GENSET

Marine Generator Sets

Models:

8C

8E

10C

10E

12.5C

12.5E

TP-5413 5/01c

Service Parts

Table of Contents

Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Numbering System Significance 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Illustrations 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Find Part Numbers 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hardware References 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specification Number Index 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 1: Gaskets and Seals 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 2: Cylinder Block 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 3: Cylinder Head and Valves 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 4: Front Cover Assembly 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 5: Camshaft and Valve Control 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 5: Camshaft and Valve Control 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 6: Crankshaft and Piston 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 6: Crankshaft and Piston 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 7: Flywheel and Clutch 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 8: Oil Pump and Pan 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 9: Fan and Water Pump 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 10: Intake Manifold 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 12: Ignition Module and Spark Plugs 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 101: Air Intake 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 103: Fuel System 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 104: Cooling System 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 105: Engine 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 107: Nameplate and Decals 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 108: Oil Pressure Switches 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 109: Skid and Plant Mounting 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 110: Water Temperature Switches 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 112: Starter 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 201: Generator and Mounting 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 301: Controller and Mounting 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 01: Literature 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A Abbreviations A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B Common Hardware Application Guidelines A-3. . . . . . . . . . . . . . . . . . . . . . . . .

Appendix C General Torque Specifications A-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix D Common Hardware Identification A-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix E Common Hardware List A-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1TP-5413 5/01

Introduction

This manual lists service replacement parts for8--12.5 kW generator sets.

At the time of print this manual applied to the generatorset specification (spec) numbers listed in theSpecification Number Index. On occasion this manualmay apply to specs not listed in the SpecificationNumber Index.

Information in this publication represents data availableat the time of print. Kohler Co. reserves the right tochange this publication and the products representedwithout notice and without any obligation or liabilitywhatsoever.

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 setspecs and groups.

Group Parts Lists. List the part numbers of parts in thegroups.

Kit Sections. List modules and accessories and theirparts.

Appendices. Include Abbreviations, CommonHardware Application Guidelines, General TorqueSpecifications, Common Hardware Identification, andCommon Hardware List.

x:in:004:002

Numbering System Significance

This manual uses the following numbering systems:

Specification Number. The product identificationnumber located on the generator set nameplate. Specnumbers break down into groups.

Group Number. A unique number representing a partsgroup needed to assemble a generator set function. Forexample, Group 101 is the Air Intake group.

Variation or Module Number. A group might haveseveral variations. Each variation performs the samefunction with different parts lists. For example, a 50 Hzgenerator alternator and a 60 Hz generator alternatorboth perform the same function, however, with differentparts. Each difference requires a group variation ormodule number.

Part Number. The part number identifies an individualassembly, subassembly, component, or accessory kit.

x:in:004:003:a

Illustrations

Illustrations (or exploded-view drawings) bestrepresenting the widest range of variations accompanymost groups in thismanual. Illustrations do not depict alldetails and may not show all parts. Do not useillustrations for assembly or disassembly instructions.

x:in:004:004

How to Find Part Numbers

Use the following steps to locate a service replacementpart.

1. Locate the generator set nameplate to identify thegenerator set spec number.

2. Locate a second generator set nameplate listingaccessories to identify installed modules. Onsomemodels the accessory nameplate ismountedinside the generator junction box.

3. Turn to the Specification Number Index. Thefirst column lists the generator set spec numbers.The headings identify the groups of parts thatmakeup the generator set.

4. Identify the group most likely to include theservice part number.

5. Find the group variation number at theintersection of the spec number row and the groupcolumn. Note the variation number.

6. Page forward to locate the group identified instep 4 or find the appropriate page in the Table ofContents.

7. Find the part on the illustration and note the itemnumber of the part or find the part description inthe parts list.

8. Select the part number that corresponds toyour group variation. The first column lists theillustration item number. Find the variationidentified in the Specification Number Index or themodule number found on the generator setnameplate in the appropriate column on the rightside of the parts list table. Find the quantity used atthe intersection of the item number row and thevariation column. A blank space at the intersectionmeans the variation/module does not use that partnumber.

x:in:004:005

Hardware References

Many common hardware items do not appear in partsmanuals or will appear as common hardware entries. Acommon 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 thefactory, use the Common Hardware List in the appendixto identify the common hardware part number andspecifications. See Common Hardware ApplicationGuidelines in the appendix for mating hardwareinstructions.

Some hardware items require a specific size or someother characteristic. In that case, use the part numberlisted in the text.

When replacing hardware, do not substitute inferiorgrade hardware. Replacement hardware grade shouldbe equal to or better than the grade of themanufacturers original hardware. Use the CommonHardware List in the appendix to identify the commonhardware hardness.

x:in:004:006

2 TP-5413 5/01

Specification Number Index

Group No. 1 2 3 4 5 6 7 8 9 10 12

Spec No. Variation Number

Group Title

8C/8E

PA-110302 1 1 1 1 1 1 1 1 1 1 1

PA-110303 3 3 1 1 1 3 3 3 1 1 1

PA-110305 3 3 1 1 1 3 3 3 1 1 1

PA-110306 3 3 1 1 1 3 3 3 1 1 1

PA-110307 3 3 1 1 1 3 3 3 1 1 1

PA-110308 3 3 1 1 1 3 3 3 1 1 1

PA-110309 3 3 1 1 1 3 3 3 1 1 1

PA-110310 3 3 1 1 1 3 3 3 1 1 1

PA-110311 2 2 2 1 2 2 2 2 1 1 1

PA-110312 2 2 2 1 2 2 2 2 1 1 1

GM17772-GA1 2 2 2 1 2 2 2 2 1 1 1

10C/10E

PA-110105 1 1 1 1 1 1 1 1 1 1 1

PA-110106 1 1 1 1 1 1 1 1 1 1 1

PA-110109 1 1 1 1 1 1 1 1 1 1 1

PA-110110 3 3 1 1 1 3 3 3 1 1 1

PA-110111 3 3 1 1 1 3 3 3 1 1 1

PA-110112 3 3 1 1 1 3 3 3 1 1 1

PA-110113 3 3 1 1 1 3 3 3 1 1 1

PA-110114 2 2 2 1 2 2 2 2 1 1 1

GM17772-GA2 2 2 2 1 2 2 2 2 1 1 1

12.5C/12.5E

PA-110205 2 2 2 1 2 2 2 2 1 1 1

PA-110206 2 2 2 1 2 2 2 2 1 1 1

PA-110209 2 2 2 1 2 2 2 2 1 1 1

PA-110210 2 2 2 1 2 2 2 2 1 1 1

PA-110211 2 2 2 1 2 2 2 2 1 1 1

PA-110212 2 2 2 1 2 2 2 2 1 1 1

GM17772-GA3 2 2 2 1 2 2 2 2 1 1 1

3TP-5413 5/01

Specification Number Index

Group No. 101 103 104 105 107 108 109 110 112 201 301 701

Spec No. Variation Number

Group Title

8C/8E

PA-110302 2 4 7 20 13 1 3 2 2 3 18 10

PA-110303 2 4 7 23 17 -- 3 2 2 3 19 10

PA-110305 2 4 7 23 26 -- 3 2 2 3 19 10

PA-110306 2 4 17 28 26 -- 3 2 2 3 24 10

PA-110307 6 12 18 31 28 -- 16 2 2 32 26 11

PA-110308 6 12 19 31 28 -- 16 2 2 32 27 11

PA-110309 6 17 19 31 30 -- 16 2 2 32 27 11

PA-110310 6 17 18 31 30 -- 16 2 2 32 26 11

PA-110311 6 17 19 32 48 -- 16 2 2 32 27 11

PA-110312 6 17 18 32 48 -- 16 2 2 32 26 11

GM17772-GA1 6 GR4 18 GR1 48 -- 16 2 2 32 GR2 11

10C/10E

PA-110105 2 4 7 5 2 1 3 2 2 7 3 10

PA-110106 2 4 11 20 13 1 3 2 2 7 14 10

PA-110109 2 4 11 20 13 1 3 2 2 7 16 10

PA-110110 2 4 7 23 17 -- 3 2 2 7 19 10

PA-110111 2 4 7 23 26 -- 3 2 2 7 19 10

PA-110112 6 12 18 29 28 -- 16 2 2 33 26 11

PA-110113 6 17 18 29 30 -- 16 2 2 33 26 11

PA-110114 6 17 18 33 48 -- 16 2 2 33 26 11

GM17772-GA2 6 GR4 18 GR1 48 -- 16 2 2 33 GR2 11

12.5C/12.5E

PA-110205 2 4 7 6 11 1 4 2 2 4 4 10

PA-110206 2 4 7 19 14 1 4 2 2 4 15 10

PA-110209 2 4 7 19 14 1 4 2 2 4 17 10

PA-110210 2 4 7 19 27 -- 4 2 2 4 17 10

PA-110211 6 12 18 30 29 -- 15 2 2 31 25 11

PA-110212 6 17 18 30 31 -- 15 2 2 31 25 11

GM17772-GA3 6 GR4 18 GR1 48 -- 15 2 2 31 GR3 11

4 TP-5413 5/01

Group 1: Gaskets and Seals

Upper and Lower Engine Gasket Kits (Items 2 and 3)do not include Items 4-9.Upper Gasket Kit does not include a cylinder head gasket.Order cylinder head gasket separately from Group 3.

Quantity

Variation Number

Item Part Number Description 1 2 3

1 224704 Engine gasket kit, complete 1 1

1 224705 Engine gasket kit, complete 1

2 224706 Engine gasket kit, upper 1 1

2 224707 Engine gasket kit, upper 1

3 279143 Engine gasket kit, lower 1 1

3 279145 Engine gasket kit, lower 1

4 246058 Gasket, fuel pump 1 1 1

5 224773 Gasket, water pump 1 1 1

6 279112 Seal, front cover 1 1 1

7 224722 Gasket, front cover 1 1 1

8 224748 Gasket, rear retainer 1

8 224749 Gasket, rear retainer 1 1

9 224782 Seal, crankshaft rear 1

9 276192 Seal, crankshaft rear 1 1

KO42802

KO42802

KO42802224704

5TP-5413 5/01

Group 2: Cylinder Block

Quantity

Variation Number


1 276194 Block, cylinder (basic) 1



2 224719 Block, cylinder (includes crank, pistons, rings, etc.) 1



3 279188 Plug, 41.6 mm 2 2 2

4 279187 Plug, 51 mm 1 1 1

5 # Plug, 1/4 NPT 3 3 3

6 # Plug, 1/4 NPT 1 1 1

7 279214 Plug, ball (oil gallery) 1 1 1

8 279193 Adapter 1 1 1

9 224726 Liner, cylinder 4 4

9 224727 Liner, cylinder 4

10 279173 Bolt, main bearing cap 6 10 10

11 224716 Transducer (speed sensor) 1 1 1

12 # Screw, M6 x 14 1 1 1

13 276456 Switch, oil pressure 1 1 1

# Common hardware; procure locally.

6 TP-5413 5/01

Group 3: Cylinder Head and Valves

Quantity

Variation Number

Item Part Number Description 1 2

1 GM24858 Cylinder head assembly 11 224723 Cylinder head assembly 12 224724 Gasket, cylinder head 12 224725 Gasket, cylinder head 13 224731 Bolt, cylinder head 10 104 224791 Dowel, cylinder head to block 2 25 224755 Valve, intake, standard 45 224757 Valve, intake, standard 45 224756 Valve, intake, 0.40 oversized 45 224758 Valve, intake, 0.40 oversized 46 224754 Valve, exhaust, standard 4 46 224753 Valve, exhaust, 0.40 oversized 4 47 224759 Spring, valve 8 88 224709 Seal, valve stem 8 89 224770 Retainer 8 8

10 224708 Lock, valve spring 16 1611 224762 Cover, rocker arm 1 112 279084 Gasket, rocker arm cover 1 113 224789 Screw, rocker cover/head 4 414 # Washer, flat, 6 mm 4 415 279188 Plug, 41.6 mm 1 116 279115 Cap, oil, breather 1 117 224730 Insert, exhaust valve seat 4 418 224728 Insert, intake valve seat 418 224729 Insert, intake valve seat 419 224794 Hose, PCV 1 1

7TP-5413 5/01

Group 4: Front Cover Assembly

Quantity

Variation Number

Item Part Number Description 1

1 224721 Cover and seal assembly 1

2 224722 Gasket, front cover 1

3 279111 Seal, front cover 1

4 # Bolt, M6 x 45 1

5 # Bolt, M6 x 40 3

6 # Bolt, M6 x 18 4

7 # Washer, split lock, B6 8


8 TP-5413 5/01

Group 5: Camshaft and Valve Control

9TP-5413 5/01

Group 5: Camshaft and Valve Control

Quantity

Variation Number


1 224739 Camshaft 1

1 224740 Camshaft 1

2 279155 Bearing, std. ID, std. OD 1 1

2 279156 Bearing, standard ID, 0.020 OD 1 1

3 279157 Bearing, standard ID, standard OD 1 1


4 279157 Bearing, standard ID, standard OD 1 1


5 279152 Pin, dowel 1 1

6 279160 Plate, thrust 1 1

7 279153 Retainer 1 1

8 # Bolt, M6 x 16 2 2

9 279067 Sprocket, camshaft 1 1

10 279154 Retainer 1 1

11 # Bolt, M8 x 16 2 2

12 279159 Chain 1 1

13 279171 Tensioner 1 1

14 # Bolt, M6 x 55 1 1

15 # Bolt, M6 x 16 1 1

16 # Washer, 1/4 split lock 2 2

17 279092 Arm, tensioner 1 1

18 279172 Pin 1 1

19 224752 Tappet, standard 8 8

20 224761 Rod, push valve 8 8

21 224760 Arm, valve rocker, right with screw 4 4

21 224771 Arm, valve rocker, left with screw 4 4

22 279163 Screw, self-locking 8 8

23 279081 Support, rocker arm shaft 4 4

24 # Washer, B10 x 20 x 2.5 4 4

25 224788 Bolt, rocker support 4 4

26 279164 Spring, locating 3 3

27 279091 Rocker arm shaft assembly 1 1

28 279170 Plug, rocker arm shaft, 11 mm 2 2

29 279085 Washer, spring 2 2

30 279048 Washer, flat 2 2

31 279055 Pin, cotter, 2.3 mm 2 2


10 TP-5413 5/01

Group 6: Crankshaft and Piston

11TP-5413 5/01

Group 6: Crankshaft and Piston

Quantity

Variation Number


1 224741 Crankshaft assembly 1

1 224742 Crankshaft assembly 1 1

2 224743 Main bearing, upper half, standard OD, standard ID 3 5 5

2 276193 Main bearing, lower half, standard OD, standard ID 3 5 5

2 224744 Main bearing standard OD, 0.005 undersized ID 3 5 5



2 224747 Main standard OD, 0.030 undersized ID 3 5 5

3 224768 Washer, main bearing, standard 2 2 2

3 224769 Washer, main bearing, 0.015 oversized 2 2 2

4 224701 Pulley, crankshaft 1 1 1

5 # Bolt, pulley/crankshaft 1 1 1

6 # Washer, pulley/crankshaft, B12 1 1 1

7 279112 Seal, timing cover 1 1 1

8 279189 Slinger, oil 1 1 1

9 279161 Sprocket 1 1 1

10 279169 Key, woodruff 1 1 1

11 224749 Gasket, rear retainer 1 1

11 224748 Gasket, rear retainer 1

12 279142 Rear retainer assembly bearing 1 1

12 279093 Rear retainer assembly 1

13 276192 Seal, crankshaft rear 1 1

13 224782 Seal, crankshaft rear 1

14 # Washer, lock, B8 4 4 4

15 # Bolt, M8 x 20 4 4 4

16 224735 Piston assembly, standard 4

16 224732 Piston assembly, standard 4 4

16 224736 Piston assembly, 0.020 oversized 4

16 224733 Piston assembly, 0.020 oversized 4 4

16 224737 Piston assembly, 0.040 oversized 4

16 224734 Piston assembly, 0.040 oversized 4 4

17 276437 Ring set, standard 4

17 276434 Ring set, standard 4 4

17 276438 Ring set, 0.020 oversized 4

17 276435 Ring set, 0.020 oversized 4 4

17 276439 Ring set, 0.040 oversized 4

17 276436 Ring set, 0.040 oversized 4 4

18 276440 Connecting rod assembly (see note below) 4 4 4

19 224738 Bolt, connecting rod 8 8 8

20 276441 Bearing, connecting rod, standard 8 8 8

20 276442 Bearing, connecting rod, 0.001 undersized 8 8 8



21 276445 Pin, connecting rod 8 8 8


Note: Verify correct part number of connecting rod with the engine serial number through Ford Motor Co.

12 TP-5413 5/01

Group 7: Flywheel and Clutch

Quantity

Variation Number


1 224750 Flywheel and ring gear assembly 1

1 224751 Flywheel and ring gear assembly 1 1

2 279190 Gear, ring 1 1 1

3 224780 Bolt, M10 x 22.5 5 6 6

4 224779 Dowel 3 3 3

5 224792 Dowel, flywheel and crankshaft 1 1 1

6 279053 Dowel 2 2 2

13TP-5413 5/01

Group 8: Oil Pump and Pan

Quantity

Variation Number


1 279191 Pump, oil 1 1 12 224790 Bolt 3 3 33 224787 Washer, lock, B8 3 3 34 224764 Gasket, oil pump 1 1 15 224763 Oil pickup tube assembly 1 1 16 279178 Rotor and shaft 1 1 17 279050 Seal, cover plate 1 1 18 279165 Gear, oil pump 1 1 19 279060 Pin, drive gear 1 1 1

10 279168 Plunger, oil pump 1 1 111 279167 Spring 1 1 112 279166 Plug 1 1 113 244766 Indicator, oil level 1 1 114 224767 Tube, oil level 1 1 115 326817 Filter, oil short (replaces filter 279218 which prohibits battery removal) 1 1 116 279087 Pan, oil 116 279141 Pan, oil 1 117 # Bolt, oil pan, M6 x 14 18 18 1818 # Washer, lock, 1/4 18 18 1819 279143 Kit, oil pan gasket 119 279145 Kit, oil pan gasket 1 120 224784 Plug, oil drain 1 1 121 224785 Gasket, oil drain plug 1 1 1

KO42802

KO42802224766

KO42802

14 TP-5413 5/01

Group 9: Fan and Water Pump

Additional cooling system components are listed inGroup 104 Cooling System.

2.75 in. (69.85 mm) or

3.00 in. (76.20 mm)

Impeller

End of

pump casting

Quantity

VariationNumber


1 254810 Connection, exhaust manifold, 90 1

2 279180 Gasket, connector 1

3 224772 Pump, water 3.00 in. (see chart below) 1

3 326618 Pump, water 2.75 in. (see chart below) 1

4 224773 Gasket, water pump 1

5 # Bolt, M6 x 40 (front cover and water pump to block) 3


Order service kit number 224300 when replacing the water pump on thegenerator set specifications listed in the chart below (kit includes pump224722). Models not listed in the chart use water pump part number224772 or 326618 as a replacement depending on the length of the pump.Measure thewater pump to determine the correct part number. See figureabove for measuring points.

Generator SpecNumber

Generator SerialNumber Prior To

PA-110302 286315

PA-110106/PA-110109 286315

PA-110206/PA-110209 295648

15TP-5413 5/01

Group 10: Intake ManifoldQuantity

VariationNumber


1 See Group 101 Gasket, intake manifold 1

2 # Bolt, M8 x 25 6

3 224786 Sensor, water temperature 1

4 See Group 101 Manifold, intake 1

NOTE: See Group 101 and Group 104 foradditional manifold components.

Group 12: Ignition Module and Spark Plugs

See Group 105 Engine foradditional ignition components.

Quantity

VariationNumber


1 224710 Coil and bracket assembly 1

2 # Screw, M8 x 14 3

3 224713 Wire, spark plug #1 1




7 224793 Separator, ignition wire 1

8 224715 Separator, ignition wire 1

9 # Screw, M4 x 10 1

10 224703 Spark plug 4


ko428021 224710 Coil and bracket assembly2 # Screw, M8 x 143 224713 Wire, spark plug #14 224711 Wire, spark plug #25 224712 Wire, spark plug #36 224714 Wire, spark plug #4

ko42802

ko42802Note: Order different part numbers for units with engine build date later than August/September 1998. See PB-95. Click here.

16 TP-5413 5/01

Group 101: Air Intake

5

4

3

2

1

6

7

8

Quantity

VariationNumber


1 X-276-5 Nut, wing, 8-32 3 3

2 X-50-13 Screw, 10-32 x 1/2 2 2

3 246067 Gasket, intake manifold 1 1

4 249900 Arrester, flame 1 1

5 249915 Manifold, intake 1 1

6 249918 Silencer 1 1

7 249928 Cover, air intake silencer 1 1

8 249954 Bracket, silencer 1 1

17TP-5413 5/01

Group 103: Fuel System

1

3

4

18

5

7

2

10

1112

9

14

15

8

Items not shown 6, 13

3

17

16

18, 19

20

21

Quantity

Variation Number

Item Part Number Description 4 12 17 GR4

1 A-344520 Carburetor assembly (see chart below) 1 1 1 12 X-400-75 Spacer, 1332 x 5/8 x 19/64 2 2 2 23 X-426-18 Clamp, hose, 7/8 2 2 2 24 X-431-38 Terminal, push-on, 1/4 M 1 1 1 15 X-509-1 Adapter, pipe, 1/4 F x 1/8 M 1 1 16 X-519-1 Plug, 1/8 NPT pipe, plastic (not shown) 1 1 16 X-519-10 Plug, 1/4 NPT pipe, plastic (not shown) 17 X-6251-1 Hose, 5/8 ID x 12 in. 1 1 17 X-6251-3 Hose 18 X-70-11 Nut, hex 10-32 1 1 1 19 246071 Lever assembly, throttle 1 1 1 1

10 249433 Filter, fuel 1 1 110 267987 Filter, fuel, 1/4 in. NPT 111 249902 Bracket, fuel pump 1 1 1 112 249931 Gasket, carburetor 1 1 1 113 249979 Tee, 11/64 ID hose, choke vacuum junction (not shown) 114 267428 Elbow, 45 street, 1/8 NPT 1 1 1 114 337553 Connector, hose 115 278490 Pump, fuel 1 1 1 116 X-19-4 Washer, lock, #10 split 2 2 2 217 X-125-28 Screw, 5/16-18 x 3 2 2 2 218 X-6238-7 Screw, 3/8-16 x 2 1/2 1 1 1 119 X-6238-17 Screw, 3/8-16 x 2 1/4 1 1 1 120 X-465-6 Screw, 1/4-20 x 1/2 2 2 2 2

21 X-25-72 Washer, plain 2 2 2 2

Carburetor Repair Parts

Kit Description Kit Number

Choke repair 249695Carburetor repair (includes *) 229370Antidieseling solenoid* 229377Gasket, carburetor* 249931Gasket, thermo case* 344252

18 TP-5413 5/01

Group 104: Cooling System

58

52

26

33

39

24

19

54

23

20

30

9

9

19

35

53

32

37

17

55

9

27

22

35

See Group 2. Original Ford cover

relocated to this position.

See Group 2.

9

22

34

56

56

31

8

8

7

38

57

7

43

44

4546

47

10

1

5

6

16

3

8

8

8

21

2

51

48

49

50

To intake manifold

8

4

11

12

40

38

14

15 42

25

28

29

3659

60

54

10

61

51

19TP-5413 5/01

Group 104: Cooling SystemQuantity

Variation Number

Item Part Number Description 7 11 17 18 19

1 X-211-10 Elbow, street 1 1 11 X-215-19 Elbow, pipe 1 11 X-217-6 Nipple, pipe (not shown) 1 12 X-284-39 Grommet 3 3 3 3 33 X-312-24 Hose 1 1 1 1 14 GM13756 Hose 1 1 1 1 15 X-380-3 Connector, hose 2 2 2 2 26 X-391-16 Connector, hose 1 1 1 1 17 X-391-26 Connector, 90 3 3 2 3 28 X-426-3 Clamp, hose 8 8 8 8 89 X-426-8 Clamp, hose 8 8 8 8 8

10 X-426-9 Clamp, hose 3 3 3 3 311 X-582-2 Connector, hose 2 2 2 2 212 M933-06016-60 Screw, hex cap, M6-1 x 16 mm 3 3 3 3 313 M933-08030-60 Screw, hex cap, M8-1.25 x 30 mm 2 2 2 2 214 M931-08120-60 Screw, hex cap, M8-1.25 x 120 mm 8 8 8 8 815 M933-08016-60 Screw, hex cap, M8-1.25 x 16 mm 1 1 1 1 116 X-651-24 Hose 1 1 1 1 117 X-672-22 Clamp, insulated 1 1 1 1 118 X-75-10 Plug, pipe, 3/8 (not shown) 1 1 1 1 119 X-75-48 Plug, pipe, 1 in. brass 2 2 2 2 220 X-75-49 Plug, pipe, 3/4 in. brass 1 1 1 1 121 229330 Screw, wing 3 3 3 3 322 229963 Gasket, water outlet 2 2 2 2 223 241311 Neck, 50 440 01 1 1 1 1 124 246060 Gasket, exhaust manifold 4 4 4 4 425 246062 Cap 1 1 1 1 126 249814 Hose, molded 1 1 1 1 127 249823 Hose, molded 1 1 1 1 128 249904 Tube, mixing 1 1 1 1 129 249905 Gasket, exhaust 1 1 1 1 130 249906 Hose, molded 2 2 2 2 231 249908 Hose, molded 1 1 1 1 132 249929 Exchanger, heat 1 1 1 1 132 229545 Gasket, end cap 1 1 1 1 132 GM17054 Cover, separator assembly 1 1 1 1 133 267928 Zinc anode, 1/4 NPT 1 1 1 1 134 249930 Thermostat 1 1 1 1 135 249942 Cover, thermostat 2 2 2 2 236 249960 Bracket, seawater pump 1 1 1 1 137 249987 Bracket, heat exchanger 1 1 1 1 138 249989 Belt, V 1 1 1 1 139 256979 Manifold, exhaust 1 1 1 1 140 260091 Pulley, water pump 1 1 1 1 142 249955 Bracket, belt guard 1 1 142 326799 Bracket, belt guard 1 143 See chart next page Pump, seawater 1 1 1 1 144 See chart next page Cover plate 1 1 1 1 145 See chart next page Gasket 1 1 1 1 146 See chart next page Impeller 1 1 1 1 147 See chart next page Ball bearing 1 1 1 1 148 See chart next page Housing 1 1 1 1 149 See chart next page Pulley 1 1 1 1 150 See chart next page Drive shaft 1 1 1 1 151 229052 Guard, belt 1 1 151 344259 Guard, belt 1 152 X-321-5 Hose 152 344581 Hose, molded 1 1 1 154 229980 Cap, manifold 1 1 1 1 155 X-465-16 Screw, 1/4-20 x 0.75 1 1 1 1 156 X-125-5 Screw, 5/16-18 x 1.00 1 1 2 2 257 X-391-27 Connector, 90 1 157 X-391-26 Connector, 90 1 1 158 X-391-2 Connector, hose 1 1 1 1 159 X-125-3 Screw, 5/16-18 x 0.75 1 1 1 1 160 X-125-23 Screw, 5/16-18 x 0.62 1 1 1 1 161 249396 Bottle, overflow 1 1 1 1 1

20 TP-5413 5/01

Group 104: Cooling System, continuedSeawater Pump Component Parts

Part Number

Item Description

Serial Numbers296898 and before

Serial Numbers296899 through

409896

Serial Numbers409897 and above

43 Seawater pump

Includes the following: 267373 344089 344371*

44 Cover plate N/A 344306 344306

45 Gasket 252475 344584 344584

46 Impeller kit, includes gasket 229955 229826 229826

47 Ball bearing N/A 344043 344043

48 Housing N/A 344585 344585

49 Pulley N/A 344606 N/A

50 Drive shaft N/A 344587 344587

51 Seal N/A GM16865 NA

Plug, plastic, 3/8 in. (not shown) N/A 344107 344107

Key (not shown) N/A GM17702 NA

* Replacement pump does not include a pulley. Order pulley part number 344606, if needed.

N/A Not available

21TP-5413 5/01

Notes

22 TP-5413 5/01

Group 105: Engine

19

53

10

24

25

2623

28

36

37

391

5

13

57

17

41

3

6

55

54

54

56

56

2

2

48

48

49

40

52

27

20

7

10

46

9

42

4716

22

35

1718

8

44

59

29

303132

33

34

See Group 301 for electronic governor controller

60

61

43

14

12

62

23TP-5413 5/01

Group 105: EngineQuantity

Part Variation Number

Item

PartNumber Description 5 6 19 20 23 28 29 30 31 32 33 GR1

1 B-260090 Engine assembly (Ford VSG-413) 1 1 1 1

1 A-246239 Engine assembly (Ford VSG-411) 1



1 B-229525 Engine assembly (Ford VSG-411) 1 1 1 1

1 C-260090 Engine assembly (Ford VSG-413) 1

2 X-101-9 Nut, elastic, 10-32 2 2 2 2 2 2 2 2 2 2 2 2

3 X-22-10 Washer, lock, 3/8 1 1 1 1 1 1 1 1 1 1 1 1

4 X-283-9 Terminal 1 1 1 1 1 1 1 1

5 X-284-2 Grommet, 1 5/8 1 1 1 1 1 1 1 1 1 1 1 1

6 X-352-79 Stud 1 1 1 1 1 1 1 1 1 1 1 1

7 X-380-3 Connector, hose 1 1 1 1 1 1 1 1 1 1 1 1

7 X-555-2 Fitting, elbow, 1/8 x 1/8 in. street 1

8 X-400-37 Spacer 3 3 3 3 3 3 3 3 3 3 3 3

9 X-426-3 Clamp, hose, 1/2-1 13/32 2 2 2 2 2 2 2 2 2 2 2 2

10 X-426-9 Clamp, hose 3 3 3 3 3 3 3 3 3 3 3 3

11 X-468-3 Tie, cable nylon 2 2 2 2 2 2 2 2 2 2 2 2

12 X-50-1 Screw, RHM, 10-32 5 5 5 5 5 5 5 5 5 5 5 5

13 X-50-3 Screw, RHM, 10-24 2 2 2 2 2 2 2 2 2 2 2 2

14 X-50-56 Screw, RHM, 10-32 x 1 2 2 2 2 2 2 2 2 2

15 X-50-6 Screw, RHM, 10-32 x 3 1 1 1 1 1 1 1 1 1 1 1 1

16 X-51-15 Screw, RHM, 8-32 1 1 1 1 1 1 1 1 1 1 1 1

17 M931-10040-60 Screw, hex cap 3 3 3 3 3 3 3 3 3 3 3 3

18 M931-10050-60 Screw, hex cap 2 2 2 2 2 2 2 2 2 2 2 2

19 X-651-3 Hose, rubber, 3/8 x 18 in. 1 1 1 1 1 1 1 1 1 1 1 1

20 X-651-13 Hose, rubber, 3/8 x 18 in. 1 1

20 226365 Hose, molded 1 1 1 1 1 1 1 1 1 1

21 246053 Hose, choke vacuum, cut to required length 1 1 1 1 1 1

22 229398 Support, engine 1 1 1 1 1 1 1 1 1 1 1 1

23 246054 Cap assembly, oil fill 1 1 1 1 1 1 1 1 1 1 1 1

24 246057 Tube, oil fill 1 1 1 1 1 1 1 1 1 1 1 1

25 246058 Gasket, fuel pump 1 1 1 1 1 1 1 1 1 1 1 1

26 246063 Cap, oil fill tube 1 1 1 1 1 1 1 1 1 1 1 1

27 246064 Pin, dowel 2 2 2 2 2 2 2 2 2 2 2 2

28 GM17891 Kit, ignition module service 1 1 1 1 1 1 1 1 1 1

29 249911 Harness, engine wiring 1 1

29 246277 Harness, engine wiring 1 1 1 1 1 1 1 1

29 344018 Harness, engine wiring 1 1

30 269366 Connector plug, 15 pos. 1 1 1 1 1 1 1 1 1 1 1 1

31 292371 Connector, jack 2 pos. 1 1 1 1 1 1 1 1 1 1 1 1

32 269190 Connector plug, 6 pos. 1 1 1 1 1 1 1 1 1 1

33 292370 Connector plug, 2 pos. 1 1 1 1 1 1 1 1 1 1 1 1

34 233959 Diode, 6 A, 100 V, inline 1 1 1 1 1 1 1 1 1 1 1 1

35 249912 Support, right engine 1 1

35 246279 Support, right engine 1 1 1 1 1 1 1 1 1 1

36 249384 Guard, adapter 1 1 1 1 1 1 1 1 1 1 1 1

37 249445 Bracket, lifting 1 1 1 1 1 1 1 1 1 1 1 1

38 See group 110 Switch, high temp. cutout 1 1 1 1 1 1 1 1 1 1 1 1

39 249889 Plate, rear engine support 1 1 1 1 1 1 1 1 1 1 1 1

40 249923 Actuator, linear 1 1 1 1 1 1 1 1 1 1 1 1

24 TP-5413 5/01

Group 105: Engine, continued

19

53

10

24

25

2623

28

36

37

391

5

13

57

17

41

3

6

55

54

54

56

56

2

2

48

48

49

40

52

27

20

7

10

46

9

42

4716

22

35

1718

8

44

59

29

303132

33

34

See Group 301 for electronic governor controller

60

61

43

14

12

62

25TP-5413 5/01

Group 105: Engine, continuedQuantity


Item

PartNumber Description 5 6 19 20 23 28 29 30 31 32 33 GR1

41 249927 Pickup, speed 1 1 1 1 1 1 1 1 1 1 1 1

42 249949 Bracket, governor mounting 1 1 1 1 1 1 1 1 1 1 1

42 GM17821 Bracket, governor mounting 1

43 249990 Bracket, governor mounting 1 1 1 1 1 1 1 1 1 1 1

43 GM17822 Bracket, MAP module mounting 1

44 249938 Bracket, lifting eye 1 1

44 254809 Bracket, lifting eye 1 1 1 1 1 1 1 1 1 1

45 See group 110 Switch, high temperature 1 1 1 1 1 1 1 1 1 1 1 1

46260106 Hose, molded,

cut off 2 1/2 for proper fit on some models 1 1 1 1 1 1 1 1 1 1 1 1

47 267959 Clip, hose 1 1 1 1 1 1 1 1 1 1 1 1

48 272456 Rod, end 2 2 2 2 2 2 2 2 2 2 2 2

49 273751 Yoke 1 1 1 1 1 1 1 1 1 1 1 1

50 276317 Washer, nylon 1 1 1 1 1 1 1 1 1 1 1 1

51 276552 Washer, nylon 1 1 1 1 1 1

52 X-465-16 Screw, 1/4-20 x .75 1 1 1 1 1 1 1 1 1 1 1 1

53 344826 Valve, oil drain 1 1 1 1 1 1 1 1 1 1 1 1

54 X-50-70 Screw, PHM 2 2 2 2 2 2 2 2 2 2 2 2

55 X-70-11 Nut, hex, 10-32 2 2 2 2 2 2 2 2 2 2 2 2

56 X-25-115 Washer, plain 3 3 3 3 3 3 3 3 3 3 3 3

57 M933-08020-60 Screw, hex head cap 2 2 2 2 2 2 2 2 2 2 2 2

59 226884 Harness, wiring (Ford engine) 1 1 1 1 1

59 246068 Harness, wiring (Ford engine) 1 1 1 1 1 1

59 GM17770 Harness, wiring (Ford engine) 1

60 GM17769 Module, ignition control 1

61 GM17771 Manifold, air pressure module 1

62 X-50-25 Screw, slotted round head machine 2

26 TP-5413 5/01

Group 107: Nameplate and Decals

2

3

6

8

9

10

11

12

13

14 15

16

1718

19

2021

21

8

1

1

11

23

24

24

27TP-5413 5/01

Group 107: Nameplate and DecalsQuantity

Variation Number

Item Part Number Description 2 13 14 17 26 27 28 29 30 31 48

1 X-6246-9 Decal, Kohler logo 1 1 1

1 X-6246-6 Decal, Kohler logo 1 1

1 249882 Kohler nameplate 1 1 1 1 1 1

2 X-793-3 Rivet, pop 4 4

3 224233 Decal, 1-800 number 1 1 1 1 1 1 1 1 1 1 1

4 226892 Decal, emission (not shown) 1

4 226888 Decal, emission (not shown) 1 1

5 Not Available Nameplate 1 1 1 1 1 1 1 1 1 1 1

6 238162 Decal, positive battery connection 1 1 1 1 1 1 1 1 1 1 1

7 Not Available Nameplate, serial number 4 4 4 4 4 4 5 5 5 5 4

8 239796 Decal, carbon monoxide warning 1 1 1 1 1 1 1 1 1 1 1

9 226917 Decal, negative battery connection 1 1 1 1 1 1 1 1 1 1 1

10 241812 Decal, UL 1 1 1 1 1

11 246099 Decal, instruction connection diagram 1 1 1 1 1 1 1 1 1 1 1

12 249494 Decal, warning explosion 1 1 1 1 1 1 1 1 1 1 1

13 249808 Decal, warning rotating parts 1 1 1 1 1 1 1 1 1 1 1

14 249809 Decal, warning hot engine 1 1 1 1 1 1 1 1 1 1 1

15 249810 Decal, warning hot coolant 1 1 1 1 1 1 1 1 1 1 1

16 267468 Decal, Coast Guard 1 1 1 1 1 1 1 1 1 1

17 246274 Decal, notice zinc anode 1 1 1 1 1 1

17 344282 Decal, notice zinc anode 1 1 1 1 1

18 344283 Decal notice loosen cover 1 1 1 1 1

19 280561 Decal, water drain 1 1 1 1 1 1

20 280562 Decal, oil drain 1 1 1 1 1 1

21 290435 Decal, equipment ground 1 1 1 1 1 1

21 344295 Decal, equipment ground 1 1 1 1 1

22 344588 Decal, CE 1 1 1 1 1

23 266450 Decal, coolant drain 1 1 1 1 1 1

24 267464 Decal, battery spark 1 1 1 1 1 1 1 1 1 1

25 GM11932 Decal, emissions 1

26 GM14167 Decal, drain 2 2 2 2 2

28 TP-5413 5/01

Group 108: Oil Pressure Switches

Quantity

VariationNumber


1 X-202-27 Bushing, reducer, 1/8-1/4 1

2 267408 Switch, low oil pressure sender 1

271662 Switch, low oil pressure, standard 1

For generator set spec PA-110209 with serial number less than 318941,replace adapter, pressure switch 271662, and terminal X-283-3 of wiringharness with 8-32 hex nut X-72-4, terminal X-283-7, and pressure switch276456.

29TP-5413 5/01

Group 109: Skid and Plant Mounting

8

4

2

1

6

7

1314

3

12

3

12

10

15

15

15

5

9

Quantity

Variation Number

Item Part Number Description 3 4 15 16

1 X-22-12 Washer, lock, 1/4 I/E tooth 2 2 2 2



4 X-25-20 Washer, plain 2 2 2 2

5 X-25-96 Washer, plain 4 4 4 4

6 X-377-11 Connector, cable 1 1 1 1

7 M933-10025-60 Screw, hex head cap 2 2 2 2

8 249948 Tray 1

8 249947 Tray 1 1 1

9 278322 Mount, vibro 4 4 4 4

10 290418 Strap, ground 1 1 1 1

12 X-125-3 Screw, 5/16-18 x .75 2 2 2 2

13 # Hardware, 1/4-20 1 1 1 1

14 X-25-53 Washer, plain 1 1 1 1

15 # Hardware, 5/16-18 12 12 12 12


30 TP-5413 5/01

Group 110: Water Temperature Switches

4

Quantity

VariationNumber


1 # Washer, split lock, 3/8 1

2 X-6238-10 Screw, 3/8-16 x 3/4 1

3 249872 Switch, high exhaust temperature 1

4 255241 Switch, high water temperature, standard 1

4 249943 Switch, high water temperature 2-terminal, red, gauge sender (optional) 1

5 249959 Adapter 1

5 276552 Washer, nylon (not shown) 1

5 X-75-10 Plug, pipe (not shown) 1

31TP-5413 5/01

Group 112: Starter

1

2 3

4

5

6

7

8

9

10

Quantity

Item Part Number Description

VariationNumber

1 X-22-11 Washer, lock, 1/4 1

2 X-22-12 Washer, shakeproof, 1/4 2

3 X-545-77 Cable, battery 1

4 X-55-27 Screw, socket head 2

5 238915 Boot 2

6 246056 Starter 1

7 249371 Spacer, starter 1

8 291891 Solenoid, starter 1

9 # Nut, 10-32 2

10 # Hardware, 1/4-20 2

11 X-6003-71 Conduit, convoluted (not shown) 1


32 TP-5413 5/01

Group 201: Generator and Mounting

1

B

B

2

3

4

8

13

27

12

16

7

5

6

15

14

10

2132

11

9

23

18

19

2825

2926

749

2224

20

30

31

8

33TP-5413 5/01

Group 201: Generator and MountingQuantity

Variation Number

Item Part Number Description 3 4 7 31 32 33

1 A-344248 Rotor assembly 1 1



2 See chart below Ball bearing (see note below) 1 1 1 1 1 1

3 241671 Ring collector 1 1 1 1 1 1

4 X-22-11 Washer, lock, 1/4 10 10 10 10 10 10

5 X-400-156 Spacer 8 8 8 8 8 8

6 X-400-31 Spacer, 1/20 x 9/32 x 1/4 8 8 8 8 8 8

7 M933-08016-60 Screw, hex head cap 6 6 6 6 6 6

8 X-67-113 Screw, self-tapping 2 2 2 2 2 2

9 229239 Washer, special 2 2 2 2 2 2

10 238211 Ring, tolerance 1 1

10 256466 O-ring 1 1

11 238246 Bolt, over 4 4 4 4

11 249401 Bolt, over 4 4

12 239646 Fan, generator 1 1 1 1 1 1

13 246074 Adapter, generator 1 1 1 1 1 1

14 249895 Stator assembly 1 1



15 256872 Disc, armature drive 1 1 1 1 1 1

16 256873 Disc, armature drive 1 1 1 1 1 1

17 A-344129 Bracket assembly, end 1 1 1 1 1 1

18 X-22-6 Washer, lock, #6 2 2 2 2 2 2

19 X-49-1 Screw, RHM, 6-32 x 5 2 2 2 2 2 2

20 X-6079-2 Tube, heat shrink 2 2 2 2 2 2

21 X-634-12 Bushing 2 2 2 2 2 2

22 X-67-113 Screw, self-tapping 4 4 4 4 4 4

23 X-97-13 Screw, hex head 3 3 3 3 3 3

24 229335 Bracket, brush holder 1 1 1 1 1 1

25 238150 Spring 2 2 2 2 2 2

26 238247 Retainer, wire 1 1 1 1 1 1

27 238248 Shim, brush holder 3 3 3 3 3 3

28 239247 Holder, brush 1 1 1 1 1 1

29 239282 Brush 2 2 2 2 2 2

30 278427 Gasket, cover 1 1 1 1 1 1

31 278804 Cover, brush holder 1 1 1 1 1 1

32 344128 Bracket, end 1 1 1 1 1 1

Generator End Bracket Identification

Kohler Co. introduced a design change to improve end bracket andbearing life. New end brackets are identified by 1) a notched bearingwhich requires a pin and 2) a letter P stamped on the outside of the endbracket. Choose the correct bearing from the chart below.

Part Number

Generator End Bracket Bearing New End Bracket

Stamped with the letter P X-758-17 344128

Not stamped with the letter P X-758-1 --

34 TP-5413 5/01

Group 301: Controller and Mounting

45, 46, 47

2

Quantity

Variation Number

Item Part Number Description 3 4 14 15 16 17 18 19 24 25 26 27 GR2 GR3

1 A-249913 Controller assembly 1


1 A-229524 Controller assembly 1 1 1 1 1




1 A-344278 Controller assembly 1 1 1 1

35TP-5413 5/01

Group 301: Controller and MountingQuantity


Item

PartNumber Description 3 4 14 15 16 17 18 19 24 25 26 27 GR2 GR3

2 C-239753 Regulator assembly, voltage 1 12 F-278598 Regulator assembly, voltage (PB3E) 1 1 1 1 1 1 1 1 1 1 1 13 # Washer, #8, split lock 8 8 8 8 8 8 8 8 8 8 8 8 8 84 # Washer, split lock, 1/4 8 8 8 8 8 8 8 8 8 8 8 85 X-22-12 Washer, int. tooth, 1/4 1 1 1 1 1 1 1 1 1 1 1 1 1 16 X-51-5 Screw, 8-32 x 7/16 4 4 4 4 4 4 4 4 4 4 4 4 4 47 X-6033-5 Grommet, nylon 1 1 1 1 1 1 1 1 1 1 1 1 1 18 # Nut, 8-32 4 4 4 4 4 4 4 4 4 4 4 4 4 49 # Nut, 1/4-20 10 10 10 10 10 10 10 10 10 10 10 10 10 10

10 241769 Mount, controller 4 410 246267 Mount, controller 4 4 4 4 4 4 4 4 4 4 4 411 249939 Bracket, controller 111 249940 Bracket, controller 111 246275 Bracket, controller 1 1 1 1 1 1 1 111 246276 Bracket, controller 1 1 1 112 249986 Spacer, 8-32 x 25/32 4 4 4 4 4 4 4 4 4 4 4 4 4 413 B-249812 PCB assembly, overspeed 1 1 1 1 1 1 1 1 1 1 1 1 1 114 A-249922 PCB assembly, electronic governor 1 1 1 1 1 1 1 1 1 1 1 1 1 115 H-239563 PCB assembly, relay 1 1 1 1 1 1 1 1 1 1 1 1 1 116 # Washer, #6, split lock 19 19 19 19 19 19 19 19 19 19 19 19 19 1917 # Washer, #8, split lock 3 3 3 3 3 3 3 3 3 3 3 3 3 318 X-22-11 Washer, split lock, 1/4 2 2 2 2 2 2 2 2 2 2 2 2 2 219 X-22-12 Washer, int. tooth, 1/4 3 3 3 3 3 3 3 3 3 3 3 3 3 320 X-49-25 Screw, 6-32 x 1/4 4 4 4 4 4 4 4 4 4 4 4 4 4 421 X-49-25 Screw, 6-32 x 1/4 18 18 18 18 18 18 18 18 18 18 18 18 18 1822 X-49-26 Screw, 6-32 x 1/2 2 2 2 2 2 2 2 2 2 2 2 2 2 223 X-49-6 Screw, 6-32 x 3/4 4 4 4 4 4 4 4 4 4 4 4 4 4 424 X-506-37 Breaker, circuit, 40 amp 124 X-506-38 Breaker, circuit, 50 amp 124 X-506-39 Breaker, circuit, 33 amp 124 X-506-48 Breaker, circuit, 70 amp 1 124 245264-BLK Plate, cover (not shown) 1 1 1 1 1 1 1 1 124 229183 Plate, cover (not shown) 1 124 249956 Terminal, jumper (not shown)25 X-51-15 Screw, 8-32 x 1/2 3 3 3 3 3 3 3 3 3 3 3 3 3 326 X-6033-4 Grommet, nylon 1 1 1 1 1 1 1 1 1 1 1 1 1 127 X-6046-1 Strap, ground 1 1 1 1 1 1 1 1 1 1 1 1 1 128 X-6216-1 Screw, 10-24 x 1/2 4 4 4 4 4 4 4 4 2 4 4 2 4 429 X-71-2 Nut, 6-32 6 6 6 6 6 6 6 6 6 6 6 6 6 630 X-72-4 Nut, 8-32 3 3 3 3 3 3 3 3 3 3 3 3 3 331 # Nut, 1/4-20 3 3 3 3 3 3 3 3 3 3 3 3 3 332 X-81-8 Nut, 1/4-20, green 1 1 1 1 1 1 1 1 1 1 1 1 1 133 223316 Fuse, 10 amp 2 2 2 2 2 2 2 2 2 2 2 2 2 234 238426 Holder, fuse 3 3 3 3 3 3 3 3 3 3 3 3 3 335 238736 Hourmeter 1 1 1 1 1 1 1 1 1 1 1 1 1 136 239651 Diode, bridge 35 A, 600 V 1 1 1 1 1 1 1 1 1 1 1 1 1 136 246465 Heat sink 1 1 1 1 1 1 1 1 1 1 1 137 239665 Washer, nylon 5 538 249406 Switch, rocker 1 1 1 1 1 1 1 1 1 1 1 138 229997 Switch, rocker 1 139 249924 Cover, controller 1 1 1 1 1 1 1 1 1 1 1 1 1 140 249925 Box, controller 1 1 1 1 1 1 1 140 344007 Box, controller 140 344287 Box, controller 1 1 1 140 344262 Box, controller 141 249950 Harness, wiring 1 1 1 1 1 1 1 1 1 1 1 141 344010 Harness, wiring 1 142 267491 Screw, 1/4-20 x 1, grade 5, full thread 2 2 2 2 2 2 2 2 2 2 2 2 2 243 283645 Fuse, 15 amp 1 1 1 1 1 1 1 1 1 1 1 1 1 144 287948 Spacer 9 9 9 9 9 9 9 9 9 9 9 9 9 945 X-49-2 Screw, 6-32 x .375 2 246 248362 Relay 2 247 287571 Adapter, tab, relay terminal A 1 1


36 TP-5413 5/01

Group 701: LiteratureQuantity

VariationNumber


1 TP-5346 Service Manual, Ford VSG-411/413 Engine 1 1

2 TP-5399 Operation Manual, 8/10/12.5C Generator Sets 1

2 TP-5811 Operation Manual, 8/10/12.5E Generator Sets 1

3 TP-5414 Service Manual, 8/10/12.5C Generator Sets 1 1

4 TP-5413 Parts Catalog, 8/10/12.5C Generator Sets 1 1

5 TP-5620 Marine Safety Precautions 1 1

37TP-5413 5/01

Accessories

Qty. Description Part No.

Circuit Breaker GM13207-KP11 Installation Instructions TT-8751 Breaker, circuit, 85 amp X-506-701 Plate, cover 2291831 Decal, notice 246242

Circuit Breaker PA-2291861 Installation Instructions TT-8751 Breaker, circuit, 70 amp X-506-481 Plate, cover 2291831 Decal, notice 246242

Circuit Breaker PA-2293931 Installation Instructions TT-8751 Breaker, circuit, 42 amp X-506-431 Decal, notice 2462421 Terminal, jumper 249956



Circuit Breaker PA-3440531 Installation Instructions TT-8751 Breaker, circuit, 50 amp X-506-381 Decal, notice 246242



Fuel Pump PA-2291721 Installation Instructions TT-8513 Nut, lock X-101-251 Bushing, reducer X-202-279 Washer X-25-403 Grommet X-284-291 Connector, 90 deg. (1/4 ID hose) X-391-201 Elbow, street X-555-21 Bracket, mounting 2290501 Pump, fuel 2290511 Lead assembly 229168

Harness, Extension (25 ft.) PA-3440131 Harness 344013

Harness, Extension (12 ft.) PA-3440141 Harness 344014

Harness, Fire System Interface PA-2298331 Harness, wiring 2298321 Installation Instructions TT-930

Harness, Remote 12-in. Pigtail PA-2499411 Harness extension 249935


Harness for Remote Panel (15 ft.) PA-2493341 Strap, wire, 5/8 X-526-31 Harness, extension 249334

Harness for Remote Panel (25 ft.) PA-2493361 Strap, wire, 5/8 X-526-31 Harness, extension 249336

Panel, Remote Start PA-2507971 Installation Instructions TT-6421 Decal, warning 2494941 Panel assembly A-250795

Includes the following:1 Connector plug, 6-position 2416171 Panel, remote 2507961 Switch, rocker 269296

Panel Kit, Remote Start and 4-Meter PAA-2674141 Decal, warning 2494941 Panel assembly, control A--2674141 Switch, rocker 2493301 Panel, meter 2494191 Gauge, oil pressure 2494381 Gauge, water temperature 2494401 Hourmeter 2494611 Voltmeter 2494621 Harness, panel 249467

Panel Kit, Remote Start and 2-Meter PAA-2674151 Decal, warning 2494941 Panel assembly, control A--2674151 Switch, rocker 2493301 Harness, panel 2493311 Panel, meter 2493321 Gauge, oil pressure 2494381 Gauge, water temperature 249440

Panel, Remote Start and 2-Meter PA-3440401 Installation Instructions TT-10721 Decal, warning 2494941 Panel assembly A-344033

Includes the following:1 Panel 3440291 Harness, wiring 3440311 Gauge, water temperature 3440351 Gauge, oil pressure 3440361 Switch, rocker 344039


Includes the following:1 Panel 3440301 Harness, wiring 3440321 Gauge, water temperature 3440351 Gauge, oil pressure 3440361 Voltmeter 3440371 Hourmeter 3440381 Switch, rocker 344039


Includes the following:1 Panel, control 2269641 Harness, wiring 2269791 Hourmeter 2387361 Switch, rocker 1 pole 344039

38 TP-5413 5/01

Accessories


Sender, Oil/Water Temperature PA-2295411 Installation Instructions TT-9141 Bushing, reducer, 1/8 x 1/4 X-202-271 Switch, high temperature 2499431 Switch, oil pressure sender 267408

Siphon Break PA-2299281 Installation Instructions TT-9271 Valve, siphon break 229928

Siphon Break PA-2679651 Installation Instructions TT-7151 Valve, siphon break 267935

Strainer, Seawater X-661-1

Switch, Ship-to-Shore,110/120V, 2 Wire PAA-2466141 Installation Instructions TT-5351 Switch, transfer 344490

Switch, Ship-to-Shore,110/120 V, 2 Wire or 220/240 V, 3 Wire PAA-2466171 Installation Instructions TT-5351 Switch, transfer A-246617

White Paint (1 Gallon Can) 221334

White Paint (Aerosol Can) 221335

White Paint (Touch-Up Bottle) GM19490

TP-5413 5/01 Appendix A-1

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampere

ABDC after bottom dead center

AC alternating current

A/D analog to digital

ADC analog to digital converter

adj. adjust, adjustment

ADV advertising dimensionaldrawing

AHWT anticipatory high watertemperature

AISI American Iron and SteelInstitute

ALOP anticipatory low oil pressure

alt. alternator

Al aluminum

ANSI American National StandardsInstitute(formerly American StandardsAssociation, ASA)

AO anticipatory only

API American Petroleum Institute

approx. approximate, approximately

AR as required, as requested

AS as supplied, as stated, assuggested

ASE American Society of Engineers

ASME American Society ofMechanical Engineers

assy. assembly

ASTM American Society for TestingMaterials

ATDC after top dead center

ATS automatic transfer switch

auto. automatic

aux. auxiliary

A/V audiovisual

avg. average

AVR automatic voltage regulator

AWG American Wire Gauge

AWM appliance wiring material

bat. battery

BBDC before bottom dead center

BC battery charger, batterycharging

BCA battery charging alternator

BCI Battery Council International

BDC before dead center

BHP brake horsepower

blk. black (paint color), block(engine)

blk. htr. block heater

BMEP brake mean effective pressure

bps bits per second

br. brass

BTDC before top dead center

Btu British thermal unit

Btu/min. British thermal units per minute

C Celsius, centigrade

cal. calorie

CARB California Air Resources Board

CB circuit breaker

cc cubic centimeter

CCA cold cranking amps

ccw. counterclockwise

CEC Canadian Electrical Code

cfh cubic feet per hour

cfm cubic feet per minute

CG center of gravity

CID cubic inch displacement

CL centerline

cm centimeter

CMOS complementary metal oxidesubstrate (semiconductor)

cogen. cogeneration

Com communications (port)

conn. connection

cont. continued

CPVC chlorinated polyvinyl chloride

crit. critical

CRT cathode ray tube

CSA Canadian StandardsAssociation

CT current transformer

Cu copper

cu. in. cubic inch

cw. clockwise

CWC city water-cooled

cyl. cylinder

D/A digital to analog

DAC digital to analog converter

dB decibel

dBA decibel (A weighted)

DC direct current

DCR direct current resistance

deg., degree

dept. department

dia. diameter

DI/EO dual inlet/end outlet

DIN Deutsches Institut fur Normunge. V.(also Deutsche IndustrieNormenausschuss)

DIP dual inline package

DPDT double-pole, double-throw

DPST double-pole, single-throw

DS disconnect switch

DVR digital voltage regulator

E, emer. emergency (power source)

EDI electronic data interchange

EFR emergency frequency relay

e.g. for example (exempli gratia)

EG electronic governor

EGSA Electrical Generating SystemsAssociation

EIA Electronic IndustriesAssociation

EI/EO end inlet/end outlet

EMI electromagnetic interference

emiss. emission

eng. engine

EPA Environmental ProtectionAgency

EPS emergency power system

ER emergency relay

ES engineering special,engineered special

ESD electrostatic discharge

est. estimated

E-Stop emergency stop

etc. et cetera (and so forth)

exh. exhaust

ext. external

F Fahrenheit, female

fglass. fiberglass

FHM flat head machine (screw)

fl. oz. fluid ounce

flex. flexible

freq. frequency

FS full scale

ft. foot, feet

ft. lbs. foot pounds (torque)

ft./min. feet per minute

g gram

ga. gauge (meters, wire size)

gal. gallon

gen. generator

genset generator set

GFI ground fault interrupter

GND, ground

gov. governor

gph gallons per hour

gpm gallons per minute

gr. grade, gross

GRD equipment ground

gr. wt. gross weight

H x W x D height by width by depth

HC hex cap

HCHT high cylinder head temperature

HD heavy duty

HET high exhaust temperature

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 airconditioning

HWT high water temperature

Hz hertz (cycles per second)

IC integrated circuit

ID inside diameter, identification

IEC International ElectrotechnicalCommission

IEEE Institute of Electrical andElectronics Engineers

IMS improved motor starting

in. inch

in. H2O inches of water

in. Hg inches of mercury

in. lbs. inch pounds

Inc. incorporated

ind. industrial

int. internal

int./ext. internal/external

I/O input/output

IP iron pipe

ISO International Organization forStandardization

J joule

JIS Japanese Industry Standard

k kilo (1000)

K kelvin

kA kiloampere

KB kilobyte (210 bytes)

TP-5413 5/01A-2 Appendix

kg kilogram

kg/cm2 kilograms per squarecentimeter

kgm kilogram-meter

kg/m3 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

L liter

LAN local area network

L x W x H length by width by height

lb. pound, pounds

lbm/ft3 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

Lwa sound power level, A weighted

LWL low water level

LWT low water temperature

m meter, milli (1/1000)

M mega (106 when used with SIunits), male

m3 cubic meter

m3/min. cubic meters per minute

mA milliampere

man. manual

max. maximum

MB megabyte (220 bytes)

MCM one thousand circular mils

MCCB molded-case circuit breaker

meggar megohmmeter

MHz megahertz

mi. mile

mil one one-thousandth of an inch

min. minimum, minute

misc. miscellaneous

MJ megajoule

mJ millijoule

mm millimeter

mOhm, mmilliohm

MOhm, Mmegohm

MOV metal oxide varistor

MPa megapascal

mpg miles per gallon

mph miles per hour

MS military standard

m/sec. meters per second

MTBF mean time between failure

MTBO mean time between overhauls

mtg. mounting

MW megawatt

mW milliwatt

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 ElectricalManufacturers Association

NFPA National Fire ProtectionAssociation

Nm newton meter

NO normally open

no., nos. number, numbers

NPS National Pipe, Straight

NPSC National Pipe, Straight-coupling

NPT National Standard taper pipethread per general use

NPTF National Pipe, Taper-Fine

NR not required, normal relay

ns nanosecond

OC overcrank

OD outside diameter

OEM original equipmentmanufacturer

OF overfrequency

opt. option, optional

OS oversize, overspeed

OSHA Occupational Safety and HealthAdministration

OV overvoltage

oz. ounce

p., pp. page, pages

PC personal computer

PCB printed circuit board

pF picofarad

PF power factor

ph., phase

PHC Phillips head crimptite (screw)

PHH Phillips hex head (screw)

PHM pan head machine (screw)

PLC programmable logic control

PMG permanent-magnet generator

pot potentiometer, potential

ppm parts per million

PROM programmable read-onlymemory

psi pounds per square inch

pt. pint

PTC positive temperature coefficient

PTO power takeoff

PVC polyvinyl chloride

qt. quart

qty. quantity

R replacement (emergency)power source

rad. radiator, radius

RAM random access memory

RDO relay driver output

ref. reference

rem. remote

RFI radio frequency interference

RH round head

RHM round head machine (screw)

rly. relay

rms root mean square

rnd. round

ROM read only memory

rot. rotate, rotating

rpm revolutions per minute

RS right side

RTV room temperature vulcanization

SAE Society of AutomotiveEngineers

scfm standard cubic feet per minute

SCR silicon controlled rectifier

s, sec. second

SI Systeme international dunites,International System of Units

SI/EO side in/end out

sil. silencer

SN serial number

SPDT single--pole, double--throw

SPST single--pole, single--throw

spec, specsspecification(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 tonormal

TDES time delay engine start

TDNE time delay normal toemergency

TDOE time delay off to emergency

TDON time delay off to normal

temp. temperature

term. terminal

TIF telephone influence factor

TIR total indicator reading

tol. tolerance

turbo. turbocharger

typ. typical (same in multiplelocations)

UF underfrequency

UHF ultrahigh frequency

UL Underwriters 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


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 1 as a guide. As a general rule, a minimum

length of one thread beyond the nut and a maximum

length of 1/2 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.

G-585

Preferred Nut/Bolt Clearance

Unacceptable Nut/Bolt Clearance

1 2

3

1. 1/2 of bolt diameter

2. Min. 1 full thread beyond top of nut3. Below top of nut

Figure 1 Acceptable Bolt Lengths

Steps for common hardware application:

1. Determine entry hole type: round or slotted.

2. Determine exit hole type: fixed female thread

(weld nut), round, or slotted.

For round and slotted exit holes, determine if

hardware is greater than 1/2 inch in diameter, or

1/2 inch in diameter or less. Hardware that is

greater than 1/2 inch in diameter takes a standard

nut and SAE washer. Hardware 1/2 inch or less in

diameter can take a properly torqued whiz nut or

spiralock nut. See Figure 2.

3. 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 2 above

for exception).

c. Use a washer under a bolt when the female

thread is fixed (weld nut).

4. Refer to Figure 2, which depicts the preceding

hardware configuration possibilities.

G-585

12

3

4

5

6

1. Cap screw

2. Entry hole types3. Standard nut and SAE washer

4. Whiz nut or spiralock: up to 1/2 in. dia. hardware

5. Weld nuts: above 1/2 in. dia. hardware6. Exit hole types

Figure 2 Acceptable Hardware Combinations


Appendix C General Torque Specifications

Use the following torque specifications when service

literature instructions give no specific torque values.

The charts list values for new plated, zinc phosphate, or

oiled threads. Increase values by 15% for nonplated

threads. All torque values are +0%/--10%.

American Standard Fasteners Torque Specifications

TorqueAssembled into Cast Iron or Steel Assembled into

AluminumSize

Torque

Measurement Grade 2 Grade 5 Grade 8AluminumGrade 2 or 5

8-32 Nm (in. lb.) 1.8 (16) 2.3 (20) 1.8 (16)

10-24 Nm (in. lb.) 2.9 (26) 3.6 (32) 2.9 (26)

10-32 Nm (in. lb.) 2.9 (26) 3.6 (32) 2.9 (26)

1/4-20 Nm (in. lb.) 6.8 (60) 10.8 (96) 14.9 (132) 6.8 (60)

1/4-28 Nm (in. lb.) 8.1 (72) 12.2 (108) 16.3 (144) 8.1 (72)

5/16-18 Nm (in. lb.) 13.6 (120) 21.7 (192) 29.8 (264) 13.6 (120)

5/16-24 Nm (in. lb.) 14.9 (132) 23.1 (204) 32.5 (288) 14.9 (132)

3/8-16 Nm (ft. lb.) 24.0 (18) 38.0 (28) 53.0 (39) 24.0 (18)

3/8-24 Nm (ft. lb.) 27.0 (20) 42.0 (31) 60.0 (44) 27.0 (20)

7/16-14 Nm (ft. lb.) 39.0 (29) 60.0 (44) 85.0 (63)

7/16-20 Nm (ft. lb.) 43.0 (32) 68.0 (50) 95.0 (70)

1/2-13 Nm (ft. lb.) 60.0 (44) 92.0 (68) 130.0 (96)

1/2-20 Nm (ft. lb.) 66.0 (49) 103.0 (76) 146.0 (108)

9/16-12 Nm (ft. lb.) 81.0 (60) 133.0 (98) 187.0 (138)

9/16-18 Nm (ft. lb.) 91.0 (67) 148.0 (109) 209.0 (154)

5/8-11 Nm (ft. lb.) 113.0 (83) 183.0 (135) 259.0 (191)

5/8-18 Nm (ft. lb.) 128.0 (94) 208.0 (153) 293.0 (216)

3/4-10 Nm (ft. lb.) 199.0 (147) 325.0 (240) 458.0 (338)

3/4-16 Nm (ft. lb.) 222.0 (164) 363.0 (268) 513.0 (378)

1-8 Nm (ft. lb.) 259.0 (191) 721.0 (532) 1109.0 (818)

1-12 Nm (ft. lb.) 283.0 (209) 789.0 (582) 1214.0 (895)

Metric Fasteners Torque Specifications, Measured in Nm (ft. lb.)

Assembled into Cast Iron or Steel Assembled intoAluminum

Size (mm) Grade 5.8 Grade 8.8 Grade 10.9Aluminum

Grade 5.8 or 8.8

M6 x 1.00 5.6 (4) 9.9 (7) 14.0 (10) 5.6 (4)

M8 x 1.25 13.6 (10) 25.0 (18) 35.0 (26) 13.6 (10)

M8 x 1.00 21.0 (16) 25.0 (18) 35.0 (26) 21.0 (16)

M10 x 1.50 27.0 (20) 49.0 (35) 68.0 (50) 27.0 (20)

M10 x 1.25 39.0 (29) 49.0 (35) 68.0 (50) 39.0 (29)

M12 x 1.75 47.0 (35) 83.0 (61) 117.0 (86)

M12 x 1.50 65.0 (48) 88.0 (65) 125.0 (92)

M14 x 2.00 74.0 (55) 132.0 (97) 185.0 (136)

M14 x 1.50 100.0 (74) 140.0 (103) 192.0 (142)

M16 x 2.00 115.0 (85) 200.0 (148) 285.0 (210)

M16 x 1.50 141.0 (104) 210.0 (155) 295.0 (218)

M18 x 2.50 155.0 (114) 275.0 (203) 390.0 (288)

M18 x 1.50 196.0 (145) 305.0 (225) 425.0 (315)


Appendix D Common Hardware Identification

Screw/Bolts/Studs

Head Styles

Hex Head or Machine Head

Hex Head or Machine Headwith Washer

Flat Head (FHM)

Round Head (RHM)

Pan Head

Hex Socket Head Cap orAllen Head Cap

Hex Socket Head or AllenHead Shoulder Bolt

Sheet Metal Screw

Stud

Drive Styles

Hex

Hex and Slotted

Phillips

Slotted

Hex Socket

Nuts

Nut Styles

Hex Head

Lock or Elastic

Square

Cap or Acorn

Wing

Washers

Washer Styles

Plain

Split Lock or Spring

Spring or Wave

External Tooth Lock

Internal Tooth Lock

Internal-External Tooth Lock

Hardness Grades

American Standard

Grade 2

Grade 5

Grade 8

Grade 8/9 (Hex SocketHead)

Metric

Number stamped onhardware; 5.8 shown

5.8

Allen head screw is a trademark of Holo-Krome Co.

Phillips screw is a registered trademark of Phillips Screw Company.

Sample Dimensions

1/4-20 x 1

Major Thread Diameter In Fractional Inches Or Screw Number Size

Length In Inches (Screws and Bolts)

Threads Per Inch

American Standard (Screws, Bolts, Studs, and Nuts)

Metric (Screws, Bolts, Studs, and Nuts)

M8-1.25 x 20

Major Thread Diameter In Millimeters

Length In Millimeters (Screws and Bolts)

Distance Between Threads In Millimeters

9/32 x 5/8 x 1/16

Plain Washers

Internal Dimension

Thickness

External Dimension

Lock Washers

Internal Dimension

5/8


Appendix E Common Hardware List

The Common Hardware List lists part numbers and dimensions for common hardware items.

American Standard

Part No. Dimensions

Hex Head Bolts (Grade 5)

X-465-17 1/4-20 x .38X-465-6 1/4-20 x .50X-465-2 1/4-20 x .62X-465-16 1/4-20 x .75X-465-18 1/4-20 x .88X-465-7 1/4-20 x 1.00X-465-8 1/4-20 x 1.25X-465-9 1/4-20 x 1.50X-465-10 1/4-20 x 1.75X-465-11 1/4-20 x 2.00X-465-12 1/4-20 x 2.25X-465-14 1/4-20 x 2.75X-465-21 1/4-20 x 5.00X-465-25 1/4-28 x .38X-465-20 1/4-28 x 1.00

X-125-33 5/16-18 x .50X-125-23 5/16-18 x .62X-125-3 5/16-18 x .75X-125-31 5/16-18 x .88X-125-5 5/16-18 x 1.00X-125-24 5/16-18 x 1.25X-125-34 5/16-18 x 1.50X-125-25 5/16-18 x 1.75X-125-26 5/16-18 x 2.00230578 5/16-18 x 2.25X-125-29 5/16-18 x 2.50X-125-27 5/16-18 x 2.75X-125-28 5/16-18 x 3.00X-125-22 5/16-18 x 4.50X-125-32 5/16-18 x 5.00X-125-35 5/16-18 x 5.50X-125-36 5/16-18 x 6.00X-125-40 5/16-18 x 6.50

X-125-43 5/16-24 x 1.75X-125-44 5/16-24 x 2.50X-125-30 5/16-24 x .75X-125-39 5/16-24 x 2.00X-125-38 5/16-24 x 2.75

X-6238-2 3/8-16 x .62X-6238-10 3/8-16 x .75X-6238-3 3/8-16 x .88X-6238-11 3/8-16 x 1.00X-6238-4 3/8-16 x 1.25X-6238-5 3/8-16 x 1.50X-6238-1 3/8-16 x 1.75X-6238-6 3/8-16 x 2.00X-6238-17 3/8-16 x 2.25X-6238-7 3/8-16 x 2.50X-6238-8 3/8-16 x 2.75X-6238-9 3/8-16 x 3.00X-6238-19 3/8-16 x 3.25X-6238-12 3/8-16 x 3.50X-6238-20 3/8-16 x 3.75X-6238-13 3/8-16 x 4.50X-6238-18 3/8-16 x 5.50X-6238-25 3/8-16 x 6.50

X-6238-14 3/8-24 x .75X-6238-16 3/8-24 x 1.25X-6238-21 3/8-24 x 4.00X-6238-22 3/8-24 x 4.50

Part No. Dimensions

Hex Head Bolts, cont.

X-6024-5 7/16-14 x .75X-6024-2 7/16-14 x 1.00X-6024-8 7/16-14 x 1.25X-6024-3 7/16-14 x 1.50X-6024-4 7/16-14 x 2.00X-6024-11 7/16-14 x 2.75X-6024-12 7/16-14 x 6.50

X-129-15 1/2-13 x .75X-129-17 1/2-13 x 1.00X-129-18 1/2-13 x 1.25X-129-19 1/2-13 x 1.50X-129-20 1/2-13 x 1.75X-129-21 1/2-13 x 2.00X-129-22 1/2-13 x 2.25X-129-23 1/2-13 x 2.50X-129-24 1/2-13 x 2.75X-129-25 1/2-13 x 3.00X-129-27 1/2-13 x 3.50X-129-29 1/2-13 x 4.00X-129-30 1/2-13 x 4.50X-463-9 1/2-13 x 5.50X-129-44 1/2-13 x 6.00

X-129-51 1/2-20 x .75X-129-45 1/2-20 x 1.25X-129-52 1/2-20 x 1.50

X-6021-3 5/8-11 x 1.00X-6021-4 5/8-11 x 1.25X-6021-2 5/8-11 x 1.50X-6021-1 5/8-11 x 1.75273049 5/8-11 x 2.00X-6021-5 5/8-11 x 2.25X-6021-6 5/8-11 x 2.50X-6021-7 5/8-11 x 2.75X-6021-12 5/8-11 x 3.75X-6021-11 5/8-11 x 4.50X-6021-10 5/8-11 x 6.00

X-6021-9 5/8-18 x 2.50

X-6239-1 3/4-10 x 1.00X-6239-8 3/4-10 x 1.25X-6239-2 3/4-10 x 1.50X-6239-3 3/4-10 x 2.00X-6239-4 3/4-10 x 2.50X-6239-5 3/4-10 x 3.00X-6239-6 3/4-10 x 3.50

X-792-1 1-8 x 2.25X-792-5 1-8 x 3.00X-792-8 1-8 x 5.00

Part No. Dimensions Type

Hex Nuts

X-6009-1 1-8 Standard

X-6210-3 6-32 WhizX-6210-4 8-32 WhizX-6210-5 10-24 WhizX-6210-1 10-32 Whiz

X-6210-2 1/4-20 SpiralockX-6210-6 1/4-28 SpiralockX-6210-7 5/16-18 SpiralockX-6210-8 5/16-24 SpiralockX-6210-9 3/8-16 SpiralockX-6210-10 3/8-24 SpiralockX-6210-11 7/16-14 SpiralockX-6210-12 1/2-13 SpiralockX-6210-15 7/16-20 SpiralockX-6210-14 1/2-20 Spiralock

X-85-3 5/8-11 StandardX-88-12 3/4-10 StandardX-89-2 1/2-20 Standard

Washers

Bolt/Part No. ID OD Thick. Screw

X-25-46 .125 .250 .022 #4X-25-9 .156 .375 .049 #6X-25-48 .188 .438 .049 #8X-25-36 .219 .500 .049 #10X-25-40 .281 .625 .065 1/4X-25-85 .344 .687 .065 5/16X-25-37 .406 .812 .065 3/8X-25-34 .469 .922 .065 7/16X-25-26 .531 1.062 .095 1/2X-25-15 .656 1.312 .095 5/8X-25-29 .812 1.469 .134 3/4X-25-127 1.062 2.000 .134 1


Metric

Hex head bolts are hardness grade 8.8 unless noted.

Part No. Dimensions

Hex Head Bolts (partial thread)

M931-05055-60 M5-0.80 x 55

M931-06040-60 M6-1.00 x 40M931-06055-60 M6-1.00 x 55M931-06060-60 M6-1.00 x 60M931-06070-60 M6-1.00 x 70M931-06070-SS M6-1.00 x 70M931-06075-60 M6-1.00 x 75M931-06090-60 M6-1.00 x 90M931-06150-60 M6-1.00 x 150

M931-08035-60 M8-1.25 x 35M931-08040-60 M8-1.25 x 40M931-08040-82 M8-1.25 x 40*M931-08045-60 M8-1.25 x 45M931-08050-60 M8-1.25 x 50M931-08055-60 M8-1.25 x 55M931-08055-82 M8-1.25 x 55*M931-08060-60 M8-1.25 x 60M931-08070-60 M8-1.25 x 70M931-08070-82 M8-1.25 x 70*M931-08075-60 M8-1.25 x 75M931-08080-60 M8-1.25 x 80M931-08090-60 M8-1.25 x 90M931-08095-60 M8-1.25 x 95M931-08100-60 M8-1.25 x 100M931-08120-60 M8-1.25 x 120M931-08130-60 M8-1.25 x 130M931-08140-60 M8-1.25 x 140

M931-10040-82 M10-1.25 x 40*M931-10040-60 M10-1.50 x 40M931-10045-60 M10-1.50 x 45M931-10050-60 M10-1.50 x 50M931-10055-60 M10-1.50 x 55M931-10060-60 M10-1.50 x 60M931-10065-60 M10-1.50 x 65M931-10070-60 M10-1.50 x 70M931-10080-60 M10-1.50 x 80M931-10090-60 M10-1.50 x 90M931-10090-82 M10-1.50 x 90*M931-10100-60 M10-1.50 x 100M931-10110-60 M10-1.50 x 110M931-10120-60 M10-1.50 x 120M931-10130-60 M10-1.50 x 130M931-10140-60 M10-1.50 x 140M931-10180-60 M10-1.50 x 180

M931-12045-60 M12-1.75 x 45M960-12050-60 M12-1.25 x 50M960-12050-82 M12-1.25 x 50*M931-12050-60 M12-1.75 x 50M931-12055-60 M12-1.75 x 55M931-12060-60 M12-1.75 x 60M931-12065-60 M12-1.75 x 65M931-12075-60 M12-1.75 x 75M931-12080-60 M12-1.75 x 80M931-12090-60 M12-1.75 x 90M931-12100-60 M12-1.75 x 100M931-12110-60 M12-1.75 x 110

M960-16090-60 M16-1.50 x 90M931-16090-60 M16-2.00 x 90M931-16100-60 M16-2.00 x 100

M931-20065-60 M20-2.50 x 65M931-20120-60 M20-2.50 x 120M931-20160-60 M20-2.50 x 160

M931-22090-60 M22-2.50 x 90M931-22120-60 M22-2.50 x 120M931-22160-60 M22-2.50 x 160

M931-24090-60 M24-3.00 x 90M931-24120-60 M24-3.00 x 120M931-24160-60 M24-3.00 x 160

Part No. Dimensions

Hex Head Bolts (full thread)

M933-04006-60 M4-0.70 x 6

M933-05035-60 M5-0.80 x 35M933-05050-60 M5-0.80 x 50

M933-06010-60 M6-1.00 x 10M933-06014-60 M6-1.00 x 14M933-06016-60 M6-1.00 x 16M933-06020-60 M6-1.00 x 20M933-06025-60 M6-1.00 x 25M933-06040-60 M6-1.00 x 40M933-06050-60 M6-1.00 x 50

M933-08012-60 M8-1.25 x 12M933-08016-60 M8-1.25 x 16M933-08020-60 M8-1.25 x 20M933-08025-60 M8-1.25 x 25M933-08030-60 M8-1.25 x 30M933-08030-82 M8-1.25 x 30*

M933-10012-60 M10-1.50 x 12M961-10020-60 M10-1.25 x 20M933-10020-60 M10-1.50 x 20M933-10025-60 M10-1.50 x 25M961-10030-60 M10-1.25 x 30M933-10030-60 M10-1.50 x 30M933-10030-82 M10-1.50 x 30*M961-10035-60 M10-1.25 x 35M933-10035-60 M10-1.50 x 35

M933-12016-60 M12-1.75 x 16M933-12020-60 M12-1.75 x 20M933-12025-60 M12-1.75 x 25M933-12025-82 M12-1.75 x 25*M961-12030-60 M12-1.25 x 30M933-12030-60 M12-1.75 x 30M933-12035-60 M12-1.75 x 35M961-12040-82 M12-1.25 x 40*M933-12040-60 M12-1.75 x 40M933-12040-82 M12-1.75 x 40*

M961-14025-60 M14-1.50 x 25M933-14025-60 M14-2.00 x 25

M961-16025-60 M16-1.50 x 25M933-16025-60 M16-2.00 x 25M961-16030-82 M16-1.50 x 30*M933-16030-82 M16-2.00 x 30*M933-16035-60 M16-2.00 x 35M961-16040-60 M16-1.50 x 40M933-16040-60 M16-2.00 x 40M933-16050-60 M16-2.00 x 50M933-16050-82 M16-2.00 x 50*M933-16060-60 M16-2.00 x 60

M933-18035-60 M18-2.50 x 35M933-18050-60 M18-2.50 x 50M933-18060-60 M18-2.50 x 60

M933-20050-60 M20-2.50 x 50M933-20055-60 M20-2.50 x 55

Pan Head Machine Screws

M7985A-03010-20 M3-0.50 x 10M7985A-03012-20 M3-0.50 x 12

M7985A-04010-20 M4-0.70 x 10M7985A-04020-20 M4-0.70 x 20M7985A-04100-20 M4-0.70 x 100

M7985A-05010-20 M5-0.80 x 10M7985A-05012-20 M5-0.80 x 12M7985A-05016-20 M5-0.80 x 16M7985A-05100-20 M5-0.80 x 100

M7985A-06100-20 M6-1.00 x 100

Flat Head Machine Screws

M965A-04012-SS M4-0.70 x 12M965A-05012-SS M5-0.80 x 12M965A-05016-20 M5-0.80 x 16

Part No. Dimensions Type

Hex Nuts

M934-03-50 M3-0.50 Standard

M934-035-50 M3.5-0.50 Standard

M934-04-50 M4-0.70 Standard

M934-05-50 M5-0.80 StandardM982-05-80 M5-0.80 Elastic Stop

M934-06-60 M6-1.00 StandardM934-06-64 M6-1.00 Std. (green)M6923-06-80 M6-1.00 SpiralockM982-06-80 M6-1.00 Elastic Stop

M934-08-60 M8-1.25 StandardM6923-08-80 M8-1.25 SpiralockM982-08-80 M8-1.25 Elastic Stop

M934-10-60 M10-1.50 StandardM934-10-60F M10-1.25 StandardM6923-10-80 M10-1.50 SpiralockM6923-10-62 M10-1.50 SpiralockM982-10-80 M10-1.50 Elastic Stop

M934-12-60 M12-1.75 StandardM934-12-60F M12-1.25 StandardM6923-12-80 M12-1.75 SpiralockM982-12-80 M12-1.75 Elastic Stop

M982-14-80 M14-2.00 Elastic Stop

M6923-16-80 M16-2.00 SpiralockM982-16-80 M16-2.00 Elastic Stop



M934-22-60 M22-2.50 Standard


M934-30-80 M30-3.50 Standard

Washers

Bolt/Part No. ID OD Thick. Screw

M125A-03-80 3.2 7.0 0.5 M3M125A-04-80 4.3 9.0 0.8 M4M125A-05-80 5.3 10.0 1.0 M5M125A-06-80 6.4 12.0 1.6 M6M125A-08-80 8.4 16.0 1.6 M8M125A-10-80 10.5 20.0 2.0 M10M125A-12-80 13.0 24.0 2.5 M12M125A-14-80 15.0 28.0 2.5 M14M125A-16-80 17.0 30.0 3.0 M16M125A-18-80 19.0 34.0 3.0 M18M125A-20-80 21.0 37.0 3.0 M20M125A-24-80 25.0 44.0 4.0 M24

* Thismetric hex bolts hardness is grade 10.9. This metric hex nuts hardness is grade 8.

KOHLER CO. Kohler, Wisconsin 53044Phone 920-565-3381, Web site www.kohlergenerators.comFax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International)For the nearest sales and service outlet in U.S.A. and CanadaPhone 1-800-544-2444 1998, 2001 by Kohler Co. All rights reserved.

TP-5413 5/01c

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