Service Parts 20ROZJB REOZJB. Industrial Generator Sets. Models:

Transcription

1 Service Parts Industrial Generator Sets Models: 20ROZJB REOZJB See Group 701: Literature, inside this manual for part numbers of engine and accessory parts catalogs See TP-6009 Parts Catalog Industrial Controllers for controller parts TP /02

2 Table of Contents Introduction... 1 Numbering System Significance... 1 Illustrations... 1 How to Find Part Numbers... 1 Hardware References... 1 Specification Number Index... 2 Group 101: Air Intake... 6 Group 104: Cooling System... 8 Group 105: Engine Group 107: Nameplate and Decals Group 109: Skid and Plant Mounting Group 201: Generator and Mounting Control and Harness Group 701: Literature Kit List Cooling System Kits Appendix A Abbreviations... A-1 Appendix B Common Hardware Application Guidelines... A-3 Appendix C General Torque Specifications... A-4 Appendix D Common Hardware Identification... A-5 Appendix E Common Hardware List... A-6

3 This manual lists service replacement parts for 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 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. 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. Illustrations Introduction x:in:004:003:a 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 instructions. x:in:004:004 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 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, 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. x:in:004:006 TP /02 1

4 Specification Number Index Group Title Group No Spec No. Variation Number 20ROZJB GM19369-GA1 * * 1 1 * * 132 GM19369-GA2 * * 2 1 * * REOZJB GM19369-GA3 * * 3 1 * * 134 GM19369-GA4 * * 4 1 * * REOZJB GM19369-GA5 * * 3 1 * * 136 GM19369-GA6 * * 4 1 * * REOZJB GM19369-GA7 * * 3 1 * * 138 GM19369-GA8 * * 4 1 * * 138 * 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 controller parts catalog TP-6009 for controller parts lists. 2 TP /02

5 Specification Number Index Group Title Group No Spec No. Variation Number 50REOZJB GM31199-GA1 * * 17 3 * * 156 GM31199-GA2 * * 18 3 * * 156 GM31199-GA3 * * 19 3 * * 156 GM31199-GA4 * * 20 3 * * REOZJB GM31199-GA5 * * 17 3 * * 158 GM31199-GA6 * * 18 3 * * 158 GM31199-GA7 * * 19 3 * * 158 GM31199-GA8 * * 20 3 * * REOZJB GM31199-GA9 * * 21 1 * * 160 GM31199-GA10 * * 22 1 * * 160 GM31199-GA11 * * 23 1 * * 160 GM31199-GA12 * * 24 1 * * REOZJB GM21528-GA1 * * 25 1 * * 162 GM21528-GA2 * * 26 1 * * 162 GM21528-GA3 * * 27 1 * * 162 GM21528-GA4 * * 28 1 * * REOZJB GM21528-GA5 * * 25 1 * * 164 GM21528-GA6 * * 26 1 * * 164 GM21528-GA7 * * 27 1 * * 164 GM21528-GA8 * * 28 1 * * 164 * 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 controller parts catalog TP-6009 for controller parts lists. TP /02 3

6 Specification Number Index Group Title Group No Spec No. Variation Number 150REOZJB GM20148-GA1 * * 5 2 * * 146 GM20148-GA2 * * 6 2 * * 146 GM20148-GA3 * * 7 2 * * 146 GM20148-GA4 * * 8 2 * * REOZJB GM19534-GA1 * * 9 2 * * 140 GM19534-GA2 * * 10 2 * * 140 GM19534-GA3 * * 11 2 * * 140 GM19534-GA4 * * 12 2 * * REOZJB GM19534-GA5 * * 13 2 * * 142 GM19534-GA6 * * 14 2 * * REOZJB GM19534-GA7 * * 15 2 * * 144 GM19534-GA8 * * 16 2 * * 144 * 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 controller parts catalog TP-6009 for controller parts lists. 4 TP /02

7 Notes TP /02 5

8 Group 101: Air Intake kw 13 Heavy-Duty kw _101 6 TP /02

9 Group 101: Air Intake Cross-reference the module number of your air intake to the letter key in the Model Number to Key Cross-Reference table below. Refer to the key column in the following table. Quantity Module Item Part Number Description A B C D E F G H I J 1 A Air cleaner 1 1 A Air cleaner, John Deere A Air cleaner, John Deere Element, air cleaner Element, air cleaner 1 3 X Clamp, hose, 2.81/3.75 in Clamp, hose, 4.31/4.62 in Hose, reducer, 3.00 in. to 2.50 in. ID X Hose,straight,3in.ID Hose, reducer, 4.00 in. to 3.00 in. ID 1 5 X Clamp, hose, 2.81/3.75 in Clamp, hose, 2.06/3 in X Clamp, hose, 3.56/4.5 in Bracket, mounting 1 7 GM22483 Bracket, mounting Mount, air cleaner Band, mounting Mount, air cleaner Cap Cap, rain Cap, rain Air cleaner 1 10 A Air cleaner A Air cleaner Element, air cleaner Element, air cleaner 1 12 X Clamp, hose, 3.56/4.5 in Clamp, hose, 6.56/6.87 in Clamp, hose, 5.56/5.87 in Clamp, hose, 3.88/4.19 in GM19837 Hose, molded 1 13 GM19838 Hose, molded Hose, molded air intake, 4.00 in. ID Hose, molded, 3.00 in. ID Hose, molded air intake, 3.00 in. ID 1 14 X Clamp, hose, 2.81/3.75 in Clamp, hose, 2.06/3 in Clamp, hose, 4.63/4.94 in Clamp, hose, 3.68/4 in Clamp, hose, 3.43/3.75 in GM19841 Bracket, mounting Bracket, air cleaner 1 15 GM16953 Bracket, mounting 1 16 GM11970 Shield, heat 1 17 GM11452 Bracket, air cleaner 1 18 M Nut, elastic stop Clamp Air cleaner, industrial Clamp, hose, 6.25/6.56 in Hose, hump, 6.00 in. ID to 5.00 in. ID Clamp, hose, 5.25/5.56 in GM11458 Insert, hose reducer, 5.00 in. to 4.00 in X Spacer,.406 ID x.625 OD x in. 2 Module Number to Key Cross-Reference Use the module number of your air intake from the generator set nameplate to determine the key. Module Number to Key Cross-Reference kw Type Module Number Key 20 (non-emissions) Standard GM19374-MA1 A 20 (non-emissions) Heavy-duty GM19375-MA1 D (emissions) Standard GM19374-MA2 B (emissions) Heavy-duty GM19375-MA2 E Standard GM19374-MA3 C Heavy-duty GM21224-MA1 J Standard GM20783-MA1 H Heavy-duty GM20784-MA1 I Standard GM19539-MA1 F Heavy-duty GM19540-MA1 G TP /02 7

10 TP /02 8 Group 104: Cooling System , _

11 Group 104: Cooling System Cross-reference the module number of your cooling system to the letter key in the Model Number to Key Cross-Reference table below. Refer to the key column in the following table. Quantity Module Item Part Number Description A B C D E F G H 1 X Screw, hex washer head, drill GM14100 Guard, radiator 1 2 GM20049 Guard, radiator GM20050 Guard, radiator 1 2 GM14100 Guard, radiator GM13843 Guard, radiator Sensor, low fluid X Conduit, convoluted GM22415 Radiator assembly 1 5 GM10988 Radiator assembly GM19944 Radiator assembly 1 5 GM20534 Radiator assembly (charger cooler) 1 5 GM14095 Radiator assembly 1 5 GM14096 Radiator assembly 1 5 A Radiator assembly 1 6 GM22997 Cap, radiator GM22998 Cap, radiator 1 7 GM17067 Support, radiator, left side GM20048 Support, radiator, left side GM17066 Support, radiator, right side GM20047 Support, radiator, right side Clamp, hose, 2.06/3 in X Clamp, hose, 2.81/3.75 in. 1 9 X Clamp, hose, 2.31/3.25 in X Clamp, hose, 1.31/2.25 in. 3 9 X Clamp, hose, 1.56/2.5 in Clamp, hose, 2.06/3 in X Clamp, hose, 1.56/2.5 in Hose, molded coolant, 2.50 in. ID GM19031 Hose, upper radiator, 38.0 mm ID 1 11 GM20051 Hose, molded coolant, 2.50 in. ID 1 11 GM20688 Hose, upper radiator 1 11 GM20738 Hose, upper radiator GM21387 Hose, upper radiator, 44.5 mm ID Hose, lower radiator, 1.88 in. ID Hose, lower radiator, 2.00 in. ID GM20052 Hose, lower radiator, 2.00 in. ID 1 12 GM20687 Hose, lower radiator 1 12 GM20739 Hose, lower radiator GM21388 Hose, lower radiator, 50.8 mm ID Spacer, radiator support Spacer, radiator 2 14 X Bushing, reducing, 1/4 x 1/2 in. NPT X Valve, drain, 1/4 in. NPT X Valve, drain, 1/2 in. NPT 1 15 X Screw, hex cap 4 15 X Bolt, hex cap M Screw, hex cap 4 16 X Washer, hardened,.406 ID x.812 in. OD X Washer, hardened,.328 ID x.719 in. OD Fan, pusher 1 17 GM22261 Fan, pusher 1 17 GM19383 Fan, pusher 1 17 GM19943 Fan, pusher GM21245 Fan, pusher GM21346 Fan, blower Spacer, fan, 1.63 in Spacer, fan, 3 in GM20545 Spacer, fan Shroud, fan Shroud, fan Shroud, fan Shroud, fan Shroud, fan 1 20 X Washer, plain,.266 ID x 1 in. OD X Washer, plain,.344 ID x.875 in. OD 4 TP /02 9

12 Group 104: Cooling System, continued , _ TP /02

13 Group 104: Cooling System, continued Quantity Module Item Part Number Description A B C D E F G H Guard, wire fan Guard, wire fan GM22311 Guard, wire fan 1 21 GM11418 Guard, wire fan 1 21 GM20740 Guard, wire fan X Insert, threaded, 5/16-18 in X Insert, threaded GM19548 Guard, belt, top GM19633 Guard, belt, top 1 23 GM20824 Guard, top rear, right side 1 23 GM20825 Guard, top rear, left side 1 23 GM20826 Guard, top 1 23 GM22162 Guard, belt, top GM19567 Guard, belt, left side GM19632 Guard, belt, left side 1 24 GM20827 Guard, left side 1 24 GM22161 Guard, belt, left side GM19550 Guard, belt, right side GM19630 Guard, belt, right side upper 1 25 GM20828 Guard, right side 1 25 GM22160 Guard, belt, right side GM19552 Guard, belt, bottom GM19631 Guard, belt, right side lower 1 27 GM19634 Guard, belt, bottom 1 27 GM20829 Guard, front lower 1 27 GM22163 Guard, belt, bottom top GM19635 Guard, belt, back Bracket, belt guard 1 29 GM19553 Bracket, mounting, lower GM21204 Bracket, belt guard mounting X Connector, hose + vibraseal X Clamp, hose,.25/.70 in X Hose, rubber, straight,.25 in. ID X Connector, hose + vibraseal Bracket GM19551 Guard, belt, front GM19549 Bracket, mounting, top GM20689 Hose, upper charge air cooler Clamp, hose, 2.06/3 in GM20588 Hose, step 2 41 GM20690 Tube, lower charge air cooler Fitting, 45 deg. street elbow + vibraseal 1 43 GM22461 Support, radiator 2 44 GM22462 Bracket, radiator support 2 Module Number to Key Cross-Reference Use the module number of your cooling system from the generator set nameplate to determine the key. Module Number to Key Cross-Reference kw Module Number Key GM19372-MA1 A 50/60 GM21202-MA1 E 80 GM21202-MA2 F 100/125 GM22243-MA1 G 150 GM20818-MA1 D 180/200 GM19537-MA1 B 200 GM19537-MA2 H 230 GM19827-MA1 C See Kit section for city water and remote radiator set-up cooling systems. TP /02 11

14 Group 105: Engine End View of Starter Solenoid, 24 Volt Breather Hose Mounting kw 7 6 3, 4, , Volt , Volt _ TP /02

15 Group 105: Engine Internal and some external engine parts are shown in a separate engine parts catalog. See Group 701: Literature for part numbers of engine parts catalogs. Item Part Number Description Quantity 1 Engine assembly (see chart on following page) 1 2 GM20743 Boot, starter terminal, kw Solenoid, 12 V Solenoid, 24 V 1 4 X Cap 1 5 X Washer, lock,.262 ID x.743 in. OD 2 6 X Washer, lock,.521 ID x 1.24 in. OD 1 6 X Washer, lock,.521 ID x 1.24 in. OD, kw 2 6 X Washer, lock,.652 ID x in. OD, 200/230 kw 1 7 GM14099 Rack, battery, 12 V 1 7 GM23203 Rack, battery, 12 V kw 7 GM19543 Rack, battery, 24 V 1 8 X Lead, battery cable, No. 2, 16 in. 1 8 X Cable, battery, kw Bolt, angle, 24 V Bolt, angle, 12 V Terminal, battery 1 11 X Nut, hex elastic stop, 5/16-24, 24 V 1 11 X Nut, hex elastic stop, 5/16-24, 12 V 2 12 X Washer, plain, 20-40, kw, 24 V 1 12 X Washer, plain, 20-40, kw, 12 V 2 12 X Washer, plain, kw, 24 V 1 12 X Washer, plain, kw, 12 V Clamp, battery, 12 V Clamp, battery, 12 V kw Clamp, battery, 24 V Terminal, battery 1 15 GM20745 Boot, battery lug 1 16 X Cable, battery, kw, 12 V 1 16 X Cable, battery, No. 2, 60 in., kw 1 16 X Cable, battery, kw, 24 V, kw Lead, battery cable, 8.5 in., 24 V 1 18 GM20748 Boot, battery, 90 deg. right, 24 V 1 19 GM20744 Boot, battery lug, 24 V 1 20 X-22-4 Washer, lock,.521 ID x.884 in. OD 1 21 X-22-9 Washer, lock,.20 ID x.373 in. OD 1 22 GM11941 Harness, 24 V starter, lead 10F Joint, ball, kw 1 24 X Nut, hex elastic stop, 1/4-28, kw Ball joint, kw 1 26 X-81-9 Nut, hex jam, 1/4-28, kw Bracket, solenoid mounting, kw Bracket, throttle stop, kw Bracket, throttle, kw Screw, hex head machine, special thread, kw 1 31 X Nut, hex elastic stop, 5/16-18, kw 1 32 X Clamp, insulated, 1.06 in., kw Solenoid, kw Solenoid, 24 V, kw 1 TP /02 13

16 Group 105: Engine, continued Engine Part Number Use this table to identify the variation number s engine part number. Variation No. Module No. Model Engine Part Number Engine Description 1 GM19370-GR1 20 GM DF120, 12 V, 60 Hz 2 GM19370-GR2 20 GM DF120, 12 V, 50 Hz 3 GM19370-GR3 20/30/40 GM TF150, 12 V, 60 Hz 4 GM19370-GR4 20/30/40 GM TF120, 12 V, 50 Hz 5 GM20149-GR1 150 GM HF120, 12 V, 50 Hz 6 GM20149-GR2 150 GM HF120, 24 V, 50 Hz 7 GM20149-GR3 150 GM HF150, 12 V, 60 Hz 8 GM20149-GR4 150 GM HF150, 24 V, 60 Hz 9 GM19535-GR1 180 GM AF001, 12 V, 50 Hz 10 GM19535-GR2 180 GM AF001, 24 V, 50 Hz 11 GM19535-GR3 180 GM AF001, 12 V, 60 Hz 12 GM19535-GR4 180 GM AF001, 24 V, 60 Hz 13 GM19535-GR5 200 GM AF001, 24 V, 50 Hz 14 GM19535-GR6 200 GM AF001, 24 V, 60 Hz 15 GM19535-GR7 230 GM AF001, 24 V, 50 Hz 16 GM19535-GR8 230 GM AF001, 24 V, 60 Hz 17 GM21200-GR1 50/60 GM TF150, 12 V, 60 Hz 18 GM21200-GR2 50/60 GM TF120, 12 V, 50 Hz 19 GM21200-GR3 50/60 GM TF150, 24 V, 60 Hz 20 GM21200-GR4 50/60 GM TF120, 24 V, 50 Hz 21 GM21200-GR5 80 GM TF250, 12 V, 60 Hz 22 GM21200-GR6 80 GM TF220, 12 V, 50 Hz 23 GM21200-GR7 80 GM TF250, 24 V, 60 Hz 24 GM21200-GR8 80 GM TF220, 24 V, 50 Hz 25 GM21529-GR1 100/125 GM TF220, 12 V, 50 Hz 26 GM21529-GR2 100/125 GM TF220, 24 V, 50 Hz 27 GM21529-GR3 100/125 GM TF250, 12 V, 60 Hz 28 GM21529-GR4 100/125 GM TF250, 24 V, 60 Hz 14 TP /02

17 Group 107: Nameplate and Decals Quantity Module Item Part Number Description GM14282-GR1 GM14282-GR2 GM14282-GR Decal, caution positive terminal only Decal, warning rotating parts Decal, caution hot engine Decal, warning hot coolant Decal, warning explosion Decal, number Decal, danger moving rotor Decal, warning lifting eye Decal, warning voltage backfeed GM13776 Decal, FRII reconnection Nameplate, model/ratings, Kohler X Decal, stripes 1 12 X Decal, stripe X Decal, Kohler Power System X Decal, Kohler Power System Decal, Fast Response GM15300 Decal, exhaust piping GM19296 Decal, fuel type 1 1 TP /02 15

18 Group 109: Skid and Plant Mounting TP /02

19 Group 109: Skid and Plant Mounting Cross-reference the module number of your cooling system to the letter key in the Model Number to Key Cross-Reference table below. Refer to the key column in the following table. Quantity Part Module Item Number Description A B C E D F G H I J K 1 X Grommet, round X Grommet GM17417 Panel, junction box, front GM17623 Panel, junction box, front GM10555 Box, junction 1 3 GM14078 Cover, side GM17640 Cover, side Cover, side 2 4 GM17419 Cover, rear GM17625 Cover, rear Cover, rear 1 5 X Screw, Phillips hex crimptite X Washer, lock,.326 ID x.883 in. OD X Washer, lock,.456 ID x in. OD GM17670 Support, junction box GM17632 Support, junction box GM19557 Bracket, junction box mounting Strap, ground X Washer, lock,.391 ID x.975 in. OD X Washer, lock,.326 ID x.883 in. OD GM17418 Panel, junction box, rear GM17624 Panel, junction box, rear X Plug, button Valve, oil drain Adapter, bushing Adapter, bushing GM11694 O-ring O-ring X Hose, rubber, straight,.62 in. ID X Hose, rubber, straight,.62 in. ID X Hose, rubber, straight,.62 in. ID X Clamp, hose,.5/1 in X Connector, hose + vibraseal X Plug, pipe, 1/2 in. NPT GM17583 Skid 1 17 GM20600 Skid 1 17 GM20709 Skid 1 17 GM19554 Skid 1 17 GM19555 Skid 1 17 GM17586 Skid 1 17 GM21151 Skid 1 17 GM17587 Skid 1 17 GM21152 Skid 1 17 GM22137 Skid 1 17 GM22138 Skid 1 18 M Nut, hex elastic stop M Nut, hex elastic stop X Washer, plain,.531 ID x 2 in. OD X Washer, plain Vibromount Vibromount Vibromount GM17579 Support, engine, left side GM19556 Bracket, engine mounting GM17601 Support, engine mount GM17578 Support, engine, right side GM19556 Bracket, engine mounting X Washer, lock,.521 ID x 1.24 in. OD X Washer, lock,.652 ID x in. OD X Spacer,.527 ID x.625 OD x 2.3 in. 2 2 Module Number to Key Cross-Reference kw Skid Width, in. Module Number Key GM19373-MA1 A GM19373-MA2 B GM21203-MA1 F GM21203-MA2 G GM21203-MA3 H GM21203-MA4 I Module Number to Key Cross-Reference Use the module number of your skid and mounting from the generator set nameplate to determine the key. Module Number to Key Cross-Reference kw Skid Width, in. Module Number Key 100/ GM21530-MA1 J 100/ GM21530-MA2 K GM20497-MA1 E GM19538-MA1 C 200/ GM19828-MA1 D TP /02 17

20 Group 201: Generator and Mounting Flywheel Items not shown _201 Item Part Number Description Qty. 1 See chart on following page Alternator assembly 1 2 See chart on following page Vibromount 2 3 See chart on following page Bolt, hex cap 6/8 4 X Washer, hardened,.406 ID x.812 OD (4P, 4Q and 4S) 6 4 X Washer, hardened,.469 ID x.922 in. OD (4UA) 8 5 X Stud, 3/8-16 x 4 in. (4P, 4Q, and 4S) 8 5 X Bolt, hex cap (4U) 8 6 X Spacer,.406 ID x.625 OD x in. (4P, 4Q, and 4S) 8 7 X Washer, hardened,.406 ID x.812 OD (4P, 4Q, and 4S) Washer, hardened,.531 ID x 1.06 in. OD (4UA) 8 8 X Nut, flange spiralock, 3/8-16 (4P, 4Q, and 4S) 8 9 See chart on following page Washer, plain 2 10 See chart on following page Nut, hex elastic stop Guard, generator fan (4P and 4Q) Guard, generator fan (4S and 4V) Guard, generator fan (4UA) 2 12 X Screw, hex washer, thread-forming 2 12 X Screw, hex washer, thread-forming (4UA) Clip, speed Clip, speed (4UA) 4 14 X Marker, wire L1 (not shown) 1 15 X Marker, wire L2 (not shown) 1 16 X Marker, wire L3 (not shown) 1 17 X Spacer,. 532 ID x.75 OD x 2.88 in. (used with vibromounts and ) 2 18 TP /02

21 Group 201: Generator and Mounting Alternator Part Number and Mount Type Use this table to identify the module number s alternator and mounting part number. Module No. Alternator Description Item 1, Alternator Assembly Item 2, Vibromount Item 3, Bolt Item 9, Washer Item 10, Nut GM19371-MA1 4P4 C (6) X M GM19371-MA2 4P4, 600 V B (6) X M GM19371-MA3 4Q4 B (6) X M GM19371-MA4 4P5 C (6) X M GM19371-MA5 4P5, 600 V C (6) X M GM19371-MA6 4P7 C (6) X M GM19371-MA7 4P7, 600 V B (6) X M GM19371-MA8 4P8 C (6) X M GM19371-MA9 4P8, 600 V C (6) X M GM19371-MA10 4Q10 B (6) X M GM17672-MA1 4S7 GM (6) X M GM17672-MA2 4S7, 600 V GM (6) X M GM17672-MA3 4S7 GM (6) X M GM17672-MA4 4S7, 600 V GM (6) X M GM17672-MA5 4S9 GM (6) X M GM17672-MA6 4S9, 600 V GM (6) X M GM17672-MA7 4S13 GM (6) X M GM17672-MA8 4S13, 600 V GM (6) X M GM17672-MA9 4V7, 1 Phase GM (6) X M GM17672-MA10 4V9, 1 Phase GM (6) X M GM17672-MA11 4V11, 1 Phase GM (6) X M GM17672-MA12 4S11 GM (6) X M GM17672-MA13 4S11, 600 V GM (6) X M GM17672-MA14 4V7, 1 Phase GM M (6) X M GM17672-MA15 4S9 GM (6) X M GM17672-MA16 4S9, 600 V GM (6) X M GM17672-MA17 4V11, 1 Phase GM (6) X M GM17672-MA18 4S11 GM (6) X M GM17672-MA19 4S11, 600 V GM (6) X M GM17672-MA20 4S13 GM (6) X M GM17672-MA21 4S13, 600 V GM (6) X M GM17672-MA22 4S15 GM (6) X M GM17672-MA23 4S15, 600 V GM (6) X M GM17672-MA24 4S7 GM M (6) X M GM17672-MA25 4S7, 600 V GM M (6) X M GM17672-MA26 4S9 GM M (6) X M GM17672-MA27 4S9, 600 V GM M (6) X M GM17672-MA28 4V9, 1 Phase GM M (6) X M GM17701-MA1 4P5 C (6) X M GM17701-MA2 4P5, 600 V C (6) X M GM17701-MA3 4P5B GM (6) X M GM17701-MA4 4P5B, 600 V GM (6) X M GM17701-MA5 4P7B GM (6) X M GM17701-MA6 4P7B, 600 V GM (6) X M GM17701-MA7 4P8 C (6) X M GM17701-MA8 4P8, 600 V C (6) X M GM17701-MA9 4P10 C (6) X M GM17701-MA10 4P10, 600 V C (6) X M GM17701-MA11 4Q5, 1 Phase B (6) X M GM17701-MA12 4Q10, 1 Phase B (6) X M GM17701-MA13 4Q10, 1 Phase B M (6) X M GM17701-MA14 4P8 C M (6) X M GM17701-MA15 4P8, 600 V C M (6) X M GM17701-MA16 4P10 C M (6) X M GM17701-MA17 4P10, 600 V C M (6) X M GM19673-MA1 4U9 B X (8) X M GM19673-MA2 4U9, 600 V B X (8) X M GM19673-MA3 4U10 B X (8) X M GM19673-MA4 4U10, 600 V B X (8) X M GM19673-MA5 4U13 B X (8) X M GM19673-MA6 4U13, 600 V B X (8) X M Alternator assembly includes items 1-32 on following page. TP /02 19

22 Group 201: Generator and Mounting, continued , _201_2 20 TP /02

23 Group 201: Generator and Mounting, continued Item Part Number Description Qty. 1 A PCB assembly, LED, FRII 1 2 See chart on following page Rotor assembly 1 3 B Heatsink (4P and 4Q alternators) 1 3 B Heatsink (4S and 4V alternators) 1 3 B Heatsink (4UA alternators) 1 4 X Bearing, ball (4P and 4Q alternators) 1 4 X Bearing, ball (4S and 4V alternators) 1 4 X Bearing, ball (4UA alternators) 1 5 A PCB assembly, photo receiver 1 6 X Nut, hex elastic stop, X Screw, hex head machine 2 8 X Washer, lock,.262 ID x.743 in. OD (4P and 4Q alternators) 2 8 X Washer, lock,.338 ID x.884 in. OD (4S and 4V alternators) 2 8 X Washer, lock,.391 ID x.975 in. OD (4UA alternators) 2 9 X-22-9 Washer, lock,.20 ID x.373 in. OD 2 10 X Washer, plain,.406 ID x.75 in. OD Washer, hardened,.531 ID x 1.06 in. OD (4UA alternators) Washer, special,.562 ID x 1.13 in. OD (4UA alternators) X Terminal, ring, male, AWG 4 11 X Terminal, fast-on, female 4 12 X Screw, Phillips pan head 4 13 X Screw, hex washer, thread-forming Washer, insulating,.195 ID x.5 in See chart on following page Disc, drive 2/3 16 See chart on following page Adapter, generator Actuator, magnetic cup 1 18 See chart on following page Exciter field assembly Cover, FR LED circuit board 1 20 X Screw, hex head machine (4P and 4Q alternators) 1 20 X Screw, hex head machine (4S and 4V alternators) 1 20 X Screw, hex head machine (4UA alternators) 1 21 X Washer, hardened,.406 ID x.812 in. (4P and 4Q alternators) 8 21 X Washer, hardened,.406 ID x.812 in. (4S, 4V, and 4UA alternators) See chart on following page Stator assembly Insulator Bracket, end (4P and 4Q alternators) Bracket, end (4S and 4V alternators) Bracket, end (4UA alternators) 1 25 See chart on following page Connector, lead Screw, cylinder head, 3/8-16 x1 1/4 (4P and 4Q alternators) Screw, cylinder head, 3/8-16 x1 1/4 (4S and 4V alternators) Screw, cylinder head, 3/8-16 x1 1/4 (4UA alternators) Fan, alternator (4P and 4Q alternators) Fan, alternator (4S and 4V alternators) 1 28 X Screw, hex cap (4P and 4Q alternators) 3 28 X Screw, hex cap (4S alternators) 3 28 X Screw, hex cap (4V alternators) 3 29 X Screw, hex cap (4P and 4Q alternators) 1 29 X Screw, hex cap (4S and 4V alternators) 1 29 X Screw, hex cap (4UA alternators) 1 30 X Screw, hex cap 4 30 X Screw, hex cap (4UA alternators) 4 31 X Screw, hex cap 4 32 X Screw, hex cap (4P and 4Q alternators) 4 32 X Screw, hex cap (4S and 4V alternators) 4 32 X Screw, hex cap (4UA alternators) 4 33 X Screw, hex cap (4P alternators) 6 33 X Screw, hex cap (4S and 4V alternators) 1 33 X Screw, hex cap (4S and 4V alternators) 5 33 X Screw, hex cap (4UA alternators) Fitting, grease 1 35 X Washer, hardened,.406 ID x.812 in. (4UA alternators) 4 TP /02 21

24 Group 201: Generator and Mounting, continued , _201_2 22 TP /02

25 Group 201: Generator and Mounting, continued Alternator Part Number and Mount Type Use this table to identify the part numbers of items 2, 15, 16, 18, 22, and 25. Item 2, Rotor Assembly Item 18, Field Exciter Item 22, Stator Assembly Item 25, Lead Connector Module No. Alternator Description Alternator Assembly Item 15, Drive Disc Item 16, Adapter GM19371-MA1 4P4 C A GM19371-MA2 4P4, 600 V B A GM19371-MA3 4Q4 B A GM19371-MA4 4P5 C A GM19371-MA5 4P5, 600 V C A GM19371-MA6 4P7 C A GM19371-MA7 4P7, 600 V B A GM19371-MA8 4P8 C A GM19371-MA9 4P8, 600 V C A GM19371-MA10 4Q10 B A GM17672-MA1 4S7 GM A GM GM17672-MA2 4S7, 600 V GM A GM GM17672-MA3 4S7 GM A GM GM17672-MA4 4S7, 600 V GM A GM GM17672-MA5 4S9 GM A GM GM17672-MA6 4S9, 600 V GM A GM GM17672-MA7 4S13 GM A GM GM17672-MA8 4S13, 600 V GM A GM GM17672-MA9 4V7, 1 Phase GM A GM GM17672-MA10 4V9, 1 Phase GM A GM GM17672-MA11 4V11, 1 Phase GM A GM GM17672-MA12 4S11 GM A GM GM17672-MA13 4S11, 600 V GM A GM GM17672-MA14 4V7, 1 Phase GM A GM GM17672-MA15 4S9 GM A GM GM17672-MA16 4S9, 600 V GM A GM GM17672-MA17 4V11, 1 Phase GM A GM GM17672-MA18 4S11 GM A GM GM17672-MA19 4S11, 600 V GM A GM GM17672-MA20 4S13 GM A GM GM17672-MA21 4S13, 600 V GM A GM GM17672-MA22 4S15 GM A GM GM17672-MA23 4S15, 600 V GM A GM GM17672-MA24 4S7 GM A GM GM17672-MA25 4S7, 600 V GM A GM GM17672-MA26 4S9 GM A GM GM17672-MA27 4S9, 600 V GM A GM GM17672-MA28 4V9, 1 Phase GM A GM GM19673-MA1 4UA9 B A GM19673-MA2 4UA9, 600 V B A GM19673-MA3 4UA10 B A GM19673-MA4 4UA10, 600 V B A GM19673-MA5 4UA13 B A GM19673-MA6 4UA13, 600 V B A GM17701-MA1 4P5 C A GM17701-MA2 4P5, 600 V C A GM17701-MA3 4P5B GM16880 A GM17701-MA4 4P5B, 600 V GM16881 A GM GM17701-MA5 4P7B GM16882 A GM17701-MA6 4P7B, 600 V GM16883 A GM GM17701-MA7 4P8 C A GM17701-MA8 4P8, 600 V C A GM17701-MA9 4P10 C A GM17701-MA10 4P10, 600 V C A GM17701-MA11 4Q5, 1 Phase B A GM17701-MA12 4Q10, 1 Phase B A GM17701-MA13 4Q10, 1 Phase B A GM17701-MA14 4P8 C A GM17701-MA15 4P8, 600 V C A GM17701-MA16 4P10 C A GM17701-MA17 4P10, 600 V C A TP /02 23

26 Control and Harness V Alternator Engine Harness TP /02

27 Control and Harness Cross-reference the module number of your control and harness and engine group variation to the letter key in the Model Number to Key Cross-Reference table below. Refer to the key column in the following table. Quantity Module Key Item Part Number Description A B C D F G H I J K P Q 1 X Coupling, pipe, 1/8 x 1 3/16 in X Nipple, pipe, 1/8 x 3/4 in Switch assembly, pressure Sender, oil pressure GM10626 Switch, sensor Switch, high temperature shutoff X Clamp, insulating X Clamp X Clamp Base, tie wrap M Nut, hex, 4 mm Marker, strip Block, terminal M7985A Screw, pan head machine Harness, wiring Harness, wiring Standoff, circuit board A PCB assembly, FRII voltage, Hz regulator A PCB assembly, FRII voltage, Hz regulator C PCB assembly, FRII voltage, Hz regulator A PCB assembly, FRII voltage, Hz regulator 1 14 GM17613 Harness, engine, kw* GM19883 Harness, engine, 180 kw* GM19884 Harness, engine, 200/230 kw* 1 14 GM22168 Harness, engine, 180 kw, 24 V* 1 14 GM20876 Harness, engine, 150 kw* GM21272 Harness, engine, kw* GM13701 Connector, weathertight, 2-position Diode, 6 A Connector, cable Connector, 24-position X Plug, button X Washer, lock,.326 ID x.883 in. OD X Washer, lock,.456 ID x in. OD (4UA alternator) 1 22 X Washer, lock,.521 ID x 1.24 in. OD (4S alternator) * Harness includes items 15-18, not shown. Module Number to Key Cross-Reference Use the module number of your control and harness from the generator set nameplate or engine group variation from the Specification Number Index to determine the key. kw Controllers Kit Number Key Decision-Maker 1 without gauges and meters, 1 phase GM19459-MA3 C Light and Decision-Maker 1 with gauges and meters, 1 phase GM19459-MA4 D Light and Decision-Maker 1 GM19459-MA1 A Decision-Maker 1 without gauges and meters GM19459-MA2 B Light and Decision-Maker 1 with gauges and meters GM21205-MA1 P Decision-Maker 1 without gauges and meters GM21205-MA2 Q Light and Decision-Maker 1 with gauges and meters GM20880-MA1 J 100/125 Decision-Maker 1 without gauges and meters GM20880-MA2 K 180/12 V 16-Light and Decision-Maker 1 with gauges and meters GM19873-MA1 F 180/12 V Decision-Maker 1 without gauges and meters GM19873-MA3 H 180/24 V 16-Light GM19873-MA4 I Light GM19873-MA2 G TP /02 25

28 Control and Harness V Alternator Engine Harness TP /02

29 Control and Harness Cross-reference the module number of your control and harness and engine group variation to the letter key in the Model Number to Key Cross-Reference table below. Refer to the key column in the following table. Quantity Module Key Item Part Number Description E L M N O R 4 GM16788 Sensor, pressure GM16787 Sensor, temperature X Clamp, insulating X Clamp X Clamp Base, tie wrap M Nut, hex, 4 mm Marker, strip X Block, terminal M7985A Screw, pan head machine GM19353 Harness, engine, kw* 1 14 GM19885 Harness, engine, 180 kw* 1 14 GM19886 Harness, engine, 200/230 kw* 1 14 GM22169 Harness, engine, 180 kw, 24 V* 1 14 GM20877 Harness, engine, 150 kw* 1 14 GM21273 Harness, engine, kw* 1 15 GM13701 Connector, weathertight, 2-position Diode, 6 A Connector, cable Connector, 24-position GM15493 Connector, 3-position X Plug, button X Washer, lock,.326 ID x.883 in. OD 1 22 X Washer, lock,.456 ID x in. OD (4UA alternator) X Washer, lock,.521 ID x 1.24 in. OD (4S alternator) Pickup, magnetic Pickup, magnetic X Washer, lock 2 23 X Washer, plain GM13980 PCB assembly, CT burden resistor Vibromount 4 * Harness includes items 15-19, not shown. Module Number to Key Cross-Reference Use the module number of your control and harness from the generator set nameplate or engine group variation from the Specification Number Index to determine the key. kw Controllers Kit Number Key Decision-Maker 550 GM19460-MA1 E Decision-Maker 550 GM21206-MA1 R Decision-Maker 550 GM20881-MA1 O 180, 24 V Decision-Maker 550 GM19878-MA3 N 180, 12 V Decision-Maker 550 GM19878-MA1 L 200/ V Decision-Maker 550 GM19878-MA2 M TP /02 27

30 Group 701: Literature Quantity Part Variation Number Item Number Description TP-5353 S/M kW, Industrial TP-5374 Warranty, 1 Yr. Ltd TP-5700 I/M Stationary Duty TP-5750 O/M kw TP-5889 O/M John Deere Engine Service Supplement TP-6009 P/C Controllers, Industrial TP-6083 O/M Decision-Maker 550 Controller TP-6116 P/C Accessories, kw Diesel, Industrial TP-6141 P/C John Deere TP-5826 P/C John Deere TP-5386 P/C John Deere 6059/ TP-5434 P/C John Deere 4039/ TP-6142 P/C REOZJB TP-6144 O/M John Deere Diesel Engine 3029DF TP-5824 O/M John Deere TP-5853 O/M John Deere 4045/ TP-6145 S/M John Deere Diesel Engine 3029DF TP-5825 S/M John Deere TP-5854 S/M John Deere 4045/ TP-6146 W/D John Deere REOZJB TP-5826 P/C John Deere TP-5386 P/C John Deere 6059/ TP-5434 P/C John Deere 4039/ TP-5824 O/M John Deere TP-5853 O/M John Deere 4045/ TP-5825 S/M John Deere TP-5854 S/M John Deere 4045/ TP /02

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. Controllers See Parts Catalog TP-6009 for parts lists kw 50/60 kw 80 kw 100/125 kw Cooling Systems Heater, block V GM19451-KA1 GM20968-KA3 GM20968-KA3 GM20968-KA V GM19451-KA2 GM20968-KA4 GM20968-KA4 GM20968-KA2 Remote radiator GM20116-MA1 GM17686-MA1 GM17686-MA1 TBD City water cooling GM20115-MA1 GM17685-MA1 GM17685-MA3 TBD City water cooling, 24 V N/A GM17685-MA2 GM17685-MA4 TBD Duct flange, radiator GM13896-KA1 GM13896-KA1 GM13896-KA1 GM13896-KA1 Optional Kits See Parts Catalog TP-6116 for parts lists. Paint and Miscellaneous Parts Paint, Kohler Cream Beige All models use spray can, gallon, GM19489 touch-up Controllers See Parts Catalog TP-6009 for parts lists. 150 kw 180/200 kw 230 kw Cooling Systems Heater, block V GM20968-KA1 GM19947-KA1 GM19947-KA V GM20968-KA2 GM19947-KA2 GM19947-KA2 Remote radiator TBD GM20579-MA1 GM20579-MA1 City water cooling TBD GM20578-MA1 GM20578-MA1 City water cooling, 24 V TBD GM20578-MA2 GM20578-MA2 Duct flange, radiator GM21035-KA1 GM21035-KA1 GM21035-KA2 Optional Kits See Parts Catalog TP-6116 for parts lists. Paint and Miscellaneous Parts Paint, Kohler Cream Beige All models use spray can, gallon, GM19489 touch-up TP /02 29

32 Cooling System Kits Qty. Description Part No. Block Heater, V GM19451-KA1 1 Heater, block Bushing, reducing, 1/2 x 1 in. NPT Bracket, block heater mounting Hose, molded,.62 in. ID X Hose, molded,.62 in. ID X Clamp, hose,.5/1 in. X Connector, hose + vibraseal X Clamp X Elbow, pipe, 90 deg. x 1/2 in. NPT X Pipe, 1/2 in. NPT x 3.00 in. X Coupling, pipe, 1/2 in. X Washer, plain M125A Washer, plain M125A Nut, hex, 6 mm M Nut, hex, 10 mm M Screw, hex cap M Screw, hex cap M Bolt, hex cap X Cable tie X Block Heater, V GM19451-KA2 1 Heater, block Bushing, reducing, 1/2 x 1 in. NPT Bracket, block heater mounting Hose, molded,.62 in. ID X Hose, molded,.62 in. ID X Clamp, hose,.5/1 in. X Connector, hose + vibraseal X Clamp X Elbow, pipe, 90 deg. x 1/2 in. NPT X Pipe, 1/2 in. NPT x 3.00 in. X Coupling, pipe, 1/2 in. X Washer, plain M125A Washer, plain M125A Nut, hex, 6 mm M Nut, hex, 10 mm M Screw, hex cap M Screw, hex cap M Bolt, hex cap X Cable tie X Block Heater, 120V GM19947-KA1 1 Heater, block Adapter, bushing O-ring Tag, hang Bracket, block heater mounting Elbow, street, 90 deg. x 3/4 in. NPTF SA Elbow, street, 90 deg. x 1/2 in. NPTF X Hose,.63 in. ID x 30 in. X Hose,.63 in. ID x 56 in. X Clamp, hose,.5/1 in. X Connector, hose + vibraseal X Connector, hose + vibraseal X Hose, rubber, straight,.25 in. ID X Block Heater, 240V GM19947-KA2 1 Heater, block Adapter, bushing O-ring Tag, hang Bracket, block heater mounting Elbow, street, 90 deg. x 3/4 in. NPTF SA Elbow, street, 90 deg. x 1/2 in. NPTF X Hose,.63 in. ID x 30 in. X Hose,.63 in. ID x 56 in. X Clamp, hose,.5/1 in. X Connector, hose + vibraseal X Connector, hose + vibraseal X Hose, rubber, straight,.25 in. ID X Qty. Description Part No. Block Heater, 1500W, 120V GM20968-KA1 1 Heater, block Hose,.63 in. ID x 30 in. X Hose,.63 in. ID x 56 in. X Elbow, street, 45 deg. x 1/2 in. NPT Adapter, bushing O-ring Tag, hang Bracket, block heater mounting Adapter, bushing O-ring, ISO 6149, 11.3 mm ID Pipe, 1/2 in. NPT x 4.00 in. X Elbow, pipe, 90 deg. x 1/2 in. NPT X Clamp, hose,.5/1 in. X Connector, hose + vibraseal X Clamp, insulating X Block Heater, 1500W, 240V GM20968-KA2 1 Heater, block Hose,.63 in. ID x 30 in. X Hose,.63 in. ID x 56 in. X Elbow, street, 45 deg. x 1/2 in. NPT Adapter, bushing O-ring Tag, hang Bracket, block heater mounting Adapter, bushing O-ring, ISO 6149, 11.3 mm ID Pipe, 1/2 in. NPT x 4.00 in. X Elbow, pipe, 90 deg. x 1/2 in. NPT X Clamp, hose,.5/1 in. X Connector, hose + vibraseal X Clamp, insulating X Block Heater, 1500W, 120V GM20968-KA3 1 Heater, block Hose,.63 in. ID x 5.5 in. X Hose,.63 in. ID x 49 in. X Elbow, street, 45 deg. x 1/2 in. NPT Adapter, bushing O-ring Tag, hang Bracket, block heater mounting Adapter, bushing O-ring, ISO 6149, 11.3 mm ID Pipe, 1/2 in. NPT x 4.00 in. X Elbow, pipe, 90 deg. x 1/2 in. NPT X Clamp, hose,.5/1 in. X Connector, hose + vibraseal X Clamp, insulating X Block Heater, 1500W, 240V GM20968-KA4 1 Heater, block Hose,.63 in. ID x 5.5 in. X Hose,.63 in. ID x 49 in. X Elbow, street, 45 deg. x 1/2 in. NPT Adapter, bushing O-ring Tag, hang Bracket, block heater mounting Adapter, bushing O-ring, ISO 6149, 11.3 mm ID Pipe, 1/2 in. NPT x 4.00 in. X Elbow, pipe, 90 deg. x 1/2 in. NPT X Clamp, hose,.5/1 in. X Connector, hose + vibraseal X Clamp, insulating X TP /02