Service Parts 8EOZD 6.5EFOZD. Marine Generator Sets. Models: TP /11b

Transcription

1 Service Parts Marine Generator Sets Models: 8EOZD 6.5EFOZD TP /b

2 Description Page Introduction... 3 Number Significance... 3 How to Find Part Numbers... 3 Hardware References... 3 Specification Number Index... 5 Group : Cylinder Block... 6 Group 2: Gear Housing... 8 Group 3: Mounting Flange & Oil Sump... 0 Group 4: Cylinder Head... 2 Group 5: Intake Manifold... 4 Group 6: Camshaft & Drive Gear... 6 Group 7: Crankshaft, Flywheel, & Pistons... 8 Group 8: Lube Oil System Group 9: Cooling Water System... 2 Group 0: Fuel Injection Pump Group : Governor Group 2: Fuel Injection Valve Group 3: Fuel Line and Filter Group 4: Starting Motor Group 5: Gasket Set Table of Contents Description Page Group 0: Air Intake Group 03: Fuel System Group 04: Cooling System Group 05: Engine Group 07: Nameplate and Decals Group 09: Skid and Plant Mounting Group 20: Generator and Mounting Group 30: Controller and Mounting Group 70: Literature Paint and Miscellaneous Parts Sound Shield Parts List: Accessories Appendix A. Glossary of Abbreviations... A- 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 6.5EFOZD/8EOZD 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. 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 0 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:004:003 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.. 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, 3/8-6 in the text means that the piece is 3/8-6 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 / 3

4 Notes 4 TP /

5 Specification Number Index Group Title Group No Spec No. Variation Number GM3949-GA GM3949-GA2 GM30220-GA Group Title Group No Spec No. Variation Number GM3949-GA GR GR2 GR3 GR4 GR6 GR7 GR8 GR9* GR0 43 GM3949-GA2 GR GR2 GR3 GR5 GR6 GR7 GR8 GR9* GR0 43 GM30220-GA * Units built before approximately April, 2007 used variation GR9. TP / 5

6 Group : Cylinder Block See Group TP /

7 Group : Cylinder Block Quantity Variation Number Item Part Number Description Block assembly, cylinder (includes items 2-20) 2 X Block assembly, cylinder 3 X Block, cylinder Plug Plug, PT /8, screw Plug Plug Plug X Bearing cap X Bearing cap Bolt, bearing cap Main bearing Main bearing undersize X Main bearing 4 5 X Main bearing Bearing, thrust 2 7 X Bearing, thrust 2 8 X Bearing, thrust Bush, camshaft Plug, PT / Bolt, M8 x 4 plated Bolt, cylinder head Gasket, cylinder head X Item not sold separately TP / 7

8 Group 2: Gear Housing Item 3 not shown TP /

9 X Group 2: Gear Housing Quantity Variation Number Item Part Number Description Housing assembly, gear Housing, gear 3 X Housing Plug Stud, M8 x Spring pin Stud, M6 x Nut, M Cover Gasket Nut w/washer Cover assembly (includes items 3 and 4) 3 X Cover, gear housing Seal, oil Pipe, knock Shim set O-ring Bolt, M6 x 6 plated Bolt, M6 x 30 plated Bolt, M6 x 60 plated Bolt, M6 x 60 plated Bolt, M6 x 80 plated Cover, blind Cap, lub. oil supply O-ring O-ring Bolt, M6 x 8 plated Gasket Cover, blind Bolt, M6 x 6 plated Gasket, liquid Item not sold separately TP / 9

10 Group 3: Mounting Flange & Oil Sump TP /

11 Group 3: Mounting Flange & Oil Sump Quantity Variation Number Item Part Number Description Back plate Parallel pin, 8 x Bolt, M0 x Bolt, M0 x Spacer, oil sump Sump assembly, lube oil (includes items 7-9) Plug 22 8 X Refer to item Seal, washer 22S Bolt, M6 x Bolt, M6 x 45 plated Parallel pin Case assembly, oil seal (includes items 4 and 5) Case, oil seal Seal, oil Bolt, M6 x 22 plated Liquid gasket AR X Item not sold separately TP /

12 Group 4: Cylinder Head Group _4 2 TP /

13 Group 4: Cylinder Head Quantity Variation Number Item Part Number Description Hose, breather Lifter, engine Bolt, M8 x 4 plated Bolt, M8 x 4 plated Head assembly, cylinder 6 X Head subassembly, cylinder 7 X Head, cylinder Guide, valve 6 0 X Plug, hot Plug, Pt / Plug, 5 x Plug Valve, intake Valve, exhaust Spring, valve Retainer, spring Cotter Seal, valve stem Seal, valve stem (exhaust) Cap, valve Protector, nozzle Gasket, nozzle Spring pin, 6 x Support assembly, rocker Shaft, rocker arm 27 X Shaft 28 X Ball Support, rocker arm Spring Arm assembly, rocker Screw, valve 6 33 X Arm, intake valve Nut, M Arm assembly, rocker Screw, valve 6 37 X Arm, intake valve Nut, M Circlip Screw, M5 x Stud Bolt, M8 x Nut, M Bonnet assembly Plate, shelter Gasket 47 X Bonnet Gasket, bonnet Joint Cap, lube oil supply Screw, 5 x 0, tapping Knob O-ring Plug, glow Connector, glow plug X Item not sold separately TP / 3

14 Group 5: Intake Manifold 4 See Group _5 4 TP /

15 Group 5: Intake Manifold Quantity Variation Number Item Part Number Description Gasket 2 GM35924 Manifold, intake Bolt, M6 x Gasket, exhaust manifold TP / 5

16 Group 6: Camshaft & Drive Gear See Group See Group See Group TP /

17 X Group 6: Camshaft & Drive Gear Quantity Variation Part Number Item Number Description Camshaft assembly (includes items 2-5) 2 X Camshaft Key Gear, camshaft Bearing, thrust Tappet Rod, push Camshaft assembly, fuel injection pump (includes items 9-2) 9 X Camshaft, fuel injection pump Key X Gear, fuel injection pump Ball bearing Bolt, M6 x 6 plated Screw, M8 x Bearing Ball bearing Retainer, idle gear Shaft, idle gear Gear w/bushing, idle (includes items 20 and 2) 20 X Gear, idle Bushing, idle gear Circlip Bolt, M6 x 2 plated 3 Item not sold separately TP / 7

18 Group 7: Crankshaft, Flywheel, & Pistons TP /

19 X Group 7: Crankshaft, Flywheel, & Pistons Quantity Variation Part Number Item Number Description Crankshaft assembly (includes items 2-6) Parallel pin, 8 x 6 3 X Crankshaft Gear, crankshaft 5 X Ball, steel Key V-pulley Washer Bolt, V-pulley Bolt, flywheel Flywheel assembly (includes items 3 and 4) 3 X Flywheel Gear, ring Piston w/rings (includes items 6 and 7) Piston w/rings (oversized 0.25) (includes items 6 and 7) 3 6 X Piston Ring set (includes items 8-20) Ring set (oversized 0.25) (includes items 8-20) 3 8 X Ring, top 3 9 X Ring, second 3 20 X Ring, oil Pin, piston Circlip Rod assembly, connecting (includes items 24-27) 3 24 X Rod, connecting Bushing, piston pin Bolt, connecting rod Bearing, crankpin Bearing, pin (undersized 0.25) 3 Item not sold separately TP / 9

20 Group 8: Lube Oil System 27 See Group 4 See Group Quantity Variation Part Number Item Number Description Pump assembly, oil (includes items 2-0) 2 X Body 3 X Cover 4 X Rotor assembly (includes items 5-8) 5 X Pin 6 X Rotor, inner 7 X Shaft 8 X Rotor, outer 9 X Gear, lube oil pump 0 X Bolt, M6 x Gasket, lube oil pump Bolt, M6 x Guide, dipstick Dipstick, lube oil Filter, lube oil Valve assembly, oil pressure (includes items 8-22) 8 X Body 9 X Spring 20 X Retainer 2 X Shim pack 22 X Valve Nut Pipe assembly, oil intake O-ring Bolt, M6 x 2 plated Switch, oil pressure Bracket, oil filter Gasket Bolt, M8 x O-ring X Item not sold separately 20 TP /

21 Group 9: Cooling Water System See Group X Quantity Variation Number Item Part Number Description Pump assembly, cooling pump (includes item 2) O-ring Plug, Pt 3/8, screw Gasket, water pump Bolt, M8 x 65 plated Bolt, M8 x 45 plated V-belt V-pulley Cover, thermostat 0 GM0849 Gasket Bolt, M8 x 65 plated Bolt, M8 x 65 plated Drain cock assembly (includes items 4 and 5) 4 X Body 5 X Valve Plug, M6 7 - See Group See Group Gasket Bolt, M8 x Adjuster, belt Item not sold separately TP / 2

22 Group 0: Fuel Injection Pump TP /

23 X Group 0: Fuel Injection Pump Quantity Variation Number Item Part Number Description Pump assembly, fuel pump (includes items 2-35) 2 X Body, fuel injection pump Plunger w/barrel (includes items 4-5) 3 4 X Barrel, plunger 3 5 X Plunger Retainer Retainer Spring, plunger Tappet assembly (includes items 0-2) 3 0 X Guide, roller 3 X Roller 3 2 X Pin, roller Shim pack Valve w/seat, delivery (includes item 5-6) 3 5 X Seat 3 6 X Valve, delivery Spring, valve Holder, delivery valve Gasket, delivery O-ring Guide, plunger Pin Rack Pinion Retainer, rack Plate Screw Pin Pin 30 X Label, caution Washer Spring washer Screw, M4 x X Rivet Screw, M4 x 0 2 Item not sold separately TP / 23

24 Group : Governor , 4, B 24 TP /

25 Group : Governor Item Part Number Description Quantity Variation Number Nut, with washer 8 mm Cover, governor case Gasket Bolt, M6 x Washer, 6 (not shown) Bolt, M6 x Driving set, governor (includes items 7-2) Weight assembly, governor (includes items 8-0) 8 X Weight, governor 3 9 X Pin, governor weight 3 0 X Support, governor weight Nut, governor weight Sleeve, governor Link, L=88.8 (no color) Link, L=88.6 (white) Link, L= Case assembly, governor (includes items 7-43) O-ring 8 X Case, governor Gasket Shim set Spacer assembly Shaft, governor lever Lever assembly, governor (includes items 24-34) Shim set 2 25 X Lever, tension 26 X Governor lever 27 X Governor lever Spring, lever Shifter, PTO 30 X Needle bearing Spring, starting Washer Circlip Spring pin, 3 x Retainer, shaft Retainer, shaft Shaft assembly, regulator (includes items 38-40) 38 X Shaft, regulator Item Part Number Description Quantity Variation Number 39 X Lever, regulator 40 X Taper pin, 3 x Spring pin, 4 x O-ring Bolt, M6 x Carb nut, limit Spring, regulator Lever, regulator Carb nut, high idle Screw, adjustment Solenoid kit (includes item 50) O-ring Bolt, M6 x Fuel limiter 53 X Shim set 54 X Body 55 X Pin 56 X Spring, controller 57 X Shim set 58 X Circlip Angleich assembly (includes items 60-66) 60 X Case, angleich 6 X Shifter 62 X Nut 63 X Spring 64 X Shim set 65 X Washer 66 X Circlip Seal washer 2S Snap pin Snap pin Bolt, M6 x Bolt, M5 x Bolt, M6 x Lock nut, M Seal washer 6 75 X Plug Plug Plug 22 X Item not sold separately TP / 25

26 Group 2: Fuel Injection Valve No. No No See Group See Group TP /

27 Group 2: Fuel Injection Valve Quantity Variation Item Part Number Description Number Valve assembly, fuel injection Nozzle assembly, fuel injection (includes items 38-39) 3 38 X Valve 3 39 X Body Nut, valve w/case Holder, valve w/case Spring, valve Seat, nozzle spring Spacer, valve stop Shim pack O-ring Retainer, injection pipe 48 X Retainer 49 X Retainer Bolt, M4 x X Pipe set, fuel inlet Pipe, fuel injection Pipe, fuel injection Pipe, fuel injection Pipe assembly, fuel (includes items 56-59, 62) Joint Joint Joint Pipe Nut Gasket, round Clamp GM33682 Hose fitting, banjo 64 GM3278 Bolt, banjo Clamp GM35483 Fuel, line, return X Item not sold separately TP / 27

28 Group 3: Fuel Line and Filter TP /

29 X Group 3: Fuel Line and Filter Quantity Variation Number Item Part Number Description Filter assembly, fuel Cup, filter O-ring Ring, retaining Spring 6 X Body Element, fuel Plug Gasket, nylon 2 0 X Spacer,.375 ID x.750 OD x.500 in. M Nut, hex Stud, M8 3 X Fuel line, flexible 4 X Clamp, hose,.25/.70 in. 2 5 X Fitting, union, banjo Gasket Bolt, w/plug & seal Plug Seal washer 20 X Bolt, joint Item not sold separately TP / 29

30 Group 4: Starting Motor 30 TP /

31 Group 4: Starting Motor Quantity Variation Number Item Part Number Description Starter (includes items 3-8) Cover, terminal Stopper set, pinion Switch, magnetic Washer set, thrust Armature Cover assembly, rear Holder assembly, brush Brush ( -) Brush (+) Spring, brush Cover kit, dust Lever set, shift Coil assembly, field Cover Through bolt Pinion Bolt Bolt, M0 x 30 plated TP / 3

32 Group 5: Gasket Set , Item 27 not shown. 32 TP /

33 Group 5: Gasket Set Quantity Variation Number Item Part Number Description Gasket set (includes items 2-26) Gasket, cylinder head Gasket O-ring Gasket Seal, valve stem Seal, valve stem Protector, nozzle Gasket, nozzle Gasket Gasket, valve cover Gasket Gasket, exhaust manifold Gasket, oil pump Gasket, water pump Gasket Gasket Gasket Gasket Gasket 4, round O-ring O-ring O-ring O-ring O-ring O-ring Gasket, liquid TP / 33

34 Group 0: Air Intake _0 Quantity Variation Number Item Part Number Description GR 2 X Clamp, hose, /2 in. 2 X Clamp, hose,.56/2.5 in Cover, plastic Adapter, nylon hose Filter, filter Element, air cleaner Clip, air cleaner Bracket, air cleaner mounting Base, air cleaner Hose, molded air intake,.75 in./.29 in. ID X Clamp, hose,.3/2.25 in. 2 X Clamp, hose,.8/.75 in Duct Duct Connector, hose 34 TP /

35 Group 03: Fuel System See Group 3 for additional fuel system parts Fuel Return Inlet _03 Quantity Part Variation Number Item Number Description GR Pump, fuel Lead assembly 3 X-555- Elbow, street, /4 x /4 4 X Connector, hose elbow 5 X Clamp, hose X Line, fuel Bracket, fuel pump 8 M25A-0-80 Washer M Bolt, hex head X-0-25 Nut, lock 3 3 # Washer, / X Grommet X Clamp, insulated,.88 in. 4 X Clamp, insulated,.44 in. 5 X-59-0 Plug, cap /4 in. 6 X-509- Adapter, pipe, /4 in. 7 X-382- Elbow, compression (90 deg.) # Common hardware; procure locally. TP / 35

36 Group 04: Cooling System To engine To mixing tube, item _04B TP /

37 Group 04: Cooling System Qty. Part Var. No. Item Number Description GR Guard, belt 2 X Grommet X Washer, plain Screw, wing Bracket, belt guard Bracket, belt guard Bracket, belt guard 8 X Washer, plain,.28 ID x.625 in. OD 9 GM3660 V-Belt, 26 in. 0 GM42280 Pulley, pump drive M25A-0-80 Washer, plain M Screw, HC M Pump, seawater (includes items 6--70) 3 GM46960 Kit, Service Seawater Pump* Bracket, seawater pump 5 M Screw, HC X Spacer,.282 ID x.5 ID x.02 in Manifold, exhaust Neck 9 M25A Washer M Screw, hex head cap M Screw, hex head cap Gasket, exhaust Tube, mixing 23 X Washer, 5/ X-25-5 Screw, 5/6-8 x GM47556 Thermostat Thermostat Gasket, water outlet Cover, thermostat 28 X Washer X-25-3 Screw, 5/6-8 x Hose, coolant 3 X Clamp, hose, 5/6 x 3/ GM30020 Hose, molded 33 X Clamp, hose, 5/6 x 3/ Cover, thermostat Gasket, water outlet 36 X Washer X-25-3 Screw, 5/6-8 x Hose, molded 39 X Clamp, hose, 5/6 x 3/ X Washer, plain,.406 ID x.656 OD X Spacer,.260 ID x.5 ID x.88 in. 42 GM30879 Exchanger, heat Exchanger, heat Zinc anode Hose 45 X Clamp, hose, /2 x 3/ X Connector, hose 47 X-39-2 Connector, hose, 5/8 x 3/8 48 X Hose 48 X Hose Hose 50 X Clamp, hose, 5/6 x 3/ Bracket, heat exchanger X Clamp, insulated # Hardware, / X-39-2 Connector, hose, 5/8 x 3/ Bottle, overflow 55 X Screw X Clamp, hose X Hose Cap Bracket, water bottle 60 GM30263 Switch, pressure Plate, cover Gasket Kit, impeller (includes gasket) Bearing, ball Housing * Seawater pump service kit replaces pump Kit includes pump GM46936 (item 74), item 4 bracket, and hardware. # Common hardware; procure locally. TP / 37

38 Group 04: Cooling System, continued To engine To mixing tube, item _04B TP /

39 Group 04: Cooling System, continued Pump Components Pump GM46936 Components Qty. Part Var. No. Item Number Description GR Cover, thermostat Gasket, water outlet 36 X Washer X-25-3 Screw, 5/6-8 x Hose, molded 39 X Clamp, hose, 5/6 x 3/ X Washer, plain,.406 ID x.656 OD X Spacer,.260 ID x.5 ID x.88 in. 42 GM30879 Exchanger, heat Exchanger, heat Zinc anode Hose 45 X Clamp, hose, /2 x 3/ X Connector, hose 47 X-39-2 Connector, hose, 5/8 x 3/8 48 X Hose 48 X Hose Hose 50 X Clamp, hose, 5/6 x 3/ Bracket, heat exchanger X Clamp, insulated # Hardware, / X-39-2 Connector, hose, 5/8 x 3/ Bottle, overflow 55 X Screw X Clamp, hose X Hose Cap Bracket, water bottle 60 GM30263 Switch, pressure Plate, cover Gasket Kit, impeller (includes gasket) Bearing, ball Housing Pulley Shaft, drive 68 GM6865 Seal 69 GM22995 Seat, ceramic 70 GM7702 Key 74 GM46936 Pump, seawater * Seawater pump service kit replaces pump Kit includes pump GM46936 (item 74), item 4 bracket, and hardware. # Common hardware; procure locally. TP / 39

40 Group 05: Engine 20 9 DISPLAY REMAINS ACTIVE DURING GENERATOR OPERATION To Oil Pan See Group 0 7 See Group , To mixing tube, Group _05a 40 TP /

41 Group 05: Engine Quantity Part Variation Number Item Number Description GR4 GR5 3 A BLK Engine assembly (not shown; see Groups -5 for parts) (3TNE74C) 2 X Hose 2 X-65-9 Hose 3 X Clamp, hose,.25/.720 in. 4 X Washer, plain 5 GM50838 Kit, valve drain (includes valve and item 2) 6 X Clip, hose 7 # Hardware, / Alternator Pulley, tension assembly (not shown) 9 M Nut, hex. 5 mm 0 M Nut, hex. 6 mm M Nut, hex. 8 mm 2 X Spacer,.344 ID x.625 OD x.4 in. 3 # Hardware, 5/ Switch, high temperature cutout 5 X Screw, 3/8-6 x X Clamp, hose,.5/ in X Hose 8 GM3660 V-Belt, 25.5 in. 9 GM28823 Sender, temperature 20 GM30245 Bushing, adapter Adapter, bushing Adapter, sender 23 GM7097- Sensor, pressure # Common hardware; procure locally. TP / 4

42 Group 07: Nameplate and Decals Quantity Part Variation Number Item Number Description GR Decal, warning Hot Coolant Decal, Notice Zinc Anode Decal, negative battery connection Decal, equipment ground 5 GM467 Decal, drain Decal, warning Rotating Parts Decal, -800 number Decal, danger High Voltage Decal, warning Hot Engine Nameplate X Decal, Kohler Power System X Decal, Kohler Power System 2 GM35838 Decal, reconnection phase Decal, CE Nameplate and decals not illustrated. 42 TP /

43 Group 09: Skid and Plant Mounting _09 Quantity Part Variation Number Item Number Description GR7 2 GM3906 Tray, drip 2 GM29302 Tray, drip Support, engine M25A-0-80 Washer M Screw, hex head X-22-4 Washer, lock, 7/6 6 # Hardware, M Vibromount X Washer, plain LK Lead Strap, ground 0 X-22-2 Washer, shakeproof, /4 4 4 # Hardware, M # Hardware, M X Connector, cable 4 X-22- Washer, lock, /4 5 M Nut, elastic stop 4 4 # Common hardware; procure locally. TP / 43

44 Group 20: Generator and Mounting , TP /

45 Group 20: Generator and Mounting Quantity Part Variation Number Item Number Description GR8 2 GM2930 Stator assembly Guard, generator fan Clip, speed 4 X Screw, tapping, Plate, locator Pin, knurled M Screw, M Disc, drive 9 X Screw, 3/8-6 x Disc, drive 2 2 M Screw, HC M M25A Washer Disc, fan locator Fan, generator Fan, generator 5 X-0-9 Nut, elastic stop, X Spacer A Rotor assembly (includes item 8) 8 X Bearing, ball O-ring 20 GM2480 Bracket, end 2 GM37365 Box, junction 2 GM29687 Box, junction 22 GM3002 Plate, circuit breaker 23 X-626- Screw, Phillips hex crimptite 4 23 X Screw, self-tapping 4 24 X Connector, cable 25 GM32289 Panel, junction box louver 25 GM29689 Panel, junction box louver 26 X-626- Screw, Phillips hex crimptite 0 26 X Screw, self-tapping 0 27 X-80-3 Washer, hardened X-22-4 Washer, lock,.39 ID x.975 in. OD 28 M Screw, hex head X-97-5 Screw, hex, Exciter, armature 3 X Washer, plain 32 X Screw, 3/8-6 x X-22- Washer, lock 33 A Circuit Board, diode board 34 X Terminal X-5-8 Screw, 8-32 x X-22-7 Washers, # X-72-7 Spacer X Screw, tapping, GM3034 Exciter assembly, field -- X Clamp, insulated,.75 in. (not shown) TP / 45

46 Group 30: Controller and Mounting See Group See Group TP /

47 Group 30: Controller and Mounting Quantity Part Variation Number Item Number Description GR9 GR Vibromount GM28483 SCR module 3 GM34969 Controller assembly, ADC 200 (kit includes instructions) 4 GM29246 Harness, engine (serviced with Kit GM50489-S that includes GM50489) 4 GM50489 Harness, engine (used with relay containing an integrated diode) 5 GM2967 PCB assembly, relay board, 2V 5 GM29779 PCB assy, relay board, 2V PCB Assy, Relay Board 2V w/opt Relay 6 X-22- Washer, lock,.262 ID x.469 in. OD X-22-2 Washer, lock,.262 ID.743 in. OD X Washer, lock,.72 ID x.373 in. OD X Screw, self-tapping X Nut, flange whiz, GM28678 Connector, weathertight Connector, 9-position 3 GM29998 Connector, 6-position, blk, male Fuse, 0 A, 250 V (F and F2) Connector, receptacle Diode, 6 A GM5493 Connector, weathertight, 3-position Connector, plug, 2-position 9 GM29249 Connector Fuse, 0 A, 250 V (F3) Relay, 24 VDC (use GM49746 and modify harness GM29246) 2 GM49746 Relay, 24 VDC (contains integrated diode, used w/harness GM50489) 22 M7985A Screw, pan head mach Grommet, round 24 M Nut, Hex 5mm 25 X-8-8 Nut, hex, / X Nut, flange spiralock, / * Units built before approximately April, 2007 used variation GR9. Group 70: Literature Quantity Variation Part Number Item Number Description 43 TP-5375 Warranty, Marine 2 TP-5620 Safety Precautions, Marine 3 TP-5876 S/M Yanmar TNE Series (AOA5063) 4 TP-5968 O/M Yanmar 4TNE98 Series 5 TP-6252 O/M 5--32EOZD, Marine 6 TP-6253 I/M 5--32EOZD, Marine 7 TP-6255 S/M EOZD/6.5--3EFOD, Marine 8 TP-6269 P/C 8EOZ/6.5EFOZD Marine Paint and Miscellaneous Parts Item Part Number Description White paint, gallon can (Chris Craft White) White paint, spray can (Chris Craft White) GM4826 White paint, spray can (Matterhorn White) The change from Chris Craft to Matterhorn White was made in production on //2006; the serial break is # TP / 47

48 Sound Shield TP /

49 Sound Shield Quantity Part Kit Number Item Number Description GM3950-KA(KP) Tube, exhaust, fiberglass, 2 in. OD Tube, exhaust elbow, 2.00 in. OD, ST 3 GM2998 Retainer 2 4 GM29920 Stud, wing head 2 5 GM3924 Base, sound shield 6 GM32052 Hose, radiator 7 GM32053 Hose, radiator 8 X-32-3 Hose,.63 in. ID 9 X Fuel line, flexible 0 X Fuel line, flexible X-50-5 Screw, pan head. 0-24x/2 8 2 X Cable, battery 3 X Cable, battery, RED+ 4 X-65-5 Hose, rubber, straight,.375 in. ID 5 X Connector, hose + vibra seal 6 X Clamp, hose,.8/2.75 in. 8 7 X Clamp, hose,.56/.06 in. 2 8 X Clamp, hose,.25/.70 in. 5 X-22-2 Washer, lock,.262 ID x.743 in. X Washer, plain,.28 ID x.625 in. OD 8 X Bolt, hex cap 4 X Bolt, hex cap 4 X Washer, nylon 2 X Screw, drill #8 stainless steel 24 TP / 49

50 Sound Shield, continued Items not shown: 7--9, , , , TP /

51 Sound Shield, continued Quantity Part Kit Number Item Number Description GM3950-KA(KP) Decal, negative battery connect Coupling, bulkhead pipe Marker, adhesive Decal, warning rotating parts Decal, caution-not a step Decal, equipment grd Insert, threaded, /4-20 in Pin, threaded, /4-20 x.8 in Insert, threaded, # Decal, fuel inlet Decal, fuel return Foam, acoustic insulation (Yanmar) 3 3 GM048 Decal, warning fire port 4 GM5486 Connector, outside corner 4 5 GM29899 Frame, circuit breaker 2 6 GM2999 Clip, speed 2 7 GM2992 Seal, dampening 2 8 GM29980 Latch, lockable 4 9 GM30025 Screen, galvanized 20 GM3025 Panel, sound shield ADC lead 2 GM33684 Terminal, block 2 22 GM3209 Panel, bulkhead connection 23 X Grommet, round 24 GM33828 Barrier, battery terminal 25 X Button, plug 2 26 X Connector, cable 27 X-582- Connector, hose + vibra seal 28 X Connector, hose 2 29 X U-channel 30 X U-channel 3 X U-channel 32 X U-channel 33 X Clip, speed 4 34 X Bushing,.672 x.875 in. NPT 35 X-22-4 Washer, lock,.39 ID x.975 in. OD 4 36 X-75-0 Plug, pipe, 3/8 in. NPTF Rail, sound shield Rail, sound shield 39 GM2937 Rail, sound shield 2 40 GM29909 Rail, sound shield 4 GM29984 Rail sound shield 42 GM25958 Duct, air outlet 43 GM29375 Door, sound shield (RH) 44 GM29377 Door, sound shield (front) 45 GM29378 Door, sound shield (LH) 46 GM29379 Door, sound shield (rear) 47 GM29380 Roof, sound shield 48 GM29826 Panel, sound shield (LH) 49 GM2994 Duct, air inlet 50 GM2995 Baffle, air intake duct 5 GM29992 Panel, junction box 52 GM3009 Duct, air outlet 53 GM3957 Panel, sound shield (RH) 54 GM3283 Rail, sound shield (front) 55 LK Lead 56 X-22- Washer, lock,.262 ID x.469 OD 57 X-22-2 Washer, lock,.262 ID x.743 in. OD 58 X-78-4 Rivet, pop,.87 in. 3 TP / 5

52 Sound Shield, continued F2 F5 F30 F27 F2 F23 F32 F4 F2 F5 F3 F7 F24 F25 F26 F3 F7 F6 F8 F4 F6 F8 F6 F3 F20 F28 F22 F29 F9 F F9 F30 F0 F 52 TP /

53 Sound Shield, continued Quantity Part Kit Number Item Number Description GM3950-KA(KP) F GM26354 Foam, acoustic insulation F2 GM26355 Foam, acoustic insulation F3 GM26356 Foam, acoustic insulation F4 GM26357 Foam, acoustic insulation F5 GM26358 Foam, acoustic insulation F6 GM26363 Foam, acoustic insulation 2 F7 GM26364 Foam, acoustic insulation F8 GM26365 Foam, acoustic insulation F9 GM30042 Foam, acoustic insulation F0 GM30043 Foam, acoustic insulation F GM30044 Foam, acoustic insulation F2 GM30045 Foam, acoustic insulation F3 GM30046 Foam, acoustic insulation F4 GM30047 Foam, acoustic insulation F5 GM30048 Foam, acoustic insulation F6 GM30049 Foam, acoustic insulation F7 GM30050 Foam, acoustic insulation F8 GM3005 Foam, acoustic insulation F9 GM30052 Foam, acoustic insulation F20 GM30053 Foam, acoustic insulation F2 GM30054 Foam, acoustic insulation F22 GM30055 Foam, acoustic insulation F23 GM30056 Foam, acoustic insulation 2 F24 GM30057 Foam, acoustic insulation F25 GM30058 Foam, acoustic insulation F26 GM30059 Foam, acoustic insulation F27 GM30060 Foam, acoustic insulation F28 GM3006 Foam, acoustic insulation F29 GM30065 Foam, acoustic insulation F30 GM30066 Foam, acoustic insulation F3 GM30067 Foam, acoustic insulation F32 GM305 Foam, acoustic insulation TP / 53

54 Parts List: Accessories Qty. Description Part No. Circuit Breakers Circuit Breaker Kit GM3033-KA(KP) Installation Instructions TT-394 Decal, notice Plate, cover Plate, circuit breaker GM Screw, pan head X-49-2 Circuit breaker, 30 A X Nut, flange whiz, 6-32 X Circuit Breaker Kit GM3033-KA(KP)3 Installation Instructions TT-394 Decal, notice Plate, cover Plate, circuit breaker GM Screw, pan head X-49-2 Circuit breaker, 70 A X Nut, flange whiz, 6-32 X Circuit Breaker Kit GM3033-KA(KP)4 Installation Instructions TT-394 Decal, notice Plate, circuit breaker GM Screw, pan head X Circuit breaker, 35 A X Circuit Breaker Kit GM3033-KA(KP)6 Installation Instructions TT-394 Decal, notice Terminal, jumper Plate, circuit breaker GM Screw, pan head X Circuit breaker, 33 A X Circuit Breaker Kit GM3033-KA(KP)7 Installation Instructions TT-394 Decal, notice Plate, circuit breaker GM Screw, pan head, 6-32 x 3/6 in. X Circuit breaker, 30 A X Electrical System Harness, 2 in., Pigtail GM32332-KP Harness, pigtail GM32324 Harness, 5 in., Remote Panel GM32333-KP Harness, extension GM30248 Harness, 25 in., Remote Panel GM32333-KP2 Harness, extension GM32323 Harness, 00 ft., Remote Panel GM32333-KP4 Harness, extension GM4739 Oil Pressure Sender GM322-KA(KP) Installation Instructions TT-438 Adapter, sender Sensor, pressure GM7097- Qty. Description Part No. Preheat Kit, 2 Volt GM327-KA(KP) Installation Instructions TT-397 Wiring harness Relay Boot Bracket, mounting GM32427 Washer, lock,.262 ID x.743 in. OD X-22-2 Remote Digital Gauge GM32337-KP Decal, warning Gauge, digital GM30565 Harness, remote GM32325 Installation instructions TT-379 Installation instructions TT-364 Remote Start Panel (2 V) GM32335-KP Decal, warning Installation instructions TT-378 Panel assembly, control (includes *) GM *Meter, runtime *Panel, control GM33847 *Switch, rocker GM33849 *Harness, wiring GM *Screw, pan head M3 x 2 M7985A *Nut, hex 3 mm M *Washer, lock,.46 ID x.285 in. OD X-22-6 Remote Start Panel (24 V) GM32335-KP2 Decal, warning Installation instructions TT-378 Panel assembly, control (includes *) GM *Meter, runtime *Panel, control GM33847 *Switch, rocker GM33850 *Harness, wiring GM *Screw, pan head M3 x 2 M7985A *Nut, hex 3 mm M *Washer, lock,.46 ID x.285 in. OD X-22-6 Ship to Shore Switch PAA Switch, transfer, 3-pole A Installation Instructions TT-535 Isolated Ground, 2V GM3865-KP Grommet, round Adapter, sender Bus, Isolated Ground GM3868 Alternator, Battery Charging GM399 Bracket, Support GM33029 Tag, Hang Battery Negative GM3543 Relay, 2 VDC GM49746 Transformer, High Impedence Iso. GM5484 Relay, Cranking, 2V GM52584 Harness, Engine 8-0EOZD Yanmar GM55382 Sender, Pressure, 0-50psi, /8-27 NPTF GM7097- TT Isolated Ground, 8-32EOZD/6.5-27EFOZD TT Spacer,.209 ID x.375 OD x.406 in. X Spacer,.406 ID x.625 OD x.297 in. X Cable, Battery X Cable, Battery (Black) X Stud (Metric) X Isulator, Standoff X TP /

55 Parts List: Accessories Qty. Description Part No. Isolated Ground, 2V w/sound Shield GM3865-KP3 Grommet, round Adapter, sender Switch, High Temp. Cut-Out GM29289 Bus, Isolated Ground GM3868 Alternator, Battery Charging GM399 Bracket, Support GM33029 Relay, 2 VDC GM49746 Transformer, High Impedence Iso. GM5484 Relay, Cranking, 2V GM52584 Harness, Engine 8-0EOZD Yanmar GM55382 Sender, Pressure, 0-50psi, /8-27 NPTF GM7097- TT Isolated Ground, 8-32EOZD/6.5-27EFOZD TT Spacer,.209 ID x.375 OD x.406 in. X Spacer,.406 ID x.625 OD x.297 in. X Cable, Battery X Cable, Battery (Black) X Cable, Battery (Black) X Stud (Metric) X Isulator, Standoff X Qty. Description Part No. Sound Shield Siphon Break Hose Connection GM32339-KA(KP) Installation Instructions TT Coupling, hose Grommet, round X Hose,.63 ID X Clamp, hose,.56/.06 in. X Tubing, Clear Flexible Plastic GM34883 Valve, Siphon Break Assy (.63 Hose) GM32985 Valve, duct Cap, Siphon Valve GM32984 Loop, Siphon Valve Vent GM32988 Isolated Standoff GM3834-KA 2 Nut, Hex 6mm M Stud (Metric) X Isulator, Standoff X Miscellaneous Accessories Fuel/Water Separator GM3994-KP Installation Instructions TT-375 Filter assembly, fuel/water separator GM403 Element, water separator GM404 Keel Cooling Conversion GM3220-KA(KP) Installation Instructions TT-474 Gasket, exhaust Flange, exhaust outlet Siphon Break PA Installation Instructions TT-268 Tubing, Clear Flexible Plastic GM34883 Valve, Siphon Break Assy (.63 Hose) GM32985 Valve, duct Cap, Siphon Valve GM32984 Loop, Siphon Valve Vent GM32988 TP / 55

56 Notes 56 TP /

57 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. lbs. 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. lbs. 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 TP / Appendix A-

58 k kilo (000) K kelvin ka kiloampere KB kilobyte (2 0 bytes) 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, kω kilo-ohm kpa kilopascal kph kilometers per hour kv kilovolt kva kilovolt ampere kvar kilovolt ampere reactive kw kilowatt kwh kilowatt-hour kwm kilowatt mechanical L liter LAN local area network 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 (/000) M mega (0 6 when used with SI units), male m 3 cubic meter m 3 /min. cubic meters per minute ma milliampere man. manual max. maximum MB megabyte (2 20 bytes) MCM one thousand circular mils MCCB molded-case circuit breaker meggar megohmmeter MHz megahertz mi. mile mil one one-thousandth of an inch min. minimum, minute misc. miscellaneous MJ megajoule mj millijoule mm millimeter mohm, mω milliohm MOhm, MΩ megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m/sec. meters per second MTBF mean time between failure MTBO mean time between overhauls mtg. mounting MW megawatt mw milliwatt μf 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 Phillips head crimptite (screw) PHH Phillips 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 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 RTV room temperature vulcanization 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 SPDT single--pole, double--throw SPST single--pole, single--throw spec, 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 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 A-2 Appendix TP /