Service Parts 4CCFOZ 4/6.5EFOZ 5CCOZ 5/8EOZ. Marine Generator Sets. Models: TP /05c. Specification Series 126

Transcription

1 Service Parts Marine Generator Sets Models: 4CCFOZ 4/6.5EFOZ 5CCOZ 5/8EOZ Specification Series 126 TP /05c

2 Description Page Introduction... 3 Numbering System Significance... 3 Illustrations... 3 How to Find Part Numbers... 3 Hardware References... 3 Specification Number Index... 4 Group 1: Cylinder Block... 6 Group 2: Gear Housing... 8 Group 3: Flywheel Housing and Oil Sump Group 4: Cylinder Head Group 5: Intake Manifold Group 6: Camshaft and Drive Gear Group 7: Crankshaft and Piston Group 8: Lube Oil System Group 9: Cooling Water System Group 10: Fuel Injection Pump Group 11: Fuel Injection Lines Group 12: Governor Table of Contents Description Page Group 13: Starting Motor Group 14: Gasket Set Group 101: Air Intake Group 103: Fuel System Group 104: Cooling System Group 105: Engine Group 107: Nameplate and Decals Group 109: Skid and Plant Mounting Group 201: Generator and Mounting Group 301: Controller and Mounting Group 501: Housing Group 701: Literature Paint and Miscellaneous Parts Parts List: Accessories Appendix A. Glossary of Abbreviations... A-72 Appendix B. Common Hardware Application Guidelines... A-74 Appendix C. General Torque Specifications... A-75 Appendix D. Common Hardware Identification A-76 Appendix E. Common Hardware List... A-77 Table of Contents TP /05

3 This manual lists service replacement parts for Kohler 4CCFOZ, 5CCOZ, 4/6.5EFOZ, and 5/8EOZ marine 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. x:in:004:002 Numbering System Significance This manual uses the following numbering systems: Specification Number. The product identification number located on the generator set nameplate. Specification numbers break down into groups. Group Number. A unique number representing a parts group needed to assemble a generator set function. For example, Group 101 is the Air Intake group. Variation or Module Number. A group might have several variations. Each variation performs the same function with different parts lists. For example, a 50 Hz generator alternator and a 60 Hz generator alternator both perform the same function; however, with different parts. Each difference requires a group variation or module number. Part Number. The part number identifies an individual assembly, subassembly, component, or accessory kit. Illustrations Introduction x:in:004:003:a Illustrations (or exploded-view drawings) best representing the widest range of variations accompany most groups in this manual. Illustrations do not depict all details and may not show all parts. Do not use illustrations for assembly or disassembly instructions. x:in:004:004 How to Find Part Numbers Use the following steps to locate a service replacement part. 1. Locate the generator set nameplate to identify the generator set spec number. 2. Locate a second generator set nameplate listing accessories to identify installed modules. On some models the accessory nameplate is mounted inside the generator junction box. 3. Turn to the Specification Number Index. The first column lists the generator set spec numbers. The headings identify the groups of parts that make up the generator set. 4. Identify the group most likely to include the service part number. 5. Find the group variation number at the intersection of the spec number row and the group column. Note the variation number. 6. Page forward to locate the group identified in step 4 or find the appropriate page in the Table of Contents. 7. Find the part on the illustration and note the item number of the part or find the part description in the parts list. 8. Select the part number that corresponds to your group variation. The first column lists the illustration item number. Find the variation identified in the Specification Number Index or the module number found on the generator set nameplate in the appropriate column on the right side of the parts list table. Find the quantity used at the intersection of the item number row and the variation column. A blank space at the intersection means the variation/module does not use that part number. Hardware References x:in:004:005 Many common hardware items do not appear in parts manuals or will appear as common hardware entries. A common hardware entry lists the size of the hardware. For example, an item that appears as Hardware, 3/8-16 in the text means that the piece is 3/8-16 size. Obtain common hardware locally or, if contacting the factory, use the Common Hardware List in the appendix to identify the common hardware part number and specifications. See Common Hardware Application Guidelines in the appendix for mating hardware instructions. Some hardware items require a specific size or some other characteristic. In that case, use the part number listedinthetext. When replacing hardware, do not substitute inferior grade hardware. Replacement hardware grade should be equal to or better than the grade of the manufacturer s original hardware. Use the Common Hardware List in the appendix to identify the common hardware hardness. x:in:004:006 TP /05 3

4 Specification Number Index Group Title Group No Spec No. Variation Number GM28311-GA TP /05

5 Specification Number Index Group Title Group No Spec. No. Variation Number GM28311-GA GR TP /05 5

6 Group 1: Cylinder Block Items not shown 3, 11, 12, See Group See Group TP /05

7 X Group 1: Cylinder Block Quantity Part Variation Number Item Number Description Block assembly, cylinder (includes items 2-30) Block assembly, cylinder (includes items 2-30) Block assembly, cylinder (includes items 2-30) 1 2 X Block subassembly (includes items 3-9) X Block, cylinder (not shown) Plug, PT1/ Plug, PT1/ Plug, 6 x Plug, PT1/8, screw Plug, Plug, Plug, Plug, Plug, Plug, Plug, Drain cock (includes items 11-13) Drain cock (includes items 11-13) X Body (not shown) X Valve (not shown) X O-ring (not shown) Bolt Bolt Main bearing (includes items 16 and 17) Bearing, main, undersize, Bearing, main (includes items 16 and 17) Bearing, main, undersize, X Bearing, main, upper X Bearing, main, lower Bearing, thrust (includes items 19 and 20) Bearing, thrust (includes items 19 and 20) 2 19 X Bearing, thrust, upper X Bearing, thrust, lower X Cap, bearing X Cap, bearing Pipe, knock Parallel pin Bushing, camshaft Bushing, camshaft Retainer, idle gear Shaft, idle gear Circlip Bolt, M6 x 12 plated Guide, dipstick Bolt, cylinder head Bolt, cylinder head Gasket, cylinder head Gasket, cylinder head Gasket, cylinder head Bolt, M6 x 12 plated Item not sold separately TP /05 7

8 Group 2: Gear Housing TP /05

9 X Group 2: Gear Housing Quantity Part Variation Number Item Number Description Housing assembly, gear (includes items 2-11) Housing, gear (includes items 3-6) Housing, gear (includes items 3-6) 1 3 X Housing Plug Plug, 10 x Stud, M8 x Spring pin Stud, M6 x Nut, M Cover Gasket Nut w/washer Cover assembly (includes items 13 and 14) Cover assembly (includes items 13 and 14) Cover, gear housing X Cover, gear housing Seal, oil Pipe, knock Pipe, knock Shim set Shim set O-ring Bolt, M6 x 16 plated Bolt, M6 x 16 plated Bolt, M6 x 30 plated Bolt, M6 x 30 plated Bolt, M6 x 40 plated Bolt, M6 x 60 plated Bolt, M6 x 50 plated Bolt, M6 x 60 plated Bolt, M6 x 65 plated Bolt, M6 x 80 plated Cover, blind Cap, lub. oil supply O-ring O-ring Bolt, M6 x 18 plated Gasket Cover, blind Bolt, M6 x 16 plated Gasket, liquid 1 1 Item not sold separately TP /05 9

10 Group 3: Flywheel Housing and Oil Sump See Group TP /05

11 Group 3: Flywheel Housing and Oil Sump X Quantity Variation Part Number Item Number Description Back plate Bolt, M10 x Parallel pin, 8 x Bolt, M10 x Case assembly, oil seal (includes items 6 and 7) Case, oil seal Seal, oil Parallel pin Parallel pin Bolt, M6 x 22 plated Sump assembly, lub. oil (includes items 11-13) Sump assembly, lub. oil (includes items 11-13) 1 11 X Refer to item Plug, M Drain plug, M O-ring 1 13 X Washer seal Spacer, oil sump Spacer, oil sump Bolt, M6 x 10 plated Bolt, M6 x Bolt, M6 x 45 plated Gasket liquid AR AR Item not sold separately TP /05 11

12 Group 4: Cylinder Head , TP /05

13 X Group 4: Cylinder Head Quantity Part Variation Number Item Number Description Head assembly, cylinder (includes items 2-19) Head assembly, cylinder (includes items 2-19) Head assembly, cylinder (includes items 2-19) 1 2 X Refer to item X Head, cylinder Guide, valve Guide, valve Plug, Pt 1/4 screw Plug, Pt 1/4 screw Plug, 5 x Plug, Plug, Valve, intake Valve, intake Valve, exhaust Valve, exhaust Spring, valve Spring, valve Retainer, spring Retainer, spring Cotter Cotter Seal, valve stem Seal, valve stem, intake Seal, valve stem, exhaust Cap, valve Cap, valve 6 15 X Plug, hot Stud Nut, M Stud, M6 x 40 plated Nut, M Protector, nozzle Gasket, nozzle Spring pin X See item Support, assembly, rocker (includes items 25-40) Support, assembly, rocker (includes items 25-40) Support, assembly, rocker (includes items 25-40) Shaft, rocker arm (includes items 26 and 27) Shaft, rocker arm (includes items 26 and 27) 1 26 X Shaft, arm X Ball Arm assembly, rocker (includes items 29-31) Arm assembly, rocker (includes items 29-31) Arm assembly, rocker (includes items 29-31) 3 29 X Arm, intake valve Screw, valve Lock nut, M6 plated Arm assembly, rocker (includes items 33-35) Arm assembly, rocker (includes items 33-35) Arm assembly, rocker (includes items 33-35) 3 33 X Arm, intake valve Screw, valve Lock nut, M6 plated Support, rocker arm Support, rocker arm Screw Screw, M5 x Bolt, M8 x 45 plated Item not sold separately TP /05 13

14 Group 4: Cylinder Head, continued TP /05

15 X Group 4: Cylinder Head, continued Quantity Part Variation Number Item Number Description Spring Spring Circlip Circlip Bonnet assembly (includes items 42-50) Bonnet assembly (includes items 42-50) Bonnet assembly (includes items 42-50) 1 42 X Bonnet Joint Cap, lub. oil supply Cap, lub. oil supply O-ring Plate, shelter Plate, shelter Gasket Gasket Spring washer Screw, M5 x Screw 5 x 10, tapping Gasket, bonnet Gasket, bonnet Pipe, vinyl X Hose 1 51 X Clamp, hose (not shown) Knob O-ring Lifter, engine Lifter, engine Bolt, M8 x 14 plated Plug, glow Connector, glow plug Item not sold separately TP /05 15

16 Group 5: Intake Manifold 5 See Group 4 Variation Variation TP /05

17 Group 5: Intake Manifold Quantity Variation Part Number Item Number Description Manifold, intake 1 1 GM35924 Manifold, intake Gasket, intake manifold Gasket, intake manifold Bolt, M6 x 16 plated Bolt, M6 x Bolt, M6 x 28 plated Gasket, exhaust manifold Gasket, exhaust manifold 1 TP /05 17

18 Group 6: Camshaft and Drive Gear Item not shown 20 See Group 1 See Group See Group TP /05

19 X Group 6: Camshaft and Drive Gear Quantity Variation Part Number Item Number Description Camshaft assembly (includes items 2-5) Camshaft assembly (includes items 2-5) 1 2 X Camshaft Key Gear, camshaft Gear, camshaft Bearing, thrust Tappet Tappet Rod, push Rod, push Camshaft assembly, fuel injection pump (includes items 9-12) Camshaft assembly, fuel injection pump (includes items 9-12) 1 9 X Camshaft, fuel injection pump Key Gear, fuel injection pump 1 11 X Gear, fuel injection pump Ball bearing Bolt, M6 x 16 plated Screw, M8 x Bearing X Ball bearing Ball bearing Retainer, idle gear Shaft, idle gear Gear w/bushing, idle (includes items 20 and 21) Gear w/bushing, idle (includes items 20 and 21) 1 20 X Gear, idle (not shown) Bushing, idle gear Circlip Bolt, M6 x 12 plated 3 3 Item not sold separately TP /05 19

20 Group 7: Crankshaft and Piston TP /05

21 X Group 7: Crankshaft and Piston Quantity Part Variation Number Item Number Description Crankshaft assembly (includes 2-6) Crankshaft assembly (includes 2-6) Crankshaft assembly (includes 2-6) 1 2 X Crankshaft Gear, crankshaft Gear, crankshaft Key X Ball, steel Parallel pin Bolt, flywheel Flywheel w/ring gear X Flywheel Gear, drive V-pulley V-pulley Bolt, M12 x Bolt, M12 x Washer Piston w/rings (includes items 15 and 16) Piston w/rings (includes items 15 and 16) Piston w/rings (includes items 15 and 16) Piston w/rings, oversized 0.25 (includes items 15 and 16) Piston w/rings, oversized 0.25 (includes items 15 and 16) Piston w/rings, oversized 0.25 (includes items 15 and 16) Piston w/rings, oversized 0.50 (includes items 15 and 16) 3 15 X Piston Ring set (includes items 17-19) Ring set (includes items 17-19) Ring set (includes items 17-19) Ring set, oversized 0.25 (includes items 17-19) Ring set, oversized 0.25 (includes items 17-19) Ring set, oversized 0.25 (includes items 17-19) Ring set, oversized 0.50 (includes items 17-19) 3 17 X Top ring, piston X Second ring, piston X Oil ring assembly Pin, piston Pin, piston Pin, piston Circlip Circlip Circlip Rod assembly, connecting (includes items 23-26) Rod assembly, connecting (includes items 23-26) Rod assembly, connecting (includes items 23-26) 3 23 X Rod, connecting Bushing, piston pin Bushing, piston pin Bolt, rod Bolt, rod Bolt, rod Bearing, crankpin Bearing, crankpin Bearing, crankpin, undersized Bearing, crankpin, undersized Item not sold separately TP /05 21

22 Group 8: Lube Oil System Items not shown See Group 1 14 See Group TP /05

23 X Group 8: Lube Oil System Quantity Part Variation Number Item Number Description Pump assembly, oil (includes items 2-10) Pump assembly, oil (includes items 2-10) 1 2 X Body X Cover X Rotor assembly (includes items 5-8) X Pin X Rotor, inner X Shaft X Rotor, outer X Gear, lube oil pump X Bolt, M6 x Gasket, lube oil pump Bolt, M6 x Guide, dipstick Dipstick, lube oil Dipstick, lube oil Filter, lube oil O-ring, lube oil filter O-ring, lube oil filter Valve assembly, oil pressure (includes items 18-22) Valve assembly, oil pressure (includes items 18-22) 1 18 X Body X Spring X Retainer (not shown) X Shim pack X Valve Nut Pipe assembly, oil intake Pipe assembly, oil intake O-ring O-ring Bolt, M6 x 12 plated Bolt, M6 x 12 plated Switch, oil pressure Switch, oil pressure Bracket, oil filter (not shown) Gasket (not shown) Bolt, M8 x 20 (not shown) O-ring (not shown) 1 Item not sold separately TP /05 23

24 Group 9: Cooling Water System Items not shown 2--9, 10, See Group TP /05

25 X Group 9: Cooling Water System Quantity Part Variation Number Item Number Description Pump assembly, cooling water (includes items 2-11) Pump assembly, cooling water (includes items 2-11) Pump assembly, cooling water (includes items 2-11) 1 2 X Body (not shown) X Plug (not shown) X Gasket (not shown) X Plate (not shown) X Impeller (not shown) X Bearing (not shown) X Flange, V-pulley X Seal, mechanical O-ring O-ring O-ring 1 11 X Screw, M6 x 12 (not shown) Gasket, water pump Gasket, water pump Plug Plug, drain (not shown) Gasket Gasket Bolt, M8 x 45 plated V-pulley V-pulley V-belt V-belt Bolt, M6 x 12 plated Adjuster, belt Bolt, M8 x Bolt, M8 x 18 plated Bolt, M8 x See Group 104 Cover, thermostat Cover, thermostat O-ring, gasket O-ring, gasket Bolt, M6 x 18 plated Bolt, M6 x 18 plated Bolt, M8 x Gasket Sender Sender Bolt, M8 x 25 plated Bolt, M8 x Plug, PT3/8, screw (not shown) 1 Item not sold separately TP /05 25

26 Group 10: Fuel Injection Pump No. 1 No No Items not shown 24, Variation See Group TP /05

27 X Group 10: Fuel Injection Pump Quantity Part Variation Number Item Number Description Pump assembly, fuel pump (includes items 2-35) Pump assembly, fuel pump (includes items 2-35) Pump assembly, fuel pump (includes items 2-35) 1 2 X Body, fuel injection pump Plunger w/barrel Plunger w/barrel 3 4 X Barrel, plunger X Plunger Retainer Retainer Spring, plunger Tappet assembly (includes items 10-12) X Guide, roller X Roller X Pin, roller Shim pack Valve w/seat, delivery Valve w/seat, delivery 3 15 X Seat X Valve, delivery Spring, valve Holder, delivery valve Gasket, delivery O-ring Guide, plunger Pin Rack Pinion (not shown) Retainer, rack Retainer, rack Plate Screw Pin Pin X Label, caution Washer Spring washer Spring washer Screw, M4 x X Rivet Screw, M4 x Valve assembly, fuel injection Valve assembly, fuel injection Nozzle assembly, fuel injection X Valve 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 (not shown) X Retainer X Retainer Bolt, M4 x Bolt, M4 x X Pipe set, fuel inlet Pipe, fuel injection Pipe, fuel injection 1 Item not sold separately TP /05 27

28 Group 10: Fuel Injection Pump, continued No. 1 No No Variation See Group TP /05

29 Group 10: Fuel Injection Pump, continued Quantity Part Variation Number Item Number Description Pipe, fuel injection Pipe, fuel injection Pipe, fuel injection Pipe, fuel injection Pipe assembly, fuel (includes items 56-59) Pipe assembly, fuel (includes items 56-59, 62) Pipe Joint Joint Joint Joint Pipe Pipe Nut Gasket, round Clamp 8 4 TP /05 29

30 Group 11: Fuel Injection Lines TP /05

31 Group 11: Fuel Injection Lines Quantity Part Variation Number Item Number Description Filter assembly, fuel Cup, filter O-ring Ring, retaining Spring X Body Element, fuel Plug Gasket, nylon X Spacer,.344 x.750 x X Nut, hex M8 x Stud Bolt, M8 x 70* 1 13 X Line, flex. fuel 1/4 x X Clamp, insulating.44 in. (not shown) X Clamp, insulating.88 in. (not shown) X Screw, M8 x 1.25 (not shown) Pipe, fuel* X Clamp, hose Clamp, hose* 2 15 X Joint, pipe Gasket Bolt, w/plug and seal Plug Seal washer Seal washer Bolt, joint 1 1 *Variation 1 only: Use this part number before generator set serial number X Item not sold separately TP /05 31

32 Group 12: Governor Variation 1 Items not shown 13, A 32 TP /05

33 X Group 12: Governor Quantity Variation Part Number Item Number Description Cover, governor case Gasket, case cover Driving set, governor Weight assembly, governor (includes items 5-9) 1 5 X Weight 3 6 X Pin, governor weight 3 7 X Support Nut, governor weight Sleeve Link, 88.8 mm, no color Link, 88.6 mm, white Link, 89.0 mm, red Case assembly, governor (includes items 14-39) O-ring Case, governor Gasket, governor case Shim set Spacer assembly Shaft, governor lever Lever assembly, governor (includes items 21-30) Shim set 1 22 X Lever, tension 1 23 X Lever, governor 1 24 X Bushing Shifter Spring, starting Washer Circlip Spring pin Spring pin Retainer, shaft Retainer, shaft Shaft assembly, control 1 34 X Shaft 1 35 X Lever, regulator Taper pin Spring pin O-ring Bolt, M6 x 10 plated Nut, cap Spring, regulator 1 Item not sold separately TP /05 33

34 34 TP /05 Group 12: Governor, continued Variation A

35 X Group 12: Governor, continued Quantity Variation Part Number Item Number Description Lever, regulator Lock nut, M Torque spring assembly 1 45 X Pin, controller (not shown) 1 46 X Body, controller (not shown) 1 47 X Spring, controller (not shown) 1 48 X Shim set (not shown) 1 49 X Lock nut, M5 plated (not shown) Lever, stop Lock nut, M Screw, adjustment Nut, cap Snap pin Snap pin O-ring Bolt, M6 x 70 plated Bolt, M5 x 10 plated Bolt, M6 x 30 plated Lock nut, M6 plated Seal washer Seal washer Screw, stop Nut w/washer 1 Item not sold separately TP /05 35

36 Group 12: Governor, continued Variations 2 and 3 Items not shown 64, B 36 TP /05

37 X Group 12: Governor, continued Quantity Variation Part Number Item Number Description Nut, with washer Cover, governor case Gasket Bolt, M6 x Washer, 6 (not shown) Bolt, M6 x Driving set, governor (includes items 7-12) Weight assembly, governor (includes items 8-10) X Weight, governor X Pin, governor weight 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 17-43) O-ring X Case, governor Gasket Shim set Spacer assembly Shaft, governor lever Lever assembly, governor (includes items 24-34) Shim set X Lever, tension X Governor lever X Governor lever Spring, lever Shifter, PTO X Needle bearing Spring, starting Washer Circlip Spring pin, 3 x Retainer, shaft Retainer, shaft Shaft assembly, regulator (includes items 38-40) X Shaft, regulator X Lever, regulator X Taper pin, 3 x Spring pin, 4 x O-ring Bolt, M6 x Carb nut limit Spring, regulator Spring, regulator Lever, regulator Carb nut high idle Screw, adjustment Screw, adjustment Solenoid kit (includes item 50) O-ring Bolt, M6 x Fuel limiter X Shim set X Body X Pin X Spring, controller 1 1 Item not sold separately TP /05 37

38 Group 12: Governor, continued Variations 2 and 3 Items not shown 64, B 38 TP /05

39 X Group 12: Governor, continued Quantity Variation Part Number Item Number Description X Shim set X Circlip Angleich assembly (includes items 60-66) X Case, angleich X Shifter X Nut X Spring X Shim set (not shown) X Washer X Circlip (not shown) Washer, seal, 12S Pin, snap, Pin, snap, Bolt, M6 x Bolt, M5 x Bolt, M5 x Bolt, M6 x Nut, lock, M Washer, seal, X Plug, Plug, X Plug, Plug, Item not sold separately TP /05 39

40 Group 13: Starting Motor Items not shown 20, TP /05

41 Group 13: Starting Motor Quantity Variation Part Number Item Number Description Starter (includes items 3-21) Cover, terminal Stopper set, pinion Switch, magnetic Washer set, thrust Armature Cover assembly, rear Cover, rear Holder assembly, brush Brush (--) Brush (+) Spring, brush Cover kit, dust Lever set, shift Coil assembly, field Cover Through bolt Pinion Bolt Bolt, M10 x 30 plated Screw, pole core (not shown) Bolt, M4 x 12 (not shown) 2 TP /05 41

42 Group 14: Gasket Set Variation A 42 TP /05

43 Group 14: Gasket Set Quantity Variation Part Number Item Number Description Gasket set (Includes items 2-34) Gasket O-ring Seal, oil Shim set Seal, oil Gasket, lube oil pump O-ring O-ring Gasket Gasket O-ring O-ring O-ring Seal washer O-ring Gasket, cylinder head O-ring Gasket Gasket, bonnet Seal, valve stem Protector, nozzle Gasket, nozzle Gasket, intake manifold Gasket, exhaust manifold Gasket, C.W. pump Packing Gasket O-ring Gasket O-ring O-ring Seal washer Gasket, pump Gasket, liquid 1 TP /05 43

44 Group 14: Gasket Set, continued Variation , 20, B 44 TP /05

45 Group 14: Gasket Set, continued Quantity Variation Part Number Item Number Description Gasket set (includes items 2-22) Gasket, cylinder head O-ring O-ring O-ring Gasket O-ring Seal, valve stem Protector, nozzle Gasket, nozzle Gasket Gasket, bonnet Gasket, intake manifold Gasket, exhaust manifold Gasket, lube oil pump Gasket Gasket, C.W. pump Packing O-ring Gasket Gasket, pump Gasket Gasket, liquid 1 TP /05 45

46 Group 14: Gasket Set, continued Variation , C 46 TP /05

47 Group 14: Gasket Set, continued Quantity Variation Part Number Item 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 14, round O-ring O-ring O-ring O-ring O-ring O-ring Gasket, liquid 1 TP /05 47

48 Group 101: Air Intake 8 7 Item not shown Quantity Variation Part Number Item Number Description Cover, plastic Adapter, nylon hose Clip, air cleaner X Clamp, hose, 1 9/16 x 2 1/ X Clamp, hose,.5/1 in Hose, air intake Hose, molded air intake 1 6 X Clamp, hose Base, air cleaner Base, air cleaner Element, filter Element, filter Filter 1 9 # Nut, # X Spacer Bracket, air cleaner Bracket, air cleaner 1 11 X Screw, 1/4-20 x # Hardware, 1/ X Line, flex (not shown) 1 # Common hardware; procure locally. 48 TP /05

49 Group 103: Fuel System See Group 11 for additional fuel system parts Fuel Return Inlet Quantity Variation Part Number Item Number Description Pump, fuel Lead assembly X Elbow, street, 1/4 x 1/ X Connector, hose elbow X Clamp, hose X Line, fuel Bracket, fuel pump # Washer, 1/ X Screw, HC, M x X Nut, lock # Washer, 1/ X Grommet X Elbow, compression X Adapter, pipe 1/4 x 1/ X Plug, cap, 1/4 1 1 # Common hardware; procure locally. TP /05 49

50 Group 104: Cooling System To engine To mixing tube, item TP /05

51 Group 104: Cooling System Quantity Part Variation Number Item Number Description Guard, belt Guard, belt Guard, belt 1 2 X Grommet # Washer, 1/ Screw, wing Bracket, belt guard Bracket, belt guard Bracket, belt guard Bracket, belt guard Bracket, belt guard Bracket, belt guard Bracket, belt guard 1 7 X Washer, plain,.281 ID x.625 in. OD 1 8 X Clamp, insulated V-Belt, seawater pump GM13660 V-Belt, 26 in Pulley, pump drive X Washer (not shown) 3 11 # Washer, 7/ X Screw, HC, M See chart on page 54 Pump, seawater Bracket, seawater pump Bracket, seawater pump 1 15 X Screw, HC, M X Screw, HC 2 15 X Screw, HC 2 16 X Spacer X Spacer 2 16 X Spacer Manifold, exhaust Manifold, exhaust Neck, # Washer, 1/ M Screw, hex hd cap X Screw, hex hd cap 2 20 X Screw, hex hd cap Gasket, exhaust Tube, mixing # Washer, 5/ X Screw, 5/16-18 x 1, ref Thermostat Gasket, water outlet Cover, thermostat # Washer, 5/ X Screw, 5/16-8 x.875, ref Hose, coolant Hose, coolant 1 31 X Clamp, hose 1 15/16 x 1 3/ Hose, molded X Clamp, hose, 1 15/16 x 1 3/ Cover, thermostat Gasket, water outlet # Washer, 5/ X Screw, 5/16-8 x.875, ref Hose, molded Hose, molded Hose, molded 1 39 X Clamp, hose, 1 15/16 x 1 3/ Cover, thermostat Gasket, water outlet Exchanger, heat GM24940 End cap, heat exchanger (not shown) GM24941 Gasket, heat exchanger (not shown) Exchanger, heat (not shown) 1 42 GM15464 Cover, heat exchanger (not shown) 1 42 GM15465 Gasket, heat exchanger (not shown) Zinc anode # Common hardware; procure locally. TP /05 51

52 Group 104: Cooling System, continued To engine To mixing tube, item TP /05

53 Group 104: Cooling System, continued Quantity Part Variation Number Item Number Description X Hose Hose 1 45 X Clamp, hose, 1/2 x 1 13/ X Connector, hose X Connector, hose X Hose X Hose Hose, coolant Hose 1 50 X Clamp, hose, 1 15/16 x 1 3/ Bracket, heat exchanger X Clamp, insulated X Clamp, insulated 2 53 # Hardware, 1/ X Connector, hose, 5/8 x 3/ X Connector, hose, 5/8 x 3/ Bottle, overflow Bottle, overflow GM13621 Bracket, water bottle Bracket, water bottle 1 55 X Screw 2 56 X Clamp, hose X Hose Cap 1 1 # Common hardware; procure locally. TP /05 53

54 Group 104: Cooling System, continued Seawater Pump Component Parts Part Number Item Description Serial Numbers and before Serial Numbers and above 59 Pump, seawater (includes the following) Plate, cover N/A Gasket Impeller kit (includes 62 gasket) Bearing, ball N/A Housing N/A Pulley N/A Shaft, drive N/A GM Seal N/A GM Key, impeller end N/A GM Seat, ceramic N/A GM Refer to item 59 X N/A 71 Impeller N/A 72 Shaft, pump N/A 73 Cam N/A 74 Screw, M4 x 10 # N/A 75 Bearing N/A 76 Seal, oil N/A 77 Key, feather N/A 78 Drip, water N/A 79 Circlip, 15-S N/A 80 Circlip, 35-H N/A 81 Cover N/A 82 Gasket N/A 83 Screw, M4 x 8 # N/A 84 Cover, bearing N/A 85 V-pulley N/A 86 U-nut, M N/A 87 Washer N/A 88 Joint, 3/8 NPT N/A #Common Hardware. Procure Locally. Multiple seawater pump pulley failures on seawater pump number indicate shaft wear. Replace both the pulley and shaft using kit GM29437 to prevent future pulley failure. Pulley Replacement Kit Components 1 2 Top View End View 1. Pulley (344606) 2. Shaft (GM29438) 3. Whiz nut (GM29441) torqued to 28/30 ft. lbs. 4. Star washer (GM29440) 5. Flat washer (GM29439) TP /05

55 Notes TP /05 55

56 Group 105: Engine Items not shown 3, CCOZ models only To Oil Pan See Group To mixing tube, Group104 See Group 9, Cooling Water System for mounting hardware TP /05

57 Group 105: Engine Quantity Part Variation Number Item Number Description GR1 1 A Engine assembly (not shown; see Groups 1-14 for parts) (3TN66) A Engine assembly (not shown; see Groups 1-14 for parts) (3TNE68C) A Engine assembly (not shown; see Groups 1-14 for parts) (3TNE74C) Solenoid, fuel See Group 12, Governor, for solenoid on engine variations 25, 28, and Solenoid, fuel* Bracket, solenoid Bracket, solenoid* Spacer, (not shown)* 2 4 X Terminal X Washer, shakeproof, 1/ # Hardware, 1/ Ball joint Ball joint* 1 8 X-81-9 Nut, hex, 1/ X Stud Ball joint Ball joint* Spacer (not shown)* 1 10 X Screw, 1/4-28 x.50, ref.* 1 11 # Nut, 1/ X Washer, lock, 1/ X Hose X Hose 1 14 X Clamp, hose X Clamp, hose X Fitting, hose 2 16 X Cap, pipe 1 17 X Washer, plain X Washer, plain Valve, drain Valve, drain Valve, drain 1 18 X Plug, pipe Bushing, adapter 1 19 X Clip, hose # Hardware, 1/ Alternator X Nut, hex. M5 x X Spacer X Spacer 1 24 # Hardware, 5/ Switch, high temperature cutout X Screw, 3/8-16 x X Clamp, hose X Hose GM13660 V-belt, 25.5 in. (not shown, see Group 104) *Variation 18 only: Use this part number before generator set serial number # Common hardware; procure locally. TP /05 57

58 Group 107: Nameplate and Decals Quantity Part Variation Number Item Number Description Decal, warning Hot Coolant Decal, Notice Zinc Anode Decal, Notice Zinc Anode Decal, negative battery connection Decal, equipment ground Decal, equipment ground GM14167 Decal, drain Decal, warning, Rotating Parts Decal, number Decal, Coast Guard Decal, warning Hot Engine Nameplate X Rivet, pop X Decal Decal, reconnection Decal, CE Decal, danger high voltage 1 1 Nameplate and decals not illustrated. 58 TP /05

59 Group 109: Skid and Plant Mounting Quantity Variation Part Number Item Number Description Tray Bracket, engine mounting # Washer, 1/ X Screw, hex hd, M X Washer, lock, 7/ # Hardware, 5/ Vibromount X Washer, plain Strap, ground X Washer, shakeproof, 1/ # Hardware, 5/ # Hardware, 1/ X Connector, cable X Washer, lock, 1/ X Nut, elastic stop, 5/ # Common hardware; procure locally. TP /05 59

60 Group 201: Generator and Mounting Item 39 Field Exciter Measurements mm (1.0 in.) OldDesignwith1.0in.Pad (Part Number A ) mm (0.5 in.) New Design with 0.5 in. Pad (Part Number ) , TP /05

61 Group 201: Generator and Mounting Quantity Part Variation Number Item Number Description Stator assembly Guard, generator fan Clip, speed X Screw, tapping, Plate, locator Pin, knurled M Screw, M Disc, drive X Screw, 3/8-16 x Disc, drive M Screw, HC, M # Washer, 5/16 W Disc, fan locator Fan, generator X Nut, elastic stop, X Spacer A Rotor assembly (includes item 18) X Bearing, ball O-ring See note below Bracket, end Bracket, end Resistor assembly Resistor assembly 1 22 X Bracket, resistor mounting # Hardware, 1/ X Screw, RHM 8-32 x X Washer, resistor # Nut, 8/ X Washer, hardened X Screw, HC, M X Screw, HC, M Exciter, armature Exciter, armature X Washer, plain X Screw, 3/8-16 x X-22-1 Washer, lock A Circuit board, diode board X Terminal X-51-8 Screw, 8-32 x # Washers, # X Spacer X Screw, tapping, See note below Exciter assembly, field Exciter assembly, field X Screw, hex, Panel, end bracket X Screw, tapping, # Common hardware; procure locally. Note The replacement part numbers of the end bracket and field exciter assembly in variation 18 depend on the length of the field exciter s (item 39) mounting pad. Measure the pad after refering to the measurement points on the drawing insert on the opposite page. Use the adjacent table to determine the end bracket and exciter part numbers. Use the following table to determine replacement service part numbers. Service Part Numbers Approximate Length Replacement Part Number of Field Exciter Mounting Pad Item 20, End Bracket Item 39, Field Exciter mm (0.5 in.) mm (1.0 in.) Order kit * * Kit includes both the end bracket and field exciter. TP /05 61

62 Group 301: Controller and Mounting To generator case A TP /05

63 Group 301: Controller and Mounting Quantity Part Variation Number Item Number Description A Controller assembly 1 1 A Controller assembly (includes items 2--27) 1 1 A Controller assembly (includes items 2--27) 1 1 A Controller assembly (includes items 2--11, 14, ) Box, controller Box, controller Switch, rocker Switch, rocker Breaker, circuit, 10 amp Hourmeter X Screw, 6-32 x X-22-6 Washer, lock, # X-71-2 Nut, hex, BLK Plate, cover X Breaker, circuit 1 9 X Breaker, circuit 1 10 X Screw, 6-32 x # Nut, Mount, controller # Nut, 1/ Cover, controller X Screw, hex head, # Washer, # Strap, ground X Washer, shakeproof # Hardware, 1/ X Washer, lock 1/ X-81-8 Nut, hex 1/4-20, green # Bolt, 1/ X Washer, shakeproof, 1/ # Hardware, 1/ X Washer, lock, 1/ X Grommet, nylon Harness, controller Harness, controller (includes the following) Fuse, 10 amp Diode, 6 amp, 100 V Connector, 22-pin Connector, 6-pin Fuse, 8 amp Connector, 9-pin Fuse holder Connector, 15-pin Connector, 6-pin (P5) X-71-2 Nut, hex # Common hardware; procure locally. TP /05 63