 M933 06016 60 Screw hex cap M6 x 16mm 1 24 GM58161 A 6594 109 TP 6594 2 14 Item 24 Note Install Service Kit GM90489 to provide enhanced monitoring of the raw water cooling system Installation of this kit involves removing the exhaust temperature switch replacing relocating the seawater pressure switch to the non service side of the unit and adding a seawater flow switch and relay See TT 1617 for instructions TP 6594 2 14 Group 116 Exhaust Service Side 6594 116 Qty Var Item Part No Description 1 1 GM53046 Catalyst assembly 1 2 M933 06025 60 Screw hex cap 4 3 M125A 06 80 Washer plain 4
12. M125A 14 80 M125A 16 80 M125A 18 80 M125A 20 80 M125A 24 80 Dimensions M3 0 50 M4 0 70 M4 0 70 5 0 80 M6 1 00 M6 1 00 M6 1 00 M6 1 00 M8 1 25 M8 1 25 M8 1 25 M10 1 50 M10 1 25 M10 1 50 M10 1 50 M10 1 50 M12 1 75 M12 1 25 M12 1 75 M12 1 75 M14 2 00 M16 2 00 M16 2 00 M18 2 5 M18 2 50 M20 2 50 M20 2 50 M22 2 50 M24 3 00 M24 3 00 M30 3 50 ID OD 32 7 0 4 3 9 0 5 3 10 0 6 4 12 0 8 4 16 0 10 5 20 0 13 0 24 0 15 0 28 0 17 0 30 0 19 0 34 0 21 0 37 0 25 0 44 0 Type Standard Standard Brass Standard Standard Std green Spiralock Elastic Stop Standard Spiralock Elastic Stop Standard Standard Spiralock Spiralockt Elastic Stop Standard Standard Spiralock Elastic Stop Elastic Stop Spiralock Elastic Stop Standard Elastic Stop Standard Elastic Stop Standard Standard Elastic Stop Standard Bolt Thick Screw 05 M3 08 M4 10 M5 16 M6 16 M8 2 0 M10 25 M12 25 M14 M16 M18 3 0 M20 4 0 M24 This metric hex nut s hardness is grade 8 40 Appendix TP 6594 2 14 Notes 6594 2 14 Appendix 41 6594 2 14 2009 2014 Kohler All rights reserved KOHLER Power Systems KOHLER CO Kohler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales and service outlet in the US and Canada phone 1 800 544 2444 KohlerPower com Kohler Power Systems Asia Pacific Hea
13. amp o s JI 2 15 01 2 6 8 5 gt dag XY 101 103 104 105 107 109 116 201 701 Spec No Variation Number 5EKD 4EFKD GM47636 GA1 1 1 1 1 1 1 1 1 21 7 5EKD 6EFKD GM47636 GA2 1 1 1 1 1 1 1 2 22 10EKD 8EFKD GM47636 GA3 1 1 1 1 1 1 1 3 23 TP 6594 2 14 Group 1 Crankshaft After engine serial number 4112200001 Qty Var Item Part No Description 25 1 66 014 318 S Crankshaft Non thrust Style 1 2 52 139 09 S Plug Cup 1 Before engine serial number 4112200011 See Group 11 TP 6594 2 14 5 Group 2 Crankcase After engine serial number 4112200001 Item Part No Description 11 Crankcase not serviced 2 25 139 62 S Plug Pipe Ctsk 3 8 2 3 66032 07 S Seal Camshaft 1 4 X 42 2 S Key 3 32 X 3 8 1 5 66 093 01 S Sprocket Camshaft 1 6 X 25 52 S Washer Flat 1 4 1 7 M 651020 S Screw Flg M6x1 0x20 1 8 24 032 19 S Seal Oil Helix Lip 1 9 52 139 02 S Plug Hd Pipe 3 8 2 13 24 380 16 S Pin Locating 2 14 24 067 30 S Rod Assy Connecting Std 2 15 24 874 43 S Kit Piston Assy W Ring Set 08 1 15 24 874 44 S Kit Piston Assy W Ring Set 25 1 15 24 874 45 S Kit Piston Assy W Ring Set 5 1 16 24 108 18 S Ring Set Piston Std 2 17 2401801 S Retainer Piston Pin 4 18 6601201 S Kit Camshaft 1 19 12 422 07 S Shim Camshaft White 028 1 19 12 422 08 S Shim
14. equipment ground gross weight height by width by depth hex cap high cylinder head temperature heavy duty high exhaust temperature high engine temperature hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output iron pipe International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin Appendix 33 kg kg cm2 kgm kg m3 kHz kJ km kOhm kO kPa kph kV kVA kVAR kW kWh L LAN LxWxH Ib Ibm ft3 LCB LCD Id shd LED Lph Lpm LOP LP LPG LS Lwa LWL LWT m M m3 m9 min mA man max MB MCM MCCB meggar MHz mi mil min misc MJ mJ mm mOhm m9 MOhm MQ MOV MPa mpg mph MS m sec MTBF kiloampere kilobyte 210 bytes kilogram kilograms per square centimeter kilogram meter kilograms per cubic meter kilohertz kilojoule kilometer kilo ohm kilopascal kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt hour kilowatt mechani
15. nptx 75 X 217 6 Remote Digital Gauge GM32337 KP1 1 Decal waring 249494 1 Gauge digital GM30565 1 Harness remote GM32325 1 Installation Instructions TT 1364 1 Installation Instructions TT 1379 Remote Digital Gauge 3 Smartcraft GM46035 KP1 1 Decal warning 249494 1 Gauge Digital GM45905 1 Harness Smartcraft GM46123 1 Diagram Accessory Interconnection GM47635 1 TT ADC 2100 Controller Replacement TT 1364 1 TT Digital Gauge 5 7 3ECD 8 4 6EFCD 1429 30 Qty Description Part No Remote Digital Gauge 2 Smartcraft GM50822 KP1 1 Decal warning 249494 1 Diagram Accessory Interconnection GM47635 1 Gauge Digital CAN 2 Inch GM50577 1 Harness Remote Digital CAN Gauge GM50821 1 TT ADC 2100 Controller Replacement TT 1364 1 TT 2 Digital Gauge ECD EGD EGZD TT 1450 Remote Start Panel 12V GM32335 KP1 TT Rmt Start Panel TT 1378 Decal warning 249494 Panel assy control 12V includes the following GM33848 1 2 Nut hex 3 mm M934 03 50 2 Washer lock 146 ID x 285 in OD 22 6 1 Panel control GM33847 1 Harness wiring panel assy control GM33851 1 Meter run time 10000 hour 238736 1 Switch rocker 12V GM33849 2 Screw pan head 12 M7985A 03012 20 Ship to Shore Switch 2 Wire PAA 246614 1 Switch transfer 344490 1 Instructions installation TT 535 Ship to Shore Switch 3 Wire PAA 246617 1 Switch transfer A 246617 1 Instructions installation TT 535 6594 2 14 Sound Shield Kits Kits GM55219 KP1 and
16. x 62 OD 1 41 GM35951 Screw wing 3 19 M125A 08 80 Washer plain 8 4 ID x 16 0 OD 4 42 M7985A 05016 20 Screw pan head machine 2 20 M934 08 60 Nut hex 1 43 GM39600 Sensor crankshaft position 1 21 238915 Boot 1 44 GM39605 Governor 32 mm electronic air 1 22 GM39902 Wire spark plug 2 45 GM42275 O ring 1 23 M931 06045 82 Screw hex cap metric 4 46 M931 06090 60 Screw hex cap 2 24 GM39603 Coil ignition 2 47 GM53154 Intake assembly air 1 25 X 400 28 Spacer 282 ID x 5 OD x 531 4 47 1 GM84052 Injector 1 in 49 66041 05 S Gasket intake manifold 1 50 GM53192 Bracket ignition coil rh 1 50 X 6216 1 Screw Phillips hex crimptite 2 51 GM58614 Harness engine 5 7 5 10 kW 1 Group 107 Nameplate and Decals Qty Var Item Part No Description 1 1 224233 Decal 1 800 number 1 2 226917 Decal negative battery connection 1 3 238162 Decal pos battery connection 1 4 239796 Decal warning 1 5 249494 Decal warning 1 6 249808 Decal warning rotating parts 1 7 249809 Decal caution hot engine 1 8 249810 Decal warning hot coolant 1 9 294520 Decal danger high voltage 1 10 344282 Decal notice 1 11 344295 Decal equipment grd 1 12 359282 Tag hang 1 13 359446 Nameplate model ratings Kohler 2 14 GM13680 Nameplate Overlay 500 per roll 2 15 GM14167 Decal drain 1 16 GM35838 Decal 4 wire reconnection 1 17 GM40626 Decal low CO emissions 1 18 GM48037
17. x 30 M5 0 80 x 35 M5 0 80 x 50 M6 1 00 x 10 M6 1 00 x 12 M6 1 00 x 14 M6 1 00 x 16 M6 1 00 x 20 M6 1 00 x 25 M6 1 00 x 30 M6 1 00 x 40 M6 1 00 x 50 M7 1 00 x 25 M8 1 25 x 10 M8 1 25 x 12 M8 1 25 x 16 8 1 25 x 20 M8 1 25 x 25 8 1 25 x 30 8 1 25 305 10 1 50 12 10 1 25 20 10 1 50 20 10 1 50 25 10 1 25 25 10 1 50 25 10 1 25 30 10 1 50 30 10 1 50 30 10 1 25 35 10 1 50 35 10 1 50 355 M10 1 25 x 40 Part No Dimensions Hex Head Bolts Full Thread continued M933 12016 60 M933 12020 60 M961 12020 60F M933 12025 60 M933 12025 82 M961 12030 60 M933 12030 82 M961 12030 82F M933 12030 60 M933 12035 60 M961 12040 82 M933 12040 60 M933 12040 82 M961 14025 60 M933 14025 60 M961 14050 82 M961 16025 60 M933 16025 60 M961 16030 82 M933 16030 82 M933 16035 60 M961 16040 60 M933 16040 60 M961 16045 82 M933 16045 82 M933 16050 60 M933 16050 82 M933 16060 60 M933 16070 60 M933 18035 60 M933 18050 60 M933 18060 60 M933 20050 60 M933 20055 60 M933 24060 60 M933 24065 60 M933 24070 60 M12 1 75 x 16 M12 1 75 x 20 M12 1 50 x 20 M12 1 75 x 25 M12 1 75 x 25 M12 1 25 x 30 M12 1 75 x 30 M12 1 50 x 30 M12 1 75 x 30 M12 1 75 x 35 M12 1 25 x 40 M12 1 75 x 40 M12 1 75 x 40 M14 1 50 x 25 M14 2 00 x 25 M14 1 50 x 50 M16 1 50 x 25 M16 2 00 x 25 M16 1 50 x 30 M16 2 00 x 30 M16 2 00 x 35 M16 1 50 x 40 M16 2 00 x
18. 1 42 GM49746 Relay 12 VDC 4 4 4 43 X 70 3 Nut hex machine screw 10 32 4 4 4 44 GM42340 Block fuse 1 1 1 45 X 67 64 Screw self tapping 8 8 8 46 GM40266 Box junction 1 1 1 47 X 6266 1 Connector cable 1 1 1 48 GM90654 Harness j box includes items 44 52 55 1 1 1 49 X 49 26 Screw machine 4 4 4 50 X 6210 3 Nut flange whiz 6 32 4 4 4 51 X 25 36 Washer plain 219 ID x 5 in OD 4 4 4 52 GM42337 Fuse 10 Amp 1 1 1 53 GM42339 Fuse 25 Amp 1 1 1 54 GM42337 Fuse 10 Amp 1 1 1 55 GM47427 Fuse 20 Amp 1 1 1 27 Group 701 Literature Qty Var Item Part No Description 21 22 23 1 TP 6691 Warranty Marine 32 kW amp Below 1 1 1 2 TP 5620 Safety Precautions Marine 1 1 1 3 TP 6592 5 10EKD and 4 8EFKD Marine 1 1 1 4 TP 6594 P C 5 10EKD and 4 8EFKD Mairne 1 1 1 5 66 590 02 LH Aegis Owners s Manual 1 1 1 6 66690 01 LH630 775 Engine Service Manual 1 1 1 7 TP 6591 O M 5 10EKD and 4 8EFKD Marine 1 1 1 8 TP 6593 S M 5 10EKD and 4 8EFKD Marine 1 1 1 9 TP 6884 Warranty CARB EPA Emissions SORE 1 1 1 Paint and Miscellaneous Parts Part Number Description 1 GM48126 White paint spray can Matterhorn White 28 TP 6594 2 14 Qty Description Part No Circuit Breaker Kits Circuit Breaker 40 A 1P Instructions installation Screw RHM Breaker circuit 40 A Plate cover Decal notice Guard circuit breaker Circuit Breake
19. 1 50 x 260 M10 1 25 x 330 M12 1 75 x 45 M12 1 25 x 50 M12 1 25 x 50 M12 1 75 x 50 M12 1 75 x 50 M12 1 75 x 55 M12 1 75 x 60 M12 1 75 x 60 M12 1 75 x 65 M12 1 75 x 75 M12 1 75 x 80 M12 1 75 x 90 M12 1 75 x 100 M12 1 75 x 110 Part No Hex Head Bolts Partial Thread continued M960 16090 60 M931 16090 60 M931 16100 60 M931 16100 82 M931 16120 60 M931 16150 60 M931 20065 60 M931 20090 60 M931 20100 60 M931 20120 60 M931 20140 60 M931 20160 60 M931 22090 60 M931 22120 60 M931 22160 60 M931 24090 60 M931 24120 60 M931 24160 60 M931 24200 60 Dimensions M16 1 50 x 90 M16 2 00 x 90 M16 2 00 x 100 M16 2 00 x 100 M16 2 00 x 120 M16 2 00 x 150 M20 2 50 x 65 M20 2 50 x 90 M20 2 50 x 100 M20 2 50 x 120 M20 2 50 x 140 M20 2 50 x 160 M22 2 50 x 90 M22 2 50 x 120 M22 2 50 x 160 M24 3 00 x 90 M24 3 00 x 120 M24 3 00 x 160 M24 3 00 x 200 Hex Head Bolts Full Thread M933 04006 60 M933 05030 60 M933 05035 60 M933 05050 60 M933 06010 60 M933 06012 60 M933 06014 60 M933 06016 60 M933 06020 60 M933 06025 60 M933 06030 60 M933 06040 60 M933 06050 60 M933 07025 60 M933 08010 60 M933 08012 60 M933 08016 60 M933 08020 60 M933 08025 60 M933 08030 60 M933 08030 82 M933 10012 60 M961 10020 60 M933 10020 60 M933 10025 60 M961 10025 60 M933 10025 82 M961 10030 60 M933 10030 60 M933 10030 82 M961 10035 60 M933 10035 60 M933 10035 82 M961 10040 60 M4 0 70 x 6 5 0 80
20. 104 Cooling System Qty Var Item Part No Description 1 1 GM55092 Hose molded seawater 1 2 X 426 12 Clamp hose 69 1 25 in 2 3 GM90472 Connector hose 2 4 GM81619 Connector Hose 5 8 x 1 2 NPT Nickel 1 5 X 426 19 Clamp hose 1 2 in 2 6 X 356 40 Hose radiator 1 7 X 426 9 Clamp hose 25 70 in 2 8 X 386 79 Hose 1 9 M933 06020 60 Screw hex cap 2 10 M125A 06 80 Washer plain 2 11 254922 Valve 1 12 X 391 3 Connector 90 deg 5 16 in ID hose 1 13 GM64136 Thermostat assembly 1 14 GM52628 Cover thermostat 1 15 GM53040 Belt V 1 16 GM63535 Pump sea water 1 17 X 426 12 Clamp hose 69 1 25 in 2 18 X 691 24 Hose 1 19 X 582 11 Connector hose vibra seal 1 20 GM66045 Bracket seawater pump mounting 1 21 GM55025 Guard pump pulley 1 22 GM66046 Bracket pump pulley guard 1 23 M933 08020 60 Screw hex cap 1 24 M125A 08 80 Washer plain 8 4 ID x 16 0 OD 3 25 M933 08030 60 Screw hex cap 1 26 M6923 08 80 Nut hex 8mm 1 27 M933 08020 60 Screw hex cap 1 28 X 426 12 Clamp hose 69 1 25 in 2 29 GM53086 Hose molded coolant 1 30 GM81621 Connector hose vibra seal 1 31 X 426 12 Clamp hose 69 1 25 in 2 32 312 43 Hose 63 ID 1 33 386 113 Coolant line flexible 1 34 X 426 9 Clamp hose 25 70 in 2 35 359037 Bottle overflow 1 36 GM53434 Bracket water bottle 1 37 359978 Impeller kit seawater pump 1 38 66 041 01 S Gasket thermostat
21. 108 19 S Ring set piston 08 1 45 24 108 20 S Ring set piston 25 1 45 24 108 21 S Ring set piston 50 1 46 24 018 01 S Retainer piston pin 4 47 66 012 01 S Kit camshaft 1 48 12 422 07 S Shim camshaft white 028 AR 48 12 422 08 S Shim camshaft blue 03 AR 48 12 422 09 5 Shim camshaft red 032 AR 48 12 422 10 S Shim camshaft yellow 034 AR 48 12 422 11 S Shim camshaft green 036 AR 48 12 422 12 S Shim camshaft gray 038 AR 48 12 422 13 S Shim camshaft black 04 AR TP 6594 2 14 15 Group 12 Engine Nameplate and Decals Artwork is representative Actual decals may differ depending on model and specification number 12 66 22 Qty Var Item Part No Description 22 1 25 113 39 5 Decal clear laminate 1 16 TP 6594 2 14 6594 2 14 Group 13 Engine Cooling System 13 66 16 Qty Var Item Part No Description 16 1 66237 07 S Clamp 1 2 66 123 10 5 Tube crossover rubber il 3 25237 12 S Clamp hose 3 4 66123 09 S Tube crossover metal 1 5 66 203 01 S Belt water 1 6 M 651040 S Screw flg M6 x 1 0 x 40 1 7 M 651020 S Screw flg M6 x 1 0 x 20 5 8 66 093 04 S Pulley crankshaft 2 9 M 851030 S Screw flg M8 x 1 25 x 30 4 10 66 422 14 S Shim crankshaft pulley 2 11 25 139 60 5 Plug ctsk pipe 1 8 1 12 66 393 01 S Pump water 1 13 66 153 01 S O ring 1 17 Group 101 Air Intake
22. 4 GM53049 Gasket exhaust 1 5 M912 08045 60 Screw socket head cap 4 6 X 55 36 Screw hex socket hd mach 1 7 GM53065 Manifold subassy exhaust 1 8 M125A 06 80 Washer plain 6 9 M933 06016 60 Screw hex cap M6 x 16mm 6 10 GM55073 Cap exhaust manifold end 2 11 GM52996 Exchanger heat 1 12 GM53066 O ring 2 13 GM52587 Manifold exhaust 1 14 GM54744 Switch pressure assembly 1 16 260085 Kit zinc anode 1 17 241311 Filler neck 1 18 229980 Cap radiator 13 14 psi 1 19 X 380 5 Connector hose vibra seal 1 20 GM39602 Sensor heated 02 1 21 X 75 52 Plug pipe 1 4 in NPTF 1 22 X 75 4 Plug pipe 1 8 in NPTF 1 23 24041 49 S Gasket exhaust 2 24 See Note 25 Group 201 Generator and Mounting o 9 e o 5 LL m o gt GM58162 A 6594_201 TP 6594 2 14 26 6594 2 14 Group 201 Generator and Mounting Quantity Variation Item Part No Description 1 2 3 1 GM53151 Cover junction box 1 1 1 2 X 6216 1 Screw Phillips hex crimptite 6 6 6 3 GM64134 Panel junction box 1 1 1 4 GM83744 Controller ADCII Service Replacement 1 1 1 5 X 25 115 Washer plain 203 ID x 438 in OD 4 4 4 6 X 117 5 Screw hex head machine 4 4 4 7 238426 Fuse holder 25 x 1 25 in 1 1 1 8 358337 Fuse 10 A 250 V 1 1 1 10 359403 Guard fan 1 1 1 11 X 6210 1 Nut flange whiz 10 32 2 2 2 12 X 22 9
23. 40 M16 1 50 x 45 M16 2 00 x 45 M16 2 00 x 50 M16 2 00 x 50 M16 2 00 x 60 M16 2 00 x 70 M18 2 50 x 35 M18 2 50 x 50 M18 2 50 x 60 M20 2 50 x 50 M20 2 50 x 55 M24 3 00 x 60 M24 3 00 x 65 M24 3 00 x 70 Pan Head Machine Screws M7985A 03010 20 M7985A 03012 20 M7985A 04010 20 M7985A 04016 20 M7985A 04020 20 M7985A 04050 20 M7985A 04100 20 M7985A 05010 20 M7985A 05012 20 M7985A 05016 20 M7985A 05020 20 M7985A 05025 20 M7985A 05030 20 M7985A 05080 20 M7985A 05100 20 M7985A 06100 20 M3 0 50 x 10 M3 0 50 x 12 M4 0 70 x 10 M4 0 70 x 16 M4 0 70 x 20 M4 0 70 x 50 M4 0 70 x 100 M5 0 80 x 10 M5 0 80 x 12 M5 0 80 x 16 M5 0 80 x 20 M5 0 80 x 25 M5 0 80 x 30 M5 0 80 x 80 M5 0 80 x 100 M6 1 00 x 100 Flat Head Machine Screws M965A 04012 SS M965A 05012 SS M965A 05016 20 M965A 06012 20 M4 0 70 x 12 M5 0 80 x 12 5 0 80 x 16 M6 1 00 x 12 Appendix 39 Metric continued Part No Hex Nuts M934 03 50 M934 04 50 M934 04 B M934 05 50 M934 06 60 M934 06 64 M6923 06 80 M982 06 80 M934 08 60 M6923 08 80 M982 08 80 M934 10 60 M934 10 60F M6923 10 80 M6923 10 62 M982 10 80 M934 12 60 M934 12 60F M6923 12 80 M982 12 80 M982 14 60 M6923 16 80 M982 16 80 M934 18 80 M982 18 60 M934 20 80 M982 20 80 M934 22 60 M934 24 80 M982 24 60 M934 30 80 Washers Part No M125A 03 80 M125A 04 80 M125A 05 80 M125A 06 80 M125A 08 80 M125A 10 80 M125A 12 80
24. 46242 GM48894 GM48895 GM59907 KP4 TT 875 49 25 X 506 43 246242 GM48894 GM48895 GM59907 KP5 TT 875 49 25 X 506 46 229183 246242 GM48893 29 Accessories continued Circuit Breaker 35A 2P GM59907 KP6 1 Instructions installation TT 875 2 Screw RHM X 49 25 1 Breaker circuit 35 A X 506 42 1 Terminal jumper 249956 1 Decal notice 246242 1 Guard circuit breaker LH GM48894 1 Guard circuit breaker RH GM48895 Circuit Breaker 35A 2P GM59907 KP7 1 Instructions installation TT 875 2 Screw RHM X 49 25 1 Breaker circuit 42 A X 506 43 1 Terminal jumper 249956 1 Decal notice 246242 1 Guard circuit breaker LH GM48894 1 Guard circuit breaker RH GM48895 Electrical System Kits Harness 12 In Pigtail GM32332 KP1 1 Harness pigtail GM32324 Harness 15 Ft Remote Panel GM32333 KP1 1 Harness extension GM30248 Harness 25 Ft Remote Panel GM32333 KP2 1 Harness extension GM32323 Harness 30 Ft Remote Panel GM32333 KP3 1 Harness extension GM45889 Harness Y Connection GM32333 KP5 1 Harness Y remote gauge GM49054 Oil Pressure Sender GM62803 KP1 1 Fitting 45 deg Street Elbow 267428 1 Sensor Pressure GM33945 Oil Pressure amp Water Temp Sender GM62803 KP2 1 Sender water temperature 249287 1 Fitting 45 deg Street Elbow 267428 1 Sender oil pressure 343473 1 Tee pipe 1 8 x 1 8 x 1 8 npt X 203 10 1 Elbow pipe 90 deg x 1 8 npt X 215 19 1 Pipe Nipple 1 8 NPT x 1 50 X 217 2 1 Pipe 1 8
25. 48025 S Screw thd frm 5 x 0 8 x 25 2 4 12086 14 S Screw flg M10 x 1 5 x 45 1 5 12468 03 S Washer flat 13 32 1 6 X 42 15 S Key 3 16 x 5 8 1 7 25132 16 S Plug spark 2 Items not shown 47 085 11 Stator assembly 1 Group 7 Starting Qty Var Item Part No Description 4 1 M 851030 S Screw flg M8 x 1 25 x 30 1 2 66 146 54 5 starter 1 Group 105 Engine for starter motor number 12 TP 6594 2 14 Notes TP 6594 2 14 13 Group 11 Long Block 66 003 26 14 6594 2 14 Group 11 Long Qty Var Item Part No Description 1 1 66318 02 5 Kit cylinder head 2 1 2 25 445 02 5 Strap lifting 2 3 66841 02 S Kit cylinder head gasket includes 220534 S 24 041 49 24 100 10 S 66 041 05 S 2 4 66072 03 S Stud 8 5 25 351 04 S Kit hydraulic valve lifter 4 6 24 402 03 S Reed breather 1 7 66 018 04 5 Retainer reed 1 8 M 545010 S Screw flg thd frm M5 x 8 x 10 1 9 24 050 11 S Filter breather 1 10 24 041 64 S Gasket breather 1 11 24 096 86 S Kit breather cover 1 12 12 755 03 S Kit retainer 4 13 12 173 01 S Cap valve spring 4 14 24 089 02 S Spring valve 4 15 235011 Retainer spring 4 16 66 032 05 S Seal valve stem 4 17 24 100 10 S Nut flg m8x1 25 8 18 220534 S Washer flat 5 16 8 19 66 318 01 S Kit cylinder head 1 1 20 24016 01 S Valve exhaust std 2 20 24016 02 S Valve exhaust 25 2
26. AC VAR VDC VED VGA VHF WCR w o xfmr relay root mean square round read only memory rotate rotating revolutions per minute right side room temperature vulcanization Society of Automotive Engineers standard cubic feet per minute silicon controlled rectifier second Systeme international d unites International System of Units side in end out silencer serial number single pole double throw single pole single throw specification s square square centimeter square inch stainless steel standard steel tachometer time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal telephone influence factor total indicator reading tolerance turbocharger typical same in multiple locations underfrequency ultrahigh frequency Underwriter s Laboratories Inc unified coarse thread was NC unified fine thread was NF universal undersize underspeed ultraviolet undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer TP 6594 2 14 Appendix Common Hardware Application Guidelines Use the information below and on the following pages to identify
27. Camshaft Blue 03 1 19 12 422 09 S Shim Camshaft Red 032 1 19 12 422 10 S Shim Camshaft Yellow 034 1 19 12422 11 5 Shim Camshaft Green 036 1 19 12422 12 S Shim Camshaft Gray 038 1 19 12422 13 S Shim Camshaft Black 04 1 25 52139 09 S Plug Cup 1 66 431 03 S Sleeve Not Shown 1 66 100 01 S Nut Not Shown 1 6 TP 6594 2 14 Group 2 Crankcase Before engine S N 4112200011 amp After S N 3932200001 Item Part No Description 32 1 25 139 62 5 Plug ctsk 3 8 2 2 X 42 2 S Key 3 32 x 3 8 1 3 X 25 52 S Washer flat 1 4 1 4 M 651020 S Screw flg m6x1 0x20 1 5 66093 01 S Sprocket camshaft 1 Before engine serial number 3832100011 Item Part No Description 28 1 25 139 62 S Plug pipe ctsk 3 8 2 2 42 2 5 3 32 3 8 1 3 25 52 5 Washer flat 1 4 1 4 M 651020 S Screw flg m6x1 0x20 1 5 66093 01 S Sprocket camshaft 1 TP 6594 2 14 Group 3 Lubrication After engine serial number 4112200001 Qty Var Item Part No Description 50 1 2503807 Dipstck Assembly 1 2 24 009 213 S Closure Plate Assembly service 1 5 GM79149 Tube oil fill service kit for 24 123 24 1 6 41 15301 5 O ring 1 14 25 032 06 S Seal 1 16 25 139 60 S Plug Ctsk Pipe 1 8 1 21 25 086 401 S Screw Thread Forming 2 22 X 25 53 S Washer Flat 1 4 O d 5 8 2
28. GM55219 KP2 Accessories continued A ch S ch S ch ch Es k k 1 1 1 8 2 1 4 6 1 2 2 4 1 1 1 1 1 1 1 2 2 4 1 1 2 1 3 Description Bracket subassembly Boot battery lug Harness extension 18 in Foam acoustic 6 5 x 7 in Foam acoustic 1 7 x 5 25 in Foam acoustic 0 78 x 1 4 in Foam acoustic 1 3 x 7 5 in Base Door service side RH Door engine end front 15 8 x 17 2 in Door nonservice side LH Panel bulkhead connection Panel exhaust 5 5 x 10 in Door generator end rear 11 5 x 12 8 in Roof Decal fuse panel Panel controller 8 3 x 15 8 in Panel junction box 6 4 x 11 2 in Screw Hex Head Machine Screw Hex Head Machine Washer plain 0 203 ID x 0 438 in OD Washer plain 0 406 ID x 0 812 in OD Washer plain 0 281 ID x 0 625 in OD Connector 90 Clamp hose 0 69 1 25 in Clamp hose 0 25 0 70 in Bolt hex cap 1 4 20 x 0 5 in Cable tie Cable battery red 21 in Cable battery black 18 5 in Fitting hose connector Connector hose Conduit convoluted 19 in Conduit convoluted 16 in Channel U 7 5 in Nut flange spiralock 1 4 20 Bolt hex cap 3 8 16 x 0 625 Line flex fuel 6 in Bushing 0 672 x 0 875 in NPT Clamp insulated 1 06 in Hose 35 in Screw Hex Head Machine 6594 2 14 Common Parts 359435 GM20748 GM42846 GM64350 G
29. Identify the group most likely to include the service part number 5 Find the group variation number at the intersection of the spec number row and the group column Note the variation number 6 Page forward to locate the group identified in step 4 or find the appropriate page in the Table of Contents 7 Findthe part onthe illustration and note the item number of the part or find the part description in the parts list 8 Select the part number that corresponds to your group variation The first column lists the illustration item number Find the variation identified in the Specification Number Index or the module number found on the generator set nameplate in the appropriate column on the right side ofthe parts listtable Find the quantity used at the intersection of the item number row and the variation column A blank space atthe intersection means the variation module does not use that part number x in 004 005 Hardware References Many common hardware items do not appear in parts manuals or will appear as common hardware entries A common hardware entry lists the size of the hardware For example an item that appears as Hardware 3 8 16 in the text means that the piece is 3 8 16 size Obtain common hardware locally or if contacting the factory use the Common Hardware List in the appendix to identify the common hardware part number and specifications See Common Hardware Application Guidelines in the appendix for mating h
30. M64351 GM64352 GM64353 GM55254 GM55257 GM55258 GM55259 GM58163 GM64073 GM64135 791 13 791 12 25 115 25 37 25 40 391 1 426 12 X 426 9 X 465 6 X 468 1 545 214 545 215 582 42 585 45 X 6008 37 6003 5 6047 27 6210 2 6238 2 6251 31 634 25 672 30 691 30 791 14 Unique Parts GM55219 KP1 GM55223 19 7 x 30 4 in GM55252 15 75 x 22 in GM55255 16 x 30 4 in GM55260 19 7 x 30 4 in GM55219 KP2 GM55224 19 7 x 31 5 in GM55253 15 75 x 23 in GM55256 16 x 31 5 in GM55261 19 7 x 31 5 in 31 Accessories continued Siphon Break Hose Connection 32 42 2222 A GM60007 KP1 Connector hose 344934 Hose 62 in ID X 312 16 Hose 62 in ID X 312 61 Grommet round X 284 7 Clamp hose 56 1 06 in X 426 3 Clamp hose 25 70 in X 426 9 Tubing clear flexible plastic GM34883 Valve siphon break includes the following GM32985 Valve duct 328666 Cap siphon valve GM32984 Loop siphon valve vent GM32988 Qty Description Part No Miscellaneous Kits Drip Tray Stainless 1 Tray Stainless Steel Dri Lifting Eye Tool 1 Eye lifting Sea Water Strainer 1 Filter water 1 2 in Siphon Break 1 Clamp hose 0 25 0 70 in 1 Installation Instructions 1 Tubing clear flexible plastic 1 Valve assy siphon break includes the following 1 Valve duct 1 Cap siphon
31. Major Thread Diameter In Fractional Inches Or Screw Number Size Metric Screws Bolts Studs and Nuts M8 1 25 x 20 L Length In Millimeters Screws and Bolts Distance Between Threads In Millimeters Major Thread Diameter In Millimeters TP 6594 2 14 Metric Number stamped on hardware 5 8 shown Plain Washers 9 32 x 5 8 x 1 16 L Thickness External Dimension Internal Dimension Lock Washers 5 8 Internal Dimension Appendix 37 Appendix Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items American Standard Part No Dimensions Part No Dimensions Part No Dimensions Hex Head Bolts Grade 5 Hex Head Bolts cont Hex Nuts X 465 17 1 4 20 x 38 X 6238 14 3 8 24 75 X 6009 1 1 8 Standard X 465 6 1 4 20 x 50 X 6238 16 3 8 24 1 25 X 465 2 1 4 20 x 62 X 6238 21 3 8 24 x 4 00 X 6210 3 6 32 Whiz X 465 16 1 4 20 75 X 6238 22 3 8 24 4 50 6210 4 8 32 Whiz X 465 18 1 4 20 x 88 X 6210 5 10 24 Whiz X 465 7 1 4 20 x 1 00 X 6024 5 7 16 14 x 75 Eaton das WIS X 6024 2 7 16 14 x 1 00 X 465 8 1 4 20 x 1 25 465 9 1 4 20 1 50 6024 8 7 16 14 1 25 6210 2 1 4 20 Spiralock X 465 10 1 4 20 x 1 75 X 6024 3 7 16 14 x 1 50 X 6210 6 1 4 28 Spiralock X 465 11 1 4 20 x 2 00 6024 4 Ge 280 6210 7 5 16 18 Spiralock X 465 12 1 4 20 x 2 25 on 1 ae 2 6210 8 5 16 24 Spiralock X 465 14 1 4 20 x 2 75 4 i
32. Service Parts Marine Generator Sets Models 5 4 7 5EKD 6EFKD 10EKD 8EFKD KOHLER Power Systems ____ 29001 N KOHLER mum POVVER SYSTEMS NATIONALLY REGISTERED TP 6594 2 14a Table of Contents Description Page Introduction SE SIS SD cece eee 3 Number Significance 3 How to Find Part 3 Hardware References 3 Specification Number Index 4 Group 1 Crankshaft 5 Group 2 6 Group 3 Lubrication 8 Group 4 Valve Covers 10 Group 5 9 12 Group 7 Starting 12 Group 11 Long Block 14 Group 12 Engine Nameplate and Decals 16 Group 13 Engine Cooling System 17 Group 101 Air Intake 18 Description Page Group 103 Fuel System 19 Group 104 Cooling System 20 Group 105 22 Group 107 Nameplate and Decals 23 Group 109 Skid and Mounting 24 Group 116 Exhaust 25 Group 201 Generator and Mounting 26 Group 701 28 Paint and lt
33. Washer lock 20 ID x 373 in OD 1 1 1 13 X 22 12 Washer lock 262 ID x 743 in OD 2 2 2 14 X 6210 2 Nut flange spiralock 1 4 20 1 1 1 15 X 22 11 Washer lock 262 ID x 469 OD 1 1 1 16 X 81 8 Nut hex 1 4 20 1 1 1 17 GM11482 Adapter alternator 1 1 1 18 X 125 30 Bolt hex cap 4 4 4 19 X 25 85 Washer plain 344 ID x 687 in OD 4 4 4 20 GC55024 Stator assembly 5kw 1 20 GC50102 Stator assembly 7 5kw 1 20 GC50103 Stator assembly 10kw 1 21 GM58045 Rotor assembly 1 1 21 GM58046 Rotor assembly 1 22 GM58617 Bolt armature thru 1 1 22 GM58618 Bolt armature thru 1 23 X 801 4 Washer hardened 328 ID x 719 in OD 5 5 5 24 359310 Bolt 5 16 18 x 9 5 in 4 4 24 GM53164 Bolt over 4 25 359477 Plate end bracket 1 1 1 26 X 465 16 Bolt hex cap 2 2 2 27 X 25 40 Washer plain 281 ID x 625 in OD 2 2 2 28 245264 BLK Plate cover 1 1 1 29 X 49 1 Screw machine 4 4 4 30 X 22 6 Washer lock 146 ID x 285 in OD 4 4 4 31 X 6210 3 Nut flange whiz 6 32 4 4 4 32 GM53052 Bracket assembly end includes items 32 39 1 1 1 33 GM52395 Bracket end 1 1 1 34 229110 O ring 2 859 in ID 1 1 1 35 GM45945 Harness wiring brush connection 1 1 1 36 X 49 1 Screw machine 2 2 2 37 X 22 6 Washer lock 146 ID x 285 in OD 2 2 2 38 X 67 113 Screw hex washer thread forming 2 2 2 39 GM41970 Brush holder assy 1 1 1 40 GM40265 Box assembly junction 1 1 1 41 GM46362 PCB assy CO sensor 1 1
34. a washer between hardware and a slot b Alwaysuse a washer under a nut see 2 above for exception Use a washer under a bolt when the female thread is fixed weld nut 4 Refer to Figure 2 which depicts the preceding hardware configuration possibilities D lt 0 G K A Cap screw Entry hole types Standard nut and SAE washer Whiz nut or spiralock up to 1 2 in dia hardware Weld nuts above 1 2 in dia hardware Exit hole types Figure 2 Acceptable Hardware Combinations Appendix 35 Appendix General Torque Specifications American Standard Fasteners Torque Specifications Assembled into Cast Iron or Steel Assembled into Torque Aluminum Measurement Grade 2 Grade 5 Grade 8 Grade 2 or 5 8 32 10 24 10 32 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7 16 14 7 16 20 Ib See Note 3 1 2 13 1 2 20 9 16 12 9 16 18 5 8 11 5 8 18 3 4 10 3 4 16 1 8 1 12 Metric Fasteners Torque Specifications Measured in Nm ft Ib Assembled into Aluminum Size mm Grade 5 8 Grade 8 8 Grade 10 9 Grade 5 8 or 8 8 Assembled into Cast Iron or Steel See Note 3 Notes 1 Do not use these values when the torque values are specified on the assembly drawing These values are based on new plates threads Increase values by 15 if non plated threads are
35. ardware instructions Some hardware items require a specific size or some other characteristic In that case use the part number listed in the text When replacing hardware do not substitute inferior grade hardware Replacement hardware grade should be equal to or better than the grade of the manufacturer s original hardware Use the Common Hardware List in the appendix to identify the common hardware hardness x in 004 006 Specification Number Index 2 D E Group Title ZS 2 21 61 Y 5 c gt 2 S E 22 38 229 58 28 8 3 8 3 58 58 3 2 2 8 CLO Y 3 0 Sro du 8 5 Group No 1 2 3 4 5 7 12 13 66 Spec No Variation Number 5EKD 4EFKD GM47636 GA1 25 39 or 50 or 41 or 33 4 22 16 1t 32 or 43 34 288 7 5EKD 6EFKD GM47636 GA2 255 39 50 41 or 33 4 22 16 17 324 437 341 288 10EKD 8EFKD GM47636 GA3 25 39 or 50 or 41 or 33 4 22 16 17 324 437 341 288 After engine serial number 4112200001 Before engine S N 4112200011 amp After S N 3932200001 Before engine serial number 4112200011 8 Before engine serial number 3832100011 2 2 2 9 2 E I I Q o 2 E Group Title SJ 2 S 5 5 RS EQ o gs e E S X 9 o amp lt 5 E 2 amp 3 2705 E 22 S E o
36. cal liter local area network length by width by height pound pounds pounds mass per cubic feet line circuit breaker liquid crystal display load shed light emitting diode liters per hour liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level A weighted low water level low water temperature meter milli 1 1000 mega 108 when used with SI units male cubic meter cubic meters per minute milliampere manual maximum megabyte 220 bytes one thousand circular mils molded case circuit breaker megohmmeter megahertz mile one one thousandth of an inch minimum minute miscellaneous megajoule millijoule millimeter milliohm megohm metal oxide varistor megapascal miles per gallon miles per hour military standard meters per second mean time between failure 34 Appendix MTBO mtg MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS NPSC NPT NPTF NR ns OC OD OEM OF opt OS OSHA OV 07 PP ph 2 PMG pot ppm PROM psi pt PTC PTO PVC qt aty R rad RAM RDO ref rem Res Coml RFI RH RHM mean time between overhauls mounting megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrica
37. dquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455
38. eak down into groups Group Number A unique number representing a parts group needed to assemble generator setfunction For example Group 101 is the Air Intake group Variation or Module Number A group might have several variations Each variation performs the same function with different parts lists For example a 50 Hz generator alternator and 60 Hz generator alternator both perform the same function however with different parts Each difference requires a group variation or module number Part Number The part number identifies an individual assembly subassembly component or accessory kit x in 004 003 Illustrations Illustrations exploded view drawings best representing the widest range of variations accompany most groups in this manual Illustrations do not depict all details and may not show all parts Do not use illustrations for assembly or disassembly x in 004 004a TP 6594 2 14 How to Find Part Numbers Use the following steps to locate a service replacement part 1 Locate the generator set nameplate to identify the generator set spec number 2 Locate a second generator set nameplate listing accessories to identify installed modules On some models the accessory nameplate is mounted inside the generator junction box 3 Turn to the Specification Number Index The first column lists the generator set spec numbers The headings identify the groups of parts that make up the generator set 4
39. ect current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator emergency power source electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge estimated emergency stop et cetera and so forth exhaust ext F fglass FHM fl oz flex freq FS ft ft Ib ft min 9 gal gen genset GFI GND Y gov gph gpm gr GRD gr wt HxWxD HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H20 in Hg in Ib Inc ind int int ext 1 0 IP 150 J JIS k K external Fahrenheit female fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross
40. l battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate certification certified cubic feet per hour TP 6594 2 14 cfm CG CID CL cm CMOS cogen com coml Coml Rec conn cont CPVC crit CRT CSA CT Cu cu in cw CWC cyl D A DAC dB dBA DC DCR deg dept dia DI EO DIN DIP DPDT DPST DS DVR E emer EDI EFR e g EG EGSA EIA EI EO EMI emiss eng EPA EPS ER ES ESD est E Stop etc exh cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current dir
41. l Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pint positive temperature coefficient power takeoff polyvinyl chloride quart quarts quantity replacement emergency power source radiator radius random access memory relay driver output reference remote Residential Commercial radio frequency interference round head round head machine screw rly rms rnd ROM rot rpm RS RTV SAE scfm SCR 5 sec SI SI EO sil SN SPDT SPST spec specs sa sq cm sa in SS std stl tach TD TDC TDEC TDEN TDES TDNE TDOE TDON temp term TIF TIR tol turbo typ UF UHF UL UNC UNF univ US UV V
42. proper fastening techniques when no specific reference for reassembly is made Bolt Screw Length When bolt screw length is not given use Figure 1 as a guide As a general rule a minimum length of one thread beyond the nut and a maximum length of 1 2 the bolt screw diameter beyond the nut is the preferred method Washers and Nuts Use split lock washers as a bolt locking device where specified Use SAE flat washers with whiz nuts spiralock nuts or standard nuts and preloading torque of the bolt in all other applications See Appendix C General Torque Specifications and other torque specifications in the service literature Preferred Nut Bolt Clearance 3 1 1 2 of bolt diameter 2 Min 1 full thread beyond top of nut 3 Below top of nut Figure 1 Acceptable Bolt Lengths TP 6594 2 14 Steps for common hardware application 1 Determine entry hole type round or slotted 2 Determine exit hole type fixed female thread weld nut round or slotted For round and slotted exit holes determine if hardware is greater than 1 2 inch in diameter or 1 2 inch in diameter or less Hardware that is greater than 1 2 inch in diameter takes a standard nut and SAE washer Hardware 1 2 inch or less in diameter can take a properly torqued whiz nut or spiralock nut See Figure 2 3 Follow these SAE washer rules after determining exit hole type a Alwaysuse
43. r 55 A 1P Instructions installation Screw RHM Breaker circuit 55 A Plate cover Decal notice Guard circuit breaker Circuit Breaker 18 A 2P Instructions installation Screw RHM Breaker circuit 18 A Decal notice Guard circuit breaker LH Guard circuit breaker RH Circuit Breaker 30 A 2P Instructions installation Screw RHM Breaker circuit 30 A Decal notice Guard circuit breaker LH Guard circuit breaker RH Circuit Breaker 22 A 2P Instructions installation Screw RHM Breaker circuit 22 A Decal notice Terminal jumper Guard circuit breaker LH Guard circuit breaker RH Circuit Breaker 22 A 2P Instructions installation Screw RHM Breaker circuit 22 A Decal notice Guard circuit breaker LH Guard circuit breaker RH Circuit Breaker 42 A 1P Instructions installation Screw RHM Breaker circuit 42 A Plate cover Decal notice Guard circuit breaker Aaa a Ad dd V ao a VE Aa a yo AN ZA e dl oa TP 6594 2 14 PA 225640 TT 875 X 49 25 X 506 50 229183 246242 GM48893 PA 229185 TT 875 X 49 25 X 506 47 229183 246242 GM48893 PA 344051 TT 875 X 49 25 X 506 41 246242 GM48894 GM48895 PA 344052 TT 875 X 49 25 X 506 36 246242 GM48894 GM48895 PA 344106 TT 875 X 49 25 X 506 57 246242 249956 GM48894 GM48895 PA 344309 TT 875 X 49 25 X 506 57 246242 GM48894 GM48895 PA 359286 TT 875 X 49 25 X 506 60 229183 246242 GM48893
44. used Hardware threaded into aluminum must have two diameters of thread engagement or may require 3096 or more reduction in the torque Torques are calculated as equivalent stress loading to American hardware and approximately a preload of 9096 of yield strength and friction coefficient of 0 125 EON 36 Appendix TP 6594 2 14 Screw Bolts Studs Head Styles Hex Head or Machine Head Fr Nut Styles Hex Head Appendix D Common Hardware Identification Hardness Grades American Standard Grade 2 Hex Head or Machine Head with Washer Lock or Elastic Grade 5 Flat Head FHM y Square Grade 8 Round Head RHM gp Cap or Acorn Grade 8 9 Hex Socket Head Pan Head Wing Hex Socket Head Cap or Allen Head Cap Hex Socket Head or Allen Head Shoulder Bolt Sheet Metal Screw K Stud a Drive Styles Hex Hex and Slotted Phillips Slotted e e Hex Socket Washers Washer Styles Plain Split Lock or Spring Spring or Wave External Tooth Lock Internal Tooth Lock Internal External Tooth Lock Allen head screw is a trademark of Holo Krome Co Phillips screw is a registered trademark of Phillips Screw Company 1 4 20x 1 Sample Dimensions American Standard Screws Bolts Studs and Nuts L Length In Inches Screws and Bolts Threads Per Inch
45. valve 1 Loop siphon valve vent GM62738 KP1 GM62739 PA 359572 359572 PA 359579 661 1 229928 426 9 1268 GM34883 GM32985 328666 GM32984 GM32988 6594 2 14 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC A D ADC adj ADV AHWT AISI ALOP alt Al ANSI AO API approx AR AS ASE ASME assy ASTM ATDC ATS auto aux A V avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min C cal CARB CB cc CCA ccw CEC cert cfh ampere after bottom dead center alternating current analog to digital analog to digital converter adjust adjustment advertising dimensional drawing anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only American Petroleum Institute approximate approximately as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator American Wire Gauge appliance wiring materia
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