Service Parts 14RESA/RESAL 20RESA/RESAL 20RESC/20RESCL. Residential/Commercial Generator Sets. Models: TP /16e

Transcription

1 Service Parts Residential/Commercial Generator Sets Models: RESA/RESAL 0RESA/RESAL 0RESC/0RESCL TP-80 /e

2 Common Replacement Parts Figure identifies 000-hour common replacement parts for your generator set. Refer to the groups on the following pages for a complete list of maintenance and service parts. Description Part Number RESA 0RESA/C Sensor, oil temperature GM88 Filter, oil S 8 Filter, oil S 8 Switch, oil pressure S Switch, oil pressure S Spark plug 5 -S Spark plug 0-S Kit, starter solenoid S Element, air filter 08 0-S Element, air filter 08 0-S Bushing, linkage retaining S Coupling, stepper motor 5858 Figure 000-Hour Replacement Parts

3 Table of Contents Common Replacement Parts... Table of Contents... Introduction... Numbering System Significance... Illustrations... How to Find Part Numbers... Hardware References... 5 Specification Number Index... Engine Groups Group : Crankshaft... Group : Crankcase... 0 Group : Oil Pan/Lubrication... Group : Cylinder Head/ Valve/ Breather... 7 Group 5: Ignition/Electrical... 0 Group : Blower Housing and Baffles... Group 7: Starter... Group 8: Carburetor... 7 Group : Engine Controls... Group 0: Air Intake/Filtration... Group : Engine Exhaust... Group : Engine Decals... Group : Gasket Set... 5 Generator Groups Fuel System... Engine... 8 Nameplate and Decals... 0 Skid... Customer Connection (Terminal Block)... Harness... Circuit Breaker... 5 Exhaust... 7 Alternator... 8 Controller... 5 Bulkhead... 5 Enclosure... Literature... Kit Parts List... 7 Appendix A. Abbreviations Appendix B. Common Hardware Application Guidelines... 7 Appendix C. General Torque Specifications... 7 Appendix D. Common Hardware Identification... 7 Appendix E. Common Hardware List... 75

4 Introduction This manual lists service replacement parts for RESA and 0RESA/C 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. Specification Number Index. Lists the generator set specs and groups. Group Parts Lists. List the part numbers of parts in the groups. Kit Sections. List modules and accessories and their parts. Appendices. Include Abbreviations, Common Hardware Application Guidelines, General Torque Specifications, Common Hardware Identification, and Common Hardware List. Numbering System Significance This manual uses the following numbering systems: Specification Number. The product identification number located on the generator set nameplate. Specification numbers break down into groups. Group Number. A unique number representing a parts group needed to assemble a generator set function. For example, Group 0 is the Air Intake group. 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 0 Hz generator alternator both perform the same function; however, with different parts. Each difference requires a group variation or module number. Part Number. The part number identifies an individual assembly, subassembly, component, or accessory kit. Illustrations Illustrations (or exploded-view drawings) best representing the widest range of variations accompany most groups in this manual. Illustrations do not depict all details and may not show all parts. Do not use illustrations for assembly or disassembly. HowtoFindPartNumbers Use the following steps to locate a service replacement part.. Locate the generator set nameplate to identify the generator set spec number.. 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.. 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.. Page forward to locate the group identified in step 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. TP-80 /

5 Hardware References Many common hardware items do not appear in parts manuals or will appear as common hardware entries. A common hardware entry lists the size of the hardware. For example, an item that appears as Hardware, /8- in the text means that the piece is /8- 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. TP-80 / 5

6 Specification Number Index Group Title Group No Spec No. Number RESA/RESAL GM8078-GA GM8078-GA GM8078-GA GM8078-GA GM8078-GA GM8078-GA RESAL-SA RESAL-SA RESAL-SA RESAL-SA RESA-SP GM587-GA GM587-GA RESA/0RESAL GM8078-GA GM8078-GA GM8078-GA GM8078-GA GM8078-GA GM8078-GA GM8078-GA GM8078-GA RESAL-SA RESAL-SA RESAL-SA RESAL-SA RESAL-SA RESA-SP RESC/0RESCL GM55-GA GM55-GA TP-80 /

7 Specification Number Index Group Title Spec No. Number RESA/RESAL GM8078-GA GM8078-GA 8 GM8078-GA * * * * * GM8078-GA * * * * * 8 GM8078-GA7 * * * * * GM8078-GA * * * * * 8 RESAL-SA 8 RESAL-SA 8 RESAL-SA 8 RESAL-SA 8 RESA-SP 7 GM587-GA 7 * * * * * 8 GM587-GA 7 * * * * * 87 0RESA/0RESAL GM8078-GA 5 GM8078-GA 5 GM8078-GA7 5 GM8078-GA8 5 GM8078-GA0 * * * * * GM8078-GA * * * * * GM8078-GA 5 * * * * * GM8078-GA8 * * * * * 0RESAL-SA 5 0RESAL-SA 5 0RESAL-SA 5 0RESAL-SA 5 0RESAL-SA5 5 0RESA-SP RESC/0RESCL GM55-GA * * * * * 8 GM55-GA * * * * * 8 * Configured group. Refer to the generator set nameplate for the module number. Turn to the respective group on the following pages for parts breakdowns. TP-80 / 7

8 Notes 8 TP-80 /

9 Group : Crankshaft RESA Qty Crankshaft assembly 5 0 Plug, cap 0RESA/RESC ---- Item Part Number Description 0 80-S Crankshaft assembly (includes item ) 5 7-S Plug, cup TP-80 /

10 Group : Crankcase RESA Illustrated parts without item reference numbers (the piston, for example) are not sold separately. Items not shown: 0,,, Qty S Camshaft S Piston w/ring set, standard S Piston w/ring set, 0.08 OS S Piston w/ring set, 0.5 OS S Piston w/ring set, 0.50 OS 08 0-S Retainer, piston pin S Ring set, standard S Ring set, S Ring set, S Ring set, S Rod, connecting, standard 07 -S Rod, connecting, S Plug, cup S Dowel, locating 0 -S Seal, oil front S Plug, cup (not shown) S Plug, cup (not shown) X-75-0 Plug, solid square head, /8 in., NPTF GM88 Sensor, oil temperature S Bushing, reducing (not shown) 0 TP-80 /

11 Group : Crankcase 0RESA Illustrated parts without item reference numbers (the piston, for example) are not sold separately Part Item Number Description S Kit, camshaft (includes S) 00 0-S Kit, camshaft M-5500-S Screw,hvyflgM5x0.8x0 0 -S Cover, lifter feed 0 -S Gasket, lifter feed cover S Pin Crankcase (use short block) 7 0 -S Seal, oil 7 0 -S Seal, oil S Rod, connecting assembly, standard S Rod, connecting assembly, S Rod, connecting assembly S Kit, piston assembly, standard (includes items 0,) 87 0-S Kit, piston assembly, S Kit, piston assembly, S Kit, piston, std (includes item 0, ) 87 8-S Kit, piston,0.5 OS 87 -S Kit, piston, 0.50 OS S Retainer, piston pin 08 0-S Ring set, standard S Ring set, S Ring set, S Ring set, standard 80 -S Pin, locating 00 0-S Bearing, crankshaft (flywheel) S Lubricant, camshaft (not shown) TP-80 /

12 Group : Crankcase 0RESC Illustrated parts without item reference numbers (the piston, for example) are not sold separately. Item Part Number Description 0 0-S Camshaft M-5500-S Screw,hvyflgM5x0.8x0 0 -S Cover, lifter feed 0 -S Gasket, lifter feed cover S Pin - Crankcase (use short block) 7 0 -S Seal, oil S Rod, connecting assembly 87 7-S Kit, piston, std (includes item 0, ) 87 8-S Kit, piston,0.5 OS 87 -S Kit, piston, 0.50 OS S Retainer, piston pin S Ring set, standard 80 -S Pin, locating - Bearing, crankshaft (flywheel) TP-80 /

13 Group : Oil Pan/Lubrication RESA Item Part Number Description S Kit, closure plate assembly 755 -S Kit, dipstick/dipstick tubes (includes item ) 08 0-S Dipstick 0 -S Kit, governor gear w/pin (includes item 5) S Pin, governor regulating 8 0-S Tab, locking 7 0-S Shaft, governor gear S Seal, oil 5 0-S Plug, hex countersunk, /8 in S O-ring 5-S Kit, oil pump assembly (includes items, ) 5 0-S O-ring 8 0-S Pickup, oil X-5-5 Washer, flat 5 M-500-S Screw, flange thread forming 08 -S Screw, hex cap, M x.7 x S Filter, oil S Kit, alum base oil cool 5 -S O-ring, oil cooler 0 05-S Nipple, oil filter S Nut, plastic S Switch, oil pressure 08 7-S Screw, hex head S Screw, hex flange TP-80 /

14 Group : Oil Pan/Lubrication 0RESA CRANKCASE Qty. Item Part Number Description Var S Filter, oil 05-S Nipple, oil filter 0 0-S Cup, oil filter 08 -S Spring, oil filter valve S Spring, oil filter cup 0-S Valve, oil filter S Housing, horizontal oil filter 8 M-8500-S Screw,flgM8x.5x S Pin 0 0-S Fitting, hose to pipe 5 -S Sleeve, anti abrasion 0-S Hose, oil supply X-5-5-S Washer,flat/in. 08 -S Screw,tapMx.7x S Gasket, oil reservoir GM88 Sensor, temperature S Bushing, reducer / -/8 in. NPT, steel 8 0-S Kit, oil reservoir M-8500-S Screw,flgM8x.5x S Screw, shd thd frm, M x.0 x S Housing assembly, oil pickup 0 -S Seal, oil pick-up tube 00 5-S Kit, closure plate (includes items [qty.], -8, 5-) 05-S Tube, oil pickup 5 M-50-S Screw, flg thd frm, M x.0 x Qty. Item Part Number Description Var S Clamp S Bearing, crankshaft (PTO) 8 0 -S Seal, oil 5 7-S Plug, pipe, / NPTF sq ctsk S Switch, oil pressure 5 0-S Strap, lifting S Screw, flg, M8 x.5 x 50 -S Bracket, dipstick tube 5 7 -S Clamp, spring hose, / in. 5 5-S Kit, dipstick tube (includes S) 08 0-S Dipstick S O-ring 8 0-S Pump assembly, oil/gerotor 5 0-S O-ring, oil pump housing Housing, oil pump 0 -S Baffle, relief valve M-05-S Screw, flg, M x.0 x 5 0 -S Gasket, oil pan 5 0-S Cooler, oil assembly 5 0-S Hose, oil return 5 -S Sleeve, anti abrasion S Clamp S O-ring, oil pick-up -S Fitting, 0 deg. barbed S Adapter, horizontal oil filter S Sealant, Loctite (not shown) TP-80 /

15 Group : Oil Pan/Lubrication, continued 0RESA ---- Qty. Item Part Number Description Var S Filter, oil 05-S Nipple, oil filter 0 0-S Cup, oil filter 08 -S Spring, oil filter valve S Spring, oil filter cup 0-S Valve, oil filter S Housing, horizontal oil filter 8 M-8500-S Screw,flgM8x.5x0 0 0-S Fitting, hose to pipe 5 -S Sleeve, anti abrasion 0-S Hose, oil supply X-5-5-S Washer,flat/in. 08 -S Screw,tapMx.7x S Gasket, oil reservoir GM88 Sensor, temperature S Bushing, reducer / -/8 in. NPT, steel 8 0-S Kit, oil reservoir M-8500-S Screw,flgM8x.5x S Screw, shd thd frm, M x.0 x S Housing assembly, oil pickup 0 -S Seal, oil pick-up tube S Plate, closure 05-S Tube, oil pickup 5 M-50-S Screw, flg thd frm, M x.0 x Qty. Item Part Number Description Var. 7 0-S Clamp 8 0 -S Seal, oil S Switch, oil pressure 5 0-S Strap, lifting S Screw, flg, M8 x.5 x 50 -S Bracket, dipstick tube 5 7 -S Clamp, spring hose, / in. 5 5-S Kit, dipstick tube (includes S) 08 0-S Dipstick S O-ring 8 0-S Pump assembly, oil/gerotor 5 0-S O-ring, oil pump housing Housing, oil pump 0 -S Gasket, oil pan 5 0-S Cooler, oil assembly 5 0-S Hose, oil return 5 -S Sleeve, anti abrasion S Clamp S O-ring, oil pick-up -S Fitting, 0 deg. barbed S Sealant, Loctite (not shown) TP-80 / 5

16 Group : Oil Pan/Lubrication 0RESC Qty. Item Part Number Description Var S Filter, oil 05-S Nipple, oil filter 0 0-S Cup, oil filter 08 -S Spring, oil filter valve S Spring, oil filter cup 0-S Valve, oil filter S Housing, horizontal oil filter 8 M-8500-S Screw,flgM8x.5x S Fitting, barbed 5 -S Sleeve, anti abrasion 0-S Hose, oil supply X-5-5-S Washer,flat/in. 08 -S Screw,tapMx.7x S Gasket, oil reservoir GM88 Sensor, temperature S Bushing, reducer / -/8 in. NPT, steel 8 0-S Kit, oil reservoir M-8500-S Screw,flgM8x.5x S Screw, shd thd frm, M x.0 x S Housing assembly, oil pickup 0 -S Seal, oil pick-up tube 00 -S Plate, closure 05-S Tube, oil pickup S Screw, flg thd frm Qty. Item Part Number Description Var S Clamp 8 0 -S Seal, oil S Switch, oil pressure 5 0-S Strap, lifting S Screw, hex flg -S Bracket, dipstick tube 5 7 -S Clamp, spring hose, / in. 5 5-S Kit, dipstick tube (includes S) 08 0-S Dipstick S O-ring 8 0-S Pump assembly, oil/gerotor 5 0-S O-ring, oil pump housing Housing, oil pump 0 -S Gasket, oil pan 5 05-S Cooler, oil assembly 5 0-S Hose, oil return 5 -S Sleeve, anti abrasion S Clamp S O-ring, oil pick-up S Connector, hose S Sealant, Loctite (not shown) TP-80 /

17 Group : Cylinder Head/Valve/Breather RESA Qty Item Part Number Description Var S Kit, valve cover-plain (includes items, ) M-500-S Screw, flange, M x.0 x S O-ring S Kit, retainer S Cap, valve spring 08 0-S Spring, valve 7 50-S Retainer, spring S Seal, valve stem 5 0-S Strap S Kit, cylinder head assembly 07 0-S Valve, intake, standard 07 0-S Valve, intake, S Valve, exhaust, standard 0 0-S Valve, exhaust, S Kit, valve train S Kit, hydraulic valve lifter 5 05-S Rod, push 8 0-S Kit, cylinder head gasket (includes, ) S Kit, cylinder head assembly 8 - Not used S Arm, rocker S Pivot, rocker arm Qty Item Part Number Description Var S Stud 8 8 -S Washer, flat S Nut, hex flange 8 M-00-S Screw, flange, M x.0 x S Kit, oil fill rocker cover 755 -S Kit, oil fill cap (includes ) S O-ring S Reed, breather 08 0-S Retainer, reed 0 M-5500-S Screw, flange thread forming, M5x0.8x S Filter, breather 0 0-S Kit, breather w/plug (includes -5) 0 7-S Gasket, breather - Cover (See item ) S Plug, pipe, /8 NPTF hex countersunk M-500-S Screw, thread forming, M x.0 x S Hose clamp 8 8-S Hose, breather - Not used 0 - Not used S Kit, cylinder head hardware (includes -8,,, 5,, 0, ) TP-80 / 7

18 Group : Cylinder Head/Valve/Breather 0RESA CRANKCASE Item Part Number Description S Screw, shoulder 0 -S Kit, cover, valve (includes items, ) 0-S Grommet, valve cover screw 0 5-S Seal, valve cover 5 8 -S Kit, cylinder head # (includes item [qty]) 8 0-S Kit, cylinder head gasket (includes 0 -S, 0 -S) S Valve, intake S Valve, exhaust 8 05-S Washer, flat, / in S Screw, flg, M0 x.5 x S Liner, exhaust port 8 -S Kit, cylinder head # (includes item [qty]) S Stud, M8 x.5 x 0-S Spacer S Arm, rocker 5 0-S Pivot, rocker arm S Screw, flg, M x.0 x S Kit, cover, valve (includes items, ) 7 0-S Cap, oil fill assembly (includes item 0) S O-ring 5 -S Plug, pipe, / NPTF sq ctsk S Kit, retainer S Cap, valve spring 08 0-S Spring, valve 08 5-S Spring, valve S Seal, valve stem 0-S Rod, push S Kit, hydraulic valve lifter (includes S) S Kit, breather assembly (includes items -) S Filter, breather S Gasket, breather M-50-S Screw, flg, M x.0 x 5-S Hose, breather horizontal generator -S Hose, breather S Clamp, band spring hose S Kit, cylinder head hardware services head. Quantities listed are for both heads) (includes items 7, 8, 5-7, -) S Lubricant, camshaft (not shown) 0 -S Gasket, exhaust (not shown) 0 -S Gasket, intake manifold (not shown) 8 TP-80 /

19 Group : Cylinder Head/Valve/Breather 0RESC 7 FUEL SYSTEM CRANKCASE ---- Item Part Number Description 0 7-S Kit, cover, valve 08 0-S Screw, flg, M x.0 x S Pivot, rocker arm S Arm, rocker S Screw, flg, M0 x.5 x S Spacer 8 0 -S Kit, cylinder head # S Stud 8 05-S Washer, flat, / in. 5 -S Plug, pipe, / NPTF sq ctsk S Kit, retainer S Cap, valve spring S Spring, valve S Seal, valve stem 0 0-S Valve, exhaust S Valve, intake 8 0-S Kit, cylinder head gasket (includes 0 -S, 0 -S) 0-S Rod, push S Kit, hydraulic valve lifter (includes S) 0 7-S Gasket, breather S Filter, breather 0 0-S Kit, breather assembly (includes items, 7) M-50-S Screw, flg, M x.0 x 5 -S Hose, breather S Screw, shoulder 0 7-S Kit, cover, valve 8 8 -S Kit, cylinder head # 08 -S Grommet, oil fill TP-80 /

20 Group 5: Ignition/Electrical RESA Part Number Item Description S Module, spark advance (DSAI) assembly 8 M-505-S Screw,sktthdfrm,M5x0.8x S Flywheel assembly S Washer, flat 08 -S Screw, flg, M0 x.5 x 5 X--5-S Key, / in. x 5/8 in. 57 -S Fan S Screw 5 57-S Clip, cable 5 -S Plug, spark S Tie (not shown) 7 7-S Harness, wiring (not shown) S Cover, regulator (not shown) 0 TP-80 /

21 Group 5: Ignition/Electrical 0RESA Part Item Number Description S Module, spark advance (DSAI) assembly S Module, Ignition 8 M-505-S Screw,sktthdfrm,M5x0.8x S Flywheel assembly 05 Flywheel S Washer, flat / in. 08 -S Screw, flg, M0 x.5 x 5 X--5-S Key, / in. x 5/8 in S Fan, front drive adapter hole 57 0 Fan S Screw,trshd,Mx.0x S Clip, cable S Clip, cable 0-S Plug, spark 7 0-S Sleeve, corrugated 5 0-S Tie, cable (not shown) S Tie (not shown) 7 5-S Harness, wiring (not shown) 7 0-S Harness, wiring (not shown) TP-80 /

22 Group 5: Ignition/Electrical 0RESC Item Part Number Description S Module, Ignition S Flywheel S Washer, flat / in. 08 -S Screw, flg, M0 x.5 x 5 X--5-S Key, / in. x 5/8 in S Fan S Bolt, Shoulder S Clip, cable 0-S Plug, spark 7 0-S Sleeve, corrugated 5 0-S Tie, cable (not shown) S Tie (not shown) 7 0-S Harness, wiring (not shown) S Screw, thread throwing (not shown) TP-80 /

23 Group : Blower Housing and Baffles RESA Item Part Number Description S Kit, blower housing assembly (includes items and ) S Nut, plastic 00 0-S Nut, plastic M-50-S Screw, flange thread forming, M5 x 0.8 x 5 M-550-S Screw, flange thread forming, M5 x 0.8 x 7 M-5500-S Screw, flange thread forming, M5 x 0.8 x S Plate, backing S Baffle, left barrel M-50-S Screw, flange thread forming, M x.0 x S Baffle, valley # side M-5500-S Screw, flange thread forming, M5 x 0.8 x 0 0 -S Baffle, valley # 0 85-S Baffle, right barrel 5 5 -S Clip, repair (U bolt speed nut) (not shown) TP-80 /

24 Group : Blower Housing and Baffles 0RESA HEAD/VALVE/ BREATHER CRANKCASE Item Part Number Description M-50-S Screw, flg thd frm, M x.0 x S Baffle, cyl barrel # side 07-S Shroud, backing 08 0-S Screw, shd thd frm S Kit, blower housing assembly (includes 07 0-S) S Clip, mounting 7 08-S Shroud, # cylinder 8 0-S Shroud, # cylinder 0 07-S Baffle, cyl barrel # side 0 0 -S Baffle, valley # side 0 -S Baffle, valley # side 07 0-S Nameplate, service (not shown) TP-80 /

25 Group : Blower Housing and Baffles 0RESC HEAD/VALVE/ BREATHER CRANKCASE 8 Item Part Number Description S Screw, flg thd frm, M x.0 x 0 0 -S Baffle, cyl barrel # side 5-S Shroud, backing 08 0-S Screw, shd thd frm S Kit, blower housing assembly 5 5 -S Clip, mounting S Shroud, # cylinder 8 8-S Shroud, # cylinder 0 -S Baffle, cyl barrel # side S Baffle, valley # side 0 7-S Baffle, valley # side TP-80 / 5

26 Group 7: Starter RESA/0RESA/0RESC Item Part Number Description 5 M-8080-S Nut, flg, M8 x S Starter assembly, solenoid shift (includes items -8) M S Screw, flg, M8 x.5 x S Kit, solenoid (includes item 5) S Screw, external torx head S Kit, starter pinion (includes item 7) S Ring, retaining S Kit, brush holder TP-80 /

27 Group 8: Carburetor RESA Item Part Number Description S Kit, carburetor w/gaskets M-8500-S Screw,flgM8x.5x0 0 -S Gasket, carburetor 5 7 -S Clamp, hose S Line, LP fuel, in. 555-S Spring 7 55-S Screw, special 8 -S Fitting X-5-8-S Washer 5 -S Sleeve, anti-abrasion (not shown) 08 0-S Screw TP-80 / 7

28 Group 8: Carburetor, continued 0RESA/RESC AIR INTAKE/ FILTRATION Item Part Number Description LP fuel line ( ) 5 7 -S Clamp, hose 5 -S Sleeve, anti-abrasion M-05-S Stud,Mx.0x S Stud 5 - Fitting, restrictor (See Fuel System group) 85 -S Kit, Carburetor (includes items 7-7) 7 0 -S Gasket, air cleaner elbow S Screw, slotted pan, M x 0.7 x 8 X--7-S Washer, int tooth lock # S Cover, idle circuit 0 0-S Gasket, idle circuit plate 0 8-S Gasket, carburetor 5 -S Fitting, 0 deg. elbow S Screw, slotted pan, M x 0.7 x S Cover, plenum 0 -S Gasket, plenum-carburetor S Bushing 8 M00-S Nut, hex flange 8 TP-80 /

29 Group : Engine Controls RESA To Governor 5 To Carburetor Illustrated parts without item reference numbers are not sold separately Item Part Number Description S Linkage, throttle S Bushing, linkage S Bushing, throttle linkage GM8 Governor assembly S Spacer 585 Coupling, stepper motor TP-80 /

30 Group : Engine Controls, continued 0RESA/RESC 5 FUEL SYSTEM IGNITION/ ELECTRICAL Item Part Number Description 5 GM85 Governor assembly - not used 07 -S Linkage, throttle S Bushing, linkage retaining Coupling, stepper motor 08 5-S Spring, linkage 0 TP-80 /

31 Group 0: Air Intake/Filtration RESA Item Part Number Description S Kit, knob w/seal 5 0-S Knob, air cleaner cover 5 0-S O-ring 0 7-S Cover, air cleaner S Nut, wing 0 0-S Cover, inner air cleaner 7 00-S Seal 08 0-S Element, air filter S Screw, flange M x.0 x 55 7-S Bracket, air cleaner 0 -S Base, air cleaner 5 -S Spacer, air cleaner 0 0-S Gasket, intake manifold S Gasket 8-S Manifold, intake S Screw, HD 0- x / in. 5 7-S O-ring, intake port 0 5-S Gasket, carburetor TP-80 /

32 Group 0: Air Intake/Filtration, continued 0RESA/RESC BLOWER HOUSING & BAFFLES 8 FUEL SYSTEM Item Part Number Description S Knob, cover 0 7-S Cover, air cleaner Not used 08 0-S Element, air filter S Clip, fuel line 0 0-S Kit, air cleaner base (includes items,7) 0 Base, air cleaner 7 -S Tube, air intake 7 7-S Tube, air intake S Screw, flg, M x.0 x 5 M-8500-S Screw, flg, M8 x.5 x 0 0 -S Kit, intake manifold (includes items,) 0 -S Gasket, intake manifold 0 8-S Gasket, carburetor 0 -S Gasket, air cleaner elbow - not used 5 - not used S Stud, air cleaner base 7 -S Hose, breather (not shown, see Group ) TP-80 /

33 Group : Engine Exhaust RESA Item Part Number Description S Stud, exhaust 0RESA/RESC Item Part Number Description M-8080-S Nut, flg, M8 x.5 0 -S Gasket, exhaust S Stud, M8 x.5 x TP-80 /

34 Group : Engine Decals Decals are not illustrated. RESA Item Part Number Description S Decal, clear laminate 5 05-S Decal, oil sentry -S Decal, CO warning 0RESA Item Part Number Description 5 -S Decal, clear laminate 5 50-S Decal, Powered by Kohler-white -S Decal, air cleaner 0RESC Item Part Number Description S Decal, clear laminate 5 50-S Decal, Powered by Kohler-white TP-80 /

35 Group : Gasket Set 0RESA Gasket set not illustrated. Item Part Number Description S Gasket set TP-80 / 5

36 Fuel System RESA GM8-5 Fuel System Parts Before Build Date //0 GM800g GM800-GR Item Part Number Description X--8 Bushing X-- Clamp, hose,./.5 in. X-0-5 Plug, Button,.7 (Hole Dia..0) X-75-5* Plug, Pipe / in * Connector, hose + Vibra Seal GM8- Fuel System Subassembly (includes items 8 -) 8 7 Jet, NG 7 5 Jet, LPG 0 Fitting, straight LPG/NG A-75 Regulator, gas - X-75-5 Plug, pipe (/ nptf) (not shown) GM8508 Valve, Gas Shut-Off X-0- Pipe (/ npt x. ) X-0- Bushing, reducing (/ x / npt) 7 GM800 Bracket, Fuel Regulator Mtg * Plug, pipe (/8 nptf) GM807* Valve, Fuel Metering 0 X--* Screw, hex socket set X-0-* Pipe (/8 npt x.00 ) * Fuel system part used before build date of //0 TP-80 /

37 Fuel System 0RESA/RESC GM8- GM800h GM800-GR Item Part Number Description X--8 Bushing X-- Clamp, hose,./.5 in. X-0-5 Plug, Button,.7 (Hole Dia..0) GM8- Fuel System Subassembly (includes items 8 -) 0-S Fitting, restrictor 0 5 -S Fitting, hose connector GM78 Regulator, Gas - X-75- Plug, pipe (/8 nptf) (not shown) GM8508 Valve, Gas Shut-Off X-0- Pipe (/ npt x. ) X-0- Bushing, reducing (/ x / npt) Connector, hose GM70 Tubing, flexible 7 GM800 Bracket, Fuel Regulator Mtg. TP-80 / 7

38 Engine RESA GM8078_g GM Item Part Number Description 7 GM50 Strap, Ground GM0 Insulation, Engine Air Inlet GM Cover, Air Inlet 5 GM8705 Vibromount Assy. (includes ) 5. GM7558 Vibromount 5. M Screw, hex cap 5. M5A-0-80 Washer, Plain, 0.5 ID x 0.0 OD 5. M Nut, hex elastic stop M5A Washer, Plain 8. ID x.0 OD 7 M-00-0 Screw, hex cap 8 M Screw, hex cap M Screw, hex cap 0 M Nut, hex elastic stop PS-CH70-0 CH70EP E KPS GM8077 X-- Washer, lock. IDx.7 in.od X-- Washer, lock. IDx.88 in.od X-- Clamp, hose,.5/.70 in. 5 X-55-0 Cable, Battery X-55- Cable, Battery 7 X--8 Hose, Oil Proof 8 X-0- Clip, panel fastener 55 Valve, oil drain (/8-8 npt) X-0- Pipe, Nipple (/8 npt x.00 ) X-- Coupling, pipe (/8 npsc) 8 TP-80 /

39 Engine 0RESA/RESC GM8078_g GM8078 -, GM5 - Item Part Number Description 5 GM50 Strap, Ground GM8 Insulation, Acoustic Foam GM8705 Vibromount Assy. (includes. -.). GM7558 Vibromount. M Screw, hex cap. M5A-0-80 Washer, Plain 0.5 ID x 0.0 OD. M Nut, hex elastic stop 5 M5A Washer, Plain 8. ID x.0 OD M-00-0 Screw, hex cap 7 M Nut, Hex 8mm 8 M Screw, hex cap M Screw, hex cap 0 M Nut, hex elastic stop PS-CH000-0 CH000EP E KPS - GM807 PS-CH CH000EP EPA PS-CH000-0 CH000EP EPA X-- Washer, lock. IDx.7 in.od X-- Washer, lock. IDx.88 in.od X-- Clamp, hose,.5/.70 in. 5 X-55-0 Cable, Battery X-55- Cable, Battery 7 X--8 Hose, Oil Proof 0 X-0-8 Bushing, reducing (/8 x / npt) 55 Valve, oil drain (/8-8 npt) TP-80 /

40 Nameplate and Decals Nameplate and decals are not illustrated. GM800 -GR Item Part Number Description 78 Decal, notice, neutral bonded to frame 808 Decal, warning rotating parts 80 Decal, caution hot engine Decal, caution stdby svc connect 578 Decal, danger moving rotor 7 50 Decal, danger, high voltage 8 GM5 Decal, rainproof enclosure 0 GM Decal, notice, fuel connection GM707 Decal, fuel type GM508 Decal, power breaker GM075 Decal, warning non gfci outlet GM7557 Decal, Kohler logo 5 GM7578 Decal, fuel type GM870 Decal, Kohler maintenance 7 GM87 Decal, Notice 0 TP-80 /

41 Skid 5 5 GM570g GM570-GR Item Part Number Description GM85 Enclosure, Base GM8 Enclosure, Wire Access Panel M5A-0-80 Washer, Plain M-00-0 Screw, Hex Cap Flange 5 PNP-00-0 Bolt, carriage (/8- x.00 ) X-0- Nut, flange spiralock, /8- GM Strap, Poly Battery TP-80 /

42 Customer Connection (Terminal Block) GM80_B GM80-GR, GR Item Part Number Description GM85 Block, Terminal 5777 Cable, Patch, ft. RJ-5 GB580 Block, Terminal GM88 Rail, Din 5 GM80 Block, Terminal GM8 Lead, Customer Connection 7 GM8 Lead, Customer Connection 8 GM8 Lead, Customer Connection GM85 Lead, Customer Connection 0 GM8 Lead, Customer Connection GM7587 Lead, jumper GM787- Screw, Sheetmetal GM7 Plate, End GM77 Block, Terminal 5 GM78 Block, Terminal GM7 Block, Terminal 7 GM80 Decal, Terminal Block 7 GM80 Decal, Terminal Block X-07- Lug, Terminal, Aluminum Note: Terminal Block Bagged Kit GM7 includes items (qty. ), -5, -. TP-80 /

43 Customer Connection (Terminal Block) GM80_F GM80- Item Part Number Description MA MA MA MA MA5 MA GM85 Block, Terminal GM8 Block, Terminal 5777 Cable, Patch, ft. RJ-5 GB580 Block, Terminal GM88 Rail, Din 5 GM80 Block, Terminal GM8 Lead, Customer Connection 7 GM8 Lead, Customer Connection 8 GM8 Lead, Customer Connection 8 GM5 Lead, Customer Connection GM85 Lead, Customer Connection GM55 Lead, Customer Connection 0 GM8 Lead, Customer Connection 0 GM5 Lead, Customer Connection GM7587 Lead, jumper GM787- Screw, Sheetmetal GM7 Plate, End GM77 Block, Terminal 5 GM78 Block, Terminal GM7 Block, Terminal 7 GM7 Decal, Terminal Block 7 GM7 Decal, Terminal Block 7 GM7 Decal, Terminal Block X-07- Lug, Terminal, Aluminum 0 X-05- Stud X-8-5 Insulator, Standoff GM7 Ferrule, Terminal (not shown) Note: Terminal Block Bagged Kit GM7 includes items (qty. ), -5, -. TP-80 /

44 Harness Alternator Load Leads GM8f GM8 - Item Part Number Description 57 Base, tie wrap snapin (not shown) GM808 Harness, Pigtail Customer Connection GM Breaker, Circuit (0 amp) GM88 Harness, Engine GM7 Harness, Engine GM Harness, Engine 5 X-8- Cable Tie (not shown) GM Harness, Thermostat TP-80 /

45 Circuit Breaker GM8c GM8-GR, GR, GR, GR Item Part Number Description GM7555 Breaker, Circuit 70 amp GM778 Breaker, Circuit pole GM00 Breaker, Circuit 50 amp GM8707 Circuit Breaker Assy. (include items -0) GM787- Screw, Sheetmetal GM807 Panel, Controller Mtg. GM808 Panel, Controller Mtg. GM8 Panel, Controller Mtg. M-00-0 Screw, Hex Cap Flange 5 M-0-8 Nut, Hex mm GM770 Breaker, Circuit 00 amp 7 GM775 Bracket, Circuit Breaker Mtg. 8 M785A Screw, pan head machine M5A Washer, Plain 0 M Nut, Hex 5mm Module Item Part Number Description GM8 -MA GM8 -MA8 GM8 -MA GM8707 Circuit Breaker Assembly GM00 Circuit Breaker Assembly GM005 Circuit Breaker Assembly GM787- Screw, Sheetmetal GM808 Panel, Controller Mtg. GM07 Panel, Controller Mtg. M-00-0 Screw, Hex Cap Flange 5 M-0-8 Nut, Hex mm GM770 Circuit Breaker GM0 Circuit Breaker (includes mounting hardware) GM07 Circuit Breaker (includes mounting hardware) 7 GM775 Bracket, Circuit Breaker Mtg. 7 GM07 Bracket, Circuit Breaker Mtg. 8 M785A Screw, pan head machine M5A Washer, Plain 0 M Nut, Hex 5mm TP-80 / 5

46 Circuit Breaker, continued GM8g GM8-MA Item Part Number Description Qty. See chart Breaker, Circuit GM787- Screw, Sheetmetal See chart Panel, Controller Mtg. Use this table to identify part numbers of items and Part Number Module Item, Circuit Breaker Item, Mounting Panel GM8 -MA GM7555 GM807 GM8 -MA5 GM07 GM075 GM8 -MA GM0 GM0758 GM8 -MA7 GM00 GM070 GM8 -MA GM0 GM075 GM8 -MA0 GM075 GM075 GM8 -MA GM08 GM075 GM8 -MA GM5 GM0755 GM8 -MA GM5 GM0755 GM8 -MA GM0 GM075 GM8 -MA5 GM05 GM0758 GM8 -MA GM0 GM50 GM8 -MA7 GM00 GM07 GM8 -MA8 GM0 GM075 GM8 -MA GM0 GM05 GM8 -MA0 GM0 GM0757 GM8 -MA GM5 GM075 GM8 -MA7 GM5 GM075 TP-80 /

47 Exhaust GM805d GM805-GR, GR Item Part Number Description 0 -S Gasket, Exhaust 0 -S Gasket, Exhaust S Liner, Exhaust Port GM787- Screw, Sheetmetal GM8 Duct, Exhaust Top 5 GM80 Silencer, Exhaust 5 GM807 Silencer, Exhaust GM80 Cover Assembly GM805 Cover Assembly 7 GM808 Shield, Heat 8 M Screw, Hex Flange M8 x 0 M Nut, Hex 8mm 0 M Screw, Hex Cap M Nut, hex elastic stop, 8MM 58 Plug, Water 580 Gasket TP-80 / 7

48 Alternator GM885e 8 TP-80 /

49 Alternator GM807-GR, GR, GR, GR Item Part Number Description 5 O-Ring (.050 ID) GM08 Adapter, Alternator GM Shim, Brush Holder GM77 Bracket, End 5 GM7 Bolt, Armature Thru GM808 Brush w/spring 7 GM808 Holder, Brush* 8 GM870 Vibromount Assembly (includes ) 8. GM7575 Vibromount 8. M Screw, hex cap 8. M5A-0-80 Washer, Plain (EXP) 0.5 ID x 0.0 OD 8. M Nut, hex elastic stop M5A Washer, Plain 8. ID x.0 OD 0 M7500D-00-8 Screw, Metric Thread Forming mm M Screw, Hex Cap (Metric) M Screw, hex cap X-5- Washer, plain,. ID x. in. OD X-8- Cable Tie 5 X-8- Cable tie, nylon X-80- Washer, hardened,. ID x. in. OD 7 X-0- Bolt, Hex Cap 8 X-08- Grommet, U-Channel (not shown) GC8 Stator Assembly GC85 Stator Assembly GC8 Stator Assembly GC8 Stator Assembly 0 GM5 Rotor Assembly (includes item 0.) 0 GM5 Rotor Assembly (includes item 0.) 0. GM50 Ring, collector M-00-0 Screw, Hex Flnge Mxmm flly thrd js500 * Brush Holder Service Kit GM88-S includes items and 7. GM885 - Item Part Number Description MA MA 5 O-Ring (.050 ID) GM08 Adapter, Alternator GM Shim, Brush Holder GM77 Bracket, End 5 GM7 Bolt, Armature Thru GM808 Brush w/spring 7 GM808 Holder, Brush* 8 GM870 Vibromount Assembly (includes ) 8. GM7575 Vibromount 8. M Screw, hex cap 8. M5A-0-80 Washer, Plain (EXP) 0.5 ID x 0.0 OD 8. M Nut, hex elastic stop M5A Washer, Plain 8. ID x.0 OD 0 M7500D-00-8 Screw, Metric Thread Forming mm M Screw, Hex Cap (Metric) M Screw, hex cap X-5- Washer, plain,. ID x. in. OD X-8- Cable Tie 5 X-8- Cable tie, nylon X-80- Washer, hardened,. ID x. in. OD 7 X-0- Bolt, Hex Cap 8 X-08- Grommet, U-Channel (not shown) GC8 Stator Assembly, PH GC07 Stator Assembly, PH 0 GM5 Rotor Assembly (includes item 0.) 0 GM88 Rotor Assembly (includes item 0.) 0. GM50 Ring, collector M-00-0 Screw, Hex Cap Flange * Brush Holder Service Kit GM88-S includes items and 7. TP-80 /

50 Alternator, continued GM88g 50 TP-80 /

51 Alternator, continued GM8080-GR, GR Item Part Number Description 5 5 O-Ring (.050 ID) GM Shim, Brush Holder GM77 Bracket, End 5 GM8 Bolt, Armature Thru GM808 Brush w/spring 7 GM808 Holder, Brush* 8 GM870 Vibromount Assembly (includes ) 8. GM7575 Vibromount 8. M Screw, hex cap 8. M5A-0-80 Washer, Plain (EXP) 0.5 ID x 0.0 OD 8. M Nut, hex elastic stop M5A Washer, Plain 8. ID x.0 OD 0 M7500D-00-8 Screw, Metric Thread Forming mm M Screw, Hex Cap (Metric) M Screw, hex cap X-8- Cable Tie 5 X-8- Cable tie, nylon X-80- Washer, hardened,. ID x. in. OD GC8 Stator Assembly GC87 Stator Assembly 0 GM5 Rotor Assembly (includes item 0.) 0. GM50 Ring, collector M-00-0 Screw, Hex Flnge Mxmm flly thrd js500 * Brush Holder Service Kit GM88-S includes items and 7. GM88 - Item Part Number Description MA MA MA 5 O-Ring (.050 ID) GM Shim, Brush Holder GM77 Bracket, End 5 GM8 Bolt, Armature Thru GM808 Brush w/spring 7 GM808 Holder, Brush* 8 GM870 Vibromount Assembly (includes ) 8. GM7575 Vibromount 8. M Screw, hex cap 8. M5A-0-80 Washer, Plain (EXP) 0.5 ID x 0.0 OD 8. M Nut, hex elastic stop M5A Washer, Plain 8. ID x.0 OD 0 M7500D-00-8 Screw, Metric Thread Forming mm M Screw, Hex Cap (Metric) M Screw, hex cap X-8- Cable Tie 5 X-8- Cable tie, nylon X-80- Washer, hardened,. ID x. in. OD GC07 Stator Assembly, PH GC080 Stator Assembly, PH 0 GM887 Rotor Assembly (includes item 0.) 0. GM50 Ring, collector M-00-0 Screw, Hex Cap Flange * Brush Holder Service Kit GM88-S includes items and 7. TP-80 / 5

52 Controller GM85 GM85-GR, GR Item Part Number Description GM8 Service Controller RDC (ref. GM775-, green board) GM8 Service Controller DC (ref. GM775-, green board) M785A Screw, Pan Head Machine If a green board controller is being replaced with a later version (red or blue board) controller on model /0RESA/L, relay kit GM50 is required. GM0 GM0-GR, GR Item Part Number Description GM08 Controller RDC (ref. red or blue boards) GM00 Controller DC (ref. red or blue boards) M785A Screw, Pan Head Machine 5 TP-80 /

53 Controller 5 GM775 GM85-GR, GR Item Part Number Description GM8 Service Controller RDC (ref. GM775-) GM8 Service Controller DC (ref. GM775-) GM77 Fuse Cover Assy GM5 Screw, Thumb GM8 Cover, Fuse 5 X--5 Ring, Retaining GM Breaker, Circuit (0A.) GM88 GM0-GR, GR Item Part Number Description GM08 Controller RDC (ref. GM88 -) GM00 Controller DC (ref. GM88 -) GM885 Plug, USB TP-80 / 5

54 Bulkhead GM75r 5 TP-80 /

55 Bulkhead GM75-GR, -GR Item Part Number Description GM778 Duct, Alt. Air Inlet GM755 Insulation, Exhaust Duct GM7587 Insulation, Exhaust Duct GM787- Screw, Sheetmetal GM800 Cover, Low Voltage Connection GM8005 Cover, High Voltage Connection 7 GM800 Box, High Voltage Connection 8 GM85 Duct, Exhaust (RH) GM85 Duct, Exhaust (LH) 0 GM80- Insulation, Bulkhead GM80- Insulation, Bulkhead GM807 Bulkhead, Rear GM808 Bulkhead, Front GM80 Duct, Front Bulkhead (RH) 5 GM80 Trough Subassembly 5 GM880 Trough Subassembly GM870 Insulation, Alternator Duct GM75-MA, MA, MA Item Part Number Description MA MA MA GM778 Duct, Alt. Air Inlet GM755 Insulation, Exhaust Duct GM7587 Insulation, Exhaust Duct GM787- Screw, Sheetmetal GM800 Cover, Low Voltage Connection GM8005 Cover, High Voltage Connection 7 GM800 Box, High Voltage Connection 8 GM85 Duct, Exhaust (RH) GM85 Duct, Exhaust (LH) 0 GM80- Insulation, Bulkhead GM80- Insulation, Bulkhead GM807 Bulkhead, Rear GM808 Bulkhead, Front GM80 Duct, Front Bulkhead (RH) 5 GM5 Trough Subassembly 5 GM Trough Subassembly 5 GM57 Trough Subassembly GM870 Insulation, Alternator Duct TP-80 / 55

56 Bulkhead, continued GM87b 5 TP-80 /

57 Bulkhead, continued GM87-MA, MA, MA Item Part Number Description MA MA MA GM778 Duct, Alt. Air Inlet GM755 Insulation, Exhaust Duct 5 GM7587 Insulation, Exhaust Duct GM787- Screw, Sheetmetal 7 GM85 Duct, Exhaust (LH) 8 GM80- Insulation, Bulkhead GM80- Insulation, Bulkhead 0 GM807 Bulkhead, Rear GM80 Duct, Front Bulkhead (RH) GM870 Insulation, Alternator Duct GM55 Cover, Low Voltage Connection GM557 Box, High Voltage Connection 5 GM5508 Panel Subassy, Protection GM7 Thermostat, 50 deg. F 7 GM Duct, Exhaust (RH) 8 GM78 Panel, Subassy Bulkhead GM550 - Trough Subassembly GM550 - Trough Subassembly GM550 - Trough Subassembly TP-80 / 57

58 Bulkhead, continued GM TP-80 /

59 Bulkhead, continued GM0085-MA, MA, MA Item Part Number Description MA MA MA GM55 Seal, Push -On Trim GM008 Rear Bulkhead, Sub -Assembly. GM008 Hinge, Composite Enclosure GM008 Front Bulkhead, Sub -Assembly. GM008 Hinge, Composite Enclosure 5 GM7587 Insulation, Exhaust Duct GM787- Screw, Sheetmetal 7 GM80 Duct, Front Bulkhead (RH) 8 GM55 Cover, Low Voltage Connection GM557 Box, High Voltage Connection 0 GM5508 Panel Subassy, Protection GM85 Air Inlet Duct, Sub -Assembly M Screw, Hex Cap Flange X - - Screw, PHillips Hex Crimptite GM550 - Trough Subassembly GM550 - Trough Subassembly GM550 - Trough Subassembly TP-80 / 5

60 Bulkhead, continued GM880 GM GM80, GM880 Item Part Number Description GM80 GM880 GM5 GM GM57 GM80 Trough Subassembly GM880 Trough Subassembly GM5 Trough Subassembly GM Trough Subassembly GM57 Trough Subassembly X Channel U 5 GM88 Rail, DIN GM7 Relay, VDC 8 M5A-0-80 Washer, Plain M-0-8 Nut, Hex mm 0 M785A Screw, pan head mach. M Screw, hex cap M Screw, hex cap M Screw, hex cap, Mx50mm full thrd M Nut, hex elastic stop, 5mm 5 X-- Washer, lock,. ID x. OD X-- Washer, lock,. ID x.7 in. OD 7 X-00-8 Spacer,.0 ID x.5 OD x. in. 7 X-00-0 Spacer 8 X-05- Stud (Metric) X-8-5 Insulator, Standoff 0 TP-80 /

61 Bulkhead, continued GM550 GM550 Item Part Number Description GM550 - GM550 - GM550 - GM550 - Trough Subassembly GM550 - Trough Subassembly GM550 - Trough Subassembly X Channel U 5 GM88 Rail, DIN GM7 Relay, VDC 8 M5A-0-80 Washer, Plain M-0-8 Nut, Hex mm 0 M785A Screw, pan head mach. M Screw, hex cap M Screw, hex cap M Screw, hex cap, Mx50mm, js500 full thrd M Nut, hex elastic stop, 5mm 5 X-- Washer, lock,. ID x. OD X-- Washer, lock,. ID x.7 in. OD 7 X-00-8 Spacer,.0 ID x.5 OD x. in. 7 X-00-0 Spacer 8 X-05- Stud (Metric) X-8-5 Insulator, Standoff TP-80 /

62 Enclosure Items not shown: 8 Enclosure Latch Bracket View GM8d TP-80 /

63 Enclosure GM8-GR GM8-MA Item Part Number Description GM80 Hinge GM87-S Panel Assy., Rear GM70-S Rear Panel Foam Kit (not shown) 5 GM7557 Bracket, Front Bulkhead (Upper) GM7575 Plug, button (not shown) 7 GM787- Screw, Sheetmetal 5 8 GM887 Roof Bracket Assy GM8-S Panel Assy., Top (includes item 5) GM8 Roof Panel Foam Kit (not shown) 0 GM8-S Panel Assy.,, Intake (includes item 5) GM8 Panel Assy., Exhaust GM8-S Panel Assy., Front GM78-S Front Panel Foam Kit (not shown) GM5 Latch Assembly (includes tool) GM8 Tool, Latch Opening GM80- Insulation, Acoustic Foam 5 GM8 Wedge, Acoustic 0 X-0- Plug, Button TP-80 /

64 Enclosure, continued Items not shown: GM0087 TP-80 /

65 Enclosure, continued GM0087-MA Item Part Number Description Foam, gasket seal (/ tape) (.88 ft) GM008 Roof Bracket Assy 5 GM87-S Panel Assy., Rear 5 GM70-S Rear Panel Foam Kit (not shown) GM7 Seal, Bulb (not shown) 7 GM7557 Bracket, Front Bulkhead (Upper) 8 GM787- Screw, Sheetmetal GM8-S Panel Assy., Top (includes item 7) GM8 Roof Panel Foam Kit (not shown) 0 GM8-S Panel Assy., Intake GM8 Panel Assy., Exhaust GM8-S Panel Assy., Front GM78-S Front Panel Foam Kit (not shown) GM8 Wedge, Acoustic GM80- Insulation, Acoustic Foam 5 GM5 Latch Assembly (includes tool) 5 GM8 Tool, Latch Opening M Screw, Hex Cap Flange 7 M -0-8 Nut, Hex 8 M785A Screw, Pan Head Machine X-0- Plug, Button 0 X - - Screw, PHillips Hex Crimptite TP-80 / 5

66 Literature Part Item Number Description CH0-80 Kohler Engine Service Manual 0 0 SM, CH8 -CH750 COMMAND TWIN TP-7 Warranty, Residential/Light Commercial TP-88 Warranty, CARB/EPA Emissions, SORE TP-885 Warranty, CARB/EPA Emissions, LSI TP-7 Warranty, 5 -Yr. Standby TP-80 I/M /0RESA/RESAL 5 TP-80 O/M /0RESA/RESAL TP-805 S/M /0RESA/RESAL 7 TP-80 P/C /0RESA/RESAL Part Item Number Description CH0-80 Kohler Engine Service Manual 0 0 SM, CH8 -CH750 COMMAND TWIN TP-7 Warranty, Residential/Light Commercial TP-88 Warranty, CARB/EPA Emissions, SORE TP-885 Warranty, CARB/EPA Emissions, LSI TP-7 Warranty, 5 -Yr. Standby TP-80 I/M /0RESA/RESAL 5 TP-80 O/M /0RESA/RESAL TP-805 S/M /0RESA/RESAL 7 TP-80 P/C /0RESA/RESAL TP-80 /

67 Kit Parts List Qty. Description Part No. Fuel System Kit Flexible Fuel Line GM05-KA Fuel line, flexible, 0.50 in. ID x in. X-50- Flexible Fuel Line GM5-KA Line, Flex Fuel GM57 Regulator Heater Kit GM7-KP-QS Spacer,.8 X.500 X.75 Steel 58 Heater, Regulator Pad GM7 Splitter, Receptacle GM877 Bushing X--8 TT Regulator Heater Kit, 0RES/RESL TT-5 Regulator Heater Kit, 0V, 00W GM7-KP-QS Spacer,.8 X.500 X.75 Steel 58 Harness, Adapter GM885 Heater, Regulator Pad GM888 Nut, Hex mm M-0-80 Screw, hex cap M Regulator Heater Kit, 0RES(A)/RESL(A) TT-5 Cable Tie X-8- Bushing X--8 Regulator Heater Kit, 0V, 00W GM7-KP-QS Spacer,.8 X.500 X.75 Steel 58 Heater, Regulator Pad GM7 Bushing X--8 TT Regulator Heater Kit, 0RES/RESL TT-5 Electrical System Kits Battery, /V, 500CCA, Wet GM755-KP Battery (Wet) GM755 Battery Heater, 80W, 0-0V PA-55 Heater, battery wrap 8 Heater, battery pad 8 Battery Heater, 80W, 0-0V GM80-KP Heater, battery wrap 8 Heater, battery pad 8 Kit, Battery Heater,50W, 0-0V GM0 -KP - QS Battery Heater,50W,0V GM0 TT Battery Heater Wrap, Res/Coml TT-- Bushing X----8 Kit, Batter Heater, 50W, 0-0V GM0 -KP -QS Harness, Adapter GM88 Battery Heater,50W,0V GM0 TT Battery Heater Wrap, Res/Coml TT-- Breaker, Kit APM -RESA GM88 -KP -QS Breaker, Circuit GM87 BRACKET, CIRCUIT BREAKER GM855 Lead LN TT Automatic Paralleling Module Kit, Res TT--5 8 Spacer,.0 ID x.75 OD x. in. X Screw, Tapping X--7-- Breaker, Kit APM -0RESA GM8 -KP -QS Breaker, Circuit GM770 BRACKET, CIRCUIT BREAKER GM855 Lead LN TT Automatic Paralleling Module Kit, Res TT--5 Screw, Tapping X--7-- Emergency Stop GM005-KP-QS Decal, Emergency Stop GB70 Harness, Assembly E-Stop GM00 Qty. Description Part No. Load Control Module, w/ Harness GM7777-KP-QS Load Control Module Assy, w/ Harness GM7777- Decal, CSA 77 Decal, equipment grd (NRP) 5 Insert, threaded, #0-58 Dimension Print, Load Control Module ADV-88 Gasket GM00 Label, Blank GM70 Decal, 0VAC Only GM75 Plate, Mounting GM777 Relay GM7778 Cover w/ Decals, Load Shed GM77 Enclosure, Load Shed GM75 Harness, Load Control GM800 Harness, Relay Control GM807 Indicator, Load Status GM8087 Decal, Wiring Diagram GM8050 Decal, Warning GM8 PCB Assy, RDC Load Control GM87- Transformer, Current GM8 Decal, LCM -- w/ whip GM85- TT Load Control Module, Res/Comm TT-57 Terminal block X-05- Washer X-08- Lug, terminal, aluminum X-07- Load Control Module, w/ Terminal Blocks GM7777-KP-QS Load Control Module Assy, w/ Term. GM7777- Decal, equipment grd (NRP) 5 Insert, threaded, #0-58 Dimension Print, Load Control Module ADV-88 Gasket GM00 Decal, Nameplate GM Label, Blank GM70 Decal, 0VAC Only GM75 Plate, Mounting GM777 Relay, GM7778 Cover w/ Decals, Load Shed GM77 Enclosure, Load Shed GM75 Harness, Relay Control GM807 8 Harness, Terminal Block GM807 Block, Terminal GM808 Indicator, Load Status GM8087 Marker, Strip GM80 Decal, Wiring Diagram GM8050 Decal, Warning GM8 PCB Assy, RDC Load Control GM87- Diagram, Wiring Load Control GM87 Diagram, Schematic Load Control GM88 Transformer, Current GM8 TT Load Control Module, Res/Comm TT-57 Terminal block X-05- Washer X-08- Lug, terminal, aluminum X-07- TP-80 / 7

68 Kit Parts List, continued Qty. Description Part No. Load Control Module, w/ Harness, CSA GM7777-KP-QS Load Control Module Assy, w/ Harness GM7777- Decal, CSA 77 Decal, equipment grd (NRP) 5 Insert, threaded, #0-58 Dimension Print, Load Control Module ADV-88 Gasket GM00 Label, Blank GM70 Decal, 0VAC Only GM75 Plate, Mounting GM777 Relay GM7778 Cover w/ Decals, Load Shed GM77 Enclosure, Load Shed GM75 Harness, Load Control GM800 Harness, Relay Control GM807 Indicator, Load Status GM8087 Decal, Wiring Diagram GM8050 Decal, Warning GM8 PCB Assy, RDC Load Control GM87- Transformer, Current GM8 Decal, LCM -- w/ whip GM85- TT Load Control Module, Res/Comm TT-57 Terminal block X-05- Washer X-08- Lug, terminal, aluminum X-07- Load Control Module, w/ Terminal Blocks, CSA GM7777-KP-QS Load Control Module Assy, w/ Term. GM7777- Decal, CSA 77 Decal, equipment grd (NRP) 5 Insert, threaded, #0-58 Dimension Print, Load Control Module ADV-88 Gasket GM00 Decal, Nameplate GM Label, Blank GM70 Decal, 0VAC Only GM75 Plate, Mounting GM777 Relay, GM7778 Cover w/ Decals, Load Shed GM77 Enclosure, Load Shed GM75 Harness, Relay Control GM807 8 Harness, Terminal Block GM807 Block, Terminal GM808 Indicator, Load Status GM8087 Marker, Strip GM80 Decal, Wiring Diagram GM8050 Decal, Warning GM8 PCB Assy, RDC Load Control GM87- Diagram, Wiring Load Control GM87 Diagram, Schematic Load Control GM88 Transformer, Current GM8 TT Load Control Module, Res/Comm TT-57 Terminal block X-05- Washer X-08- Lug, terminal, aluminum X-07- Programmable Interface Module (PIM) GM85-KP-QS Dimension Print, Programable Intf Module ADV-8 Diagram, Wiring PIM GM8085 Diagram, Schematic PIM GM808 Programmable Interface Module (PIM) TT-58 PIM, Assy NEMA R GM85- Gasket GM00 Decal, Nameplate GM PCB Assy, RDC Programmable Int. GM87- Enclosure, PIM GM857 Silkscreen, Cover GM88 Decal, Torque GM8855 Qty. Description Part No. Programmable Interface Mod. (PIM),CSAGM85-KP-QS Dimension Print, Programable Intf Module ADV-8 Diagram, Wiring PIM GM8085 Diagram, Schematic PIM GM808 Programmable Interface Module (PIM) TT-58 PIM, Assy NEMA R GM85- Gasket GM00 Decal, Nameplate GM PCB Assy, RDC Programmable Int. GM87- Enclosure, PIM GM857 Silkscreen, Cover GM88 Decal, Torque GM8855 Automatic Paralleling Module, 00A GM85 -KP -QS APM,OnCue,RDC/DC/VSC GM885-- AUTOMATIC PARALLELING MODULE,00A NR GM85-- TRANSFORMER, CURRENT ASSY GM80 Harness, Adapter GM80 Software, RDC Paralleling GM87 TT Automatic Paralleling Module Kit, Res TT--5 Miscellaneous Kits Carburetor Heater 0 V GM-KP-QS Heater, Inlet 7W 0V GM Tube, Breather (.75 OD) Copper GM Insulator, breather line (.5 ID x ) GM5 Plug, button X-0- Bushing,. x.50 in. NPT X-- Screw, Hex Head X-7- Decal, Caution Hot Carburetor Heater GM87 TT Carburetor Heater, TT-7 Carburetor Heater 0 V GM-KP-QS Tube, Breather (.75 od) Copper GM Insulator, breather line (.5 id x ) GM5 Decal, Caution Hot Carburetor Heater GM87 Heater, Plate 7W/0V GM88 TT Carburetor Heater,8.5/RMY,8.5/RES TT--7 Plug,button X--0-- Bushing,. x.50 in. NPT X---- Screw, Hex Head X--7-- Carburetor Heater 0 V GM-KP-QS Heater, Inlet 7W 0V GM Cord, Way Extension GM58 Tube, Breather (.75 od) Copper GM Insulator, breather line (.5 id x ) GM5 Decal, Caution Hot Carburetor Heater GM87 Plug,button X--0-- Bushing,. x.50 in. NPT X---- Screw, Hex Head X--7-- TT Carburetor Heater,8.5/RMY,8.5/RES TT--7 Carburetor Heater 0 V GM57-KP-QS Decal, caution hot carburetor GM87 Heater, carburetor GM578 Bushing,.000 x.75 in. NPT X--5 Bushing,. x.50 in. NPT X-- Installation Instructions TT-8 Carburetor Heater 0 V GM57-KP-QS Decal, Caution Hot Carburetor Heater GM87 Heater, Carburetor GM888 Carburetor Heater, 7/8/0kW, Res/Coml TT-8 Bushing,.000 x.75 in. NPT X--5 Bushing,. x.50 in. NPT X-- 8 TP-80 /

69 Kit Parts List, continued Qty. Description Part No. Carburetor Heater, 0W, 0V GM57-KP-QS Decal, Caution Hot Carburetor Heater GM87 Heater, Carburetor GM578 Cord, Extension GM0 Adapter, Carb Heater GM CarbHeater, 7/8/0, 8--0RESV, Res/Coml TT--8 Carburetor Heater, 0W, 0V GM57-KP5-QS Decal, Caution Hot Carburetor Heater GM87 Heater, Carburetor GM578 Adapter, Carb Heater GM Cord, Way Extension GM58 CarbHeater, 7/8/0, 8--0RESV, Res/Coml TT--8 CSA Certification / Residential GM0-KA Decal, CSA GM8788 CSA Certification / Residential GM0-KA Decal, CSA GM8788 Concrete Mounting Pad, Thick GM0 -KP -QS Pad, Concrete Mounting GM0 Concrete Mounting Pad, Thick GM0 -KP -QS Pad, Concrete Mounting GM070 Maintenance Service Kits (includes oil, oil filter, air filter, spark plugs, and instructions (TT-5)) Kit, Residential Maint (RESA) GM-SKP-QS Kit, Residential Maint (0kW) GM7-SKP-QS OnCue,RDC/DC/VSC Controller GM885-KP-QS OnCue Welcome Letter G8--8 Decal, OnCue Activation Code GM88 Dwg, OnCue Decal Placement GM8770 Connector, RJ5 Female to RJ5 Female GM85 O/M OnCue Software, /0RES(L) TP--7 OnCue Plus,RDC/DC/VSC GM885-KP-QS OnCue Plus Welcome Letter G8-- OnCue App Quick Start Guide G8--7 Decal, OnCue Activation Code GM88 Dwg, OnCue Decal Placement GM8770 Connector, RJ5 Female to RJ5 Female GM85 O/M OnCue Plus TP--0 OnCue Plus, Wireless, RDC/DC/VSC GM885-KP-QS Cable, Patch, Ft. RJ Decal, OnCue Activation Code GM88 Dwg, OnCue Decal Placement GM8770 Kit, Wireless Router GM7 Tape, VHB /, 0in Long GM05 O/M OnCue Plus Res/Coml TP--8 Install Guide WiFi Kit Res/Coml TT--8 TP-80 /

70 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC advanced digital control; analog to digital converter adj. adjust, adjustment ADV advertising dimensional drawing Ah amp-hour AHWT anticipatory high water temperature AISI American Iron and Steel Institute ALOP anticipatory low oil pressure alt. alternator Al aluminum ANSI American National Standards Institute (formerly American Standards Association, ASA) AO anticipatory only APDC Air Pollution Control District API American Petroleum Institute approx. approximate, approximately AQMD Air Quality Management District AR as required, as requested AS as supplied, as stated, as suggested ASE American Society of Engineers ASME American Society of Mechanical Engineers assy. assembly ASTM American Society for Testing Materials ATDC after top dead center ATS automatic transfer switch auto. automatic aux. auxiliary avg. average AVR automatic voltage regulator AWG American Wire Gauge AWM appliance wiring material bat. battery BBDC before bottom dead center BC battery charger, battery charging BCA battery charging alternator BCI Battery Council International BDC before dead center BHP brake horsepower blk. black (paint color), block (engine) blk. htr. block heater BMEP brake mean effective pressure bps bits per second br. brass BTDC before top dead center Btu British thermal unit Btu/min. British thermal units per minute C Celsius, centigrade cal. calorie CAN controller area network CARB California Air Resources Board CB circuit breaker cc cubic centimeter CCA cold cranking amps ccw. counterclockwise CEC Canadian Electrical Code cert. certificate, certification, certified cfh cubic feet per hour 70 Appendix 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 cul Canadian Underwriter s Laboratories CUL Canadian Underwriter s Laboratories cu. in. cubic inch cw. clockwise CWC city water-cooled cyl. cylinder D/A digital to analog DAC digital to analog converter db decibel db(a) decibel (A weighted) DC direct current DCR direct current resistance deg., degree dept. department DFMEA Design Failure Mode and Effects Analysis dia. diameter DI/EO dual inlet/end outlet DIN Deutsches Institut fur Normung e. V. (also Deutsche Industrie Normenausschuss) DIP dual inline package DPDT double-pole, double-throw DPST double-pole, single-throw DS disconnect switch DVR digital voltage regulator E, emer. emergency (power source) ECM electronic control module, engine control module EDI electronic data interchange EFR emergency frequency relay e.g. for example (exempli gratia) EG electronic governor EGSA Electrical Generating Systems Association EIA Electronic Industries Association EI/EO end inlet/end outlet EMI electromagnetic interference emiss. emission eng. engine EPA Environmental Protection Agency EPS emergency power system ER emergency relay ES engineering special, engineered special ESD electrostatic discharge est. estimated E-Stop emergency stop etc. et cetera (and so forth) exh. exhaust ext. external F Fahrenheit, female fglass. fiberglass FHM flat head machine (screw) fl. oz. fluid ounce flex. flexible freq. frequency FS full scale ft. foot, feet ft. lb. foot pounds (torque) ft./min. feet per minute ftp file transfer protocol g gram ga. gauge (meters, wire size) gal. gallon gen. generator genset generator set GFI ground fault interrupter GND, ground gov. governor gph gallons per hour gpm gallons per minute gr. grade, gross GRD equipment ground gr. wt. gross weight H x W x D height by width by depth HC hex cap HCHT high cylinder head temperature HD heavy duty HET high exhaust temp., high engine temp. hex hexagon Hg mercury (element) HH hex head HHC hex head cap HP horsepower hr. hour HS heat shrink hsg. housing HVAC heating, ventilation, and air conditioning HWT high water temperature Hz hertz (cycles per second) IC integrated circuit ID inside diameter, identification IEC International Electrotechnical Commission IEEE Institute of Electrical and Electronics Engineers IMS improved motor starting in. inch in. H 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 TP-80 /

71 k kilo (000) K kelvin ka kiloampere KB kilobyte ( 0 bytes) KBus Kohler communication protocol kg kilogram kg/cm kilograms per square centimeter kgm kilogram-meter kg/m kilograms per cubic meter khz kilohertz kj kilojoule km kilometer kohm, k kilo-ohm kpa kilopascal kph kilometers per hour kv kilovolt kva kilovolt ampere kvar kilovolt ampere reactive kw kilowatt kwh kilowatt-hour kwm kilowatt mechanical kwth kilowatt-thermal L liter LAN local area network L x W x H length by width by height lb. pound, pounds lbm/ft 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 when used with SI units), male m cubic meter m /hr. cubic meters per hour m /min. cubic meters per minute ma milliampere man. manual max. maximum MB megabyte ( 0 bytes) MCCB molded-case circuit breaker MCM one thousand circular mils meggar megohmmeter MHz megahertz mi. mile mil one one-thousandth of an inch min. minimum, minute misc. miscellaneous MJ megajoule mj millijoule mm millimeter MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard ms millisecond m/sec. meters per second MTBF mean time between failure MTBO mean time between overhauls mtg. mounting MTU Motoren-und Turbinen-Union MW megawatt mw milliwatt F microfarad N, norm. normal (power source) NA not available, not applicable nat. gas natural gas NBS National Bureau of Standards NC normally closed NEC National Electrical Code NEMA National Electrical Manufacturers Association NFPA National Fire Protection Association Nm newton meter NO normally open no., nos. number, numbers NPS National Pipe, Straight NPSC National Pipe, Straight-coupling NPT National Standard taper pipe thread per general use NPTF National Pipe, Taper-Fine NR not required, normal relay ns nanosecond OC overcrank OD outside diameter OEM original equipment manufacturer OF overfrequency opt. option, optional OS oversize, overspeed OSHA Occupational Safety and Health Administration OV overvoltage oz. ounce p., pp. page, pages PC personal computer PCB printed circuit board pf picofarad PF power factor ph., phase PHC Phillipsr head Crimptiter (screw) PHH Phillipsr hex head (screw) PHM pan head machine (screw) PLC programmable logic control PMG permanent magnet generator pot potentiometer, potential ppm parts per million PROM programmable read-only memory psi pounds per square inch psig pounds per square inch gauge pt. pint PTC positive temperature coefficient PTO power takeoff PVC polyvinyl chloride qt. quart, quarts qty. quantity R replacement (emergency) power source rad. radiator, radius RAM random access memory RDO relay driver output ref. reference rem. remote Res/Coml Residential/Commercial RFI radio frequency interference RH round head RHM round head machine (screw) rly. relay rms root mean square rnd. round ROM read only memory rot. rotate, rotating rpm revolutions per minute RS right side RTU remote terminal unit RTV room temperature vulcanization RW read/write SAE Society of Automotive Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier s, sec. second SI Systeme international d unites, International System of Units SI/EO side in/end out sil. silencer SN serial number SNMP simple network management protocol SPDT single-pole, double-throw SPST single-pole, single-throw spec specification specs specification(s) sq. square sq. cm square centimeter sq. in. square inch SS stainless steel std. standard stl. steel tach. tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to normal TDES time delay engine start TDNE time delay normal to emergency TDOE time delay off to emergency TDON time delay off to normal temp. temperature term. terminal THD total harmonic distortion TIF telephone influence factor TIR total indicator reading tol. tolerance turbo. turbocharger typ. typical (same in multiple locations) UF underfrequency UHF ultrahigh frequency UL Underwriter s Laboratories, Inc. UNC unified coarse thread (was NC) UNF unified fine thread (was NF) univ. universal US undersize, underspeed UV ultraviolet, undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency W watt WCR withstand and closing rating w/ with w/o without wt. weight xfmr transformer TP-80 / Appendix 7

72 Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made. Bolt/Screw Length: When bolt/screw length is not given, use Figure as a guide. As a general rule, a minimum length of one thread beyond the nut and a maximum length of / the bolt/screw diameter beyond the nut is the preferred method. Washers and Nuts: Use split lock washers as a bolt locking device where specified. Use SAE flat washers with whiz nuts, spiralock nuts, or standard nuts and preloading (torque) of the bolt in all other applications. See Appendix C, General Torque Specifications, and other torque specifications in the service literature. Preferred Nut/Bolt Clearance Steps for common hardware application:. Determine entry hole type: round or slotted.. Determine exit hole type: fixed female thread (weld nut), round, or slotted. For round and slotted exit holes, determine if hardware is greater than / inch in diameter, or / inch in diameter or less. Hardware that is greater than / inch in diameter takes a standard nut and SAE washer. Hardware / inch or less in diameter can take a properly torqued whiz nut or spiralock nut. See Figure.. Follow these SAE washer rules after determining exit hole type: a. Always use a washer between hardware and a slot. b. Always use a washer under a nut (see above for exception). c. Use a washer under a bolt when the female thread is fixed (weld nut).. Refer to Figure, which depicts the preceding hardware configuration possibilities. Unacceptable Nut/Bolt Clearance. / of bolt diameter. Min. full thread beyond top of nut. Below top of nut G-585 Figure Acceptable Bolt Lengths 5. Cap screw. Entry hole types. Standard nut and SAE washer. Whiz nut or spiralock: up to / in. dia. hardware 5. Weld nuts: above / in. dia. hardware. Exit hole types G-585 Figure Acceptable Hardware Combinations 7 Appendix TP-80 /

73 Appendix C General Torque Specifications American Standard Fasteners Torque Specifications Torque Assembled into Cast Iron or Steel Size Measurement Grade Grade 5 Grade 8 8- Nm (in. lb.).8 (). (0) 0- Nm (in. lb.). (). () 0- Nm (in. lb.). (). () /-0 Nm (in. lb.).8 (0) 0.8 (). () /-8 Nm (in. lb.) 8. (7). (08). () 5/-8 Nm (in. lb.). (0).7 ().8 () 5/- Nm (in. lb.). (). (0).5 (88) /8- Nm (ft. lb.).0 (8) 8.0 (8) 5.0 () /8- Nm (ft. lb.) 7.0 (0).0 () 0.0 () 7/- Nm (ft. lb.).0 () 0.0 () 85.0 () 7/-0 Nm (ft. lb.).0 () 8.0 (50) 5.0 (70) /- Nm (ft. lb.) 0.0 ().0 (8) 0.0 () /-0 Nm (ft. lb.).0 () 0.0 (7).0 (08) /- Nm (ft. lb.) 8.0 (0).0 (8) 87.0 (8) /-8 Nm (ft. lb.).0 (7) 8.0 (0) 0.0 (5) 5/8- Nm (ft. lb.).0 (8) 8.0 (5) 5.0 () 5/8-8 Nm (ft. lb.) 8.0 () 08.0 (5).0 () /-0 Nm (ft. lb.).0 (7) 5.0 (0) 58.0 (8) /- Nm (ft. lb.).0 ().0 (8) 5.0 (78) -8 Nm (ft. lb.) 5.0 () 7.0 (5) 0.0 (88) - Nm (ft. lb.) 8.0 (0) 78.0 (58).0 (85) Assembled into Aluminum Gradeor5 SeeNote Metric Fasteners Torque Specifications, Measured in Nm (ft. lb.) Assembled into Cast Iron or Steel Assembled into Aluminum Size (mm) Grade 5.8 Grade 8.8 Grade 0. Grade 5.8 or 8.8 M x.00. (.).5 (7). (0) M8 x ().0 (7).0 () M8 x.00.0 ().0 (8).0 (5) M0 x () 5.0 () 5.0 (8) M0 x.5.0 () 7.0 (5) 8.0 (50) M x () 80.0 (5) 5.0 (85) M x () 85.0 ().0 (0) SeeNote M x ().0 () 80.0 () M x ().0 (8) 0.0 (0) M x ().0 () 78.0 (05) M x.50.0 (7) 0.0 (8) 87.0 () M8 x () 7.0 (0) 0.0 (88) M8 x (0) 8.0 ().0 (05) Notes:. The torque values above are general guidelines. Always use the torque values specified in the service manuals and/or assembly drawings when they differ from the above torque values.. The torque values above are based on new plated threads. Increase torque values by 5% if non-plated threads are used.. Hardware threaded into aluminum must have either two diameters of thread engagement or a 0% or more reduction in the torque to prevent stripped threads.. Torque values are calculated as equivalent stress loading on American hardware with an approximate preload of 0% of the yield strength and a friction coefficient of 0.5. TP-80 / Appendix 7

74 Appendix D Common Hardware Identification Screw/Bolts/Studs Head Styles Nuts Nut Styles Hardness Grades American Standard Hex Head or Machine Head Hex Head Grade Hex Head or Machine Head with Washer Lock or Elastic Grade 5 Flat Head (FHM) Square Grade 8 Round Head (RHM) Cap or Acorn Grade 8/ (Hex Socket Head) Pan Head Hex Socket Head Cap or Allent Head Cap Hex Socket Head or Allent Head Shoulder Bolt Wing Washers Washer Styles Plain Metric Number stamped on hardware; 5.8 shown 5.8 Sheet Metal Screw Split Lock or Spring Stud Spring or Wave Drive Styles Hex External Tooth Lock Hex and Slotted Internal Tooth Lock Phillipsr Internal-External Tooth Lock Slotted Hex Socket Allent head screw is a trademark of Holo-Krome Co. Phillipsr screw is a registered trademark of Phillips Screw Company. Sample Dimensions American Standard (Screws, Bolts, Studs, and Nuts) /-0 x Length In Inches (Screws and Bolts) Threads Per Inch Major Thread Diameter In Fractional Inches Or Screw Number Size Metric (Screws, Bolts, Studs, and Nuts) M8-.5 x 0 Length In Millimeters (Screws and Bolts) Distance Between Threads In Millimeters Major Thread Diameter In Millimeters Plain Washers / x5/8x/ Lock Washers 5/8 Thickness External Dimension Internal Dimension Internal Dimension 7 Appendix TP-80 /

75 Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions HexHeadBolts(Grade5) X-5-7 /-0 x.8 X-5- /-0 x.50 X-5- /-0 x. X-5- /-0 x.75 X-5-8 /-0 x.88 X-5-7 /-0 x.00 X-5-8 /-0 x.5 X-5- /-0 x.50 X-5-0 /-0 x.75 X-5- /-0 x.00 X-5- /-0 x.5 X-5- /-0 x.75 X-5- /-0 x 5.00 X-5-5 /-8 x.8 X-5-0 /-8 x.00 X-5-5/-8 x.50 X-5-5/-8 x. X-5-5/-8 x.75 X-5-5/-8 x.88 X-5-5 5/-8 x.00 X-5-5/-8 x.5 X-5-5/-8 x.50 X-5-5 5/-8 x.75 X-5-5/-8 x /-8 x.5 X-5-5/-8 x.50 X-5-7 5/-8 x.75 X-5-8 5/-8 x.00 X-5-5/-8 x.50 X-5-5/-8 x 5.00 X-5-5 5/-8 x 5.50 X-5-5/-8 x.00 X-5-0 5/-8 x.50 X-5-5/- x.75 X-5-5/- x.50 X-5-0 5/- x.75 X-5-5/- x.00 X-5-8 5/- x.75 X-8- /8- x. X-8-0 /8- x.75 X-8- /8- x.88 X-8- /8- x.00 X-8- /8- x.5 X-8-5 /8- x.50 X-8- /8- x.75 X-8- /8- x.00 X-8-7 /8- x.5 X-8-7 /8- x.50 X-8-8 /8- x.75 X-8- /8- x.00 X-8- /8- x.5 X-8- /8- x.50 X-8-0 /8- x.75 X-8- /8- x.50 X-8-8 /8- x 5.50 X-8-5 /8- x.50 Part No. Dimensions Hex Head Bolts, cont. X-8- /8- x.75 X-8- /8- x.5 X-8- /8- x.00 X-8- /8- x.50 X-0-5 7/- x.75 X-0-7/- x.00 X-0-8 7/- x.5 X-0-7/- x.50 X-0-7/- x.00 X-0-7/- x.75 X-0-7/- x.50 X--5 /- x.75 X--7 /- x.00 X--8 /- x.5 X-- /- x.50 X--0 /- x.75 X-- /- x.00 X-- /- x.5 X-- /- x.50 X-- /- x.75 X--5 /- x.00 X--7 /- x.50 X-- /- x.00 X--0 /- x.50 X-- /- x 5.50 X-- /- x.00 X--5 /-0 x.75 X--5 /-0 x.5 X--5 /-0 x.50 X-0-5/8- x.00 X-0-5/8- x.5 X-0-5/8- x.50 X-0-5/8- x /8- x.00 X-0-5 5/8- x.5 X-0-5/8- x.50 X-0-7 5/8- x.75 X-0-5/8- x.75 X-0-5/8- x.50 X-0-0 5/8- x.00 X-0-5/8-8 x.50 X-- /-0 x.00 X--8 /-0 x.5 X-- /-0 x.50 X-- /-0 x.00 X-- /-0 x.50 X--5 /-0 x.00 X-- /-0 x.50 X x.5 X x.00 X x 5.00 Part No. Dimensions Type Hex Nuts X Standard X-0- - Whiz X-0-8- Whiz X Whiz X-0-0- Whiz X-0- /-0 Spiralock X-0- /-8 Spiralock X-0-7 5/-8 Spiralock X-0-8 5/- Spiralock X-0- /8- Spiralock X-0-0 /8- Spiralock X-0-7/- Spiralock X-0- /- Spiralock X-0-5 7/-0 Spiralock X-0- /-0 Spiralock X-85-5/8- Standard X-88- /-0 Standard X-8- /-0 Standard Washers Bolt/ Part No. ID OD Thick. Screw X # X # X #8 X #0 X / X / X /8 X / X / X /8 X / X TP-80 / Appendix 75

76 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Hex Head Bolts (Partial Thread) M M x 55 M M-.00 x 0 M M-.00 x 55 M M-.00 x 0 M-000-SS M-.00 x 0 M M-.00 x 70 M-0070-SS M-.00 x 70 M M-.00 x 75 M M-.00 x 0 M-05-0 M-.00 x 5 M M-.00 x 50 M M8-.5 x 5 M M8-.5 x 0 M M8-.5 x 5 M M8-.5 x 50 M M8-.5 x 55 M M8-.5 x 55* M M8-.5 x 0 M M8-.5 x 70 M M8-.5 x 70* M M8-.5 x 75 M M8-.5 x 80 M M8-.5 x 0 M M8-.5 x 5 M M8-.5 x 00 M M8-.5 x 0 M M8-.5 x 0 M M8-.5 x 0 M M8-.5 x 0 M M8-.5 x 50 M M8-.5 x 00 M M0-.5 x 0* M M0-.50 x 0 M M0-.50 x 5 M M0-.50 x 50 M M0-.5 x 50* M M0-.50 x 55 M M0-.50 x 0 M M0-.50 x 5 M M0-.50 x 70 M M0-.50 x 80 M M0-.5 x 80* M M0-.50 x 0 M M0-.50 x 0* M M0-.50 x 00 M-00-0 M0-.50 x 0 M-00-0 M0-.50 x 0 M-00-0 M0-.50 x 0 M-00-0 M0-.50 x 0 M M0-.50 x 80 M-05-0 M0-.50 x 5 M-00-0 M0-.50 x 0 M M0-.5 x 0 M-05-0 M-.75 x 5 M M-.5 x 50 M M-.5 x 50* M M-.75 x 50 M M-.75 x 50* M M-.75 x 55 M-00-0 M-.75 x 0 M-00-8 M-.75 x 0* M-05-0 M-.75 x 5 M M-.75 x 75 M M-.75 x 80 M-00-0 M-.75 x 0 M-00-0 M-.75 x 00 M-0-0 M-.75 x 0 Part No. Dimensions Hex Head Bolts (Partial Thread), continued M M-.50 x 0 M-00-0 M-.00 x 0 M-00-0 M-.00 x 00 M-00-8 M-.00 x 00* M-0-0 M-.00 x 0 M-50-0 M-.00 x 50 M M0-.50 x 5 M M0-.50 x 0 M M0-.50 x 00 M-00-0 M0-.50 x 0 M-00-0 M0-.50 x 0 M-00-0 M0-.50 x 0 M-00-0 M-.50 x 0 M-0-0 M-.50 x 0 M-0-0 M-.50 x 0 M-00-0 M-.00 x 0 M-0-0 M-.00 x 0 M-0-0 M-.00 x 0 M-00-0 M-.00 x 00 Hex Head Bolts (Full Thread) M M-0.70 x M M x 0 M M x 5 M M x 50 M M-.00 x 0 M-00-0 M-.00 x M-00-0 M-.00 x M-00-0 M-.00 x M M-.00 x 0 M M-.00 x 5 M M-.00 x 0 M M-.00 x 0 M M-.00 x 50 M M7-.00 x 5 M M8-.5 x 0 M M8-.5 x M M8-.5 x M M8-.5 x 0 M M8-.5 x 5 M M8-.5 x 0 M M8-.5 x 0* M-00-0 M0-.50 x M M0-.5 x 0 M M0-.50 x 0 M M0-.50 x 5 M M0-.5 x 5 M M0-.50 x 5* M M0-.5 x 0 M M0-.50 x 0 M M0-.50 x 0* M M0-.5 x 5 M M0-.50 x 5 M M0-.50 x 5* M M0-.5 x 0 Part No. Dimensions Hex Head Bolts (Full Thread), continued M-0-0 M-.75 x M-00-0 M-.75 x 0 M-00-0F M-.50 x 0 M-05-0 M-.75 x 5 M-05-8 M-.75 x 5* M-00-0 M-.5 x 0 M-00-8 M-.75 x 0* M-00-8F M-.50 x 0* M-00-0 M-.75 x 0 M-05-0 M-.75 x 5 M-00-8 M-.5 x 0* M-00-0 M-.75 x 0 M-00-8 M-.75 x 0* M-05-0 M-.50 x 5 M-05-0 M-.00 x 5 M M-.50 x 50* M-05-0 M-.50 x 5 M-05-0 M-.00 x 5 M-00-8 M-.50 x 0* M-00-8 M-.00 x 0* M-05-0 M-.00 x 5 M-00-0 M-.50 x 0 M-00-0 M-.00 x 0 M-05-8 M-.50 x 5* M-05-8 M-.00 x 5* M M-.00 x 50 M M-.00 x 50* M-00-0 M-.00 x 0 M M-.00 x 70 M M8-.50 x 5 M M8-.50 x 50 M M8-.50 x 0 M M0-.50 x 50 M M0-.50 x 55 M-00-0 M-.00 x 0 M-05-0 M-.00 x 5 M M-.00 x 70 Pan Head Machine Screws M785A M-0.50 x 0 M785A-00-0 M-0.50 x M785A M-0.70 x 0 M785A-00-0 M-0.70 x M785A M-0.70 x 0 M785A M-0.70 x 50 M785A M-0.70 x 00 M785A M x 0 M785A M x M785A M x M785A M x 0 M785A M x 5 M785A M x 0 M785A M x 80 M785A M x 00 M785A M-.00 x 00 Flat Head Machine Screws M5A-00-SS M-0.70 x M5A-050-SS M x M5A M x M5A-00-0 M-.00 x * This metric hex bolt s hardness is grade Appendix TP-80 /

77 Metric, continued Part No. Dimensions Type Hex Nuts M-0-50 M-0.50 Standard M-0-50 M-0.70 Standard M-0-B M-0.70 Brass M M Standard M-0-0 M-.00 Standard M-0- M-.00 Std. (green) M-0-80 M-.00 Spiralock M M-.00 Elastic Stop M-08-0 M8-.5 Standard M M8-.5 Spiralock M M8-.5 Elastic Stop M-0-0 M0-.50 Standard M-0-0F M0-.5 Standard M-0-80 M0-.50 Spiralock M-0- M0-.50 Spiralock[ M M0-.50 Elastic Stop M--0 M-.75 Standard M--0F M-.5 Standard M--80 M-.75 Spiralock M8--80 M-.75 Elastic Stop M8--0 M-.00 Elastic Stop M--80 M-.00 Spiralock M8--80 M-.00 Elastic Stop M-8-80 M8-.5 Standard M8-8-0 M8-.50 Elastic Stop M-0-80 M0-.50 Standard M M0-.50 Elastic Stop M--0 M-.50 Standard M--80 M-.00 Standard M8--0 M-.00 Elastic Stop M-0-80 M0-.50 Standard Washers Bolt/ Part No. ID OD Thick. Screw M5A M M5A M M5A M5 M5A M M5A M8 M5A M0 M5A M M5A M M5A M M5A M8 M5A M0 M5A M [ This metric hex nut s hardness is grade 8. TP-80 / Appendix 77

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80 KOHLER CO. Kohler, Wisconsin 50 Phone 0-57-, Fax 0-5- TP-80 /e E 0, 0, 05, 0 by Kohler Co. All rights reserved. Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 5 Phone (5) -, Fax (5) -55 For the nearest KOHLER authorized installation, service, and sales dealer in the US and Canada: Call or visit KOHLERPower.com