Service Parts REOZJ REOZJB. Industrial Generator Sets. Models:

Transcription

1 Service Parts Industrial Generator Sets Models: REOZJ REOZJB See Group 701: Literature inside this manual for part numbers of engine and controller parts catalogs TP /18d

2 Common Replacement Parts Figure 1 identifies common replacement parts for your generator set. Refer to the groups on the following pages and the engine parts manual listed in Group 701: Literature for a complete list of maintenance and service parts. Engine Part Number Fan Belt Oil Filter Fuel Filter Fuel Filter (primary) Engine Description 350/400REOZJ/B 6135HF485/ GM76154/ GM80275, GM80277 GM80434 GM80469 GM HFG84 GM REOZJ/B 6135HFG75 GM76155 GM80275, GM80277 GM80434 GM80469 GM80460 Figure 1 Common Replacement Parts

3 Table of Contents Introduction... 4 Numbering System Significance... 4 Illustrations... 4 How to Find Part Numbers... 4 Hardware References... 4 Specification Number Index... 5 Air Intake... 6 Standard Duty... 6 Heavy Duty... 7 Cooling System... 8 Engine Nameplate and Decals Skid and Plant Mounting Alternator and Mounting Control and Harness Decision-Maker 550 Controller APM402/Decision-Maker 3000 Controller Literature Kit List Cooling System Kits Appendix A Abbreviations Appendix B Common Hardware Application Guidelines Appendix C General Torque Specifications Appendix D Common Hardware Identification Appendix E Common Hardware List Index TP /18 Table of Contents 3

4 Introduction This manual lists service replacement parts for generator set models as listed on the front cover. 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. Specification Number Index. Lists the generator set specs and groups. Group Parts Lists. List the 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. 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. 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 may not show all parts. Do not use illustrations for assembly or disassembly. HowtoFindPartNumbers 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 variation column. A blank space at the intersection means the variation/module does not use that part number. 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 listedinthetext. 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. 4 TP /18

5 Specification Number Index Group Title Group No Spec No. Variation Number 350REOZJ GM76156-GA1 * * 1 GR1 * * [ REOZJB GM85455-GA1 * * 1 GR1 * * [ 495 GM85455-GA4 * * 3 GR1 * * [ REOZJ GM76156-GA2 * * 1 GR1 * * [ REOZJB GM85455-GA2 * * 1 GR1 * * [ 496 GM85455-GA5 * * 3 GR1 * * [ REOZJ GM76157-GA2 * * 2 GR1 * * [ REOZJB GM85455-GA3 * * 2 GR1 * * [ 497 * Configured group. Refer to the generator set nameplate for the module number. Turn to the respective group on the following pages for parts breakdowns. [ Configured group. Refer to the generator set nameplate for the module number. See Group 701: Literature for list of controller parts manuals. TP /18 5

6 Air Intake Standard Duty GM A Find the installed module number on the generator set nameplate. Quantity Part Module Number Item Number Description GM75806-MA1 GM75806-MA Hose, 90 deg. reducer ( ID) Clamp, hose, 6.56/6.87 in Element, Air Indust Clamp, hose, 7.5/7.81 in Clamp, air cleaner (11.00 ID) GM77329 Bracket, Air Cleaner, 4M M125A Washer, Plain, 10.5 ID x 20.0 OD M125A Washer, Plain M Nut, Hex 10mm M Screw, Hex Cap M Screw, hex cap,fully thrd M10 x 25mm X Spacer,.531 ID x 1 OD x 1 in Clamp, hose, 6.56/6.87 in Clamp, hose, 6.25/6.56 in Tube assembly Tube assembly 1 17 X Cap, pipe (1/8 npt) Hose, hump reducer (6.00 to 5.50 ID) Clamp, hose, 5.81/6.12 in. 1 6 TP /18

7 Air Intake Heavy Duty GM A Find the installed module number on the generator set nameplate. Quantity Part Module Number Item Number Description GM75807-MA1 GM75807-MA Cap, rain Clamp, hose, 6.56/6.87 in Mount, Air Cleaner/Exhaust (18.00 ID) Hose, hump reducer (8.00 to 7.00 ID) Clamp, hose, 8.38/8.69 in Clamp, hose, 7.5/7.81 in GM23198 Hose, 90 Deg. Reducer (7.00 to 6.00 ) GM69932 Cleaner Ass y, Air GM77329 Bracket, Air Cleaner, 4M M125A Washer, Plain, 10.5 ID x 20.0 OD M125A Washer, Plain M Nut, Hex 10mm M Screw, Hex Cap M Screw, hex cap,fully thrd M10 x 25mm X Spacer,.531 ID x 1 OD x 1 in X Tube, steel Clamp, hose, 6.56/6.87 in Clamp, hose, 6.25/6.56 in Tube assembly Tube assembly 1 22 X Cap, pipe (1/8 npt) Clamp, hose, 5.81/6.12 in Hose, hump reducer (6.00 to 5.50 ID) 1 25 GM69997 Element, Primary (Outer) GM69998 Element, Secondary (Inner) 1 1 TP /18 7

8 TP /18 8 Cooling System GM C

9 Cooling System Find the installed module number on the generator set nameplate. Quantity Module Item Part Number Description 2 X Hose, radiator, straight, 1 in. ID X Hose, rubber, straight,.25 in. ID Valve, drain ( 3/8 nptf) Clamp, hose, 3.25/3.56 in Clamp, hose, 2.63/2.94 in Spacer, fan, 4 in Bracket, support GM21337 Fan GM64267 Bracket, Belt Guard GM75788 Radiator/CAC Assy, 50C GM84821 Radiator Assembly GM77292 Hose, Radiator (Upper) GM84897 Hose, Radiator (Upper) GM77293 Hose, Radiator (Lower) GM77294 Tube, Intake GM84895 Tube, Intake GM77297 Guard, Belt (RH) GM77298 Guard, Belt (LH) GM77299 Guard, Belt (Top) GM77300 Guard, Belt (Bottom) GM77301 Bracket, Belt Guard Mtg GM77303 Support, Radiator (RH) GM77304 Support, Radiator (LH) GM77635 Gasket, CAC Graphite GM77637 Connector, Hose GM77638 Clamp, Exhaust (5.25 In.) GM78800 Clamp, Hose M125A Washer, Plain, 8.4 ID x 16.0 OD M125A Washer, Plain, 10.5 ID x 20.0 OD M125A Washer, Plain M Screw, Hex Flnge M6x16mm flly thrd js M Nut, Hex 10mm M Screw, Hex Cap M Screw, Hex Cap M Screw, hex cap,fully thrd M10 x 25mm M Screw, Hex Cap M Screw, Hex Cap X Pipe (1/4 npt x 1.50 ) X Coupling, reducer ( 3/8 x 1/4 npt) X Clamp, hose,.69/1.25 in X Clamp, hose,.25/.70 in X Connector, hose X Washer,hardened,.406 ID x.812 in.od X Hose, Radiator Wire Inset 3.00 ID X Hose, Radiator Wire Inset 4.00 ID GM77295 Tube, Turbo CAC 1 50 GM78799 Tube, Turbo CAC 1 50 GM84896 Tube, Turbo CAC 1 50 GM85634 Tube, Turbo CAC 1 51 GM77635 Gasket, CAC Graphite GM77638 Clamp, Exhaust (5.25 In.) Clamp, hose, 3.06/3.38 in GM85118 Hose, Charged Air Cooler GM80658 Bracket, Belt Guard (LH) GM80659 Bracket, Belt Guard (RH) GM84769 Bracket, Tube CAC (not shown) Clamp, muffler, 4.12 in. (not shown) Clamp, muffler, 3.12 in. (not shown) GM84770 Bracket, CAC Tube (not shown) GM75802-MA1 GM75802-MA2 GM84898-MA1 GM84898-MA2 TP /18 9

10 Engine GM C 10 TP /18

11 Engine Quantity Part Variation Number Item Number Description GM13268 Bolt, Angle (NRP) Clamp, battery GM11694 O-ring, ISO 6149 (15.3mm ID) GM20745 Boot, Battery Lug GM22991 Bushing, Adapter GM39538 Fitting, Fuel GM63164 Rack, Battery GM74535 Terminal, Ground M125A Washer, Plain, 8.4 ID x 16.0 OD M Nut, Hex 8mm M Screw, Hex Cap M Screw, Hex Cap M Nut, Hex 12mm X Washer, Plain,.531 IDx1.062 in.od X Washer, plain,.406 ID x.812 in. OD M Nut, hex elastic stop, 8MM X Elbow, Street(90 deg x 1/2 nptf) X Cable Tie X Cable, battery (No.0 x 30 ) red X Cable, Battery X Cable, battery (No.0 x 8 ) black X Screw, hex head machine X Washer, spring,.515 ID x 1.06 in.od X Nut, flange spiralock, 3/ GM76154 Engine, JD6135HF485, 350/400kW 60Hz,24V 1 26 GM76155 Engine, JD6135HFG75, 450/500kW 60Hz,24V 1 26 GM88213 Engine, 24V 6135HFG84 1 Nameplate and Decals Nameplate and Decals are not illustrated. Quantity Part Var. Number Item Number Description GR Decal, Negative Battery Conn Decal, Caution Positive Term.Only Decal, Warning Rotating Parts Decal, Caution Hot Engine Decal, Warning Hot Coolant Decal, Warning Explosion Decal, Caution-Not A Step Decal, Ground Decal, Caution Welding Disconnect 2 10 GM15300 Decal, Exhaust Piping 1 11 GM19296 Decal, Fuel Type 1 12 GM20171 Decal, Warning Fan 1 13 GM78897 Decal, Lift Warning Decal, Number Decal, Caution Stdby Svc Connect Decal, Danger Moving Rotor Decal, Warning Voltage Backfeed Decal, Danger, High Voltage Decal, Ground 1 20 GM39683 Tag, Hang Lug Selection 1 21 GM49352 Tag, Hang 1 22 GM60531 Decal, Control Height 1 23 GM79042 Decal, Phasing A-B-C 2 24 GM79043 Decal, Phasing C-B-A 2 25 X Decal, Stripe 2 26 X Decal, Kohler Power System 2 TP /18 11

12 Skid and Plant Mounting GM A Find the installed module number on the generator set nameplate. Quantity Module Item Part Number Description 2 X Hose, rubber, straight,.62 in. ID Vibromount GM21085 Strap, ground (16 in.) GM59015 Fitting, Bulkhead Drain GM64142 Bracket, Engine Mounting M125A Washer, Plain M125A Washer, Plain, 10.5 ID x 20.0 OD M125A Washer, Plain M Nut, Hex 10mm M7985A Screw, Pan Head Machine M Screw, Hex Cap M Screw, Hex Cap M Screw, Hex Cap M Screw, Hex Cap M Screw, Hex Cap M Nut, Hex 5mm M Nut, hex elastic stop X Washer,lock,.456 ID x in.od X Washer,lock,.521 ID x 1.24 in. OD X Washer, plain X Washer, Plain,.531 IDx1.062 in.od X Plug, Pipe X Bolt, Hex Cap (1/2-13 x 1 ) Gr X Clamp, hose,.5/1 in X Connector, hose + Vibra Seal GM78894 Skid, 4M 1 26 GM78895 Skid, 5M 1 26 GM84830 Skid, 4M 1 26 GM84831 Skid, 5M 1 GM75803-MA1 GM75803-MA2 GM85632-MA1 GM85632-MA2 12 TP /18

13 Skid and Plant Mounting Find the installed module number on the generator set nameplate. Quantity Module Item Part Number Description 2 X Hose, rubber, straight,.62 in. ID GM86134 Engine Mount, Seismic GM84169 Engine Mount, Seismic GM21085 Strap, ground (16 in.) GM59015 Fitting, Bulkhead Drain GM84174 Bracket, Engine Mounting Seismic M125A Washer, Plain M125A Washer, Plain, 10.5 ID x 20.0 OD M125A Washer, Plain M Nut, Hex 10mm M7985A Screw, Pan Head Machine M Screw, Hex Cap M Screw, Hex Cap M Screw, Hex Cap M Screw, Hex Cap M Nut, Hex 5mm M Nut, hex elastic stop X Washer,lock,.456 ID x in.od X Washer,lock,.521 ID x 1.24 in. OD X Washer, plain X Washer, Plain,.531 IDx1.062 in.od X Plug, Pipe X Bolt, Hex Cap (1/2-13 x 1 ) Gr X Clamp, hose,.5/1 in X Connector, hose + Vibra Seal GM78894 Skid, 4M 1 26 GM78895 Skid, 5M 1 26 GM84830 Skid, 4M 1 26 GM84831 Skid, 5M 1 GM84173-MA1 GM84173-MA2 GM84829-MA1 GM84829-MA2 TP /18 13

14 Alternator and Mounting GM B 14 TP /18

15 Alternator and Mounting Find the installed module number on the generator set nameplate. Quantity Module Item Part Number Description Washer, hardened,.531 IDx1.06 in.od Vibromount Plate, generator mounting Bus, ground GM75910 Panel, Component Mtg M125A Washer, Plain M125A Washer, Plain M Nut, Hex 6mm M Nut, Hex M Screw, Hex Cap M Screw, Hex Head M Screw, Hex Cap M Screw, Hex Cap M Nut, hex 10mm M Nut, hex elastic stop X Washer, lock,.391 ID x.975 in. OD X Washer, plain,.406 ID x 1 in. OD X Washer, plain,.8 ID x 4.25 in. OD X Washer, plain,.8 ID x 3 in. OD X Screw, hex washer, thread-forming X Bolt, Hex Cap X Washer,hardened,.469 ID x.922 in. OD X Bolt, Hex Cap X Washer,spring,.39 ID x.81 in. OD X Nut, flange spiralock, 1/ M Screw, Hex Cap X Grommet Screen Screen GM Junction Box Assembly 4M (See page 24) GM Junction Box Assembly 5M (See page 24) GM Alternator Assy, 4M4021, Reconn, SAE GM Alternator Assy, 5M4027, Reconn, SAE GM Alternator Assy, 5M4028, Reconn, SAE GM Alternator Assy, 4M4266, 600V, SAE GM Alternator Assy, 5M4272, 600V, SAE GM Alternator Assy, 4M4019, Reconn, SAE X Washer, plain,.406 ID x 1 in. OD X-83-7 Nut, hex, 3/8-16, zinc X Washer,spring,.39 ID x.81 in. OD X Standoff insulator, 3/8-16 x 2 in X Bolt, Hex Cap X Stud GM75808-MA1 GM75808-MA2 GM75808-MA3 GM75808-MA4 GM75808-MA5 GM75808-MA6 TP /18 15

16 Alternator and Mounting, continued GM B 16 TP /18

17 Alternator and Mounting, continued Find the installed module number on the generator set nameplate. Quantity Module Item Part Number Description Washer, hardened,.531 IDx1.06 in.od Vibromount Plate, generator mounting Bus, ground GM75910 Panel, Component Mtg M125A Washer, Plain M125A Washer, Plain M Nut, Hex 6mm M Nut, Hex M Nut, Hex X Bolt, Hex Cap M Screw, Hex Cap M Screw, Hex Head M Screw, Hex Cap M Screw, Hex Cap M Nut, hex 10mm M Nut, hex elastic stop X Washer, lock,.391 ID x.975 in. OD X Washer, plain,.406 ID x 1 in. OD X Washer, plain,.8 ID x 4.25 in. OD X Washer, plain,.8 ID x 3 in. OD X Screw, hex washer, thread-forming X Bolt, Hex Cap X Washer,hardened,.469 ID x.922 in.od X Washer,spring,.39 ID x.81 in. OD X Nut, flange spiralock, 1/ M Screw, Hex Cap X Grommet Screen Screen GM ** Junction Box Assembly 5M (See page 24) GM ** Junction Box Assembly 4M (See page 24) GM Alternator Assy, 5M4024, Reconn, SAE GM Alternator Assy, 5M4027, Reconn, SAE GM Alternator Assy, 5M4028, Reconn, SAE GM Alternator Assy, 5M4270, 600V, SAE GM Alternator Assy, 5M4272, 600V, SAE GM Alternator Assy, 4M GM Alternator Assy, 4M GM Alternator Assy, 4M X Washer, plain,.406 ID x 1 in. OD X-83-7 Nut, hex, 3/8-16, zinc X Washer,spring,.39 ID x.81 in. OD X Standoff insulator, 3/8-16 x 2 in X Bolt, Hex Cap X Stud ** Use the Kit number and chart below to identify the color suffix. Add a suffix to this color dependant part number before ordering. GM78808-MA1 GM78808-MA2 GM78808-MA3 GM78808-MA4 GM78808-MA5 GM78808-MA6 GM78808-MA7 GM78808-MA8 Color Dependant Parts Kit No. Part Number Suffix Part Number Example (item 31) GM MA1 -BLK - BLK GM BLK GM MA2 -BLK -BLK GM BLK GM MA3 -BLK -BLK GM BLK GM MA4 -BLK -BLK GM BLK GM MA5 -BLK -BLK GM BLK GM MA6 -BLK -BLK GM BLK GM MA7 -BLK -BLK GM BLK GM MA8 -BLK -BLK GM BLK TP /18 17

18 Alternator and Mounting, continued GM B 18 TP /18

19 Alternator and Mounting, continued Find the installed module number on the generator set nameplate. Quantity Module Item Part Number Description Washer, hardened,.531 IDx1.06 in.od GM84170 Alternator Mount, Seismic GM84170 Alternator Mount, Seismic Bus, ground GM75910 Panel, Component Mtg M125A Washer, Plain M125A Washer, Plain M Nut, Hex 6mm M Nut, Hex M Screw, Hex Cap M Screw, Hex Head M Screw, Hex Cap M Screw, Hex Cap M Nut, hex 10mm M Nut, hex elastic stop X Washer, lock,.391 ID x.975 in. OD X Washer, plain,.406 ID x 1 in. OD X Washer, plain,.8 ID x 4.25 in. OD X Screw, hex washer, thread-forming X Bolt, Hex Cap X Washer,hardened,.469 ID x.922 in. OD X Bolt, Hex Cap X Washer,spring,.39 ID x.81 in. OD X Nut, flange spiralock, 1/ M Screw, Hex Cap X Grommet Screen Screen GM ** Junction Box Assembly 4M (See page 24) GM ** Junction Box Assembly 5M (See page 24) GM Alternator Assy, 5M GM Alternator Assy, 5M4027, Reconn, SAE GM Alternator Assy, 5M4028, Reconn, SAE GM Alternator Assy, 5M4270, 600V, SAE GM Alternator Assy, 5M4272, 600V, SAE GM Alternator Assy, 4M4021, Reconn, SAE GM Alternator Assy, 4M4266, 600V, SAE GM Alternator Assy, 4M4019, Reconn, SAE X Washer, plain,.406 ID x 1 in. OD X-83-7 Nut, hex, 3/8-16, zinc X Washer,spring,.39 ID x.81 in. OD X Standoff insulator, 3/8-16 x 2 in X Bolt, Hex Cap X Stud ** Use the Kit number and chart below to identify the color suffix. Add a suffix to this color dependant part number before ordering. GM84175-MA1 GM84175-MA2 GM84175-MA3 GM84175-MA4 GM84175-MA5 GM84175-MA6 GM84175-MA7 GM84175-MA8 Color Dependant Parts Kit No. Part Number Suffix Part Number Example (item 31) GM MA1 -BLK - BLK GM BLK GM MA2 -BLK -BLK GM BLK GM MA3 -BLK -BLK GM BLK GM MA4 -BLK -BLK GM BLK GM MA5 -BLK -BLK GM BLK GM MA6 -BLK -BLK GM BLK GM MA7 -BLK -BLK GM BLK GM MA8 -BLK -BLK GM BLK TP /18 19

20 Alternator and Mounting, continued GM B 20 TP /18

21 Alternator and Mounting, continued Find the installed module number on the generator set nameplate. Quantity Module Item Part Number Description Washer, hardened,.531 IDx1.06 in.od GM84170 Alternator Mount, Seismic GM84170 Alternator Mount, Seismic Bus, ground GM84527 Panel, Component Mtg M125A Washer, Plain M125A Washer, Plain M Nut, Hex 6mm M Nut, Hex M Screw, Hex Cap M Screw, Hex Head M Screw, Hex Cap M Screw, Hex Cap M Nut, hex 10mm M Nut, hex elastic stop X Washer, lock,.391 ID x.975 in. OD X Washer, plain,.406 ID x 1 in. OD X Washer, plain,.8 ID x 4.25 in. OD X Screw, hex washer, thread-forming X Bolt, Hex Cap X Washer,hardened,.469 ID x.922 in. OD X Bolt, Hex Cap X Washer,spring,.39 ID x.81 in. OD X Nut, flange spiralock, 1/ M Screw, Hex Cap X Grommet Screen Screen GM ** Junction Box Assembly 4M (See page 25) GM ** Junction Box Assembly 5M (See page 25) GM Alternator Assy, 5M GM Alternator Assy, 5M4027, Reconn, SAE GM Alternator Assy, 5M4028, Reconn, SAE GM Alternator Assy, 5M4270, 600V, SAE GM Alternator Assy, 5M4272, 600V, SAE GM Alternator Assy, 4M4021, Reconn, SAE GM Alternator Assy, 4M4266, 600V, SAE GM Alternator Assy, 4M4019, Reconn, SAE X Washer, plain,.406 ID x 1 in. OD X-83-7 Nut, hex, 3/8-16, zinc X Washer,spring,.39 ID x.81 in. OD X Standoff insulator, 3/8-16 x 2 in X Bolt, Hex Cap X Stud ** Use the Kit number and chart below to identify the color suffix. Add a suffix to this color dependant part number before ordering. GM84918-MA1 GM84918-MA2 GM84918-MA3 GM84918-MA4 GM84918-MA5 GM84918-MA6 GM84918-MA7 GM84918-MA8 Color Dependant Parts Kit No. Part Number Suffix Part Number Example (item 31) GM MA1 -BLK - BLK GM BLK GM MA2 -BLK -BLK GM BLK GM MA3 -BLK -BLK GM BLK GM MA4 -BLK -BLK GM BLK GM MA5 -BLK -BLK GM BLK GM MA6 -BLK -BLK GM BLK GM MA7 -BLK -BLK GM BLK GM MA8 -BLK -BLK GM BLK TP /18 21

22 Alternator and Mounting, continued GM B 22 TP /18

23 Alternator and Mounting, continued Find the installed module number on the generator set nameplate. Quantity Module Item Part Number Description Washer, hardened,.531 IDx1.06 in.od Vibromount Plate, generator mounting Bus, ground GM84527 Panel, Component Mtg M125A Washer, Plain M125A Washer, Plain M Nut, Hex 6mm M Nut, Hex M Screw, Hex Cap M Screw, Hex Head M Screw, Hex Cap M Screw, Hex Cap M Nut, hex 10mm M Nut, hex elastic stop X Washer, lock,.391 ID x.975 in. OD X Washer, plain,.406 ID x 1 in. OD X Washer, plain,.8 ID x 4.25 in. OD X Washer, plain,.8 ID x 3 in. OD X Screw, hex washer, thread-forming X Bolt, Hex Cap X Washer,hardened,.406 ID x.812 in.od M Bolt, Hex Cap X Washer,spring,.39 ID x.81 in. OD X Nut, flange spiralock, 1/ M Screw, Hex Cap X Grommet Screen Screen GM ** Junction Box Assembly 4M (See page 25) GM ** Junction Box Assembly 5M (See page 25) GM Alternator Assy, 4M4021, Reconn, SAE GM Alternator Assy, 5M GM Alternator Assy, 5M4027, Reconn, SAE GM Alternator Assy, 5M4028, Reconn, SAE GM Alternator Assy, 4M4266, 600V, SAE GM Alternator Assy, 5M GM Alternator Assy, 5M4272, 600V, SAE GM Alternator Assy, 4M4019, Reconn, SAE X Washer, plain,.406 ID x 1 in. OD X-83-7 Nut, hex, 3/8-16, zinc X Washer,spring,.39 ID x.81 in. OD X Standoff insulator, 3/8-16 x 2 in X Bolt, Hex Cap X Stud GM85633-MA1 GM85633-MA2 GM85633-MA3 GM85633-MA4 GM85633-MA5 GM85633-MA6 GM85633-MA7 GM85633-MA8 ** Use the Kit number and chart below to identify the color suffix. Add a suffix to this color dependant part number before ordering. Color Dependant Parts Kit No. Part Number Suffix Part Number Example (item 31) GM MA1 -BLK - BLK GM BLK GM MA2 -BLK -BLK GM BLK GM MA3 -BLK -BLK GM BLK GM MA4 -BLK -BLK GM BLK GM MA5 -BLK -BLK GM BLK GM MA6 -BLK -BLK GM BLK GM MA7 -BLK -BLK GM BLK GM MA8 -BLK -BLK GM BLK TP /18 23

24 Alternator and Mounting, continued Items not shown: 3, 8, 9 6 GM B Quantity Part Module Number Item Number Description GM GM GM GM Insert, Threaded (M6 x 1.0 Hex) GM75889** Box, Junction (4M) 1 4 GM75890** Box, Junction (5M) 1 4 GM75891** Box, Junction (7M) 1 5 GM75892 Panel, J-Box (Louvered) GM75895 Panel, J-Box (Cable Entry) M Screw, Hex Flnge M6x16mm flly thrd js X Grommet, round Base, tie wrap snapin X Grommet, round ** Use the Kit number and chart below to identify the color suffix. Add a suffix to this color dependant part number before ordering. Color Dependant Parts Module No. Part Number Suffix Part Number Example (item 4) GM BLK - BLK GM BLK GM BLK -BLK GM BLK GM BLK -BLK GM BLK 24 TP /18

25 Alternator and Mounting, continued Items not shown: 8, 9 6 GM A Quantity Part Module Number Item Number Description GM GM GM84524** Box, Junction (4M) 1 4 GM84525** Box, Junction (5M) 1 5 GM75892 Panel, J-Box (Louvered) GM75895 Panel, J-Box (Cable Entry) GM Screw, Sheetmetal X Grommet, round Base, tie wrap snapin X Grommet, round 1 1 ** Use the Kit number and chart below to identify the color suffix. Add a suffix to this color dependant part number before ordering. Color Dependant Parts Module No. Part Number Suffix Part Number Example (item 4) GM BLK - BLK GM BLK GM BLK -BLK GM BLK TP /18 25

26 Control and Harness GM B 26 TP /18

27 Control and Harness Find the installed module number on the generator set nameplate. Quantity Part Module Number Item Number Description GM75795-MA1 GM75795-MA2 GM85393-MA1 1 GM77970 Harness, Engine kw JD Tier III GM77977 Harness, Diagnostic kw JD Switch, toggle, 1 pole Plug, Black Plastic Lamp assy 28VDC yel/amb led GM51705 Switch, low water temp Base, tie wrap snapin GM79677 PCB assy Marathon excitation interface GM13980 PCB Assy CT Burden Resistor GM49747 Relay, 24V DC GM62565 Decal, Diagnostic GM66270 Sensor, Low Coolant Level GM77904 Bracket, Mtg (Diagnostic) GM77909 Cover, Diagnostic M Screw GM Insert, Threaded (M6 x 1.0 Hex) M7985A Screw, Pan Head Machine X Screw, Tapping X Screw, Tapping X Plug, Button X Plug, Button X Plug, Button GM77981 Harness, Control Box kw JD 1 30 GM77976 Harness, Control Box kw JD 1 30 GM85395 Harness, Control Box kw JD 1 TP /18 27

28 Control and Harness, continued APM402/Decision-Maker 3000 Controller , 21 25, GM C 28 TP /18

29 Control and Harness, continued Find the installed module number on the generator set nameplate. Quantity Module Part Number Item Number Description GM75799-MA1 GM MA1 1 GM77978 Harness, A/C Control Box Plug, black plastic Lamp assy 28VDC yel/amb led Base, tie wrap snapin GM39458 Sender, Temperature GM Insert, Threaded (M6 x 1.0 Hex) GM13980 PCB Assy CT Burden Resistor GM49747 Relay, 24V DC GM66270 Sensor, Low Coolant Level GM69565 Decal, Diagnostic GM77903 Bracket, Mtg (Diagnostic) GM77909 Cover, Diagnostic GM77970 Harness, Engine kw JD Tier III GM77977 Harness, Diagnostic kw JD GM77979 Harness, Control Box kw JD GM79677 PCB assy Marathon excitation interface M Screw, Hex Flnge M6x16mm flly thrd js M7985A Screw, Pan Head Machine X Screw, Tapping X Screw, Tapping X Plug, Button X Plug, Button X Plug, Button 1 1 TP /18 29

30 Literature Quantity Part Variation Number Item Number Description TP-5374 Warranty 1 -Year Limited, Industrial TP-5700 I/M kW, Industrial TP-6140 O/I/M Cntrlr Setup & Appl, DecMaker TP-6200 O/M kw, DecMaker550, Ver TP-6694 O/M DEC3000 Controller TP-6747 O/I/M DPS System Installation and Setup TP-6750 O/M DEC 6000 Controller TP-6373 S/M Pilot -Excited PM Altrntr, kW TP-6356 S/M Controllers, kw, Ind TP-6785 P/C 350/400REOZJ, Ind TP-6746 P/C DPS System TP-6780 P/C DEC 550 Controller (J -Box Panel Mt) TP-6781 P/C DEC 3000 Controller TP-6797 W/D REOZJ, Industrial TP-6787 O/M John Deere 6135HF485 Engine TP-6371 S/M JD Alt & Starting Motors, (CTM77) TP-6788 S/M John Deere 6135HF485 Engine TP-6789 S/M John Deere 6135HF485 Engine Electronic Fuel System TP-6786 P/C John Deere 6135HF485 Engine TP-5578 O/I/S/M Marathon Altntr MmaxDVR (GPN008) TP /18

31 Kit List This section lists the part numbers of modules/kits not listed in the group parts lists. Refer to the generator set nameplate or the list below to identify the module/kit number installed on your generator set. See the sections following this page for the parts list of the module/kit. 350/400 kw 500 kw Controllers See Group 701: Literature for list of controller parts manuals. Cooling Systems Heater, block V GM75809-KA1 GM75809-KA V GM75809-KA2 GM75809-KA V GM75809-KA3 GM75809-KA V GM75809-KA4 GM75809-KA4 Duct flange, radiator GM75810-KA1 GM75810-KA1 GM85627-KA1 GM85627-KA1 Remote Radiator Setup GM78803-MA1 GM78803-MA2 TP /18 31

32 Cooling System Kits Qty. Description Part No. Block Heater, 2500W, 90/120V, 1Ph GM75809-KA1 1 Heater, Block GM Block Heater Service Element 120V/2500W GM Tag, hang Valve, Shutoff (3/4-14npt) GM Tag, Hang GM Bracket, Block Heater GM Washer, Plain, 8.4 ID x 16.0 OD M125A Washer, Plain, 10.5 ID x 20.0 OD M125A Nut, Hex 6mm M Nut, Hex 8mm M Screw, Hex Cap M Screw, Hex Cap M Screw, hex cap,fully thrd M10 x 25mm M Pipe, Nipple (3/4 npt x 1.38 ) X Pipe (3/4 npt x 3.50 ) X Washer, Plain M125A Clamp, hose,.69/1.25 in. X Connector, hose + Vibra Seal X Hose, Coolant 44 X Clamp, insulated, 1.25 in. X Hose, Coolant 65 X Elbow, pipe (90 deg x 3/4 npt) X Block Heater, 2500W, 190/208V, 1 Ph GM75809-KA2 1 Heater, Block GM Block Heater Service Element 208V/2500W GM Tag, hang Valve, Shutoff (3/4-14npt) GM Tag, Hang GM Bracket, Block Heater GM Washer, Plain, 8.4 ID x 16.0 OD M125A Washer, Plain, 10.5 ID x 20.0 OD M125A Nut, Hex 6mm M Nut, Hex 8mm M Screw, Hex Cap M Screw, Hex Cap M Screw, hex cap,fully thrd M10 x 25mm M Pipe, Nipple (3/4 npt x 1.38 ) X Pipe (3/4 npt x 3.50 ) X Washer, Plain M125A Clamp, hose,.69/1.25 in. X Connector, hose + Vibra Seal X Hose, Coolant 44 X Clamp, insulated, 1.25 in. X Hose, Coolant 65 X Elbow, pipe (90 deg x 3/4 npt) X Qty. Description Part No. Block Heater, 2500W, 210/240V, 1Ph GM75809-KA3 1 Heater, Block GM Block Heater Service Element 240V/2500W GM Tag, hang Valve, Shutoff (3/4-14npt) GM Tag, Hang GM Bracket, Block Heater GM Washer, Plain, 8.4 ID x 16.0 OD M125A Washer, Plain, 10.5 ID x 20.0 OD M125A Nut, Hex 6mm M Nut, Hex 8mm M Screw, Hex Cap M Screw, Hex Cap M Screw, hex cap,fully thrd M10 x 25mm M Pipe, Nipple (3/4 npt x 1.38 ) X Pipe (3/4 npt x 3.50 ) X Washer, Plain M125A Clamp, hose,.69/1.25 in. X Connector, hose + Vibra Seal X Hose, Coolant 44 X Clamp, insulated, 1.25 in. X Hose, Coolant 65 X Elbow, pipe (90 deg x 3/4 npt) X Block Heater, 2500W, 380/480V, 1Ph GM75809-KA4 1 Heater, Block GM Block Heater Service Element 480V/2500W GM Tag, hang Valve, Shutoff (3/4-14npt) GM Tag, Hang GM Bracket, Block Heater GM Washer, Plain, 8.4 ID x 16.0 OD M125A Washer, Plain, 10.5 ID x 20.0 OD M125A Nut, Hex 6mm M Nut, Hex 8mm M Screw, Hex Cap M Screw, Hex Cap M Screw, hex cap,fully thrd M10 x 25mm M Pipe, Nipple (3/4 npt x 1.38 ) X Pipe (3/4 npt x 3.50 ) X Washer, Plain M125A Clamp, hose,.69/1.25 in. X Connector, hose + Vibra Seal X Hose, Coolant 44 X Clamp, insulated, 1.25 in. X Hose, Coolant 65 X Elbow, pipe (90 deg x 3/4 npt) X TP /18

33 Cooling System Kits Qty. Description Part No. Duct Flange, Radiator GM75810-KA1 2 Frame, Air Duct (Vertical) GM Frame, Air Duct (Horizontal) GM70151 Duct Flange, Radiator GM85627-KA1 2 Frame, Air Duct (Vertical) GM Frame, Air Duct (Horizontal) GM85626 Qty. Description Part No. Remote Radiator Setup GM78803-MA1 1 Tube, Turbo CAC GM Gasket, CAC Graphite GM Clamp, Exhaust (5.25 in.) GM Bracket, Support Hose, Radiator (Upper) GM Bracket, Belt Guard GM Hose, Radiator Lower GM Tube, Intake GM Guard, Belt (RH) GM Guard, Belt (LH) GM Guard, Belt (Top) GM Guard, Belt (Bottom) GM Bracket, Belt Guard Mtg GM Clamp, Hose, 4.13/4.44 GM Guard, Pulley Cover GM Guard, Belt GM Washer, Plain 10.5 Id X 20.0 OD M125A Washer, Plain M125A Screw, Hex Flnge M6x16mm Flly Thrd Js500 M Nut, Hex 10mm M Screw, Metric Thread Forming 12mm M7500D Screw, Hex Cap,Fully Thrd M10 X 25mm M Screw, Hex Cap M Clamp, hose,.69/1.25 in. X Hose, Radiator Wire Inset 4.00 ID X Connector, Hose + Vibra Seal 6.4 X Remote Radiator Setup GM78803-MA2 1 Clamp, muffler, 3.12 in Clamp, Hose, 3.06/3.38 in Tube, Turbo CAC GM Bracket, CAC Tube GM Hose, Charged Air Cooler GM Bracket, Support Hose, Radiator (Upper) GM Bracket, Belt Guard GM Hose, Radiator Lower GM Tube, Intake GM Guard, Belt (RH) GM Guard, Belt (LH) GM Guard, Belt (Top) GM Guard, Belt (Bottom) GM Bracket, Belt Guard Mtg GM Clamp, Hose, 4.13/4.44 GM Guard, Pulley Cover GM Guard, Belt GM Washer, Plain 10.5 Id X 20.0 OD M125A Washer, Plain M125A Screw, Hex Flnge M6x16mm Flly Thrd Js500 M Nut, Hex 10mm M Screw, Metric Thread Forming 12mm M7500D Screw, Hex Cap,Fully Thrd M10 X 25mm M Screw, Hex Cap M Clamp, hose,.69/1.25 in. X Hose, Radiator Wire Inset 4.00 ID X Connector, Hose + Vibra Seal 6.4 X TP /18 33

34 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC advanced digital control; analog to digital converter adj. adjust, adjustment ADV advertising dimensional drawing Ah amp-hour AHWT anticipatory high water temperature AISI American Iron and Steel Institute ALOP anticipatory low oil pressure alt. alternator Al aluminum ANSI American National Standards Institute (formerly American Standards Association, ASA) AO anticipatory only APDC Air Pollution Control District API American Petroleum Institute approx. approximate, approximately AQMD Air Quality Management District AR as required, as requested AS as supplied, as stated, as suggested ASE American Society of Engineers ASME American Society of Mechanical Engineers assy. assembly ASTM American Society for Testing Materials ATDC after top dead center ATS automatic transfer switch auto. automatic aux. auxiliary avg. average AVR automatic voltage regulator AWG American Wire Gauge AWM appliance wiring material bat. battery BBDC before bottom dead center BC battery charger, battery charging BCA battery charging alternator BCI Battery Council International BDC before dead center BHP brake horsepower blk. black (paint color), block (engine) blk. htr. block heater BMEP brake mean effective pressure bps bits per second br. brass BTDC before top dead center Btu British thermal unit Btu/min. British thermal units per minute C Celsius, centigrade cal. calorie CAN controller area network CARB California Air Resources Board CB circuit breaker cc cubic centimeter CCA cold cranking amps ccw. counterclockwise CEC Canadian Electrical Code cert. certificate, certification, certified cfh cubic feet per hour cfm cubic feet per minute 34 Appendix CG center of gravity CID cubic inch displacement CL centerline cm centimeter CMOS complementary metal oxide substrate (semiconductor) cogen. cogeneration com communications (port) coml commercial Coml/Rec Commercial/Recreational conn. connection cont. continued CPVC chlorinated polyvinyl chloride crit. critical CRT cathode ray tube CSA Canadian Standards Association CT current transformer Cu copper cul Canadian Underwriter s Laboratories CUL Canadian Underwriter s Laboratories cu. in. cubic inch cw. clockwise CWC city water-cooled cyl. cylinder D/A digital to analog DAC digital to analog converter db decibel db(a) decibel (A weighted) DC direct current DCR direct current resistance deg., degree dept. department DFMEA Design Failure Mode and Effects Analysis dia. diameter DI/EO dual inlet/end outlet DIN Deutsches Institut fur Normung e. V. (also Deutsche Industrie Normenausschuss) DIP dual inline package DPDT double-pole, double-throw DPST double-pole, single-throw DS disconnect switch DVR digital voltage regulator E, emer. emergency (power source) ECM electronic control module, engine control module EDI electronic data interchange EFR emergency frequency relay e.g. for example (exempli gratia) EG electronic governor EGSA Electrical Generating Systems Association EIA Electronic Industries Association EI/EO end inlet/end outlet EMI electromagnetic interference emiss. emission eng. engine EPA Environmental Protection Agency EPS emergency power system ER emergency relay ES engineering special, engineered special ESD electrostatic discharge est. estimated E-Stop emergency stop etc. et cetera (and so forth) exh. exhaust ext. external F Fahrenheit, female fglass. fiberglass FHM flat head machine (screw) fl. oz. fluid ounce flex. flexible freq. frequency FS full scale ft. foot, feet ft. lb. foot pounds (torque) ft./min. feet per minute ftp file transfer protocol g gram ga. gauge (meters, wire size) gal. gallon gen. generator genset generator set GFI ground fault interrupter GND, ground gov. governor gph gallons per hour gpm gallons per minute gr. grade, gross GRD equipment ground gr. wt. gross weight H x W x D height by width by depth HC hex cap HCHT high cylinder head temperature HD heavy duty HET high exhaust temp., high engine temp. hex hexagon Hg mercury (element) HH hex head HHC hex head cap HP horsepower hr. hour HS heat shrink hsg. housing HVAC heating, ventilation, and air conditioning HWT high water temperature Hz hertz (cycles per second) IC integrated circuit ID inside diameter, identification IEC International Electrotechnical Commission IEEE Institute of Electrical and Electronics Engineers IMS improved motor starting in. inch in. H 2 O inches of water in. Hg inches of mercury in. lb. inch pounds Inc. incorporated ind. industrial int. internal int./ext. internal/external I/O input/output IP iron pipe ISO International Organization for Standardization J joule JIS Japanese Industry Standard k kilo (1000) K kelvin ka kiloampere TP /16

35 KB kilobyte (2 10 bytes) KBus Kohler communication protocol kg kilogram kg/cm 2 kilograms per square centimeter kgm kilogram-meter kg/m 3 kilograms per cubic meter khz kilohertz kj kilojoule km kilometer kohm, k 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 kwth kilowatt-thermal L liter LAN local area network L x W x H length by width by height lb. pound, pounds lbm/ft 3 pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld. 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 L wa sound power level, A weighted LWL low water level LWT low water temperature m meter, milli (1/1000) M mega (10 6 when used with SI units), male m 3 cubic meter m 3 /hr. cubic meters per hour m 3 /min. cubic meters per minute ma milliampere man. manual max. maximum MB megabyte (2 20 bytes) MCCB molded-case circuit breaker MCM one thousand circular mils 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, m milliohm MOhm, M megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard ms millisecond m/sec. meters per second MTBF mean time between failure MTBO mean time between overhauls mtg. mounting MTU Motoren-und Turbinen-Union MW megawatt mw milliwatt F microfarad N, norm. normal (power source) NA not available, not applicable nat. gas natural gas NBS National Bureau of Standards NC normally closed NEC National Electrical Code NEMA National Electrical Manufacturers Association NFPA National Fire Protection Association Nm newton meter NO normally open no., nos. number, numbers NPS National Pipe, Straight NPSC National Pipe, Straight-coupling NPT National Standard taper pipe thread per general use NPTF National Pipe, Taper-Fine NR not required, normal relay ns nanosecond OC overcrank OD outside diameter OEM original equipment manufacturer OF overfrequency opt. option, optional OS oversize, overspeed OSHA Occupational Safety and Health Administration OV overvoltage oz. ounce p., pp. page, pages PC personal computer PCB printed circuit board pf picofarad PF power factor ph., phase PHC Phillipsr head Crimptiter (screw) PHH Phillipsr hex head (screw) PHM pan head machine (screw) PLC programmable logic control PMG permanent magnet generator pot potentiometer, potential ppm parts per million PROM programmable read-only memory psi pounds per square inch psig pounds per square inch gauge pt. pint PTC positive temperature coefficient PTO power takeoff PVC polyvinyl chloride qt. quart, quarts qty. quantity R replacement (emergency) power source rad. radiator, radius RAM random access memory RDO relay driver output ref. reference rem. remote Res/Coml Residential/Commercial RFI radio frequency interference RH 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 RTU remote terminal unit RTV room temperature vulcanization RW read/write SAE Society of Automotive Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier s, sec. second SI Systeme international d unites, International System of Units SI/EO side in/end out sil. silencer SN serial number SNMP simple network management protocol SPDT single-pole, double-throw SPST single-pole, single-throw spec specification specs specification(s) sq. square sq. cm square centimeter 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 THD total harmonic distortion 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 W watt WCR withstand and closing rating w/ with w/o without wt. weight xfmr transformer TP /16 Appendix 35