Kohler 3.5EFOZ User's Manual
Contents
1. N y tc Q 2 z e N ala gt E Kg KU Kg lt lt sols 2 5 ol tIS e E88 TP 6138 5 02 Group 1 Crankcase 2018 19 18 6138 1 Quantity Part Variation No Item Number Description 1 1 GM24007 Crankcase Assembly 1 2 GM23884 Stud Cylinder Block 2 3 GM23885 Stud Cylinder Block 2 4 GM23886 Stud Crankcase 4 5 GM23870 Switch Oil Pressure 1 7 GM23934 Gasket Crankcase 1 10 GM23955 O ring 99 x 3 mm 1 11 GM23927 Housing Main Bearing 1 12 GM23965 Retainer Ring 1 13 GM23973 Seal Oil 60 x 80 x 8 1 14 4 Nut Hex Head M8 4 15 8 Washer Tooth 18 mm 4 16 GM23925 Pump Assembly Oil 1 17 GM23937 Gasket Oil Pump 1 18 Washer Split 6 mm ID 3 19 8 Screw Hex Head Cap M6 x 20 1 20 4 Screw Hex Head Cap M6 x 30 2 4 Common hardware procure locally TP 6138 5 02 4 Group 2 Crankshaft and Piston 6138 2 4 TP 6138 5 02 Group 2 Crankshaft and Piston 10 GM23975 Key 6x 4x 12 mm 11 GM23945 Bearing Main 12 GM23906 Governor Assembly RPM 3000E 12 GM23907 Governor Assembly RPM 3000 12 GM23908 Governor Assembly RPM 3600E 13 GM23974 Pin 4 x 27 8 mm 15 GM24010 Piston Assembly 16 GM24006 Set Piston Ring 17 GM23983 Clip Piston Pin 18 G2. Items Not Shown GM24017 GM24018 GM24049 GM24050 GM24128 GM24129 GM24130 GM24130 GM24131 GM24132 GM24133 GM24134 GM24135 GM24136 GM24137 GM24138 Junction Corner Mounting Upper Rear Mounting Upper Front Mounting Upper Left Right Mounting Vertical Clip Screw Self Threading Housing Electrical Board Plate Connecting Panel Electrical Board Base Sound Shield Front Stud Coupling Grommet Panel Left Removable Panel Top Removable Panel Right Removable Base Sound Shield Right Screw Hex Head M6 x 20 Washer Plain 6 mm ID Screw Flat Phillips Head M6 x 45 Latch Panel Front Rear Base Sound Shield Rear Base Capacitor Base Sound Shield Left Cover Grooved Screw Round Phillips Head M5 x 14 Washer Tooth 5 mm ID Grommet Grommet Plug Grommet Clamp Hose Tube Exhaust Elbow Exhaust Tube 40 50 mm OD Elbow Exhaust Tube 40 mm OD Rivet Nut Jaw M6 Nut Jaw M8 Gasket Adhesive 20 mm wide x 3 mm high Gasket Adhesive 30 mm wide x 3 mm high Gasket Sealing Tar Base Front Rear Gasket Sealing Tar Base Right Left Foam Acoustic Front Base Foam Acoustic Front Base Foam Acoustic Rear Base Foam Acoustic Left Base Foam Acoustic Right Base Foam Acoustic Left Panel Foam Acoustic Control Panel Foam Acoustic Right Panel Foam Acoustic Top Panel Foam Acoustic Upper and Vertical Mounting Common hardware procure locally
3. 2 x 710 M961 16030 82 16 1 50 x 30 Bolt 1 50 x 120 M933 16030 82 M16 2 00 x 30 M931 10130 60 10 1 50 x 130 M933 16035 60 16 2 00 35 Part No ID OD Thick Screw M931 10140 60 10 1 50 x 140 M961 16040 60 16 1 50 x 40 125 03 80 32 70 05 M3 M931 10180 60 10 1 50 x 180 M933 16040 60 16 2 00 x 40 125 04 80 43 90 08 M4 M931 12045 60 12 1 75 x 45 M933 16050 60 16 2 00 x 50 125 05 80 5 3 100 10 5 M960 12050 60 12 1 25 x 50 M933 16050 82 16 2 00 x 505 125 06 80 64 120 16 M6 M960 12050 82 12 1 25 x 50 M933 16060 60 16 2 00 x 60 125 08 80 8 4 16 0 16 M8 M931 12050 60 12 1 75 x 50 933 18035 60 M18 2 50 x 35 M125A 10 80 10 5 20 0 20 M10 M931 12055 60 12 1 75 x 55 M933 18050 60 18 2 50 x 50 125 12 80 13 0 240 25 M12 M931 12060 60 12 1 75 x 60 M933 18060 60 18 2 50 x 60 125 14 80 15 0 280 25 M14 931 12065 60 M12 1 75 x 65 M933 20050 60 20 2 50 x 50 125 16 80 17 0 300 3 0 M16 M931 12075 60 12 1 75 75 M933 20055 60 20 2 50 55 Ne 210 ap 30 m M31 12090 60 M12 1 78 x 80 Pan Head Machine Screws 125 24 80 250 440 40 M24 M7985A 03010 20 M3 0 50 x 10 M7985A 03012 20 M3 0 50 x 12 M7985A 04010 20 M4 0 70 x 10 M931 12100 60 M931 12110 60 M12 1 75 x 100 M12 1 75 x 110 This metric hex bolt s hardness is grade 10 9 M960 16090 60 16 1 50 90 M7985A 04020 20 M4 0 70 x 20 This metric hex nut s hardness is grade 8 M931 16090 60 16 2 00 x 90 7
4. 57 x 2 5 mm 56 Washer Split 6 mm ID 57 Screw Hex Head M6 x 16 58 GM23930 Gasket Plate 59 GM23985 Cover 60 GM23979 Washer Copper 5 mm ID 61 Screw Hex Head M5 x 16 62 GM24511 Ring snap A hihi A3 i i N i m Mi ch sch lt sch h sch m sch sch Ai ch Common hardware procure locally TP 6138 5 02 9 Group 5 Speed Control Shaft 6138 5 Quantity Part Variation No Item Number Description 1 1 23949 Spring Torsion Return 1 2 GM23916 Arm Governor 1 3 GM23888 Screw Adjustment 1 4 GM23992 Tab Locking 1 5 Nut Hex Head M6 1 6 GM23952 Retainer 1 7 GM23871 Shaft Speed Control 1 8 GM23953 O ring 10 x 2 2 mm 1 9 GM23950 Spring Torsion Return 1 10 GM23986 Plate Control 1 11 GM23984 Lever 1 12 4 Washer Tooth 8 mm 1 13 Nut Hex Head 8 1 14 GM23913 Bolt 1 Common hardware procure locally TP 6138 5 02 Group 6 Fuel Lines 2 4 4 5 10 6 6 8 6138 6 Quantity Part Variation No Item Number Description 1 1 23999 Line Return Fuel 1 2 GM23982 Bolt Banjo Union 2 3 GM23959 Washer Copper 8 mm ID 1 4 GM23978 Washer Copper 8 mm ID 3 5 GM23892 Connector 1 6 GM23980 Washer Copper 12 mm ID 4 7 GM23988 Clamp Fuel Line 1 8 GM23998 Pipe Fuel Injector 1 9 GM24072 Solenoid Shutoff 1 10 GM24099 Bolt
5. X 6238 11 3 8 16 x 1 00 X 6238 4 3 8 16 x 1 25 6238 5 3 8 16 x 1 50 6238 1 3 8 16 x 1 75 X 6238 6 3 8 16 x 2 00 X 6238 17 3 8 16 x 2 25 X 6238 7 3 8 16 x 2 50 6238 8 3 8 16 x 2 75 6238 9 3 8 16 x 3 00 X 6238 19 3 8 16 x 3 25 X 6238 12 3 8 16 x 3 50 X 6238 20 3 8 16 x 3 75 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 X 6238 14 3 8 24 x 75 X 6238 16 3 8 24 x 1 25 X 6238 21 3 8 24 x 4 00 X 6238 22 3 8 24 x 4 50 A 6 Appendix Part No Dimensions Hex Head Bolts cont 6024 5 7 16 14 75 X 6024 2 7 16 14 1 00 X 6024 8 7 16 14 x 1 25 6024 3 7 16 14 x 1 50 6024 4 7 16 14 2 00 6024 11 7 16 14 2 75 6024 12 7 16 14 6 50 129 15 1 2 13 x 75 129 17 1 2 13 1 00 129 18 1 2 13 1 25 129 19 1 2 13 1 50 129 20 1 2 13 1 75 129 21 1 2 13 2 00 X 129 22 1 2 13 x 2 25 X 129 23 1 2 13 x 2 50 X 129 24 1 2 13 2 75 X 129 25 1 2 13 x 3 00 129 27 1 2 13 3 50 129 29 1 2 13 x 4 00 129 30 1 2 13 x 4 50 463 9 1 2 13 x 5 50 X 129 44 1 2 13 x 6 00 129 51 1 2 20 75 X 129 45 1 2 20 x 1 25 X 129 52 1 2 20 x 1 50 X 6021 3 5 8 11 x 1 00 6021 4 5 8 11 x 1 25 X 6021 2 5 8 11 x 1 50 X 6021 1 5 8 11 1 75 273049 5 8 11 x 2 00 6021 5 5 8 11 x 2 25 6021 6 5 8 11 x 2 50 X 6021 7 5 8 11x 2 75 X 6021 12 5 8 11 x 3 75 X 6021 11 5 8 11 x 4 50 X 6021 10 5 8 11 x 6 00 6021 9 5 8 18 x 2 50 X 6239 1 3 4 10 x 1 00 X 6239 8 3 4 10 x
6. variation column A blank space at the 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 hardware 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 1 Specification Number Index Group Title 13 12 11 10 1 VARIATION NUMBER 1 1 Group No Spec No 3 5EFOZ GM20642 SA1 4 2 GM20641 SA1 Group Title
7. 18 Generator and Mounting 26 Group 19 Controller and Mounting 28 Group 20 Control Panel 30 Group 21 Siphon Break and 31 Group 22 Literature 32 Paint and Miscellaneous Parts 32 ACCeSSOLIBS ic aloes ea ee ee 32 Appendix A Abbreviations A 1 Appendix Common Hardware Application Guidelines A 3 Appendix C General Torque A 4 Appendix D Common Hardware Identification A 5 Appendix E Common Hardware List A 6 Introduction This manual lists service replacement parts for 4 kW generator sets At the time of print this manual applied to the generator set specification spec numbers listed in the Specification Number Index On occasion this manual may apply to specs not listed in the Specification Number Index 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
8. 35 M931 06055 60 6 1 00 x 55 M933 05050 60 5 0 80 x 50 M934 035 50 3 5 050 Standard M931 06060 60 6 1 00 60 M933 06010 60 6 1 00 10 934 04 50 4 0 70 Standard M931 06070 60 6 1 00 x 70 933 06014 60 M6 1 00 x 14 931 06070 55 1 00 x 70 M933 06016 60 M6 1 00 x 16 M931 06075 60 M6 1 00 x 75 M933 06020 60 6 1 00 x 20 i M931 06090 60 6 1 00 x 90 M933 06025 60 6 1 00 x 25 M934 06 60 M6 1 00 Standard M931 06150 60 6 1 00 x 150 M933 06040 60 M6 1 00 x 40 Moi p E Groen M931 08035 60 M8 1 25 35 M933 06050 60 6 1 00 x 50 Ke pu piraloc M931 08040 60 8 1 25 x 40 M933 08012 60 8 1 25 x 12 982 06 80 M6 1 00 Elastic Stop M931 08040 82 8 1 25 40 M933 08016 60 8 1 25 16 M934 08 60 8 1 25 Standard M931 08045 60 8 1 25 x 45 M933 08020 60 8 1 25 x 20 M6923 08 80 8 1 25 Spiralock M931 08050 60 8 1 25 x 50 M933 08025 60 8 1 25 25 M982 08 80 8 1 25 Elastic Stop M931 08055 60 8 1 25 55 M933 08030 60 8 1 25 x 30 M931 08055 82 8 1 25 55 M933 08030 82 8 1 25 x 30 Mo E E a M931 08060 60 8 1 25 x 60 M933 10012 60 10 1 50 x 12 M6923 10 80 M10 1 50 Spiralock 931 08070 60 8 1 25 70 961 10020 60 10 1 25 20 6923 10 62 10 1 50 Spiralockt 931 08070 82 8 1 25 705 933 10020 60 10 1 50 20 982 10 80 10 1 50 Elastic Stop M931 08075 60 8 1 25 x 75 M933 10025 60 10 1 50 x 25 M931 08080 60 8 1 25 x 80 M961 10030 60 10 1 25 x 30 M934 12
9. 9151 30 Rz 5 9 32 j 2 s 28 6138 4 8 TP 6138 5 02 Group 4 Gear Timing and Cover Quantity Part Variation No Item Number Description 1 23923 Cover Timing Gear 3 GM23933 Gasket Cover 4 GM23976 Pin 10 x 16 mm 8 Washer Split 5 mm ID 9 GM23887 Screw Hex Head 10 GM23958 Gasket 11 24003 Cap Oil Filler 12 GM23929 Dipstick 13 GM23968 Stud M8 x 20 14 GM24013 Screen Assembly Oil Filter 17 GM23938 Gasket Oil Filter 18 GM23977 Washer Copper 6 mm ID 19 8 Screw Hex Head M6 x 20 20 4 Screw Hex Head Cap M8 x 70 21 GM24004 Handle 24 GM24008 Primer Assembly 25 8 Screw Hex Head Cap M8 x 80 26 GM23993 Shim Adjusting 0 2 mm 26 GM23994 Shim Adjusting 0 5 mm 26 GM23995 Shim Adjusting 0 4 mm 26 GM23996 Shim Adjusting 1 0 mm 27 GM23939 Gasket 28 GM23901 Roller Tappet 29 GM23896 Pump Fuel Injection 30 Washer Split 8 mm ID 31 4 Nut Hex Head M8 32 GM23897 Washer 33 GM23900 Valve 34 GM23898 Spring Valve 35 GM23899 Plunger Fuel 36 GM23875 Push Rod 37 GM23957 O ring 32 x 3 mm 38 4 Screw Hex Head Cap M5 x 30 39 GM23922 Release Compression 40 GM23936 Gasket Plate 0 3 mm 40 GM23940 Gasket Plate 0 4 mm 42 GM23966 Bearing Grooved Ball 43 GM23960 O ring 32 7 x 1 3 mm 44 23873 Bolt 45 GM23924 Camshaft 46 GM23880 Gear 47 GM23975 Key 6x 4x 12 mm 53 GM23917 Cover 55 GM23961 O ring
10. hardware procure locally TP 6138 5 02 Group 10 Oil Cooler and Lines 6138 10 TP 6138 5 02 Quantity Part Variation No Item Number Description 1 1 GM24114 Element Oil Cooler 1 2 GM24112 Elbow 2 8 Washer Tooth 6 mm ID 6 4 8 Screw Hex Head Cap M6 x 30 6 5 24021 Clamp Hose 8 6 GM24121 Hose 1 7 GM24104 Tube 1 8 GM24122 Hose 1 9 GM24118 Hose 1 10 GM24116 Hose 1 11 GM24027 Adapter Rubber Hose 3 12 GM24102 Tube 1 Common hardware procure locally 15 Group 11 Seawater Pump Note Item 1 Seawater bi lE c pump does not include items T 9 x 2 and 5 4 X i 6138_11 Quantity Part Variation No Item Number Description 1 GM24052 Pump Assembly Seawater GM24106 Shaft Seawater Pump GM24032 Seal GM24053 Housing Seawater Pump Screw Hex Head Cap M5 x 40 GM24031 O ring GM20852 Impeller GM24054 Cover Seawater Pump Screw Hex Head M4 x 8 Qo E ch 0 ch sch ch 4 Common hardware procure locally 16 TP 6138 5 02 Group 12 Oil Draining Lines 6138 5 02 4 6138_12 Quantity Part Variation No Item Number Description 1 1 GM24143 Bushing Reducer 1 2 GM23980 Washer Copper 12 mm ID 2 3 GM24142 Eye Banjo Union 1 4 GM24141 Bolt Banjo Union 1 5 GM24020 Clamp Hose 2 6 GM24117 Hose Oil Draining 1 7 GM24111 Adapte
11. material about part numbers illustrations and hardware Specification Number 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 The product identification number located on the generator set nameplate Specification numbers break down into groups Group Number A unique number representing a parts group needed to assemble a generator set function 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 a 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 a Illustrations Illustrations or exploded view drawings best representing the widest range of variations accompany most groups in this manual Illustrations do not depict all details and
12. may not show all parts Do not use illustrations for assembly or disassembly x in 004 004 a TP 6138 5 02 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 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 Find the part on the 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 of the parts list table Find the quantity used at the intersection of the item number row and the
13. 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 6138 5 02 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 Always use a washer between hardware and a slot b Always use 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 E Cap screw Entry hole types Standard nut and S
14. 0 35 132 0 97 M14 x 1 50 100 0 4 140 0 103 M16 x 2 00 115 0 5 200 0 148 M16 x 1 50 141 0 104 M18 x 2 50 155 0 114 275 0 203 M18 x 1 50 A 4 Appendix 196 0 145 210 0 155 305 0 225 TP 6138 5 02 Appendix D Common Hardware Identification Screw Bolts Studs Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head i Y with Washer Lock or Elastic Grade 5 Flat Head FHM Square Grade 8 Grade 8 9 Hex Socket Head Metric Round Head RHM Cap or Acorn Pan Head Wing Number stamped on Hex Socket Head Cap or Washers hardware 5 8 shown Allen Head Cap Washer Styles Hex Socket Head or Allen Head Shoulder Bolt Plain Sheet Metal Screw Split Lock or Spring Stud Spring or Wave Drive Styles External Tooth Lock Hex Internal Tooth Lock Hex and Slotted Internal External Tooth Lock Phillips Slotted Hex Socket Allen head screw is a trademark of Holo Krome Co Phillips screw is a registered trademark of Phillips Screw Company Sample Dimensions American Standard Screws Bolts Studs and Nuts Plain Washers 1 4 20x1 L Length In Inches Screws and Bolts 9 32 x 5 8 x 116 Thickness Threads Per Inch L External Dimension Major Thread Diameter In Fractional Inches Or Screw Numbe
15. 0 2 2 41 Nut Collar 6 4 4 42 GM24068 Capacitor 60 Hz gen 1 4 43 Washer Tooth 8 mm ID 1 1 44 Nut Hex Head M8 1 1 45 GM24043 Protector Rubber 1 1 4 Common hardware procure locally 42 GM30673 50 Hz gen 29 Group 20 Control Panel 6138 20 Quantity Part Variation No Item Number Description 1 1 GM24161 Panel Control 1 28 Screw Flat Phillips Head M3 x 12 4 3 GM24069 Connector 1 4 GM24156 Connector to Remote Start Stop Switch Harness 1 5 GM24152 Connector to Remote Control Panel Harness 1 68 Nut Hex Head M3 2 7 8 Screw Special Head x 12 2 8 GM24034 Grommet Control Box Harness GM34930 1 9 GM24456 Connector to Remete Start Step Switeh Harneses 1 10 GM24514 Fuse 0 63 Amp 1 4 Common hardware procure locally 30 TP 6138 5 02 Group 21 Siphon Break and Lines S 2 6138 21 Quantity Part Variation No Item Number Description 1 1 PA 229928 Kit Siphon Break 1 2 GM24021 Clamp Hose 4 3 GM24105 Connection Hose 2 4 GM24023 Hose 2 5 GM24035 Grommet 2 TP 6138 5 02 31 Group 22 Literature Quantity Part Variation No Item Number Description 1 1 TP 5620 Safety Precautions Marine 1 2 TP 6069 3 5 150EOZ EFOZ Marine 1 3 TP 6134 O M 3 5EFOZ 4EOZ Marine 1 4 TP 6137 S M 4 2 3 5 2 Marine 1 5 T
16. 1 25 X 6239 2 3 4 10 x 1 50 X 6239 3 3 4 10 x 2 00 X 6239 4 3 4 10 x 2 50 6239 5 3 4 10 x 3 00 X 6239 6 3 4 10 x 3 50 792 1 1 8 x 2 25 X 792 5 1 8 x 3 00 X 792 8 1 8 x 5 00 Part No Hex Nuts X 6009 1 X 6210 3 X 6210 4 X 6210 5 X 6210 1 X 6210 2 X 6210 6 X 6210 7 X 6210 8 X 6210 9 X 6210 10 X 6210 11 X 6210 12 X 6210 15 X 6210 14 X 85 3 X 88 12 X 89 2 Washers Part No X 25 46 X 25 9 X 25 48 X 25 36 X 25 40 X 25 85 X 25 37 X 25 34 X 25 26 X 25 15 X 25 29 Dimensions ID 125 156 188 219 281 344 406 469 531 656 812 X 25 127 1 062 1 8 6 32 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 1 2 13 7 16 20 1 2 20 5 8 11 3 4 10 1 2 20 1 062 1 312 1 469 2 000 Bolt OD Thick Screw 022 4 049 6 049 8 049 10 065 1 4 065 5 16 065 3 8 065 7 16 095 1 2 095 5 8 134 3 4 134 1 Standard Whiz Whiz Whiz Whiz Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock Standard Standard Standard TP 6138 5 02 Metric Hex head bolts are hardness grade 8 8 unless noted Part No Dimensions Part No Dimensions Part No Dimensions Hex Head Bolts partial thread Hex Head Bolts full thread Hex Nuts M931 05055 60 5 0 80 x 55 M933 04006 60 M4 0 70 x 6 934 03 50 M3 0 50 Standard M931 06040 60 6 1 00 x 40 M933 05035 60 5 0 80
17. 5 lt lt sch sch lt lt h ch ODD 25 Group 18 Generator and Mounting 6138 18 26 TP 6138 5 02 TP 6138 5 02 Group 18 Generator and Mounting Quantity Part Variation No Item Number Description 1 2 1 24070 Alternator Engine Charging 1 1 2 GM24085 Bracket Lifting 1 1 3 GM24100 Hub Engine Stator Connection 1 1 4 8 Washer Special Notch 8 mm ID 4 4 5 Screw Hex Head M8 x 35 4 4 6 GM24101 Stud 1 1 7 GM24065 Varistor 2 2 8 GM24066 Diode 2 2 9 GM24151 Rotor Assembly 1 1 10 GM24033 Bearing 1 1 11 GM24149 Stator Assembly 50 Hz 1 11 GM24150 Stator Assembly 60 Hz 1 12 GM24028 Bushing Reducing 3 8 1 4 1 1 13 GM20853 Plug Zinc Electrode d 1 14 Washer Plain 10 mm ID 4 4 15 8 Screw Hex Head M10 x 140 4 4 16 GM24030 O ring 1 1 17 GM24091 Cover 1 1 18 Washer Tooth 5 mm ID 2 2 19 8 Screw Hex Head M5 x 12 2 2 20 Plug 3 8 1 1 21 amp Plug M10 1 1 22 H Screw Flat Head Cap M6 x 16 3 3 23 8 Washer Split 6 mm ID 3 3 23 Screw Hex Head Cap M8 x 55 3 3 24 8 Nut Hex Head M6 3 3 25 Screw Hex Head Cap M6 x 30 5 5 26 Washer Tooth 6 mm ID 5 5 Common hardware procure locally 27 Group 19 Controller and Mounting 6138 19 TP 6138 5 02 28 TP 6138 5 02 Group 19 Controller and Mounting Quantity Part Variation No Item Number D
18. 60 12 1 75 Standard M931 08090 60 8 1 25 x 90 M933 10030 60 10 1 50 30 SCH 2 28 M931 08095 60 8 1 25 95 M933 10030 82 10 1 50 30 Ee Eee prs M931 08100 60 8 1 25 100 M961 10035 60 10 1 25 x 35 12 8 1 75 asile Stop M931 08120 60 8 1 25 120 M933 10035 60 10 1 50 x 35 M982 14 80 M14 2 00 Elastic Stop M931 08130 60 8 1 25 x 130 M933 12016 60 12 1 75 x 16 M931 08140 60 8 1 25 140 M933 12020 60 12 1 75 x 20 Mons Spiralo pum M931 10040 82 10 1 25 x 405 M933 12025 60 12 1 75 x 25 M931 10040 60 10 1 50 x 40 933 12025 82 M12 1 75 x 25 M934 18 80 18 25 Standard M931 10045 60 10 1 50 x 45 M961 12030 60 12 1 25 x 30 M982 18 80 18 250 Elastic Stop M931 10050 60 10 1 50 x 50 M933 12030 60 12 1 75 x 30 934 20 80 M20 2 50 Standard M931 10055 60 10 1 50 x 55 M933 12035 60 12 1 75 x 35 982 20 80 M20 2 50 Elastic Stop M931 10060 60 10 1 50 x 60 961 12040 82 12 1 25 x 40 M931 10065 60 10 1 50 x 65 M933 12040 60 12 1 75 x 40 M22 2 507 Standard M931 10070 60 10 1 50 70 M933 12040 82 M12 1 75 x 40 M934 24 80 M24 3 00 A Standard M931 10080 60 10 1 50 x 80 961 14025 60 14 1 50 x 25 M982 24 80 24 300 X Elastic Stop M931 10090 60 10 1 50 x 90 M933 14025 60 14 2 00 x 25 M934 30 80 M30 3 50 Standard M931 10090 82 10 1 50 905 M961 16025 60 16 1 50 x 25 M931 10100 60 10 1 50 x 100 M933 16025 60 16 2 00 x 25 Washers
19. 6138 5 02 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC ADC adj ADV AHWT AISI ALOP alt ANSI AO API approx AR AS ASE ASME assy ASTM ATDC ATS auto aux 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 CCW CEC cert cfh TP 6138 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 material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower
20. 7 Spring Valve 9 GM23895 Retainer Valve Spring 10 GM24005 Valve Cotter 11 GM23877 Valve Exhaust 12 GM23894 Ring 14 GM23911 Rotocap Valve 15 GM23948 Spring Valve 16 GM23951 Spring Retainer 17 GM23967 Stud M5 x 10 18 Washer 5 mm ID 19 4 Nut Hex Head M5 20 GM23872 Shaft Rocker Arm 21 GM23919 Arm Assembly Rocker 22 GM23918 Arm Assembly Rocker 23 GM23889 Screw Adjusting 24 8 Nut Hex Head M7 25 GM23902 Injector Fuel 26 GM23962 Washer 27 GM23903 Nozzle Fuel Injector 28 GM23904 Seat Spring 29 GM23905 Spring Nozzle 30 GM23991 Flange Injector 31 GM23972 Stud M6 x 50 32 GM23971 Stud M6 x 45 33 4 Washer Split 6 mm ID 34 4 Nut Hex Head M6 35 GM23987 Tube Push Rod 36 GM23956 O ring 24 x 3 5 mm 37 Plug 22 mm 38 4 Plug 18 mm 39 GM23932 Gasket Rocker Cover 40 GM23920 Cover Rocker 418 Washer 5 mm ID 42 GM23989 Bracket Lifting 44 GM23890 Nut Collar 45 Plug 18 mm 47 GM23914 Switch Temperature Alarm 48 GM23981 Washer Copper 14 mm ID 49 Screw Hex Head Cap M8 x 20 50 Washer Split 8 mm ID 52 GM23931 Gasket 53 GM23912 Thermostat 54 GM24140 Cover Thermostat I ch NO NO hihi N hl 2 hihi sch O sch sch sch h sch i sch sch i 4 Common hardware procure locally TP 6138 5 02 7 Group 4 Gear Timing and Cover
21. 985 04100 20 M4 0 70 x 100 M931 16100 60 16 2 00 100 GE M931 20065 60 20 2 50 x 65 M7985A 05012 20 5 0 80 12 M7985A 05016 20 5 0 80 x 16 M7985A 05100 20 M5 0 80 x 100 M7985A 06100 20 M6 1 00 x 100 M931 20120 60 M931 20160 60 M931 22090 60 M20 2 50 x 120 M20 2 50 x 160 M22 2 50 x 90 M931 22120 60 M931 22160 60 M931 24090 60 M931 24120 60 M931 24160 60 TP 6138 5 02 M22 2 50 x 120 M22 2 50 x 160 24 3 00 x 90 M24 3 00 x 120 24 3 00 x 160 Flat Head Machine Screws 965 04012 4 0 70 x 12 M965A 05012 SS 5 0 80 x 12 965 05016 20 5 0 80 16 Appendix A 7 TP 6138 5 02 2002 by Kohler Co All rights reserved KOHLER POWER SYSTEMS KOHLER CO Kohler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPowerSystems com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 264 6422 Fax 65 264 6455
22. AE washer 4 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 A 3 Appendix C General Torque Specifications Use the following torque specifications when service literature instructions give no specific torque values The charts list values for new plated zinc phosphate or oiled threads Increase values by 1596 for nonplated threads All torque values are 0 10 American Standard Fasteners Torque Specifications Torque Assembled into Cast or Steel Assembled into Aluminum Measurement Grade 2 1 8 Grade 5 Grade 8 Grade 2 or 5 1 8 2 9 2 9 2 9 6 8 6 8 8 1 8 1 13 6 13 6 14 9 14 9 24 0 24 0 27 0 39 0 43 0 60 0 66 0 81 0 91 0 113 0 128 0 199 0 147 222 0 164 259 0 191 283 0 209 Metric Fasteners Torque Specifications Measured in Nm ft Ib Assembled into Cast or Steel Size mm M6 x 1 00 Grade 5 8 5 6 Grade 8 8 9 9 7 Grade 10 9 Assembled into Aluminum Grade 5 8 or 8 8 M8 x 1 25 13 6 25 0 18 M8 x 1 00 21 0 25 0 18 M10 x 1 50 27 0 49 0 5 M10 x 1 25 39 0 M12 x 1 75 47 0 83 0 1 M12 x 1 50 65 0 88 0 5 M14 x 2 00 74 0 49
23. Banjo Union 1 11 X 6288 1 Eye Fuel Supply Line 1 Jd Gemmen hardware procure locally TP 6138 5 02 7 Group 7 Flywheel 6138 7 Quantity Part Variation No Item Number Description 1 1 23928 Flywheel 1 2 GM23881 Gear 1 4 Common hardware procure locally 12 TP 6138 5 02 Group 8 Starter Motor 6138 8 Quantity Part Variation No Item Number Description 1 1 23910 Starter Assembly 12 Volt 1 2 Screw Hex Head Cap M8 x 20 4 3 GM24083 Plate Connecting 1 4 GM24109 Spacer 3 5 Washer Tooth 8 mm ID 4 6 GM24097 Housing Flywheel 1 7 GM23909 Bushing 1 8 GM23969 Stud M10 x 25 3 9 GM23970 Stud M10 x 25 1 10 4 Washer Spring 10 mm ID 4 11 Nut Hex Head M10 4 4 Common hardware procure locally TP 6138 5 02 13 Group 9 Exhaust System 6138 9 Quantity Part Variation No Item Number Description 1 1 GM24074 Tube Mixing 1 218 Washer Plain 8 mm ID 2 3 8 Washer Split 8 mm ID 2 4 8 Screw Hex Head Cap M8 x 55 2 5 GM24021 Clamp Hose 8 6 GM24120 Hose 1 7 GM24103 Nipple 1 8 GM24512 Hose 1 9 GM24119 Adapter Rubber Tube 10 GM24063 Hose 1 11 GM24051 Switch Temperature Alarm 1 12 Washer Tooth 3 mm ID 2 13 Screw Round Phillips Head M3 X 6 1 14 GM23935 Gasket 1 15 4 Plug Cap 1 8 1 16 GM24124 Hose 1 4 Common
24. M23874 Pin Piston 19 GM23926 Rod Assembly Connecting 20 GM23883 Bolt Connecting Rod 21 GM23890 Nut Collar 22 GM23882 Bushing Connecting Rod 24 8 Plug 22 mm 25 GM23997 Connector Water Tube 26 GM23953 O ring 10 x 2 2 mm 27 GM24011 Cylinder Assembly Quantity Part Variation No Item Number Description 1 2 1 24009 Crankshaft Assembly 1 1 3 GM23954 O ring 32 x 2mm 1 1 4 GM23893 Ring Angle 1 1 5 GM23946 Washer Spring 52 x 36 x 1 2 mm 2 2 6 GM23891 Nut Flywheel 1 1 7 GM23879 Gear Timing Crankshaft 1 1 8 GM23942 Bushing Main Standard 1 1 8 GM23943 Bushing Main 0 25 mm Undersize 1 1 8 GM23944 Bushing Main 0 50 mm Undersize 1 1 9 GM24000 Bearing Standard 1 1 9 GM24001 Bearing 0 25 mm Undersize 1 1 9 GM24002 Bearing 0 50 mm Undersize 1 1 2 2 1 1 1 1 hihi ck Ah h sch P sch Common hardware procure locally 6138 5 02 5 Cylinder Head Group 3 i i i i s i L B 2 8 zn 36 6138 3 TP 6138 5 02 D x Pi Group 3 Cylinder Head Quantity Part Variation No Item Number Description 1 24012 Head Assembly Cylinder 2 GM23921 Valve Breather 3 GM23941 Gasket Cylinder Head 4 GM23878 Valve Intake 5 GM23990 Washer 6 GM23876 Guide Valve 7 GM23964 Guide Oil Seal 8 GM2394
25. 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 RHM round head machine screw rly relay rms root mean square rnd round ROM read only memory rot rotate rotating rpm revolutions per minute RS right side RTV room temperature vulcanization SAE Society of Automotive Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier S sec second Sl Systeme international d unites International System of Units SI EO side in end out sil silencer SN serial number SPDT single pole double throw SPST single pole single throw Spec specs specification s Sq square 4 cm square centim
26. P 6138 P C 4 2 3 5 2 Farymann 18W 1 6 TP 6143 O M Farymann 18W 1 7 TP 6149 Warranty 4EOZ 3 5EFOZ Marine 1 8 TP 6163 S M Farymann 18W 903 04 08 1 5 1 Paint and Miscellaneous Parts Paint White Gallon 221334 Paint White Spray Can 221335 Paint White 75 oz Bottle w Brush GM19490 Accessories Qty Description Part No Harness Control Wiring to Plug Remote Start 1 Harness Wiring Harness Remote Panel 15 Ft 1 Harness Wiring Extension Harness Remote Panel 25 Ft 1 Harness Wiring Extension Panel Remote Start ee ee ee ee Harness Remote for GM20770 KP1 25 Ft 1 Decal Warning Installation Instructions Remote Start Panel Panel Assembly includes the following Panel Control Harness Wiring Meter Run Time Switch Rocker Screw Pan Head M3 x 12 Nut Hex 3 mm Washer Lock 146 ID x 285 in OD Cable RS 232 Panel Remote Start 1 Panel Assembly Remote Ship to Shore Switch 1 1 Switch Transfer Installation Instructions Ship to Shore Transfer Switch Strainer Seawater 1 32 Filter Water 1 2 x 1 2 in NPT GM22474 KP1 GM22474 PA 249334 249334 PA 249336 249336 PA 359581 249494 TT 1245 A 226965 226964 226979 238736 344039 7982 03012 20 934 03 50 22 6 20971 1 GM23202 GM20770 KP1 GMO0768 PAA 246617 A 246617 535 359579 X 661 1 TP
27. Service Parts Marine Generator Sets Models 3 5EFOZ 4EOZ geg POWER SYSTEMS NATIONALLY REGISTERED KOHLER POWER SYSTEMS TP 6138 5 02 Table of Contents Introduction 244255 eae ae ad EE 1 Numbering System Significance 1 IM stratioris eit DeL IRE UR YI RENE ite ie REL 1 How to Find Part Numbers 1 Hardware References 0 1 Specification Number Index 2 Group 1 ieu res XY ubi y elk Bee bib vei hp bday 3 Group 2 Crankshaft and Piston 4 Group 3 Cylinder Head 6 Group 4 Gear Timing and Cover 8 Group 5 Speed Control hett 10 Group 6 eue Lr Sere a rie 11 Group 7 hh 12 Group 8 Starter Motor ss isis e x Ee Y exa Ya v x quer Y P 13 Group 9 Exhaust System 14 Group 10 Oil Cooler and Lines 15 Group 11 Seawater 2 16 Group 12 Oil Draining Lines 17 Group 13 Fuel Filter and Pump 18 Group 14 Air Intake Filler 19 Group 15 Gasket Get 20 Group 16 Base and Mounting 22 Group 17 Sound Shield wees eed kis ex Pek bad e ER dd 24 Group
28. 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 5 02 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 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 direct current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package do
29. ead 8 6 4 Screw Hex Head M10 x 70 4 7 GM24047 Ring Rubber 2 8 GM24078 Bracket Engine Right 1 9 GM24110 Spacer 2 10 GM24046 Bushing Rubber 2 119 Washer Plain 10 mm ID 4 12 4 Washer Split 10 mm ID 6 13 Nut Hex Head M10 6 14 Screw Hex Head M8 x 40 2 15 GM24079 Bracket Engine Left 1 16 4 Washer Tooth 8 mm ID 4 17 GM24056 Strap Ground 1 18 Screw Hex Head 8 x 20 2 19 8 Washer Plain 8 mm ID 1 20 GM24084 Bracket Generator 1 21 Screw Hex Head M10 x 25 2 22 GM24115 Base 1 23 GM24139 Plate Sound Shield 1 4 Common hardware procure locally 23 Group 17 Sound Shield 15 21 22 13 20 14 12 20 e 6138_17 6138 5 02 24 TP 6138 5 02 Group 17 Sound Shield Part Item Number Description Quantity Variation No GM24159 GM24145 GM24148 GM24146 GM24147 GM24019 GM24095 GM24094 10 GM24089 11 GM24077 12 GM24160 13 GM24035 14 GM24088 15 GM24090 16 GM24087 17 GM24082 18 19 20 21 GM24158 22 GM24086 23 GM24076 24 GM24081 25 GM24075 26 GM24096 27 28 29 GM24039 30 GM24041 31 GM24042 32 GM24037 33 GM24022 34 GM24123 35 GM24107 35 GM24108 36 GM24048
30. escription 1 2 1 GM24098 Box Controller 1 1 506 68 2 GM24015 Breaker Circuit 15 2 18 amp 1 506 46 2 GM24016 Breaker Circuit 16 Amp 2 Pole 35 amp 1 3 GM24093 Plate Circuit Breaker 1 1 48 Screw Round Phillips Head M3 x 6 4 4 58 Screw Round Phillips Head M5 x 12 8 8 6 GM24040 Grommet 1 1 7 GM20851 Fuse 25 Amp 1 1 8 GM24062 Carrier Fuse 1 1 9 GM24061 Carrier Fuse 1 1 10 GM20849 Fuse 10 Amp 1 1 119 Nut Hex Head M4 5 5 12 4 Washer Split 4 mm ID 5 5 13 4 Washer Plain 4 mm ID 5 5 14 Screw Hex Head M4 x 16 5 5 15 GM24067 Rectifier Assembly 1 1 16 GM24092 Cover Controller Box 1 1 17 8 Nut Hex Head M6 4 4 18 4 Washer Plain 6 mm ID 5 5 19 8 Washer Tooth 6 mm ID 12 12 20 4 Screw Hex Head M6 x 25 1 1 21 8 Nut Hex Head M5 4 4 22 H Washer Plain 5 mm ID 6 6 23 4 Washer Tooth 5 mm ID 2 2 24 Screw Hex Head M5 x 20 1 1 25 Screw Hex Head M5 10 2 2 26 GM24060 Base Relay 3 3 27 GM24059 Relay 3 3 28 GM24064 Diode 3 Amp 400 Volt 3 3 29 GM24057 Base Electrical Connection 1 1 30 GM24058 Plate Electrical Connection 1 1 31 GM24157 Harness Control Box 1 1 32 GM24153 Harness Control Box to Engine 1 1 33 GM24154 Harness Engine 1 1 34 GM24155 Harness Control Box to Panel 1 1 35 GM24045 Vibromount 4 4 36 GM24036 Grommet 1 1 37 GM24038 Grommet 1 1 38 GM24071 Voltage Regulator 1 1 39 4 Washer Plain 6 mm ID 2 2 40 4 Screw Hex Head M6 x 2
31. eter sq in square inch SS stainless steel std standard stl steel tach tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to normal TDES time delay engine start TDNE time delay normal to emergency TDOE time delay off to emergency TDON time delay off to normal temp temperature term terminal TIF telephone influence factor TIR total indicator reading tol tolerance turbo turbocharger typ typical same in multiple locations UF underfrequency UHF ultrahigh frequency UL Underwriter s Laboratories Inc UNC unified coarse thread was NC UNF unified fine thread was NF univ universal US undersize underspeed UV ultraviolet undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency watt WCR withstand and closing rating w with w o without wt weight xfmr transformer TP 6138 5 02 Appendix Common Hardware Application Guidelines Use the information below and on the following pages to identify 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
32. illi 1 1000 M mega 106 when used with SI units male m3 cubic meter m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 22 bytes MCM one thousand circular mils MCCB molded case circuit breaker meggar megohmmeter MHz megahertz mi mile mil one one thousandth of an inch min minimum minute misc miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm milliohm MOhm MQ megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m sec meters per second A 2 Appendix MTBF 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 0 OV OZ pF PF ph PHC PHH PHM PLC PMG pot ppm PROM psi pt PTC PTO PVC qt qty R rad RAM RDO ref rem Res Coml RFI RH mean time between failure mean time between overhauls mounting megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrical 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
33. r Rubber Hose 1 8 GM24113 Plug M8 x 10 1 9 GM24513 Clip hose 1 Common hardware procure locally 17 Group 13 Fuel Filter and Pump 6138 13 Quantity Part Variation No Item Number Description 1 1 GM24125 Hose Fuel 1 2 GM24020 Clamp Hose 8 3 GM20850 Filter Fuel 1 4 GM24126 Hose Fuel Supply 2 5 GM24055 Pump Fuel 1 68 Washer Plain 6 mm ID 2 78 Washer Split 6 mm ID 2 8 Screw Hex Head M6 x 16 2 9 GM24127 Hose Fuel Return d 10 GM24025 Adapter Fuel Hose 2 11 GM24024 Connector Fuel Hose 2 12 Plug 1 4 NPT 2 4 Common hardware procure locally TP 6138 5 02 Group 14 Air Intake Filter 213 6138 14 6138 5 02 Quantity Part Variation No Item Number Description 1 1 GM24073 Screen Air Intake 1 218 Washer Plain 8 mm ID 2 3 8 Washer Split 8 mm ID 2 4 8 Screw Hex Head M8 25 2 5 20848 Screen 1 68 Washer Plain 5 mm ID 2 7 8 Washer Split 5 mm ID 2 8 8 Screw Hex Head M5 x 12 2 9 Washer Tooth 5 mm ID 6 10 8 Screw Hex Head M5 x 25 6 11 GM24144 Hose Air Intake 1 12 GM24022 Clamp Hose 1 13 GM23935 Gasket 1 Common hardware procure locally 19 Gasket Set Group 15 O 8 i o gQ i o Washer Gasket C Q O Ring 6138_15 TP 6138 5 02 20 Group 15 Gasket Set Quan
34. r Size L Internal Dimension Metric Screws Bolts Studs and Nuts M8 1 25 x 20 Lock Washers Length In Millimeters Screws and Bolts 5 8 Distance Between Threads In Millimeters E Internal Dimension Major Thread Diameter In Millimeters 6138 5 02 Appendix 5 Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items American Standard Part No Dimensions Hex Head Bolts Grade 5 465 17 1 4 20 x 38 X 465 6 1 4 20 x 50 X 465 2 1 4 20 x 62 X 465 16 1 4 20 x 75 X 465 18 1 4 20 x 88 X 465 7 1 4 20 x 1 00 X 465 8 1 4 20 x 1 25 X 465 9 1 4 20 1 50 465 10 1 4 20 1 75 X 465 11 1 4 20 2 00 X 465 12 1 4 20 x 2 25 X 465 14 1 4 20 x 2 75 X 465 21 1 4 20 x 5 00 465 25 1 4 28 x 38 X 465 20 1 4 28 x 1 00 125 33 5 16 18 x DO 125 23 5 16 18 x 62 125 3 5 16 18 x 75 125 31 5 16 18 88 125 5 5 16 18 x 1 00 X 125 24 5 16 18 x 1 25 125 34 5 16 18 x 1 50 125 25 5 16 18 x 1 75 X 125 26 5 16 18 x 2 00 230578 5 16 18 x 2 25 X 125 29 5 16 18 x 2 50 125 27 5 16 18 x 2 75 X 125 28 5 16 18 x 3 00 X 125 22 5 16 18 x 4 50 125 32 5 16 18 x 5 00 125 35 5 16 18 x 5 50 125 36 5 16 18 x 6 00 X 125 40 5 16 18 x 6 50 125 43 5 16 24 x 1 75 125 44 5 16 24 x 2 50 125 30 5 16 24 75 125 39 5 16 24 x 2 00 125 38 5 16 24 2 75 X 6238 2 3 8 16 62 X 6238 10 3 8 16 x 75 X 6238 3 3 8 16 x 88
35. tity Part Variation No Item Number Description 1 24014 Set Gasket 2 GM23934 Gasket Crankcase 3 GM23955 O ring 99 x 3mm 4 GM23937 Gasket Oil Pump 5 GM23954 O ring 32 x 2mm 6 GM23953 O ring 10 x 2 2 mm 7 GM23941 Gasket Cylinder Head 8 GM23962 Washer 9 GM23956 O ring 24 x 3 5 mm 10 GM23932 Gasket Rocker Cover 1119 Washer 5 mm ID 12 23931 Gasket 13 GM23933 Gasket Cover 14 GM23939 Gasket 15 GM23979 Washer Copper 5 mm ID 16 GM23958 Gasket 17 GM23938 Gasket Oil Filter 18 GM23977 Washer Copper 6 mm ID 19 GM23957 O ring 32 x 3 mm 20 GM23936 Gasket Plate 0 3 mm 21 GM23940 Gasket Plate 0 4 mm 22 GM23960 O ring 32 7 x 1 3 mm 23 GM23961 O ring 57 x 2 5 mm 24 GM23930 Gasket Plate 25 GM23959 Washer Copper 8 mm ID 26 GM23963 Washer Copper 8 mm ID 27 GM23935 Gasket 28 GM23981 Washer Copper 14 mm ID 29 GM23980 Washer Copper 12 mm ID 30 GM24029 O Ring h EA 23 424242424 Ai M sch ch MO MO CG sch b 4 Common hardware procure locally TP 6138 5 02 21 ing Base and Mount Group 16 6138 16 TP 6138 5 02 22 TP 6138 5 02 Group 16 Base and Mounting Quantity Part Variation No Item Number Description 1 1 GM24080 Tray 1 2 GM24044 Vibromount 4 3 Washer Plain 6 4 8 Washer Split 8 mm ID 11 5 Nut Hex H
36. uble 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 exh ext F fglass FHM fl oz flex freq FS ft ft Ibs ft min g ga gal gen genset GFI GND gov gph gpm gr GRD gr wt exhaust 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 equipment ground gross weight HxW xD height by width by depth 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 Ibs Inc ind int int ext IP ISO J JIS hex cap high cylinder head temperature heavy duty high exhaust temperature high engine temperature hexagon merc
37. ury 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 Appendix 1 k kilo 1000 K kelvin kA kiloampere KB kilobyte 219 bytes kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm kilo ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt hour kWm kilowatt mechanical L liter LAN local area network LxWxH length by width by height Ib pound pounds Ibm ft3 pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display shd load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side Lwa sound power level A weighted LWL low water level LWT low water temperature m meter m
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