Service Parts. 5E/4EF 7.3E/6EF 5ECD/4EFCD -Low CO 7.3ECD/6EFCD -Low CO. Marine Generator Sets. Models: TP /06e

Transcription

1 Service Parts Marine Generator Sets Models: 5E/4EF 7.E/6EF 5ECD/4EFCD -Low CO 7.ECD/6EFCD -Low CO TP /06e

2 Table of Contents Description Page Description Page Introduction... Number Significance... How to Find Part Numbers... Group 10: Fuel System Group 104: Cooling System Group 105: Engine Hardware References... Group 107: Nameplate and Decals Specification Number Index... 4 Group 109: Skid and Plant Mounting Group 1: Cylinder and Crankcase... 6 Group 116: Exhaust... 0 Group 2: Piston and Crankshaft... 7 Group 201: Generator and Mounting... 2 Group 01: Controller and Mounting... 4 Group : Valves and Camshaft... 8 Group 701: Literature... 8 Group 4: Lubrication and Oil Filter... 9 Accessories... 9 Group 5: Ignition Appendix A Glossary of Abbreviations Group 6: Governor Appendix B Common Hardware Group 7: Carburetor Application Guidelines Group 9: Starter Appendix C General Torque Specifications Group 10: Engine Cooling Appendix D Common Hardware Identification Group 101: Air Intake Appendix E Common Hardware List... 50

3 This manual lists service replacement parts for 5E/7.E and 5ECD/7.ECD 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. 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. x:in:004:002 Numbering System Significance This manual uses the following numbering systems: Specification Number. A six-digit number with a PAprefix. The Specification Number Index does not show the prefix. Spec 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 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 Introduction x:in:004:00 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. x:in:004:004a 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.. 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 x:in:004:005 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, /8-16 in the text means that the piece is /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. x:in:004:006 TP /06

4 Specification Number Index Group Title Group No Spec No. Variation Number 5E PA PA PA GM2925-GA GM5004-GA E PA PA PA GM2925-GA GM5004-GA Group Title Group No Spec No. Variation Number 5E PA PA PA GM2925-GA GM5004-GA E PA PA PA GM2925-GA GM5004-GA TP /06

5 Specification Number Index Group Title Group No Spec No. Variation Number 4EFCD GM9685-GA ECD GM9685-GA EFCD GM9685-GA ECD GM9685-GA Group Title Group No Spec No. Variation Number 4EFCD GM9685-GA ECD GM9685-GA EFCD GM9685-GA ECD GM9685-GA TP /06 5

6 Group 1: Cylinder and Crankcase _1 Qty. Var. Item Part No. Description Gasket, head Cylinder head (for engine model AS 04) Cylinder head Cylinder head (for engine model AS 04) Cylinder head Case, rocker Case, rocker (includes oil fill spout) Gasket, rocker case Gasket Gasket, crankcase cover Plate Plate Cover Valve Cover, crankcase Crankcase, complete Joint Screw Pin Seal, oil Seal, oil Seal, oil Plug Collar Bolt Clamp Tube Bolt, flanged Bolt, flanged Bolt, flanged Bolt, flanged 6 TP /06

7 Group 2: Piston and Crankshaft _2 Qty. Var. Item Part No. Description Piston (generator set serial numbers before 75809) 2 1 GM29868 Piston (engine model ES04; generator set serial numbers and after) 2 1 GM29868 Piston Piston, 0.25 OS AR Piston, 0.50 OS (generator set serial numbers before 75809) AR 1 GM29871 Piston, 0.50 OS (engine model ES04; generator set serial numbers and after) AR 1 GM29871 Piston, 0.50 OS AR Pin, piston Ring set, piston (generator set serial numbers before 75809) 2 GM29869 Ring set, piston (engine model ES04; generator set serial numbers and after) 2 GM29869 Ring set, piston Ring set, piston, OS AR 5978 Ring set, piston, 0.50 OS (generator set serial numbers before 75809) AR GM29870 Ring set, piston, 0.50 OS (engine model ES04; generator set serial numbers and after) AR GM29870 Ring set, piston, 0.50 OS AR Connecting rod assembly Crankshaft assembly (generator set serial numbers before 75809) 1 5 GM29872 Crankshaft assembly (engine model ES04; generator set serial numbers and after) 1 5 GM29872 Crankshaft assembly Gear spur (generator set serial numbers before 75809) 1 6 GM2987 Gear spur (engine model ES04; generator set serial numbers and after) 1 6 GM2987 Gear spur Ring, snap Bolt, connecting rod Pin, dowel 1 1 AR As Required TP /06 7

8 Group : Valves and Camshaft _ Qty. Var. Item Part No. Description Valve, intake (for engine model AS 04 and BS 04) Valve, intake Valve, exhaust (for engine model AS 04 and BS 04) Valve, exhaust Retainer, valve spring (for engine model AS 04 and BS 04) Retainer, valve spring Arm, rocker Shaft, rocker Tappet Rod, push Seat, spring Spring, engine valve (for engine model AS 04 and BS 04) Spring, engine valve Camshaft, complete (generator set serial numbers before 75809) 1 10 GM29874 Camshaft, complete (engine model ES04; generator set serial numbers and after) 1 10 GM29874 Camshaft, complete Screw Nut Seal, oil Circlip Collet TP /06

9 Group 4: Lubrication and Oil Filter _4 Qty. Var. Item Part No. Description Gasket, drain plug Shaft, oil pump Plate Cover Dipstick Cap, oil fill Rotor, oil pump (in) Rotor, oil pump (out) Oil filter Oil filter screen Gear spur (generator set serial numbers before 75809) 1 11 GM29875 Gear spur (engine model ES04; generator set serial numbers and after) 1 11 GM29875 Gear spur Pin Ring, 0.20 mm Plug, drain Spring Bolt, flanged Screw, pan Ball, steel 1 1 TP /06 9

10 Group 5: Ignition _5 Qty. Var. Item Part No. Description Gasket Voltage regulator Igniter Coil, ignition 2 4 Coil (See Group 105) Cap, spark plug 2 5 Cap (See Group 105) Flywheel assembly Harness Harness Harness Harness Switch, oil pressure Switch, temperature Coil, pulsing Coil, charging Nut, hex 1 1 Qty. Var. Item Part No. Description Washer Clamp Tube Spark plug (for engine model AS 04) Spark plug 2 19 GM46180 Spark plug Band Clamp Clamp Bolt, flanged Bolt, flanged Screw, pan Screw, pan Screw, pan Screw, pan Key, woodruff X Screw, hex washer, thread- forming TP /06

11 Group 6: Governor See groups 10 and 104 for additional fuel system parts _6 Qty. Var. Item Part No. Description Bracket Lever Link Pivot arm Spring, governor Sleeve Arm, governor (for engine model AS 04 and BS 04) Arm, governor Governor assembly (generator set serial numbers before 75809) 1 8 GM29878 Governor assembly (engine model ES04; generator set serial numbers and after) 1 8 GM29878 Governor assembly Panel, control Bolt Screw Nut Washer Spacer Spring Collar Washer Stud Bolt (for engine model AS 04 and BS 04) Bolt Bolt Nut, hex Nut, hex Washer 1 1 TP /06 11

12 12 TP /06 Group 7: Carburetor _7

13 Group 7: Carburetor Qty. Var. Item Part No. Description Gasket Gasket Gasket Gasket, air filter Gasket, carburetor Gasket, intake pipe Gasket, intake manifold Gasket, intake manifold Plate Carburetor assembly 1 10 GM24510 Carburetor repair kit Screw, pilot air Float chamber Screw, throttle stop Valve, throttle Float valve Float Air jet Air jet Gasket Shaft, carburetor choke Shaft, carburetor Pipe, intake Pipe, intake Valve, choke Solenoid Wire lead Pipe Limiter Nozzle, main Holder, main jet Intake manifold Fitting Screw Screw Screw Screw Washer Collar Collar Ring, snap Pin O-ring Main jet Pilot jet Plug Spring Spring Seal Seal Spring Bolt Bolt Clamp Clamp Tube Bolt, flanged Bolt, flanged Bolt, flanged Bolt, flanged Screw 1 TP /06 1

14 Group 9: Starter _9 Qty. Var. Item Part No. Description Clutch assembly Holder assembly Cover assembly Cover assembly Brush Spring, brush Armature Starter Nut Washer Washer Collar 1 Qty. Var. Item Part No. Description Bushing Bushing Ring, snap O-ring O-ring O-ring Spring Bolt Bolt Bolt, flanged 1 2 Not sold separately 1 14 TP /06

15 Group 10: Engine Cooling _10b Qty. Var. Item Part No. Description Cap Bracket Bracket (See Group 105) Bracket Gasket, water pump Gasket, water pump Gasket, thermostat cover Shaft, impeller Cover, thermostat Cover, pump Hose, cooling Hose, cooling Hose, cooling Reservoir Water pump (generator set serial numbers before 75809) 1 14 GM29876 Water pump (engine model ES04; generator set serial numbers and after) 1 14 GM29876 Water pump Mechanical seal Spur gear (generator set serial numbers before 75809) 1 16 GM29877 Spur gear (engine model ES04; generator set serial numbers and after) 1 Qty. Var. Item Part No. Description GM29877 Spur gear Joint Impeller Pump case Nut Clamp Clamp Pin Seal, oil Ball Collar Clamp Clamp Tube Washer Bolt, flanged Bolt, flanged Bolt, flanged Bolt, flanged Bolt, flanged Bolt, flanged Pin, dowel O-ring O-ring Mount 2 TP /06 15

16 Group 101: Air Intake 4 6 1, , a Qty. Var. Item Part No. Description 1 1 X Grommet 4 2 M Screw, hex head cap 4 X Screw, pan head machine Guard, flywheel Duct, air inlet Arrester, flame Gasket, air intake Insulation, acoustic foam* Duct, air intake* Cover, air intake* Mount 2 12 X Washer, lock,.262 ID x.74 ID 2 * Item is included in service kit GM See the table below for a list of generator set serial numbers for which installation of kit GM11698 Air Intake Duct will improve the engine air/fuel mixture ratio and decreases the air intake noise level. Serial Numbers Note: A dash (-) indicates a range of serial numbers TP /06

17 Group 101: Air Intake, continued 1, , , , 19 16, 17, GM9685-GR1 Qty. Var. Item Part No. Description 2 1 GM24212 Arrestor, flame 1 2 GM957 Gasket, air intake 1 GM2501 Duct, air intake 1 4 GM9521 Foam Kit, Acoustic (include items 5-10) 1 5 GM9522 Foam, acoustic 1 6 GM952 Foam, acoustic 1 7 GM9524 Foam, acoustic 1 8 GM9525 Foam, acoustic 1 9 GM9526 Foam, acoustic 1 10 GM9527 Foam, acoustic 1 11 X Grommet, round 2 12 GM2587 Panel, air intake 1 1 GM2496 Screw, thread forming GM2588 Bracket, intake duct mounting 1 15 GM461 Adapter, air intake 1 16 GM979 Hose, molded breather 1 17 X Clamp, hose,.5/1 in X Washer 2 19 X Clamp, hose, 1/2 in X Screw, pan head x 1/ GM4628 Plate, air intake 1 22 X Clamp, hose 1 TP /06 17

18 Group 10: Fuel System b Qty. Var. Item Part No. Description 1 1 X Connector, 7/16-20 x 1/8 in Elbow, 45 street Pump, fuel Line, fuel Adapter, pipe Filter, fuel, 1/4 in. NPT 1 8 X-652- Fitting, hose 1 9 X Elbow, street, 90 x1/8in TP /06

19 Group 10: Fuel System, continued GM9685-GR2 Qty. Var. Item Part No. Description 2 1 GM9671 Line, fuel 1 2 X Fitting, half union Fitting, 45 deg. street elbow 1 4 X-652- Connector, hose + vibra seal Filter, fuel, 1/4 in. NPT Fitting, 45 deg. street elbow 1 7 X Elbow, street (90 deg. x 1/8 in. NPTF) Pump, fuel 1 9 GM9858 Bracket, fuel line support 1 10 GM9595 Module, fuel pump 1 TP /06 19

20 Group 104: Cooling System Variation 1: See Group 10 GRD LO See Group 10 for connector part number , 12 4 STOP START AC CIRCUIT BREAKER INPUT BATT. CHRG. VOLT. REG , b 20 TP /06

21 Group 104: Cooling System Qty. Var. Item Part No. Description X-91-2 Connector, 90 hose, 5/8 in. ID hose X-91-2 Elbow, hose (on bottom of exhaust manifold) 1 1 X Clamp, hose X-426- Clamp, hose, 1/2-1 1/ X Screw, hex head, 5/16-24 x X Connector, hose X Hose, rubber X Adapter, hose, 1 in. x 1 in Cap, manifold Neck ( ) Thermostat (160 deg.) Thermostat (195 deg.) Exchanger, heat Hose, molded coolant Hose, molded coolant Hose, molded seawater Hose, molded seawater O-ring Plate, seawater pump mounting GM28487 Pump, seawater Sleeve, drive Fitting, end drive X-125- Screw X Screw Zinc anode kit Impeller kit, seawater GM20716 Cover, back GM579 Seal/seat assembly X-91-4 Connector, 90 hose, /4 in. ID hose X-80-5 Connector, hose 1 28 X Line, flexible 1 29 X Clamp, hose,.25/.70 in. 2 0 X-91- Connector, 90, 5/16 in. ID hose 1 1 GM5002 Gasket, coolant bypass 1 2 GM5001 Plate, coolant bypass 1 TP /06 21

22 Group 104: Cooling System, continued , 21,22, 2 2 See Group GM9685-GR 22 TP /06

23 Group 104: Cooling System, continued Qty. Var. Item Part No. Description 1 X-91-2 Connector, 90, 5/8in.IDhose 1 2 X-91-4 Connector, 90, /4in.IDhose 1 X-91-2 Connector, 90, 1in.IDhose 1 4 X Clamp, hose,.75/1.5 in. 4 5 X-426- Clamp, hose,.56/1.06 in. 6 6 X Screw, hex socket head machine 2 7 X Connector, hose + vibra seal 8 X Hose, rubber 1 9 X Connector, hose + vibra seal Cap, radiator psi Filler neck Thermostat 1 1 GM914 Exchanger, heat Hose, molded coolant, 1.00 in. ID 1 15 GM9871 Hose, molded coolant 1 16 X Hose,.6 ID 1 17 GM9660 Hose, molded seawater O-ring, 60.0 mm ID Plate, seawater pump mounting 1 20 GM28487 Pump, seawater (includes items 21-2) Impeller kit 1 22 GM20716 Cover, back 1 2 GM579 Seal, seat assembly Sleeve, drive, 1.14 in. OD Fitting, end drive 1 26 GM5001 Plate, coolant bypass 1 27 GM5002 Gasket, coolant bypass 1 28 X-80-5 Connector, hose + vibra seal 1 29 X-91- Connector, 90, 5/16 in. ID hose 1 0 X Fuel line, flexible 1 1 X Clamp, hose,.25/.70 in. 2 2 X Hose,.6 ID 1 GM026 Switch, pressure assembly Kit, zinc anode 1 TP /06 2

24 Group 105: Engine , 9, , , , 1 To vacuum port on intake manifold 5 Choke Housing Assembly STOP START INPUT AC CIRCUIT BREAKER 11 BATT. CHRG. VOLT. REG. Lifting Eye View _1a 24 TP /06

25 Group 105: Engine Solenoid Front View Solenoid Side View Item 6 is not shown _2 Qty. Var. Item Part No. Description B Engine assembly (see Groups 1-9 for parts) C Engine assembly (see Groups 1-9 for parts) 1 2 X-14-6 Screw, FHM, 8-2 x X Washer, lock, 1/4 in. interior-exterior tooth X Washer, lock, 5/16 in. interior-exterior tooth X Line, flexible fuel, 1/4 in. x 9 in X Clamp, hose X Screw, PHM., 6-2 x 0.25 in. slot X-49-1 Screw, PHM., 6-2 x 5/ X Cable, battery X Strap, ground M Screw, hex head cap M Screw, hex head cap X Cap, plastic X Screw, pan head metric Boot Switch, high temperature cutout Bumper Lever assembly, choke Retainer, thermostat coil Gasket Pin Piston, choke Plate, baffle Valve, shutoff Solenoid, starter Coupling, stepper motor Bushing Linkage, choke Shaft, choke Bolt, banjo Strap, lifting Housing assembly, choke Heater assembly, choke* Washer, pressure sealing Washer, pressure sealing Bolt, M5 x X Conduit (not shown) GM29564 Cover. choke 1 8 X Spacer 2 9 X Screw, pan head, 8-2 x 1 / X Washer, plain,.188 ID x.48 in. OD 2 *Choke Repair Assembly GM1226 includes items 2, 7, , , 1, 2 TP /06 25

26 Group 105: Engine, continued Solenoid Front View Solenoid Side View 6 Lifting Eye View Oil Drain Connection Oxygen Sensor Assembly , Air Intake Assembly , GM9685-GR4 26 TP /06

27 Group 105: Engine, continued Quantity Variation Item Part No. Description GM9605 Governor, 2 mm electronic air Boot GM4596 Starter solenoid Bolt, M x 1.10 in Bracket, lifting eye Washer, sealing, 0. mm OD Washer, sealing, 0.1 mm OD Valve, oil drain, /8-18 NPT C Engine assembly X Cable, battery (No. 6 x 18 in.) red X Conduit GM9570 Wheel, encoder Gasket, intake manifold GM9902 Wire, spark plug M7985A Screw, pan head machine M7985A Screw, pan head machine GM9597 Bracket, ignition coil GM9598 Bracket, crank position sensor GM46910 Controller, 60 Hz SECM 1 24 GM47252 Controller, 50 Hz SECM 1 25 GM9600 Sensor, crankshaft position GM9601 Sensor, coolant temperature GM9602 Sensor, heated GM960 Coil, ignition GM9606 Assembly, air intake (includes item 5) Gasket, intake manifold GM41974 O-ring GM42275 O-ring 1 1 M Socket, head cap screw GM9604 Sensor, TMAP GM41940 Elbow, manifold 1 1 TP /06 27

28 Group 107: Nameplate and Decals Qty. Var. Item Part No. Description X Decal, Kohler Power Systems X Decal, Kohler Power System Decal, number Decal, reconnection 1 1 GM588 Decal, reconnection Decal, positive battery connection GM46200 Decal, positive battery connection Decal, warning carbon monoxide Decal, warning rotating parts Decal, warning hot engine and exhaust Decal, warning hot coolant and steam Decal, danger high voltage Decal, check zinc anode GM14167 Decal, drain Decal, equipment ground Tag, hang notice 1/4 in. ID fuel line required Decal, UL Decal, warning explosion Decal, CE Decal, negative battery connection GM42444 Decal, emissions 1 19 GM4005 Decal, fuse panel GM4807 Decal, notice replace CO sensor (generator sets with serial number and above) TP /06

29 Group 109: Skid and Plant Mounting a Qty. Var. Item Part No. Description 1 1 X Nut, elastic stop, 5/16-18 in. 2 2 X Washer, lock, 5/16 in. interior-exterior tooth 2 X-22-5 Washer, lock, 5/16 in. interior tooth 1 4 M Screw, hex head cap Strap, ground Tray, drip 1 7 GM28419 Kit, vibromount* 1 8 X Stud 1 9 X Washer, plain 2 10 X Washer, plain 2 * Vibromount kit GM28419 includes: 1 X Nut, elastic stop, 5/16-18 in. 2 4 M Screw, hex head cap 2 9 X Washer, plain 2 10 X Washer, plain 2 GM120 Mount, vibromount 4 X-125- Bolt, hex cap, 5/16-18 x 0.75 in. (not shown) 2 X Nut, flange spiralock, 5/16-18 in. (not shown) 8 M125A Washer, plain #8 (not shown) 2 TT-150 Instructions, mounting/installation 1 TP /06 29

30 Group 116: Exhaust STOP START AC CIRCUIT BREAKER INPUT BATT. CHRG. VOLT. REG. 1 2 Exhaust Manifold Mounting GM9685-GR9 0 TP /06

31 Group 116: Exhaust Qty. Var. Item Part No. Description M Screw, HC Screw, socket hex cap GM10105 Manifold, exhaust 1 GM500 Manifold, exhaust 1 GM9129 Manifold, exhaust Gasket GM9607 Catalyst assembly 1 6 GM40060 O-ring, 7.77 mm ID 1 7 GM40061 O-ring, 61.6 mm ID 1 TP /06 1

32 Group 201: Generator and Mounting 17 12, 15, GM9685-GR7 2 TP /06

33 Group 201: Generator and Mounting Qty. Var. Item Part No. Description A Rotor assembly (includes item 24) X-22-6 Washer, lock #6 int. star 2 2 X-49-1 Screw, RHM, 6-2 x.12 slot X Screw, hex head, 5/ X Screw, hex head X Screw, self-tapping X Screw, self-tapping X Washer, hardened X Screw, self-tapping O-ring GM41969 Bracket, brush holder Spring Retainer, wire Shim, brush holder Holder, brush Brush Adapter, generator GM11876 Bracket, end Overbolt Stator assembly 1 20 GM909 Stator assembly Guard, fan Fitting, end drive X Screw X Bearing, ball GM9040 Box, junction 1 26 GM9041 Cover, junction box 1 27 GM9042 Bracket, junction box mounting 1 28 X Bushing Mount, controller 4 0 X Washer, lock,.262 ID x.74 in. OD 4 1 GM45945 Harness, wiring, brush connection 1 TP /06

34 Group 01: Controller and Mounting See Group 5 for voltage regulator , Items 7 and 49 not shown. 7 26, , GRD LO Controller Ground Wires A597a 4 TP /06

35 Group 01: Controller and Mounting Quantity Variation Item Part No. Description X Washer, lock, 1/4 in. interior-exterior tooth X Screw, RHM, 6-2-/ X Breaker, circuit 1 X Breaker, circuit 1 X Breaker, circuit 1 X Breaker, circuit 1 Breaker, circuit (see accessories) 1 4 X Screw, hex head Mount, controller Cover, controller Harness, engine wiring (includes items 8-41) B-597 Controller assembly (includes items 9-48) G PCB assembly (PBIIIE) GM10516 PCB assembly X Washer, lock, 1/4 in. interior tooth X Washer, lock, 1/4 in. interior-exterior tooth X-22-1 Washer, lock, #10, interior-exterior tooth X-22-6 Washer, lock, #6, interior X-22-7 Washer, lock, #8, interior tooth X Screw, PHM., 6-2 x 0.25 slot X Screw, PHM., 6-2 x 0.50 slot X-67-1 Screw, hex washer, thread-forming X-51-5 Screw, RHM, 8-2 x 7/ X Bushing X Connector, cable X-71-2 Nut, hex, 6-2 zinc X-81-8 Nut, hex, 1/4-20 green Tab, ID grd in Tab, ident Fuse, 10 A, 250 V BLK Plate, cover Holder, fuse, 0.25 x Hourmeter Switch, rocker, 1 pole Spacer Relay, SPDT 0A, 12V coil sealed Fuse, 25A, 125 V Holder, fuse GM1050 Spacer Box, silkscreened GM0675 Harness, controller (includes items 42-47) Connector plug, 22-position Connector plug, 2-position Diode, 6 A, 100 V Connector, receptacle Connector panel, 22-position Connector plug, 6-position Connector plug, 9-position Connector plug, 15-position Connector plug, 4-position Diode, 6 A, 100 V X-49-1 Screw, slotted pan head machine X Conduit, convoluted (not shown) 1 TP /06 5

36 Group 01: Controller and Mounting, continued See Group 5 for voltage regulator. Items (harness) are not shown Ground Leads , 2 (F1) 1, 2 (F2), (F) , 2 (F4), (F5), (F6), 4 (F7) GM9685-GR8 6 TP /06

37 Group 01: Controller and Mounting Qty. Var. Item Part No. Description Fuse, 10 A, 250 V (F2, F) Fuse holder,.25 x 1.25 in Fuse, 25 A, 125 V (F7) Fuse holder Fuse, 15 A, 250 V (F4, F5, F6) Fuse, 10 A, 250 V (F1) Standoff, circuit board BLK Plate, cover 1 9 GM2848 SCR module 1 10 GM4800 Service kit, ADC 2100 controller (with upgrade to CO sensor module) (generator serial number and 1 below, see note) 10 GM4801 Controller assembly, ADC 2100 (generator serial number and above) 1 11 GM28787 Relay, SPDT 0A,12V coil sealed 1 12 GM29671 PCB assy., relay board 12V 1 1 X Nut 1 14 LK Lead 1 15 X Washer, lock,.262 ID x.469 OD 2 16 X Washer, lock,.262 ID x.74 in. OD 4 17 X-22-1 Washer, lock,.20 ID x.595 in. OD 1 18 X-22-6 Washer, lock,.146 ID x.285 in. OD 4 19 X-49-1 Screw, pan head 6-2 x 5/ X Connector, cable 1 21 X Screw, self-tapping 8 22 X-81-8 Nut, hex, 1/ X Nut 1 24 GM985 Harness, engine (includes items ) Connector, receptacle Diode, 6 A Connector, plug, 2-position Connector, 9-position 1 29 GM1697 Connector, weathertight, 2-position 1 0 GM28678 Connector, weathertight 1 1 GM29998 Connector, 6-position, blk, male 1 2 GM6156 Connector 6-position 1 GM6161 Connector, 4-position 1 4 GM616 Connector, 2-position 1 5 GM9876 Connector, 24-position 1 6 GM9881 Connector, 5-position 2 7 GM9888 Connector, 6-position 1 8 GM9889 Connector, 4-position 1 9 GM989 Connector, 2-position 1 40 GM9895 Connector, 2-position 1 41 GM9900 Connector, 2-position 1 42 GM45941 Connector, 10-position 1 4 GM4662 PCB assy., CO sensor (generator sets with serial number and above) 1 Note: Service Kit GM4800 upgrades serial numbers and below with a CO sensor module. The GM4800 includes the ADC 2100 controller, CO sensor harness GM4802, and CO sensor (item 4). Serial numbers and above were factoryshipped with the ADC2100 controller and CO sensor. Service serial numbers and above with the GM4801 ADC 2100 controller assembly. TP /06 7

38 Group 701: Literature Qty. Var. Item Part No. Description TP-5982 Installation Manual, Gasoline Marine TP-5985 Operation Manual, 5/7.E and 4/6EF TP-690 Operation Manual, 5/7.ECD 1 1 TP-5986 Service Manual, 5/7.E and 4/6EF 1 1 TP-691 Service Manual, 5/7.ECD TP-5987 Parts Catalog, 4-6EF/5-7.E TP-6001 Operation Manual, Kawasaki FD501D TP-6002 Service Manual, Kawasaki FD501D TP-6008 Service Manual Supplement, Kawasaki FD501D TP-575 Warranty, Marine TP-5620 Safety Precautions, Marine TP /06

39 Accessories Qty. Description Part No. Circuit Breaker Kits Circuit Breaker PA Instructions, installation TT Screw, RHM, 6-2-/16 X Breaker, circuit, 40 A X Plate, cover Decal, notice Circuit Breaker PA Instructions, installation TT Screw, RHM, 6-2-/16 X Breaker, circuit, 60 A X Plate, cover Decal, notice Circuit Breaker PA Instructions, installation TT Screw, RHM, 6-2-/16 X Breaker, circuit, 55 A X Plate, cover Decal, notice Circuit Breaker PA Instructions, installation TT Screw, RHM, 6-2-/16 X Breaker, circuit, 18 A X Decal, notice Terminal, jumper Circuit Breaker PA Instructions, installation TT Screw, RHM, 6-2-/16 X Breaker, circuit, 0 A X Decal, notice Terminal, jumper Circuit Breaker PA Instructions, installation TT Screw, RHM, 6-2-/16 X Breaker, circuit, 18 A X Decal, notice Circuit Breaker PA Instructions, installation TT Screw, RHM, 6-2-/16 X Breaker, circuit, 0 A X Decal, notice Circuit Breaker PA Instructions, installation TT Screw, RHM, 6-2-/16 X Breaker, circuit, 22 A X Decal, notice Terminal, jumper Circuit Breaker PA Instructions, installation TT Screw, RHM, 6-2-/16 X Breaker, circuit, A X Decal, notice Qty. Description Part No. Circuit Breaker PA Instructions, installation TT Screw, RHM, 6-2-/16 X Breaker, circuit, 42 A X Plate, cover Decal, notice Circuit Breaker PA Instructions, installation TT Screw, RHM, 6-2-/16 X Breaker, circuit, 18 A X Plate, cover Decal, notice Circuit Breaker PA Instructions, installation TT Screw, RHM, 6-2-/16 X Breaker, circuit, 27 A X Plate, cover Decal, notice Harness Kits Harness, Fire System Interface PA Harness, wiring Instructions, installation TT-90 Harness, Remote 12 In. Pigtail PA Harness, extension Harness for Remote Panel (15 Ft.) PA Strap, wire, 5/8 in. X Harness, extension 2494 Harness for Remote Panel (25 Ft.) PA Strap, wire, 5/8 in. X Harness, extension 2496 Harness, Fuel Solenoid Wiring GM16829-KP1 1 Harness, wiring GM16829 Harness, 12 In. Pigtail GM22-KP1 1 Harness, pigtail GM224 Harness, 15 Ft., Remote Panel GM2-KP1 1 Harness, extension GM0248 Harness, 25 Ft., Remote Panel GM2-KP2 1 Harness, extension GM22 TP /06 9

40 Accessories, continued Qty. Description Part No. Qty. Description Part No. Panel and Meter Kits Panel, Remote Start PA Instructions, installation TT Decal, warning Panel assembly (includes the following) A Connector Plug, 6 position Panel, remote Switch, rocker Panel, Remote Start PA Instructions, installation TT Decal, warning Panel assembly (includes the following) A Panel, control Harness, wiring Meter, run time Switch, rocker, 1 pole 4409 Paint, White (1 gallon can) 2214 Paint, White (aerosol can) 2215 Panel, Remote Start and 2 Meter (12 V) PA Instructions, installation TT Decal, warning Panel assembly (includes the following) A Panel Harness, wiring Gauge, water temperature Gauge, oil pressure Switch, rocker 4409 Panel, Remote Start and 4 Meter (12 V) PA Instructions, installation TT Decal, warning Panel assembly (includes the following) A Panel Harness, wiring Gauge, water temperature Gauge, oil pressure Voltmeter Switch, rocker Gauge, hourmeter GM Bezel, gauge GM289 1 Bulb, light GM Nut, hex M94-04-B Remote Start Panel, 12V GM25-KP1 1 Panel assy, control 12V GM Nut, hex, mm M Washer, lock.146 ID x.285 in. OD X Panel, control GM847 1 Harness, wiring panel assy, control GM851 1 Meter, run time, hour Switch, rocker, 12V GM849 2 Screw, pan head M x 12 M7985A TT Rmt Start Panel TT Decal, warning Filters Sea Water Strainer PA Filter, water, 1/2 in. X Fuel Filter GM1414-KP1 1 Filter, fuel, 1/4 in. NPT Adapter, pipe Connector, hose X-652- Sender Kits Sender Kit PA Adapter, bushing Sender, water temperature Sender, oil pressure Adapter, sender Sender Kit GM45891-KA1 1 Sender, water temperature Sender, oil pressure Adapter, sender Instructions, installation TT-120 Ship-To-Shore Switch Kits Transfer Switch Kit PAA Switch, transfer Instructions, installation TT-55 Transfer Switch Kit PAA Switch, transfer A Instructions, installation TT TP /06

41 Accessories, continued Qty. Description Part No. Qty. Description Part No. Siphon Break Kits Siphon Break (Generator Set without Sound Shield) PA Instructions, installation TT Clamp, hose,.25/.70 in X Tubing, clear flexible plastic GM488 1 Valve, siphon break (includes the following)gm Valve, duct Cap, siphon valve GM Loop, siphon valve vent GM2988 Siphon Break (Generator Set with Sound Shield) PA Instructions, installation TT Grommet, 7/8 X Hose,.62 ID X Clamp, hose, /2 X Clamp, hose,.25/.70 in. X Connector, hose Hose, molded seawater Tubing, clear flexible plastic GM488 1 Valve, siphon break (includes the following)gm Valve, duct Cap, siphon valve GM Loop, siphon valve vent GM2988 Siphon Break Hose Connection (Generator Set with Sound Shield) GM41786-KP1 2 Grommet, 7/8 X Clamp, hose, /2 X Clamp, hose,.25/.70 in. X Connector, hose Tubing, clear flexible plastic GM488 1 Hose, molded seawater GM Hose, molded seawater GM Valve, siphon break (includes the following)gm Valve, duct Cap, siphon valve GM Loop, siphon valve vent GM2988 Siphon Break GM24866-KA1 1 Valve, siphon break (includes the following)gm Valve, duct Cap, siphon valve GM Loop, siphon valve vent GM2988 Sound Shield Kits Sound Shield Kit Screw, hex head, x 5/8 X Washer, plain X Washer, plain X Washer, plain X Clamp, hose X Screw X Channel, U X Nut, whiz X Hose X Channel, U, in. X Rivet, pop X Screw, slotted HC X Washer, fiber Hose, connector, 1/4 in. x 2 in Base, sound shield Duct, air outlet Foam, acoustical (kit) Insulation, acoustic Roof subassembly, sound shield Decal, caution not a step 4165 Insert, threaded Roof, sound shield Insulation, acoustic Corner, sound shield 5994 Pin, threaded Insulation, acoustic Door subassembly (LH) Washer, plain X Screw, flat head machine X Nut, hex X Port, fire extinguisher Decal, warning Decal, warning Insert, threaded Door, sound shield Insulation, acoustic Latch Pin, threaded Door subassembly, sound shield (front) Insert, threaded Door, sound shield Insulation, acoustic Latch Pin, threaded Insulation, acoustic Door subassembly, sound shield (RH) Insert, threaded, Door, sound shield Insulation, acoustic Roof subassembly, sound shield Grommet X Rivet, pop X Insert, threaded Roof, sound shield Insulation, acoustic Corner, sound shield Support subassembly TP /06 41

42 Accessories, continued Qty. Description Part No. Sound Shield Kit Grommet X Seal, push on trim X Insert, threaded, Support, sound shield Insulation, acoustic Insulation, acoustic Housing subassembly, alternate Grommet D Channel, U X Channel, U X Decal X Grommet Insert, threaded, Housing, alternator Insulation, acoustic Insulation, acoustic Insulation, acoustic Insulation, acoustic Panel subassembly, access Rivet, pop X Clip, spring Panel, seawater pump access Insulation, acoustic foam Bracket subassembly, sound Insert, threaded, Bracket, sound shield 5979 Qty. Description Part No. Sound Shield Kit GM10056-KA1 9 Screw, hex head, #10-24 x X Washer, plain, x 0.5 x X Washer, plain, x x X Washer, plain, x x X Bolt, 1/4-20 x 0.50 X Nut, whiz, 1/4-20 X Bolt, /8-16 x 0.62 X Rivet, pop X Screw, #10-24 x X Washer, plain, 0.20 in. ID x 0.48 in. OD X Duct, air outlet, 15.8 x 7.8 in. GM Roof, engine, 2.98 x in. GM22726 Roof, engine (serial numbers before ) Door, service side, 2.99 x in Door, nonservice side, 2.99 x in Roof, alternator, x 6.46 in Support, x in Bracket, 1.06 x 0.81 in Panel, access, 5.8 x.25 in. GM Panel, access,.61 x 1.94 in. GM Housing, alternator, x 6.68 in Panel, seawater pump access, 8.72 x 8.80 in Door, engine end, x in. GM22724 Door, engine end (includes latch) (serial numbers before ) GM Base, x 0.44 in. GM Screw, hex head, #10-24 x 2.0 X Kit, acoustic foam (include the following) GM Insulation, acoustic, 8.5 x 1.72 in Insulation, acoustic, x 2.5 in Insulation Insulation, acoustic, 5.44 x 2.8 in Insulation, acoustic, 10.8 x 5.44 in Insulation Insulation, acoustic, x in Insulation, acoustic, 7.08 x.4 in Insulation Insulation Insulation Insulation, acoustic foam Insulation, acoustic foam Insulation, acoustic foam Insulation, acoustic foam Insulation, acoustic foam GM Insulation, acoustic foam GM Insulation, acoustic foam GM Insulation, acoustic foam GM TP /06

43 Accessories, continued Qty. Description Part No. Sound Shield Kit GM41781-KP1 1 Bracket, sound shield subassembly Base, sound shield GM Door subassy, sound shield (RH) GM Door subassy, sound shield (rear) GM Door subassy, sound shield (front) GM Roof subassy, sound shield GM Door subassy, sound shield (LH) GM Panel subassy, bulkhead connection GM Panel subassy. sound shield (rear) GM Duct, subassy, air intake GM Cable, battery (red) X Cable, battery (black) X Conduit, convoluted X Foam, sound hsg kit (includes the following) GM Foam, acoustic (bulkhead panel) GM Foam, acoustic (bulkhead panel) GM Foam, acoustic (rear door) GM Foam, acoustic (front door) GM Foam, acoustic (front door) GM Foam, acoustic (front door) GM Foam, acoustic (RH door) GM Foam, acoustic (roof) GM Foam, acoustic (rear panel) GM Foam, acoustic (RH door) GM Foam, acoustic (LH door) GM Foam, acoustic (RH door) GM424 1 Foam, acoustic (RH door) GM425 Qty. Description Part No. Miscellaneous Kits Lifting Eye Tool PA Eye, lifting Oil Drain Extension Kit GM10102-KA1 1 Panel, oil hose GM Hose, rubber, straight,.75 in. X Clamp, hose,.25/.70 in X Coupling, hose X Decal, drain GM Plug, pipe, /8 in. white nylon X Corrosion Protection Kit GM29572-KP1 2 Spacer X Screw, slotted round head machine X Washer, plain,.154 ID x.1 in. OD X Cover, choke GM Cover, generator air inlet GM Tray, drip GM29571 Drip Tray, Stainless GM29979-KA1 1 Tray, drip GM29571 TP /06 4

44 Notes 44 TP /06

45 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 analog to digital converter adj. adjust, adjustment ADV advertising dimensional drawing 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 API American Petroleum Institute approx. approximate, approximately 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 A/V audiovisual 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 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 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 cu. in. cubic inch cw. clockwise CWC city water-cooled cyl. cylinder D/A digital to analog DAC digital to analog converter db decibel dba decibel (A weighted) DC direct current DCR direct current resistance deg., degree dept. department 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) 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 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 temperature, high engine temperature 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 TP /06 Appendix 45