Service Parts

Service Parts Residential/Commercial Generator Sets

Models:

8.5/11RMY 8.5/12RES

TP-5868 1/04f

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: Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Group 2: Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Group 3: Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Group 4: Cylinder Head/Valve/Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Group 5: Ignition/Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Group 6: Blower Housing & Baffles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Group 7: Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Group 8: Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Group 9: Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Group 10: Air Intake/Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Group 11: Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Group 12: Gasket Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Group 103: Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Group 105: Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Group 107: Nameplate and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Group 109: Skid and Plant Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Group 112: Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Group 116: Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Group 201: Generator and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Group 301: Controller and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Group 501: Housing and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Group 701: Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Fuel System Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Exhaust System Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Electrical System Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Miscellaneous Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 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

Introduction This manual lists service replacement parts for 8.5/11RMY and 8.5/12RES generator sets. At the time of print this manual applied to the generator set specification (spec) numbers listed in the Specification Number Index. On occasion this manual may apply to specs not listed in the Specification Number Index. Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever. This manual includes the following main sections: Table of Contents. Lists the sections of the manual. Introduction (and other information sections). Contains introductory material about part numbers, illustrations, and hardware. Specification Number Index. Lists the generator set specs and groups. Group Parts Lists. List the part numbers of parts in the groups. Kit Sections. List modules and accessories and their parts. Appendices. Include Abbreviations, Common Hardware Application Guidelines, General Torque Specifications, Common Hardware Identification, and Common Hardware List. x:in:004:002

Numbering System Significance This manual uses the following numbering systems: Specification Number. The product identification number located on the generator set nameplate. Specification numbers break down into groups. Group Number. A unique number representing a parts group needed to assemble a generator set function. For example, Group 101 is the Air Intake group. Variation or Module Number. A group might have several variations. Each variation performs the same function with different parts lists. For example, a 50 Hz generator alternator and a 60 Hz generator alternator both perform the same function; however, with different parts. Each difference requires a group variation or module number. Part Number. The part number identifies an individual assembly, subassembly, component, or accessory kit. x:in:004:003:a

Illustrations Illustrations (or exploded-view drawings) best representing the widest range of variations accompany most groups in this manual. Illustrations do not depict all details and may not show all parts. Do not use illustrations for assembly or disassembly. x:in:004:004:a

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. x:in:004:005

Hardware References Many common hardware items do not appear in parts manuals or will appear as common hardware entries. A common hardware entry lists the size of the hardware. For example, an item that appears as “Hardware, 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 listed in the text. 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-5868 1/04

1

Specification Number Index

Group Title

Group No.

1

2

3

4

5

6

7

8

9

10

11

12

Variation Number

Spec No. 8.5RMY PA-195007

35

92

77

34

347

224

13

214

98

20

90

1

PA-195016

35

92

77

34

347

224

13

214

98

20

90

1

PA-195017

35

92

77

34

347

224

13

214

98

20

90

1

PA-195021

35

92

77

34

347

224

13

214

98

20

90

1

PA-195025

35

92

77

34

347

224

13

214

98

20

90

1

GM16902-GA1

35

92

77

34

347

224

13

214

98

20

90

1

GM24829-GA1

35

92

337

268

347

224

13

214

98

20

90

1

35

193

528

34

695

352

13

559

98

20

90

1

PA-195008

35

146

376

96

348

225

13

342

98

47

90

1

PA-195018

35

146

376

96

348

225

13

342

98

47

90

1

PA-195019

35

146

376

96

348

225

13

342

98

47

90

1

PA-195022

35

146

376

96

348

225

13

342

98

47

90

1

PA-195026

35

146

376

96

348

225

13

342

98

47

90

1

GM16902-GA2

35

146

376

96

348

225

13

342

98

47

90

1

GM24829-GA2

35

146

376

96

348

225

13

342

98

47

90

1

35

192

528

273

689

350

13

558

98

47

90

1

8.5RES GM29253-GA1

11RMY

12RES GM29253-GA2

2

TP-5868 1/04

Specification Number Index

Group Title

Group No.

103

105

107

109

112

116

201

301

501

701

Variation Number

Spec No. 8.5RMY PA-195007

3

2

4

3

4

3

5

4

1

7

PA-195016

3

2

12

3

4

3

5

4

1

7

PA-195017

3

2

12

3

4

3

5

4

1

7

PA-195021

8

5

13

6

6

6

10

9

4

7

PA-195025

8

5

14

6

6

6

10

10

4

7

GM16902-GA1

GR3

GR1

GR10

GR5

GR1

GR6

GR7

GR8

GR9

11

GM24829-GA1

29-3

29-1

29-5

29-6

29-1

29-7

29-8

29-11

29-10

11

53-3

53-1

53-5

53-6

53-1

53-1

53-7

53-8

53-9

11

PA-195008

7

3

4

3

4

3

5

4

1

7

PA-195018

7

3

12

3

4

3

5

4

1

7

PA-195019

7

3

12

3

4

3

5

4

1

7

PA-195022

8

6

13

6

6

6

10

9

4

9

PA-195026

8

6

14

6

6

6

10

10

4

9

GM16902-GA2

GR3

GR2

GR4

GR5

GR1

GR6

GR7

GR8

GR9

11

GM24829-GA2

29-3

29-2

29-4

29-6

29-2

29-7

29-8

29-9

29-10

11

53-3

53-2

53-5

53-6

53-2

53-2

53-7

53-8

53-9

11

8.5RES GM29253-GA1

11RMY

12RES GM29253-GA2

TP-5868 1/04

3

Group 1: Crankshaft

1 2

A358191_7

Item

Part Number

1 2

24 014 106-S 52 139 09

4

Description Crankshaft assembly Plug, cap

Qty. Variation No. 35 1 1

TP-5868 1/04

Group 2: Crankcase 1

2 6 4

5 7 3

8 Illustrated parts without item reference numbers (the piston, for example) are not sold separately.

14 9

Items not shown: 10, 12, 13, 15

Item 1 1 2 2 2 2 2 2 2 3 3 3 3 3 3 4 5 5 5 5 5 6 6 7 8 9 10 10 11 12 13 13 14 14 15

Part Number 24 012 10-S 24 012 18-S 12 422 09-S 12 422 13-S 12 422 07-S 12 422 08-S 12 422 10-S 12 422 11-S 12 422 12-S 24 874 17-S 24 874 08-S 24 874 18-S 24 874 16-S 24 874 14-S 24 874 19-S 24 018 01-S 24 108 01-S 24 108 05-S 24 108 11-S 24 108 12-S 24 108 19-S 24 067 13-S 24 067 14-S 52 139 09-S 24 380 13-S 24 032 01-S 25 139 57-S 25 139 28-S X-75-10 24 522 162 24 782 17 24 782 33 24 418 02 GM28823 25 158 12-S

Description Camshaft Camshaft Shim, camshaft, red, 0.03125--0.03275 Shim, camshaft, black, 0.0395--0.04075 Shim, camshaft, white, 0.02725--0.02875 Shim, camshaft, blue, 0.02925--0.03075 Shim, camshaft, yellow, 0.03325--0.03475 Shim, camshaft, green, 0.03525--0.0367 Shim, camshaft, gray, 0.03725--0.0387 Piston w/ring set, standard Piston w/ring set, standard Piston w/ring set, 0.25 OS Piston w/ring set, 0.08 OS Piston w/ring set, 0.08 OS Piston w/ring set, 0.50 OS Retainer, piston pin Ring set, standard Ring set, standard Ring set, standard Ring set, 0.25 Ring set, 0.50 Rod, connecting, standard Rod, connecting, 0.25 Plug, cup Dowel, locating Seal, oil front Plug, cup (not shown) Plug, cup (not shown) Plug, solid square head, 3/8 in., NPTF Short block (not shown) Miniblock (not shown) Miniblock (not shown) Sensor, oil temperature Sensor, oil temperature Bushing, reducing (not shown)

A358191_54

11

92 1 AR AR AR AR AR AR AR 2

Qty. Variation No. 146 181 192 1

1

AR AR AR AR AR AR AR

1 AR AR AR AR AR AR AR

1 AR AR AR AR AR AR AR

2

2

2

2

2

2

2

4 2

193 AR AR AR AR AR AR AR 2 2

4

4

2

2

4

2 2 4 2

2 2 2 2 1 6 1 1

2 2 1 6 1 1

2 2 1 6 1 1

2 2 1 6 1 1 1

1 1

1 1

1

2 1 1 1

2 2 1 6 1 1 1 1

1 1

1 1

AR as required TP-5868 1/04

5

Group 3: Lubrication 13 9

15

2 6 1 24

12 11 8

23 25 26

5 4 7

22 3

21 19

28

19

17

1

18

19 20 19

27

16 10 Items not shown: 14, 29, 30, 31, 32

6

Illustrated parts without item reference numbers are not sold separately.

A358191_77

TP-5868 1/04

Group 3: Lubrication Item

Part Number

1 2 3 4 5 6 7 8 8 9 9 10 11 12 13 14 15 15 16 16 17 17 18 19 19 20 21 21 22 22 23 24 25 26 27 28 29 30 31 32

24 009 92-S 24 153 08-S 24 393 37-S 24 153 01-S 24 381 04-S 52 032 08-S 24 755 121-S 24 755 121-S 24 038 10-S X-75-23 25 139 60-S 12 050 01-S M-645025-S M-631005--S 24 086 16-S 24 086 17-S 25 099 24-S 25 099 26-S 24 755 120-S 54 755 21-S 24 136 02 24 136 05-S 24 594 10-S 24 237 03 24 237 10 24 326 16 24 326 17 24 326 15 24 153 13-S 24 153 21-S 24 029 01 24 041 29 24 153 01 24 211 01 24 086 12-S 24 100 01-S 24 146 11 41 037 10 25 113 25-S 25 113 05-S

TP-5868 1/04

Description Plate, closure O-ring Oil pump assembly (includes 4 and 5) O-ring, oil pickup Pickup, oil Seal, oil Kit, dipstick/dipstick tubes Dipstick Dipstick Plug, Allen head, 1/8 in. Plug, pipe 1/8 NPTF Filter, oil Screw, hex flange, M6 x 1 x 25 Washer, plain, 6mm Screw, hex flange, M8 x 1.25 x 45 Screw, hex flange, M8 x 1.25 x 45 (not shown) Switch, oil pressure Switch, oil pressure Kit, oil cooler Cooler, oil Nipple, oil filter Nipple, oil filter Cooler, oil assembly Clamp, hose Clamp, hose Hose, oil, 97 mm Hose, oil, 140 mm Hose O-ring O-ring Adapter, oil filter Gasket, oil filter adapter O-ring Bolt, oil filter adapter Screw, hex cap, M6 x 1.7 x 18 Nut, plastic Plate, backing, #2 side (not shown) Decal, write-on nameplate (not shown) Decal, oil sentry (not shown) Decal, oil cooler (not shown)

77 1 1 1 1 1 1 1 1

Qty. Variation No. 376 337

528

1 1 1 1 1 1 1

1 1 1 1 1 1

1 1 1 1 1 1

1

1

1

1 2 2 9 1 1

1 1 2 2 9 1 1

1 1 2 2 9 1

2 1 2 2 9 1 1

1 1

1 1

1

1 1 4

1 1

1

1

1

1

1

2 2 1 1 1 1

2 2

2 2

4 1 1 2 1 1 1 1 1 2 2 1 1 1 1

7

Group 4: Cylinder Head/Valve/Breather 27

1 28, 33 31

24

26

20

25 34

21

5 23

6 4

7

32

22

19 5 6

42

37

11

18

7

39 41

16

17

36

8 9

14

29, 35

15

13

10 12

30 3 2

40 44

38 Items not shown: 44---47

8

A358191_34

TP-5868 1/04

Group 4: Cylinder Head/Valve/Breather Item 1 1 1 1 2 2 2 2 3 4 5 6 7 8 9 9 10 10 11 11 12 13 13 14 15 16 17 18 19 20 21 22 23 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47

TP-5868 1/04

Part Number 24 318 68-S 24 318 65-S 24 318 88-S 24 318 92-S 24 318 71-S 24 318 66-S 24 318 94-S 24 318 90-S 12 086 16 12 755 03-S 12 173 01-S 24 089 02-S 235011-S 66 032 05-S 24 017 01-S 24 017 02-S 24 041 08 24 041 37-S 24 016 01-S 24 016 02-S 24 402 03-S 12 018 01 66 018 04-S M-545010-S 24 033 01-S 24 041 23 24 096 02 25 139 60-S M-645020-S M-645030-S 24 326 26-S 25 237 14-S 12 445 05-S 24 445 01 24 755 46-S 25 153 02 12 173 04 24 755 74-S 24 112 08 24 153 23-S 24 755 75-S 24 086 32 24 096 21 24 112 08-S 24 153 23-S 24 153 23-S 24 050 01-S M-640034-S 24 755 66-S 24 599 01-S 24 411 05-S 25 186 01-S M-651030-S 25 351 01-S 24 072 09-S 24 100 10-S 24 468 16-S 24 605 01-S

Description Head assembly, #1 cylinder Head assembly, #1 cylinder Head assembly, #1 cylinder Head assembly, #1 cylinder Head assembly, #2 cylinder Head assembly, #2 cylinder Head assembly, #2 cylinder Head assembly, #2 cylinder Screw, hex flange, M10 x 1.5 x 90 Kit, retainer Cap, valve spring Spring, valve Retainer, spring Seal, valve stem Valve, intake, standard Valve, intake, 0.25 Gasket, cylinder head Gasket, cylinder head Valve, exhaust, standard Valve, exhaust, 0.25 Reed, breather Retainer, breather reed Retainer, reed Screw, hex flange, M5 x 0.8 x 10 Kit, breather Gasket, breather Cover, breather Plug, 1/8 in. Screw, hex flange, M6 x 1.0 x 20 Screw, thread forming, M6 x 1.0 x 30 Hose, breather Clamp, breather Strap, lifting Strap, lifting Kit, oil fill cap (includes 25, 26) O-ring, oil fill cap Cap, oil fill tube Kit, valve cover, plain (includes 27, 28, 31, 33, 35, 42) Spacer O-ring Kit, valve cover, oil fill (includes 31, 32, 33, 34, 35) Screw, shoulder Rocker cover, oil fill Spacer O-ring O-ring Filter, breather Screw, hex flange, M6 x 1.0 x 34 Kit, valve train (includes 39, 40, 41) Pivot, rocker arm Rod, push Arm, rocker Screw, valve cover Lifter, valve Stud (not shown) Nut, hex flange (not shown) Washer, flat (not shown) Liner, exhaust port (not shown)

34

Qty. Variation No. 96 268

273

1 1 1 1 1 1 1 8 4 4 4 4 2 2 2 2 2 2 1 1 1 1 1 1 1 1 3 1 1 2 1 1 1 1 4 1 1 4 1 4 1 1 1 4 1 4 4 4 8 4

8 4 4 4 4 2 2 2 2 2 2 1 1 1 1 1 1 1 1 3 1 1 2 1 1 1 1 4 1 1 4 1 4 1 1 1 4 1 4 4 4 8 4

1 8 4 4 4 4 2 2 2 2 2 2 1 1 1 1 1 1 1 1 3 1 1 2 1 1 1 1 4 1 1 4 1 4 1 1 1 4 1 4 4 4 8 4

8 4 4 4 2 2 2 2 2 2 1 1 1 1 1 1 1 1 3 1 1 2 1 1 1 1 4 1 1 4 1 4 1 1 1 4 1 4 4 4 8 4 8 8 8 2

9

Group 5: Ignition/Electrical 1, 2 6

9

10 16

25 26

4 13

27

5

3

8

19 7

11

12

22

18

20

28 Items not shown: 14, 15, 17, 23, 24, 29---31

Item 1 2 3 4 4 4 4 5 6 7 8 9 9 10 10 11 12 13 14 15 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

10

Part Number 54 755 09 24 126 71 X-42-15-S 24 025 14-S 24 025 05-S 24 025 15-S 66 025 01-S 12 132 02-S M-0548025 12 086 14-S 24 157 07-S 24 584 01-S 24 584 15-S 24 584 10-S 24 584 34-S 24 086 18-S 25 403 03 236602 25 518 28 24 176 43-S 24 176 90-S M-561025-S X-22-11 25 086 47-S 12 468 03-S 24 126 85-S 24 418 09-S X-25-92-S 24 518 18 24 518 17 24 086 41 24 100 02 X-25-63-S 54 755 15-S 25 096 04-S 235173-S M-551016-S

21 A358191_347

Description Kit, 15-amp stator Bracket, stator wire Key Flywheel Flywheel Flywheel Flywheel Spark plug Screw, hex cap, M5 x 0.8 x 25 Screw, hex flange, M10 x 1.5 x 46 Fan Module, ignition Module, ignition Module, speed advance Module, digital spark advanced (DSAM) Screw, Phillips head, 11-16 x 7/8 Rectifier-regulator Connector, 3-contact Lead, black, 4 in. 18 gauge, insulated grip barrel eyelet terminals (not shown) Harness, wiring (not shown) Harness, wiring (not shown) Screw, hex socket head, M5 x 0.8 x 25 Washer, lock, 1/4 in. (not shown) Bolt, shoulder Washer, plain, 3/8 in. Bracket, sensor mounting Sensor, magnetic Washer, plain, 3/6 in. Lead, white, 19 in. 18 gauge push-on tab terminals (not shown) Lead, red, 19 in. 18 gauge push-on tab terminals (not shown) Screw, hex cap, 10-24 x 3/8 in. Nut, plastic Washer, plain, 1/4 in. Screen Cover, regulator (not shown) Clip, cable (not shown) Screw (not shown)

347 1 1 1 1

Qty. Variation No. 348 689 1 1 1

1

695 1

1 1 2 2 1 1 2

2 1 1 1 1 4 1 4 1 1 1 2

1

2 2 1 1

2

2 1

2

2 1 1 1

1 1

1 2

1 2 1 1 2

2

1 4 1 4 1 1 1 1 1 2 2 1 1

1 4 1 4 1 1 1

4 4 1 1 1 2

1 1 1 1

1

TP-5868 1/04

Group 6: Blower Housing & Baffles 12

6

14

11

15

9

13 1 11

4

3

10

7

8

2

Items not shown: 5, 16, 17

TP-5868 1/04

A358191_224

Item

Part Number

1 1 1 2 3 4 5 6 7 8 9 9 10 10 11 12 12 13 13 14 14 15 16 16 17

24 027 30 24 027 53-S 24 027 195-S 24 100 01 24 100 02 25 139 16 24 063 36 M-545010-S M-545016-S M-551016 24 146 08 24 146 20-S 24 146 11 24 146 19-S M-645016-S 24 063 24 24 063 59-S 24 063 20 24 063 39-S 24 063 08 24 063 58-S 24 063 17-S 24 113 12 24 113 34 M-545020-S

Description Housing, blower assembly (includes 2--6) Housing, blower assembly (includes 2--6) Housing, blower assembly (includes 2--4) Nut, plastic Nut, plastic Plug, button, 9/16 in. Baffle, blower housing (not shown) Screw, hex flange, M5 x 0.8 x 10 Screw, hex flange, M5 x 0.8 x 16 Screw, hex flange, M5 x 0.8 x 16 Plate, backing, #1 side Plate, backing, #1 side Plate, backing, #2 side Plate, backing, #2 side Screw, hex flange, M6 x 1.0 x 16 Baffle, valley, #1 side Baffle, valley, #1 side Baffle, cylinder barrel, #2 side Baffle, left barrel Baffle, cylinder barrel, #1 side Baffle, right barrel Baffle, valley, #2 side Decal, HP (not shown) Decal, HP (not shown) Screw (not shown)

224

Qty. Variation No. 225 350

352

1 1 3 2 1 1 2 6 1 1

2 2 1 1 2 5 1 1

1

1

8 1

8 1

1

1

1

1

1 1

1

1

1

2 6

2 7

1

1

1 8

1 8

1

1

1

1

1 1

1 1

2

2

1

11

Group 7: Starting System

2

1

3

6

11 18, 20 5

8

12

7 16 14

10 13 Item 21 not shown.

Item 1 2 3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

12

Part Number M-839080-S M-841080-S 24 098 01 25 098 09-S 24 081 04 12 090 10 12 170 04 12 239 01 24 301 01 12 471 01 24 755 84 52 100 09 52 100 10 52 168 01 52 211 05 52 221 01 52 089 09 52 323 03 52 435 02 25 221 01-S 25 435 05-S 25 755 33-S

17 15, 19

4

A358191_5

9

Description Screw, hex flange, M8 x 1.25 x 80 Nut, hex flange, M8 x 1.25 Starter, solenoid shift Nipendenso label (includes 4--18) Starter, solenoid shift Delco-Remy label (includes 19--21) Drive, end cap Lever, starter drive Armature, starter Drive, pinion Commutator, end cap Frame Kit, starter repair Nut, starter Nut, starter Insulator Bolt, thru, M5 x 0.8 x 99 Kit, brush and spring (includes 16) Spring, brush Holder, brush Solenoid Kit, brush Solenoid kit Kit, starter pinion (not shown)

Qty. Variation No. 13 2 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 4 1 1 1 1 1

TP-5868 1/04

Group 8: Carburetor 3

4

2 7 5

1 10

9

6 8

A358191_214

Item 1 1 2 3 4 4 5 6 7 8 9 9 9 10 10

TP-5868 1/04

Part Number 24 853 30-S 24 853 49-S 24 041 26-S M-851030-S 24 053 30 24 053 49 232556-S 232555-S 24 294 05-S X-25-8-S 24 353 35 24 353 39 24 353 40-S 25 237 09 25 237 12-S

Description Kit, carburetor w/gasket (includes 2, 3) Kit, carburetor w/gasket (includes 2, 3) Gasket, carburetor Screw, hex flange, M6 x 1.25 x 30 Carburetor assembly (not available separately) Carburetor assembly (not available separately) Screw, idle adjusting Spring, adjusting screw Fitting, elbow Washer, plain, 1/4 in. Line, fuel Line, fuel Line, fuel (29 in.) Clamp, hose 3/4 in. Clamp, hose

214

Qty. Variation No. 342 558

1 1 2 1 1 1 1 1 1

559 1

1 1 2

1 1 2

1 1 1 1 1

1 1 1 1 1

1 1 1 1

1

1

1

1

1 2 1

1 1

1

13

Group 9: Engine Controls 2 To Governor 3

1 4

To Carburetor

5

6 Illustrated parts without item reference numbers are not sold separately. A358191_53

Item 1 2 3 4 5 6

14

Part Number 24 079 09-S 25 158 08-S 25 158 11-S 24 310 03-S 25 112 09-S 358359

Description Linkage, throttle Bushing, linkage Bushing, throttle linkage Governor (actuator/stepper motor) Spacer Coupling, stepper motor

Qty. Variation No. 98 1 1 1 1 3 1

TP-5868 1/04

Group 10: Air Intake/Filtration 15, 16, 17

13 3

9

2

4 5 7

1

18

12

6

10

11

8 14 A358191_20

Item 1 2 2 3 3 4 5 6 6 7 8 8 9 10 11 12 13 14 15 16 17 18

TP-5868 1/04

Part Number 277093-S 24 094 12-S 24 094 29-S 24 126 49-S 24 126 74-S 12 100 01-S 24 032 03-S 24 083 02-S 24 083 05-S 24 096 01-S 24 083 08-S 24 083 09-S 24 096 67-S 24 041 01-S 24 164 18-S 24 112 21-S 25 086 48-S 25 086 84-S 54 755 01-S 24 153 20-S 25 341 03-S 230046-S

Description Gasket, air cleaner base Base, air cleaner Base, air cleaner Bracket, air cleaner Bracket, air cleaner Nut, wing Seal, air intake Element, precleaner Element, precleaner Cover, inner air cleaner Element, air filter Element, air filter Cover, air cleaner Gasket, intake manifold Manifold, intake Spacer Screw, composite, 10-32 x 3/4 in. Screw, hex flange, M6 x 1.0 x 55 Kit, knob w/seal (includes 16, 17) O-ring Knob, cover Seal, breather

Qty. Variation No. 20 47 2 1

2 1

1 1 1 1 1 1 1 2 1 1 4 4 1 1 1

1 1 1 1 1 1 2 1 1 4 4 1 1 1 1

15

Group 11: Exhaust

1 3 2 A358191_6

Item 1 2 3

Part Number 24 041 49-S M-841080-S 25 072 04-S

Description Gasket, exhaust manifold Nut, hex flange, M8 x 1.25 Stud, M8 x 1.25 x 33

Qty. Variation No. 90 2 4 4

Group 12: Gasket Set Item 1

16

Part Number 24 755 03 230046 12 032 01 12 153 01 12 153 02 12 153 03 24 032 01 24 032 03 24 032 04 24 032 05 24 041 01 24 041 02 24 041 06 24 041 08 24 041 12 24 041 13 24 041 14 24 041 15 24 041 16 24 041 23 24 153 08 52 032 08

Description Gasket set (includes all of the following) Seal, breather Seal, valve stem O-ring O-ring O-ring Seal, front Seal, inner Seal Seal, valve stem Gasket, intake manifold Gasket, exhaust Gasket, air cleaner Gasket, cylinder head Gasket, oil filter Gasket, fuel Gasket, air cleaner Gasket, carburetor Gasket, cylinder head Gasket, breather O-ring Seal, oil

Qty. Variation No. 1 1 1 1 1 1 1 1 1 1 2 2 2 1 2 1 1 1 1 2 1 1 1

TP-5868 1/04

Notes

TP-5868 1/04

17

Group 103: Fuel System 6

13

4

8

11

7

6

9

20

6

5 1

19 15, 16

18 2 14

16, 17

12

3

23 21 10

24

13

22

6

26, 27, 28 1, 10

2

View of Dual Fuel System

25

12 3

5868_103

18

TP-5868 1/04

Group 103: Fuel System Item 1 2 3 4 5 6 7 8 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Part Number A-227531 X-202-41 X-209-2 X-216-29 X-391-13 X-426-18 X-582-4 X-6219-8 X-6219-9 X-6242-9 X-75-51 226550 227648 344508 358147 X-465-8 # X-465-2 # 320828 243488 GM16807 X-204-9 X-75-10 X-6219-9 X-211-3 GM31888 X-50-15 X-25-36

Description

3

7

Regulator assembly, gas Bushing, reducer, 3/4 x 1/2 in. Nipple, pipe, 1/2 NPT x 1.19 in. Coupling, pipe, 1/4 in. brass Connector, 90_ hose, 3/8 NPTF x 1/2 in. Clamp, hose, 0.38 x 0.88 in. Connector, hose, 3/8 NPT x 1/2 in. Screw, set, 3/8-24 x 0.5 in. (LP gas, CARB cert.) Screw, set, 3/8-24 x 0.375 in. (natural gas, CARB cert.) Line, flexible fuel, 1/2 x 8.0 in. Plug, pipe, 1/4 NPT (not shown) Block, fuel adjustment Valve, gas solenoid Connector, hose, 1/4 NPT x 1/2 in. Bracket, fuel mounting Screw, 1/4-20 x 1.25 Washer, 1/4 Screw, 1/4-20 x 0.625 1/4-20 Insert, threaded Grommet Valve, fuel metering Pipe, 3/8 in. NPT x 1.00 in. Plug, pipe, 3/8 in. NPT Screw, set, 3/8-24 x 0.375 in. (dual fuel) Elbow, street 90 deg. x 1/2 in. NPT) Plate, gas solenoid retainer Screw, pan head, 10-24 x1/2 Washer, plain, .219 ID x .5 in. OD

1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 4 2 2 2 1

1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 2 4 2 2 2 1

Qty. Variation No. 8 GR3 29-3 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 2 4 2 2 2 1

53-3

1 1 1

1 1 1

1 1 1

1

1

1

2

2

2

1 1 1

1 1 1

1 1

1 1 1 2

1 1 1 2

1 1 1 2 1 1 4 4

# Common hardware; procure locally.

TP-5868 1/04

19

Group 105: Engine 8.5RMY & 11RMY

12 2 4 3 11 5, 7 13 6 10

10

9 8, 1, 3, 4

8.5RES & 12RES 14

21 15 20

17 16 18

2, 3 5, 7, 22, 23

16 See Group 5 18 19

6 8, 1, 3, 4

5868_105

20

TP-5868 1/04

Group 105: Engine Item

Part Number

1 2 2 3 4 5 5 6 7 8 9 9 10 11 12 13 14 14 14 14 15 16 17 18 19 19 20 21 21 22 23 24 24

X-204-9 X-268-9 GM20548 X-426-18 X-582-4 M933-06010-60 M933-06040-60 X-422-19 345045 345090 358092 GM10165 233959 269190 278775 A-278782 B-358191 GM22470 GM29359 GM24792 239332 346258 GM28341 X-50-15 X-634-9 X-301-24 X-67-143 GM24928 358384 X-400-190 M6923-06-80 X-426-18 X-309-11

Description

2

3

5

6

Nipple, pipe, 3/8 x 1 Cap, pipe, 3/8 NPT Plug, hose 1/2 Clamp, hose, 0.38-0.88 in. Connector, hose, 3/8 NPT x 1/2 in. Screw, hex head cap, M6-1 x 0.394 in. Screw, hex head cap Line, oil drain Clip, hose Valve, oil drain Harness, engine (includes 10, 11, 12) Harness, engine (includes 10, 11, 12) Diode Connector, 6-pin Connector, 20-pin Sensor assembly, magnetic Engine assembly, CH20 (EK64607) Engine assembly, CH25 (EK68706) Engine assembly, CH20 (EK64693) Engine assembly, CH740 (EK CH740-0035) Clip, speed Insert, threaded, #10-24 Charger, battery Screw, slotted pan head machine Bushing, .625 x .750 in NPT Plug, button Screw, cross recess, sheet metal Breaker, circuit (40 A) Breaker, circuit (50 A) Spacer, .282 ID x .5 OD x 1 in. Nut, hex 6 mm Clamp, hose, 0.38-0.88 in. Clamp, hose 3/4

1 1

1 1

1 1

1 1

1 3 1

1 3 1

1 3 1

1 1 1 1

1 1 1 1

2 1 1 1 1

2 1 1

Qty. Variation No. GR1 GR2 29-1 29-2 53-1 53-2 1

1

1

1

1

1

1 3 1

1 1 1 1

1 1 1 1

1 1 1 1

1 1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1 1

1 1 1 1

1 2 1 1 1 1

1 2 1 1

1 2 1 1

1 2 1 1

1 2 1 1

1 2 1 1

1

1 1

1 1

1 1 4 4 1 1 4 1

1

1

1

1 4 6 1 2 1 4

1 1

1 1 1

1

1

1 1

1

1

1

See Group 112 Starter for additional engine group parts.

Group 107: Nameplate and Decals Part Number

Item 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

X-6348-2 X-6348-8 224233 227620 239789 249808 249809 255798 255882 257438 358313 GM14197-1 GM20577 294520 GM29924 GM15301

TP-5868 1/04

Qty. Variation No. 14 GR4 GR10

Description

4

12

13

Decal, Kohler Power Systems Decal, Kohler Power Systems Decal, 1-800 number Decal, flag Decal, notice neutral bonded to frame Decal, warning (rotating parts) Decal, warning (hot engine) Tag, instruction (warning when mounting) Decal, transfer switch caution Decal, danger (voltage/rotor) Decal, electrical equipment Decal, Kohler Generator (black) Decal, fuel type Decal, danger high voltage Decal, notice fuel connection Decal, power breaker

1

1

1

1

1 1

1 1 1 1 1 1 1 1 1

1 1

1 1 1 1 1 1 1 1

1 1 1

1 1 1 1

1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1

29-4

29-5

1

1

53-5

1 1 1 1 1

1 1 1 1 1

1 1 1

1 1 1

1

1 1

1 1

1 1 1 1

1 1 1 1 1 1

21

Group 109: Skid and Plant Mounting 8.5RMY & 11RMY

3, 5, 3

10

7

8 11

14, 17

14, 17

4, 13, 15

8 11

14, 16, 17

4, 12, 15

14, 16, 17 View D-D

View E-E

8.5RES & 12RES

Starter Side View 9

10 18 20 19 Vibromount Detail 7 21

22

22 23

8 5868_109

TP-5868 1/04

Group 109: Skid and Plant Mounting Item

Part Number

1 2 3 4 5 6 7 8 9 10 10 10 10 11 12 13 14 15 16 17 18 19 20 21 22 23

X-101-13 X-22-12 X-22-16 X-25-96 M933-08020-60 X-67-115 229127 258659 290418 358137 358387 GM24791 GM29256 358285 X-6238-9 X-6238-10 X-125-3 # # # GM11040-2 GM11040-3 347176 GM29255 GM29982 X-781-14

Description

3

Nut, elastic stop, 3/8-16 Washer, lock, 1/4 in., interior/exterior tooth Washer, lock, 5/16 in., interior/exterior tooth Washer, plain, 0.406 in. ID Screw, hex head cap, M8-1.25 x 0.787 in. Screw, self-tapping, 1/4-20 Vibromount Vibromount Strap, ground, 8.0 in. Base, sub Base, sub Base, sub Base, sub Plate, mounting Bolt, hex cap, 3/8-16 x 3.0 Bolt, hex cap, 3/8-16 x 0.75 Bolt, hex cap, 5/16-18 x 0.75 Washer, plain, 3/8 Nut, 5/16 Washer, 5/16 Insert, threaded (6 mm) Insert, threaded (8 mm) Weight, balance Base, plastic mounting Channel, base support Rivit, pop, .187 in.

2 1 1 3 1 1 1 2 1 1

Qty. Variation No. 6 GR5 29-6 2 1 1 3 1 1 1 2 1

2 1 1 3 1 1 1 2 1

1

1

2 1 1 3 1 1 1 2 1

53-6

1 2 1

1 1 2 2 1 8 3 4 8

2 2 1 8 3 4 8

2 2 1 8 3 4 8

2 2 1 8 3 4 8 12 6 6 1 2 10

# Common hardware; procure locally.

TP-5868 1/04

23

Group 112: Starter Engine Front View

7

8, 7

1, 6 Items 7, 9 not shown.

2, 6

4, 9 2, 5

112-187-6a

Item

Part Number

1 1 2 3 3 4 5 6 7 8 9 10

X-22-12 X-22-11 X-22-16 X-545-133 X-545-155 X-545-134 M933-08020-60 X-67-115 238915 345079 GM20748 X-25-40

24

Qty. Variation No. GR2 29-1 29-2

Description

4

6

GR1

Washer, lock 1/4 in. interior/exterior tooth Washer, lock, .262 ID x .469 OD Washer, lock 5/16 in. interior/exterior tooth Cable, battery black (--), 22 in. Cable, battery black (--), 35.43 in. Cable, battery red (+), 44 in. Screw, hex head cap, M8-1.25 x 0.787 in. Screw, self-tapping, 1/4-20 Boot (not shown) Relay, cranking Boot, battery lug (not shown) Washer, plain, .281 ID x .625 in. OD

2

2

2

2

2

53-1

53-2

2 1

2 2 2 1

3 2 3 1

3 2 3

2 1

2 1

2 1

2 1

1 2 2 1 1

1 2 2 1 1

1 2 2 3 1 1

1 2 2 3 1 1

1 2 2 3 1 1

1 2 2 3 1 1

1 2

1 1 2

3 1 1 1

3 1 1 1

TP-5868 1/04

Notes

TP-5868 1/04

25

Group 116: Exhaust 8.5RMY & 11RMY 3, 12, 13

4, 5, 6, 10, 11

2

17 16

8, 9 18 1

7

14 15

8.5RES & 12RES 2 17 16

18

19 8, 9

5868_116

26

TP-5868 1/04

Group 116: Exhaust Item 1 2 2 3 3 4 4 5 5 6 6 7 7 8 9 10 11 12 13 14 15 16 17 18 19

Part Number 320828 358073 GM10138 358106 GM24800 358123 GM24802 358124 GM24803 358135 GM24804 358214 GM24801 358224 358306 X-781-8 X-25-45 X-465-2 # # # GM11720 X-722-8 345107 GM29983

Description Insert, threaded Muffler Silencer, exhaust Duct, exhaust top Duct, exhaust top Insulation, top Insulation, top Insulation, side Insulation, side Insulation Insulation Duct, exhaust bottom Duct, exhaust bottom Plug, oxygen test hole, M18 x 1.5 Gasket Rivet, 0.187 pop diameter Washer, plain, 0.208/0.198 ID Bolt, hex cap, 1/4-20 x 0.625 Washer, plain, 1/4 Hardware, 3/8-16 Hardware, 1/4-20 Elbow, exhaust tube Clamp, muffler, 1.37 in. Arrester, spark Shield, heat

3 4 1

Qty. Variation No. 6 GR6 29-7 4

4

4

1 1

1 1

1

1 1

1

1

2

2

2

1

1

1

1

1

1

1 1 10 10 4 4 2 2

1 1 10 10 4 4 2 2 1 1 1

1 1 10 10 4 4 2 2 1 1 1

53-1 1

1 1 1 1 1 1 1 10 10 4 4 2 2 1 1 1

1 1

1 1 1

# Common hardware; procure locally.

TP-5868 1/04

27

Group 201: Generator and Mounting

3, 9

8, 12 2, 4

21 19

12, 17 14

26

9, 16

13 28 8, 10 15

25 24 23 1, 5, 18

7

6 8, 22

31, 32

27 11

30

29

20

5868_201

28

TP-5868 1/04

Group 201: Generator and Mounting Item 1 2 3 4 5 6 6 7 8 9 10 11 12 12 13 14 15 16 17 18 19 20 20 20 21 22 23 24 25 26 27 28 29 30 31 32

TP-5868 1/04

Part Number X-22-24 X-22-6 X-468-3 X-49-1 X-49-35 X-6003-46 X-6003-123 X-634-5 X-67-113 X-97-13 227473 229239 229335 238150 238214 238247 238248 239247 239282 241623 256466 358014 GM10565 GM29774 358054 358056 358066 358067 358072 358090 358102 359654 A-358031 X-758-1 X-6024-2 X-25-34

Qty. Variation No. 10 GR7 29-8

Description

5

Washer, lock #4, internal tooth Washer, lock #6, internal tooth Tie, cable nylon Screw, pan head machine, #6-32 x 0.312 Screw, pan head machine, #4-40 x 0.875 Conduit, convoluted Conduit, convoluted Bushing, nylon, 0.375 ID Screw, self-tapping, 10-32 x 0.375 Screw, hex head machine, 10-32 x 0.438 Cover, brush holder Washer, overbolt Bracket, brush holder Spring Guard, generator fan Retainer, wire Shim, brush holder Holder, brush Brush Sensor, ferromagnetic O-ring Stator assembly Stator assembly Stator assembly Bracket, end Bracket, sensor mounting Actuator, magnetic Guard, alternator adapter Bolt, thru Harness, sensor Overbolt Adapter, generator Rotor assembly (includes 30) Bearing, ball Bolt, hex cap, 7/16-14 x 1.0 Washer, 7/16

2 2 3 2 2 1

2 2 3 2 2 1

2 2 3 2 2 1

2 2 3 2 2 1

1 8 5 1 4 1 2 1 1 2 1 2 1 1 1

1 8 5 1 4 1 2 1 1 2 1 2 1 1

1 8 5 1 4 1 2 1 1 2 1 2 1 1

1 8 5 1 4 1 2 1 1 2 1 2 1 1

1

1

1

1 1 1 1 1 1 4 1 1 1 4 4

1 1 1 1 1 1 4 1 1 1 4 4

1 1 1 1 1 1 4 1 1 1 4 4

53-7 2 3 2 1

1 1 1 1 1 1 4 1 1 1 4 4

6 5 1 4 1 2 1 1 2 1 2 1 1 1 1 1 1 4 1 1 1 4 4

29

Group 301: Controller and Mounting 8.5RMY & 11RMY

5, 6

24 Detail A

21

49

42 22

25 53

10

9

12 10 26

2

Detail B 50

8 9

36

32, 51 16, 33, 40, 51

32, 51

13, 19, 20

41

3

18, 30, 34, 39, 50

17, 35, 52

11, 14, 23, 31

55

27 See Detail B

4, 7, 15, 54

28 See Detail A

38

24

29, 37

29, 37 Front View Controller

24 11, 14, 23, 31

30

13, 19, 20 Top View Controller

301-187-4

TP-5868 1/04

Group 301: Controller and Mounting Item 1 1 1 2 2 3 4 5 6 7 8 9 10 11 12 13 13 14 15 16 17 18 19 20 13 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 41 41 42 43 44 45 46 278775 47 48 49 50 51 52 53 54 55

Part Number A-358076 B-358076 GM10615 B-358095 GM10064 C-284507 D-278670 F-278598 X-101-12 X-101-22 X-22-11 X-22-12 X-22-13 X-22-6 X-22-9 X-67-143 239332 X-49-39 X-49-46 X-49-6 X-50-1 X-50-70 X-506-43 358384 GM24928 X-634-14 X-6047-35 X-71-2 X-781-14 X-81-8 X-97-16 201620-152 201620-94 223316 238582 238736 241736 254821 254822 259391 267491 267996 287812 292940 295313 358086 GM10399 GM10616 GM10618 239408 239411 241605 269190 269366 278774 358145 # # # # X-25-48 269373

Description

4

Controller assembly (includes items 2--54) Controller assembly (includes items 2--54) Controller assembly (includes items 2, 4--12, 14--18, 21--55) PCB assembly, relay controller PCB assembly, relay controller PCB assembly, cyclic cranking Governor assembly, electronic PCB assembly, PB3E Nut, elastic stop, 10-32 Nut, elastic stop, 6-32 Washer, lock, 1/4, internal tooth Washer, lock, 1/4, interior/exterior tooth Washer, lock #10, interior/exterior tooth Washer, lock #6, interior/exterior tooth Washer, lock #10, internal tooth Screw, cross recess, sheet metal Clip, speed Screw, PHM 6-32 x 0.50 Screw, PHM 6-32 x 1.75 Screw, RHM 6-32 x 0.75 Screw, RHM 10-32 x 0.50 Screw, PHM 10-24 x 1.0 Breaker, circuit, 42 amp Breaker, circuit Breaker, circuit Bushing, nylon Channel, U Nut, hex, 8-32 Rivet, pop, 0.187, aluminum/aluminum Nut, hex, 1/4-20, green Screw, hex head machine, 10-24 x 1.0 Tab, identification, GRD Tab, identification, L0 Fuse, 10A Terminal Meter, hour Relay Marker, strip TB1 Marker, strip TB2 Relay, 20A Screw, hex cap, 1/4-20 x 1.0 Holder, fuse Switch, toggle Strip, terminal Block, terminal Box, silkscreen Box, silkscreen Box, silkscreen Harness, controller (includes 43--48) Connector, 4 pin, P2 Connector, 4 pin, J8 Connector, 12 pin, P7 Connector, 6 pin, P10 Connector, 15 in, P1 20 pin, P1 Connector, 20 pin, J4 Panel, controller bottom Nut, 10-24 Nut, 6-32 Nut, 10-32 Nut, 1/4-20 Washer, plain, .188 ID x .438 OD Lamp, 14 V, .33 W

1

9

Qty. Variation No. 10 GR8 29-9

29-11

1 1

1

1

1

1

1

1

1

1 1 4 4 1 2 2 2 1 4 4 2 4 2

1 1 4 4 1 2 2 2 1 4 4 2 4 2

1 1 4 4 1 2 2 2 1 4 4 2 4 2

1 1 4 4 1 2 2 2 1 4 4 2 4 2

1

1

1

1

1 1 2 5 1 1 1 1 2 4 1 2 1 1 1 1 2 1 1 1

1 1 2 5 1 1 1 1 2

1 1 2 5 1 1 1 1 2

1 1 2 5 1 1 1 1 2

1 1 1 2 5 1 1 1 1 2

1

1

1

1

1

1

1

1

1 2 1

1 2 1

1 2 1

1 2 1

1

1

1

1

1 1 1 1 1 1 1 1 1 2 2

1 1 1 1 1 1 1 1 1 2 2

1 1 1 1 1 1 1 1 1 2 2

1 1 1 1 1 1 1 1 1 2 2

1 4 1

1 4 1

1 4 1

1 4 1

1

1

1 1 1 4 4 1 2 2 2 1 4

1 1 1 4 4 1 2 2 2 1 4

2 4 2 1 2 1

2 4 2 1 2

1 1 2 5 1 1 1 1 2 4 1 2 1 1 1 1 2 1 1 1 1

1 1 1 1 1 1 1 1 1 4 2 2 1 4

1 1 1 1 1 1 1 1 4 2 2 1 4

# Common hardware; procure locally.

42

TP-5868 1/04

GM11693 269366

Harness, controller Connector, 15 pin, P1

1

1

1

1

31

Group 301: Controller and Mounting, continued 8.5RES & 12RES

15

6 7 8 17 15

15 Top View of Box

18

1 2

5 3 4

9

18

Ground Stud Location 16 12 13

20 21

12 14 14

GM29253

32

TP-5868 1/04

Group 301: Controller and Mounting, continued Item 1 2 3 4 5 6 7 8 9 12 13 14 15 16 17 18 19 20 21

Part Number 257442 X-50-15 GM30226 X-6216-1 GM29671 GM28483 X-51-5 X-101-11 GM29352 M6923-06-08 X-22-11 X-22-12 X-634-7 GM28707 X-25-118 361567 233959 223316 292937

Description Clip, speed Screw, slotted pan head machine Cover, controller Screw, Phillips hex crimptite Circuit board, relay board (12 V) SCR module Screw, slotted pan head machine 8-32 x 7/16 Nut, hex elastic stop, 8-32 Harness, engine wiring (includes items 19--21) Nut Washer, lock, .262 ID x .469 OD Washer, lock, .262 ID x .743 in. OD Bushing Controller, ADC 2100* Washer, plain, .406 ID x 1 in. OD Base, tie wrap snapin Diode, 6 A (not shown) Fuse, 10 A, 250 V (F2, F3) Fuse, 20 A, 250 V (F1)

Qty. Variation No. 53-8 4 4 1 2 1 1 2 4 1 2 2 4 3 1 2 3 2 2 1

* Refer to the generator set service manual for controller programming instructions.

TP-5868 1/04

33

Group 501: Housing and Mounting 8.5RMY & 11RMY Variation 1

5, 11, 19, 20

4

7, 8

15

5, 14, 19, 20 19, 20

12, 19, 20 13 5, 17, 19, 20

2, 5, 6

16 3, 18

1 9

5, 17, 19, 20 501-187-1

34

TP-5868 1/04

Group 501: Housing and Mounting Item

Part Number

Description

1 X-284-31 Grommet, 3.00 ID 2 X-284-45 Grommet, 0.31 ID 3 X-6340-2 Clip, panel fastener 4 294515 Latch, locking 5 320828 Insert, threaded 6 345283 Pin, threaded 7 358084 Duct, air intake 8 358097 Seal, foam, 9.75 ID 9 358098 Seal, foam, 10.75 ID 10 358136 Kit, heat insulation 11 358138 Panel, rear 12 358139 Panel, alternator end 13 358140 Panel, engine end 14 358141 Panel, top 15 358142 Door, housing 16 358143 Duct, engine intake 17 358146 Panel, access 18 358227 Guard, air inlet 19 X-465-2 Bolt, hex cap, 1/4-20 x 0.625 20 # Washer, plain, 1/4 # Common hardware; procure locally.

TP-5868 1/04

Qty. Variation No. 1 1 2 8 1 17 2 1 1 1 1 1 1 1 1 1 1 1 1 17 17

35

Group 501: Housing and Mounting, continued 8.5RMY & 11RMY Variations 4, GR9, 29-10

9, 38 28 (inside)

20 46

5

45

14, 30, 31, 32 15, 25, 34, 38 6, 39 2 10 7 22

Generator End

3, 8

Engine End

12, 22, 23 18, 33

13, 22, 24 11, 29

4

17, 22, 38

16, 22, 26, 27

36, 37

1, 22, 35 19, 3 21, 38 Items not shown: 40, 41, 42, 44

36

501-187-4 TP-5868 1/04

Group 501: Housing and Mounting, continued Item 1 2 3 4 5 5 6 7 8 9 10 11 12 13 13 14 14 15 15 16 17 18 19 20 21 22 23 23 24 24 25 25 26 27 27 28 28 29 30 30 31 31 32 32 33 33 33 34 34 35 36 37 38 39 40 41 42 43 44 45 46

TP-5868 1/04

Part Number X-284-45 X-284-31 X-6340-2 294515 243488 X-284-3 358143 358098 358227 358389 358393 358395 358416 358397 GM24795 358391 GM24793 358392 GM24794 358394 358415 358388 358396 358097 358417 320828 GM10060 GM25911 GM10040 GM25915 GM10047 GM24797 GM10051 GM10059 GM25913 GM10041 GM25914 GM10042 GM10045 GM24798 GM10048 GM24799 GM10049 GM25327 GM10038 GM10038 GM25916 GM10044 GM25912 345283 358142 GM10039 X-781-14 X-781-15 X-781-11 GM10137 GM10043 GM10046 X-301-45 X-634-16 GM15299

Description Grommet, round Grommet, round Clip, panel fastener Latch, locking Grommet, round Grommet, round Duct, engine intake Seal, foam Guard, air inlet Panel, access Panel, access Panel, access Duct, air, RS Panel, back Panel, back Duct, air intake, mounting Duct, air intake Duct, air intake, mounting Duct, air intake Panel, alternator end, outer Duct, air, LS Panel, top Guard, air inlet Seal, foam Duct, air, bottom Insert, threaded, 1/4-20 in. Insulation Insulation Insulation, 35.75 x 25.75 cm Insulation Insulation, 4.5 x 12.5 cm Insulation Insulation Insulation Insulation Insulation Insulation Insulation, 20.38 x 20.38 cm Insulation, 12.38 x 11.5 cm Insulation Insulation, 2 x 12.38 cm Insulation Insulation, 2 x 10.5 cm Insulation Insulation, 52 x 25 cm Insulation (intake end) Insulation (exhaust end) Insulation, 24 x 11.5 cm Insulation Pin, threaded Door, housing Insulation, 30.75 x 23.25 cm Rivet, pop, .187 in. Rivet, pop, .187 in. Rivet, pop, .187 in. (not shown) Insulation, controller side, 7.5 x 85 cm (not shown) Insulation controller back, 19 x 8.5 cm (not shown) Insulation, 7.5 x 12.5 cm Plug, button (not shown) Bushing, 1.312 x 1.50 in. NPT Decal, rainproof enclosure

Qty. Variation No. 4 GR9 29-10 2 1 24 1 1

2 1 24 1 1

1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1

1

1

1

1

1 1 1 2 1 2 25 2

1 1 1 2 1 2 25 2

1

1

1

1

1 1

1 1

1

1

1 1

1 1

1

2

2

1

1

1

2 1 24 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 25 1 1 1 1 1 1 1 1 1 2 1 1 1 1

1

1

2 1 1 20 4 5 1 1 1 1

2 1 1 20 4 5 1 1 1 1 2 1

1 2 1 1 24 4 5 1 1 1 4 2 1

37

Group 501: Housing and Mounting, continued 8.5RES & 12RES Variation 53-9

14 15

31

2

9 6 8

4 28

10

7

27

1

5 17

4 24 21

26

23

22

19

25 12

13 3

11

20

35

4

24

29 28 18

32

30

16

32 34 33

See Group 109

GM29253-GR9

38

TP-5868 1/04

Group 501: Housing and Mounting, continued Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

TP-5868 1/04

Part Number GM29258 X-6204-10 GM29270 X-301-24 GM29265 GM29261 GM11040-2 GM29269 GM29259 X-284-3 GM29260 GM29271 GM29268 GM29262 GM29350 GM29263 294515 GM29355 GM29266 GM29267 GM29272 GM29273 GM29274 X-6422-20 GM29357 X-634-27 GM30226 GM30219 GM30225 GM30937 GM29983 -GM29256 X-301-45 GM15299 GM31074-1

Description Housing, air intake duct Retainer, nut Insulation Plug, button Housing, controller mounting panel Housing, side panel Insert, threaded (metric) 6 mm Insulation Housing, front panel Grommet, round Housing, rear panel Insulation Insulation Housing, roof Insulation Housing, door Latch, locking Insulation Duct, alternator air Duct, alternator air Insulation Insulation Insulation Seal, push-on trim Shield, exhaust Bushing Cover, controller Duct, air intake Duct, air intake bottom Insulationm door Shield, heat See Group 105 Base Plug, button Decal, rainproof enclosure Bushing, molded (not shown)

Qty. Variation No. 53-9 1 5 1 6 1 1 11 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 1 2 1 4 1 2

39

Group 701: Literature Item 1 2 2 2 3 3 4

40

Part Number TP-2428-A TP-5865 TP-6049 TP-6195 TP-5867 TP-6196 TP-5868

Qty. Variation No. 9 11

Description

7

Service Manual, Kohler CH20/25 Operation Manual, 8.5/11RMY Operation Manual, 8.5/11RMY (sound enclosure models) Operation Manual, 8.5/12RES Service Manual, 8.5/11RMY Service Manual, 8.5/12RES Parts Catalog, 8.5/11RMY & 8.5/12RES

1 1 1

1 1 1

1

1

1

1

1

1

1

13 1

1 1 1 1

TP-5868 1/04

Kit Parts List Qty.

Description

Part No.

Fuel System Kit Gas Strainer 1

Strainer, gas

Flexible Fuel Line 1

Fuel line, flexible ( .50 in. ID x 12 in.)

1 1 1

Clamp, muffler, 2.12 in. Clamp, muffler, 1.37 in. Hose, flexible exhaust

Exhaust Elbow and Guard (for units without sound shields) 1 4 1 1 1 1

Clamp, muffler, 1.37 in. Screw, hex washer, thread-forming Guard, exhaust Arrester, spark Fitting, elbow, exhaust Installation instructions

292485

1

Battery, wet charged

Battery Heater 2 1 1

Tie, cable Heater, battery wrap Heater, battery pad

Battery Charger, Float 12 V, 6 A 1

Battery charger, 12 V, 6 A float-equalize

Battery Charger, Trickle Charger 1 1 1 2 1 9 2 4 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1

Installation Instructions Battery charger assembly Includes the following: Terminal Block, terminal Terminal, female Terminal, female Connector, non-metallic Screw, drill Holder, fuse Cord, power Cover, battery charger Ammeter, DC Transformer Spacer, screen Fuse, 1.5 A Lamp Resistor Switch, high/low slide Switch, 12/24 V slide Rectifier, silicon Resistor Cable, positive Cable, negative Nameplate, part number Breaker, circuit Rheostat Box battery charger

TP-5868 12/03

1 1 1

GM31054-KP1 X-504-1

358226 X-722-5 X-722-8 X-797-41

GM10671-KP1 X-722-8 X-67-133 GM10792 345107 337332 TT-1255

Electrical System Kits Battery

Description

Battery Charger, Equalize/Float PA-290275

Exhaust System Kit Flexible Exhaust Connector

Qty.

PA-324553 324367

PA-358225 X-468-1 336814 336825

GM11849-KP1 GM11849

PAA-248952 TT-938 A-248952

1 2 2 3 2 1 1 2 1 2 1 1 1 2 4 1 1 1 1 1 1 1 1 1 1 1 1 2 1 4 1 1 1

Installation Instructions Installation Instructions, circuit board Battery charger assembly Includes the following: Board, circuit Terminal, ring, 4--6 screw Terminal, ring, 8--10 screw Terminal, ring, 6--8 screw Tubing, heat shrink Decal, connection Fuse, 5 A Clip, speed Fuse, 25 A Holder, fuse Transformer Decal, warning Clip, cable Holder, fuse Spacer, circuit board Lamp Decal, explosion battery gases Sink, heat Strip, terminal Ammeter, DC Voltmeter, DC Module, SCR Resistor, power Fuse, 7 A Harness, wiring Marker, strip Marker, strip Retainer Block, terminal Nut, captive Box, battery charger Door, silkscreen Nameplate

Part No. PAD-292862 TT-680 TT-729 D-292862 C-262377 X-283-1 X-283-11 X-283-2 X-6081-3 233966 239298 257442 262389 263156 262394 262397 262399 263156 287948 291208 292387 292938 292940 292941 292942 292945 292947 292948 292958 292961 292962 295010 295314 298810 325593 325596 325609

X-283-8 X-405-2 X-431-27 X-431-28 X-567-1 X-794-2 238426 246185 246604 269202 269204 270833 291207 291208 291209 291210 291211 291212 291213 291215 291216 291221 291265 291975 325389

41

Kit Parts List Qty.

Description

Battery Charger, Equalize/Float (with alarms) 1 1 1 1 1 2 2 3 2 1 1 2 1 1 1 1 2 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1

Installation Instructions Installation Instructions, circuit board Battery charger assembly Includes the following: Board, circuit alarm Board, circuit Terminal, ring, 4--6 screw Terminal, ring, 8--10 screw Terminal, ring, 6--8 screw Tubing, heat shrink Decal, connection Fuse, 5 A Clip, speed Fuse, 25 A Transformer Decal, warning Clip, cable Holder, fuse Spacer, circuit board Lamp Decal, explosion battery gases Sink, heat Strip, terminal Ammeter, DC Voltmeter, DC Module, SCR Resistor, power Fuse, 7 A Harness, wiring Marker, strip Marker, strip Retainer Block, terminal Nut, captive Box, battery charger Door, silkscreen Nameplate

Relay, Run 4 1 2 2 1 1

Washer, plain Tie, cable Screw, pan head machine, #6-32 x 0.50 Nut, hex, #6-32 Relay assembly Installation instructions

Relay, Fault 1 1 1

Part No.

PAD-292863 TT-680 TT-729 D-292863 B-262374 C-262377 X-283-1 X-283-11 X-283-2 X-6081-3 233966 239298 257442 262389 262394 262397 262399 263156 287948 291208 292387 292938 292940 292941 292942 292945 292947 292948 292958 292961 292962 295010 295314 298810 325593 325596 325609

Miscellaneous Kits Air Outlet Duct Flange 4 4 4 8 2 2

Block Heater 1

GM16284-KA1 GM16283

GM19462-KP1

Heater, inlet 37 W, 120 V Tube, breather (.375 in. OD) copper Insulator, breather line Decal, caution hot carburetor Plug, button Screw, hex head Installation instructions

Carburetor Heater 12 VDC 2 1 1 1 1 1 1 1 1 1 2 4 1

X-25-36 X-50-8 X-6210-5 X-781-11 226930 226931

Heater, block

Carburetor Heater 120 V 1 1 1 1 1 4 1

PA-226932

Washer, plain Screw, RHM, 10-24 x 5/8 Nut, 10-24 Rivet, pop Flange, air duct (sides) Flange, air duct (top/bottom)

GM19463 GM19464 GM19465 GM22387 X-301-23 X-97-22 TT-1297

GM21285-KP1

Cover, blower housing Tube, breather (.375 in. OD) copper Insulator, breather line Heater, plate 37 W, 12 V Diode assembly Decal, caution hot carburetor Washer, plain, .188 ID x .438 in. OD Plug, button Screw, cross recess pan head machine Nut, flange whiz, 6-32 Screw, hex washer head, drill Screw, hex head Installation instructions

24 096 17 GM19464 GM19465 GM21278 GM21283 GM22387 X-25-48 X-301-23 X-49-6 X-6210-3 X-794-2 X-97-22 TT-1313

Paint 1 1

Generator paint, Kohler Cream Beige, spray can Generator paint, Kohler Cream Beige, gallon can

221338 221337

358371

Run/Common Fault Relay, 12 V

GM30414-KP1

42

Part No.

X-25-9 X-468-1 X-49-26 X-6210-3 273705 TT-700 X-50-1 259391 358375

PCB assembly, relay board 12 V Harness, wiring relay board

Description

PA-273743

Screw, slotted pan head machine Relay, 12 VDC, .20 A Harness, fault relay kit

1 1

Qty.

GM29779 GM30539

TP-5868 1/04

Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ABDC AC A/D ADC adj. ADV AHWT AISI ALOP alt. Al ANSI

AO API approx. AR AS ASE ASME assy. ASTM ATDC ATS auto. aux. A/V avg. AVR AWG AWM bat. BBDC BC BCA BCI BDC BHP blk. blk. htr. BMEP bps br. BTDC Btu Btu/min. C cal. CARB CB cc CCA ccw. CEC cert. cfh

ampere after bottom dead center alternating current analog to digital analog to digital converter adjust, adjustment advertising dimensional drawing anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute (formerly American Standards Association, ASA) anticipatory only American Petroleum Institute approximate, approximately as required, as requested as supplied, as stated, as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger, battery charging battery charging alternator Battery Council International before dead center brake horsepower black (paint color), block (engine) block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius, centigrade calorie California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate, certification, certified cubic feet per hour

TP-5868 1/04

cfm CG CID CL cm CMOS

cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate (semiconductor) cogen. cogeneration com communications (port) coml commercial Coml/Rec Commercial/Recreational conn. connection cont. continued CPVC chlorinated polyvinyl chloride crit. critical CRT cathode ray tube CSA Canadian Standards Association CT current transformer Cu copper cu. in. cubic inch cw. clockwise CWC city water-cooled cyl. cylinder D/A digital to analog DAC digital to analog converter dB decibel dBA decibel (A weighted) DC direct current DCR direct current resistance deg., ° degree dept. department dia. diameter DI/EO dual inlet/end outlet DIN Deutsches Institut fur Normung e. V. (also Deutsche Industrie Normenausschuss) DIP dual inline package DPDT double-pole, double-throw DPST double-pole, single-throw DS disconnect switch DVR digital voltage regulator E, emer. emergency (power source) EDI electronic data interchange EFR emergency frequency relay e.g. for example (exempli gratia) EG electronic governor EGSA Electrical Generating Systems Association EIA Electronic Industries Association EI/EO end inlet/end outlet EMI electromagnetic interference emiss. emission eng. engine EPA Environmental Protection Agency EPS emergency power system ER emergency relay ES engineering special, engineered special ESD electrostatic discharge est. estimated E-Stop emergency stop etc. et cetera (and so forth)

exh. ext. F fglass. FHM fl. oz. flex. freq. FS ft. ft. lbs. ft./min. g ga. gal. gen. genset GFI

exhaust external Fahrenheit, female fiberglass flat head machine (screw) fluid ounce flexible frequency full scale foot, feet foot pounds (torque) feet per minute gram gauge (meters, wire size) gallon generator generator set ground fault interrupter

GND, gov. gph gpm gr. GRD gr. wt. HxWxD HC HCHT HD HET

ground governor gallons per hour gallons per minute grade, gross equipment ground gross weight height by width by depth hex cap high cylinder head temperature heavy duty high exhaust temperature, high engine temperature hexagon mercury (element) hex head hex head cap horsepower hour heat shrink housing heating, ventilation, and air conditioning high water temperature hertz (cycles per second) integrated circuit inside diameter, identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal/external input/output iron pipe International Organization for Standardization joule Japanese Industry Standard

hex Hg HH HHC HP hr. HS hsg. HVAC HWT Hz IC ID IEC IEEE IMS in. in. H2O in. Hg in. lbs. Inc. ind. int. int./ext. I/O IP ISO J JIS

Appendix A-1

k K kA KB kg kg/cm2

kilo (1000) kelvin kiloampere kilobyte (210 bytes) kilogram kilograms per square centimeter kgm kilogram-meter kilograms per cubic meter kg/m3 kHz kilohertz kJ kilojoule km kilometer kOhm, kΩ kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical L liter LAN local area network L x W x H length by width by height lb. pound, pounds lbm/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 SI units), male cubic meter m3 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, mΩ milliohm MOhm, MΩ megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m/sec. meters per second

A-2 Appendix

MTBF MTBO mtg. MW mW µF N, norm. NA nat. gas NBS NC NEC NEMA

mean time between failure mean time between overhauls mounting megawatt milliwatt microfarad normal (power source) not available, not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association NFPA National Fire Protection Association Nm newton meter NO normally open no., nos. number, numbers NPS National Pipe, Straight NPSC National Pipe, Straight-coupling NPT National Standard taper pipe thread per general use NPTF National Pipe, Taper-Fine NR not required, normal relay ns nanosecond OC overcrank OD outside diameter OEM original equipment manufacturer OF overfrequency opt. option, optional OS oversize, overspeed OSHA Occupational Safety and Health Administration OV overvoltage oz. ounce p., pp. page, pages PC personal computer PCB printed circuit board pF picofarad PF power factor ph., ∅ phase PHC Phillips head crimptite (screw) PHH Phillips hex head (screw) PHM pan head machine (screw) PLC programmable logic control PMG permanent-magnet generator pot potentiometer, potential ppm parts per million PROM programmable read-only memory psi pounds per square inch pt. pint PTC positive temperature coefficient PTO power takeoff PVC polyvinyl chloride qt. quart, quarts qty. quantity R replacement (emergency) power source rad. radiator, radius RAM random access memory RDO relay driver output ref. reference rem. remote Res/Coml Residential/Commercial RFI radio frequency interference RH round head

RHM rly. rms rnd. ROM rot. rpm RS RTV SAE

round head machine (screw) relay root mean square round read only memory rotate, rotating revolutions per minute right side room temperature vulcanization Society of Automotive Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier s, sec. second SI Systeme international d’unites, International System of Units SI/EO side in/end out sil. silencer SN serial number SPDT single--pole, double--throw SPST single--pole, single--throw spec, specs specification(s) sq. square sq. cm square centimeter sq. in. square inch SS stainless steel std. standard stl. steel tach. tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to normal TDES time delay engine start TDNE time delay normal to emergency TDOE time delay off to emergency TDON time delay off to normal temp. temperature term. terminal TIF telephone influence factor TIR total indicator reading tol. tolerance turbo. turbocharger typ. typical (same in multiple locations) UF underfrequency UHF ultrahigh frequency UL Underwriter’s Laboratories, Inc. UNC unified coarse thread (was NC) UNF unified fine thread (was NF) univ. universal US undersize, underspeed UV ultraviolet, undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency W watt WCR withstand and closing rating w/ with w/o without wt. weight xfmr transformer

TP-5868 1/04

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.

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.

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.

3. Follow these SAE washer rules after determining exit hole type: a. Always use a washer between hardware and a slot.

Preferred Nut/Bolt Clearance 1

b. Always use a washer under a nut (see 2 above for exception).

2

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. Unacceptable Nut/Bolt Clearance 3

2

1

3 G-585

1. 1/2 of bolt diameter 2. Min. 1 full thread beyond top of nut 3. Below top of nut

Figure 1

Acceptable Bolt Lengths 5 4

6

G-585

1. 2. 3. 4. 5. 6.

Cap screw Entry hole types Standard nut and SAE washer Whiz nut or spiralock: up to 1/2 in. dia. hardware Weld nuts: above 1/2 in. dia. hardware Exit hole types

Figure 2

TP-5868 1/04

Acceptable Hardware Combinations

Appendix A-3

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

Size

Assembled into Aluminum Grade 2 or 5

Assembled into Cast Iron or Steel

Torque Measurement

Grade 2

Grade 5

Grade 8

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)

27.0

(20)

3/8-24

Nm (ft. lb.)

27.0

(20)

42.0

(31)

60.0

(44)

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 Size (mm)

A-4 Appendix

Grade 5.8

Grade 8.8

Grade 10.9

Assembled into Aluminum 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)

—

TP-5868 1/04

Appendix D Common Hardware Identification Screw/Bolts/Studs

Nuts

Hardness Grades

Head Styles

Nut Styles

American Standard

Hex Head or Machine Head

Hex Head

Grade 2

Hex Head or Machine Head with Washer

Lock or Elastic

Grade 5

Flat Head (FHM)

Square

Grade 8

Round Head (RHM)

Cap or Acorn

Grade 8/9 (Hex Socket Head)

Pan Head

Wing

Hex Socket Head Cap or Allent Head Cap

Washers

Metric 5.8

Washer Styles

Hex Socket Head or Allent Head Shoulder Bolt

Plain

Sheet Metal Screw

Split Lock or Spring

Stud

Spring or Wave

Drive Styles

Number stamped on hardware; 5.8 shown

External Tooth Lock

Hex Internal Tooth Lock Hex and Slotted Internal-External Tooth Lock Phillipsr Slotted Hex Socket Allent head screw is a trademark of Holo-Krome Co. Phillipsr screw is a registered trademark of Phillips Screw Company.

Sample Dimensions American Standard (Screws, Bolts, Studs, and Nuts) 1/4-20 x 1 Length In Inches (Screws and Bolts)

Plain Washers 9/32 x 5/8 x 1/16 Thickness

Threads Per Inch

External Dimension

Major Thread Diameter In Fractional Inches Or Screw Number Size

Internal Dimension

Metric (Screws, Bolts, Studs, and Nuts) M8-1.25 x 20 Length In Millimeters (Screws and Bolts) Distance Between Threads In Millimeters

Lock Washers 5/8 Internal Dimension

Major Thread Diameter In Millimeters

TP-5868 1/04

Appendix A-5

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)

Part No. Dimensions Hex Head Bolts, cont.

Part No.

X-465-17 X-465-6 X-465-2 X-465-16 X-465-18 X-465-7 X-465-8 X-465-9 X-465-10 X-465-11 X-465-12 X-465-14 X-465-21 X-465-25 X-465-20

1/4-20 x .38 1/4-20 x .50 1/4-20 x .62 1/4-20 x .75 1/4-20 x .88 1/4-20 x 1.00 1/4-20 x 1.25 1/4-20 x 1.50 1/4-20 x 1.75 1/4-20 x 2.00 1/4-20 x 2.25 1/4-20 x 2.75 1/4-20 x 5.00 1/4-28 x .38 1/4-28 x 1.00

X-6238-14 X-6238-16 X-6238-21 X-6238-22

3/8-24 x .75 3/8-24 x 1.25 3/8-24 x 4.00 3/8-24 x 4.50

X-6009-1

1-8

Standard

X-6024-5 X-6024-2 X-6024-8 X-6024-3 X-6024-4 X-6024-11 X-6024-12

7/16-14 x .75 7/16-14 x 1.00 7/16-14 x 1.25 7/16-14 x 1.50 7/16-14 x 2.00 7/16-14 x 2.75 7/16-14 x 6.50

X-6210-3 X-6210-4 X-6210-5 X-6210-1

6-32 8-32 10-24 10-32

Whiz Whiz Whiz Whiz

X-125-33 X-125-23 X-125-3 X-125-31 X-125-5 X-125-24 X-125-34 X-125-25 X-125-26 230578 X-125-29 X-125-27 X-125-28 X-125-22 X-125-32 X-125-35 X-125-36 X-125-40

5/16-18 x .50 5/16-18 x .62 5/16-18 x .75 5/16-18 x .88 5/16-18 x 1.00 5/16-18 x 1.25 5/16-18 x 1.50 5/16-18 x 1.75 5/16-18 x 2.00 5/16-18 x 2.25 5/16-18 x 2.50 5/16-18 x 2.75 5/16-18 x 3.00 5/16-18 x 4.50 5/16-18 x 5.00 5/16-18 x 5.50 5/16-18 x 6.00 5/16-18 x 6.50

X-129-15 X-129-17 X-129-18 X-129-19 X-129-20 X-129-21 X-129-22 X-129-23 X-129-24 X-129-25 X-129-27 X-129-29 X-129-30 X-463-9 X-129-44

1/2-13 x .75 1/2-13 x 1.00 1/2-13 x 1.25 1/2-13 x 1.50 1/2-13 x 1.75 1/2-13 x 2.00 1/2-13 x 2.25 1/2-13 x 2.50 1/2-13 x 2.75 1/2-13 x 3.00 1/2-13 x 3.50 1/2-13 x 4.00 1/2-13 x 4.50 1/2-13 x 5.50 1/2-13 x 6.00

X-6210-2 X-6210-6 X-6210-7 X-6210-8 X-6210-9 X-6210-10 X-6210-11 X-6210-12 X-6210-15 X-6210-14

1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24 7/16-14 1/2-13 7/16-20 1/2-20

Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock

X-85-3 X-88-12 X-89-2

5/8-11 3/4-10 1/2-20

Standard Standard Standard

X-129-51 X-129-45 X-129-52

1/2-20 x .75 1/2-20 x 1.25 1/2-20 x 1.50

X-125-43 X-125-44 X-125-30 X-125-39 X-125-38

5/16-24 x 1.75 5/16-24 x 2.50 5/16-24 x .75 5/16-24 x 2.00 5/16-24 x 2.75

X-6238-2 X-6238-10 X-6238-3 X-6238-11 X-6238-4 X-6238-5 X-6238-1 X-6238-6 X-6238-17 X-6238-7 X-6238-8 X-6238-9 X-6238-19 X-6238-12 X-6238-20 X-6238-13 X-6238-18 X-6238-25

3/8-16 x .62 3/8-16 x .75 3/8-16 x .88 3/8-16 x 1.00 3/8-16 x 1.25 3/8-16 x 1.50 3/8-16 x 1.75 3/8-16 x 2.00 3/8-16 x 2.25 3/8-16 x 2.50 3/8-16 x 2.75 3/8-16 x 3.00 3/8-16 x 3.25 3/8-16 x 3.50 3/8-16 x 3.75 3/8-16 x 4.50 3/8-16 x 5.50 3/8-16 x 6.50

X-6021-3 X-6021-4 X-6021-2 X-6021-1 273049 X-6021-5 X-6021-6 X-6021-7 X-6021-12 X-6021-11 X-6021-10

5/8-11 x 1.00 5/8-11 x 1.25 5/8-11 x 1.50 5/8-11 x 1.75 5/8-11 x 2.00 5/8-11 x 2.25 5/8-11 x 2.50 5/8-11 x 2.75 5/8-11 x 3.75 5/8-11 x 4.50 5/8-11 x 6.00

X-6021-9

5/8-18 x 2.50

X-6239-1 X-6239-8 X-6239-2 X-6239-3 X-6239-4 X-6239-5 X-6239-6

3/4-10 x 1.00 3/4-10 x 1.25 3/4-10 x 1.50 3/4-10 x 2.00 3/4-10 x 2.50 3/4-10 x 3.00 3/4-10 x 3.50

X-792-1 X-792-5 X-792-8

1-8 x 2.25 1-8 x 3.00 1-8 x 5.00

A-6 Appendix

Dimensions

Type

Hex Nuts

Washers Part No.

ID

X-25-46 .125 X-25-9 .156 X-25-48 .188 X-25-36 .219 X-25-40 .281 X-25-85 .344 X-25-37 .406 X-25-34 .469 X-25-26 .531 X-25-15 .656 X-25-29 .812 X-25-127 1.062

OD .250 .375 .438 .500 .625 .687 .812 .922 1.062 1.312 1.469 2.000

Bolt/ Thick. Screw .022 .049 .049 .049 .065 .065 .065 .065 .095 .095 .134 .134

#4 #6 #8 #10 1/4 5/16 3/8 7/16 1/2 5/8 3/4 1

TP-5868 1/04

Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Hex Head Bolts (Partial Thread) M931-05055-60 M931-06040-60 M931-06055-60 M931-06060-60 M931-06060-SS M931-06070-60 M931-06070-SS M931-06075-60 M931-06090-60 M931-06145-60 M931-06150-60

M5-0.80 x 55 M6-1.00 x 40 M6-1.00 x 55 M6-1.00 x 60 M6-1.00 x 60 M6-1.00 x 70 M6-1.00 x 70 M6-1.00 x 75 M6-1.00 x 90 M6-1.00 x 145 M6-1.00 x 150

M931-08035-60 M931-08040-60 M931-08045-60 M931-08050-60 M931-08055-60 M931-08055-82 M931-08060-60 M931-08070-60 M931-08070-82 M931-08075-60 M931-08080-60 M931-08090-60 M931-08095-60 M931-08100-60 M931-08110-60 M931-08120-60 M931-08130-60 M931-08140-60 M931-08150-60 M931-08200-60

M8-1.25 x 35 M8-1.25 x 40 M8-1.25 x 45 M8-1.25 x 50 M8-1.25 x 55 M8-1.25 x 55* M8-1.25 x 60 M8-1.25 x 70 M8-1.25 x 70* M8-1.25 x 75 M8-1.25 x 80 M8-1.25 x 90 M8-1.25 x 95 M8-1.25 x 100 M8-1.25 x 110 M8-1.25 x 120 M8-1.25 x 130 M8-1.25 x 140 M8-1.25 x 150 M8-1.25 x 200

M931-10040-82 M931-10040-60 M931-10045-60 M931-10050-60 M931-10050-82 M931-10055-60 M931-10060-60 M931-10065-60 M931-10070-60 M931-10080-60 M931-10080-82 M931-10090-60 M931-10090-82 M931-10100-60 M931-10110-60 M931-10120-60 M931-10130-60 M931-10140-60 M931-10180-60 M931-10235-60 M931-10260-60 M960-10330-60

M10-1.25 x 40* M10-1.50 x 40 M10-1.50 x 45 M10-1.50 x 50 M10-1.25 x 50* M10-1.50 x 55 M10-1.50 x 60 M10-1.50 x 65 M10-1.50 x 70 M10-1.50 x 80 M10-1.25 x 80* M10-1.50 x 90 M10-1.50 x 90* M10-1.50 x 100 M10-1.50 x 110 M10-1.50 x 120 M10-1.50 x 130 M10-1.50 x 140 M10-1.50 x 180 M10-1.50 x 235 M10-1.50 x 260 M10-1.25 x 330

M931-12045-60 M960-12050-60 M960-12050-82 M931-12050-60 M931-12050-82 M931-12055-60 M931-12060-60 M931-12060-82 M931-12065-60 M931-12075-60 M931-12080-60 M931-12090-60 M931-12100-60 M931-12110-60

M12-1.75 x 45 M12-1.25 x 50 M12-1.25 x 50* M12-1.75 x 50 M12-1.75 x 50* M12-1.75 x 55 M12-1.75 x 60 M12-1.75 x 60* M12-1.75 x 65 M12-1.75 x 75 M12-1.75 x 80 M12-1.75 x 90 M12-1.75 x 100 M12-1.75 x 110

Part No. Dimensions Hex Head Bolts (Partial Thread), continued

Part No. Dimensions Hex Head Bolts (Full Thread), continued

M960-16090-60 M931-16090-60 M931-16100-60 M931-16100-82 M931-16120-60 M931-16150-60

M16-1.50 x 90 M16-2.00 x 90 M16-2.00 x 100 M16-2.00 x 100* M16-2.00 x 120 M16-2.00 x 150

M931-20065-60 M931-20090-60 M931-20100-60 M931-20120-60 M931-20140-60 M931-20160-60

M20-2.50 x 65 M20-2.50 x 90 M20-2.50 x 100 M20-2.50 x 120 M20-2.50 x 140 M20-2.50 x 160

M933-12016-60 M933-12020-60 M961-12020-60F M933-12025-60 M933-12025-82 M961-12030-60 M933-12030-82 M961-12030-82F M933-12030-60 M933-12035-60 M961-12040-82 M933-12040-60 M933-12040-82

M12-1.75 x 16 M12-1.75 x 20 M12-1.50 x 20 M12-1.75 x 25 M12-1.75 x 25* M12-1.25 x 30 M12-1.75 x 30* M12-1.50 x 30* M12-1.75 x 30 M12-1.75 x 35 M12-1.25 x 40* M12-1.75 x 40 M12-1.75 x 40*

M931-22090-60 M931-22120-60 M931-22160-60

M22-2.50 x 90 M22-2.50 x 120 M22-2.50 x 160

M961-14025-60 M933-14025-60 M961-14050-82

M14-1.50 x 25 M14-2.00 x 25 M14-1.50 x 50*

M931-24090-60 M931-24120-60 M931-24160-60 M931-24200-60

M24-3.00 x 90 M24-3.00 x 120 M24-3.00 x 160 M24-3.00 x 200

M961-16025-60 M933-16025-60 M961-16030-82 M933-16030-82 M933-16035-60 M961-16040-60 M933-16040-60 M961-16045-82 M933-16045-82 M933-16050-60 M933-16050-82 M933-16060-60 M933-16070-60

M16-1.50 x 25 M16-2.00 x 25 M16-1.50 x 30* M16-2.00 x 30* M16-2.00 x 35 M16-1.50 x 40 M16-2.00 x 40 M16-1.50 x 45* M16-2.00 x 45* M16-2.00 x 50 M16-2.00 x 50* M16-2.00 x 60 M16-2.00 x 70

M933-18035-60 M933-18050-60 M933-18060-60

M18-2.50 x 35 M18-2.50 x 50 M18-2.50 x 60

M933-20050-60 M933-20055-60

M20-2.50 x 50 M20-2.50 x 55

M933-24060-60 M933-24065-60 M933-24070-60

M24-3.00 x 60 M24-3.00 x 65 M24-3.00 x 70

Hex Head Bolts (Full Thread) M933-04006-60

M4-0.70 x 6

M933-05030-60 M933-05035-60 M933-05050-60

M5-0.80 x 30 M5-0.80 x 35 M5-0.80 x 50

M933-06010-60 M933-06012-60 M933-06014-60 M933-06016-60 M933-06020-60 M933-06025-60 M933-06030-60 M933-06040-60 M933-06050-60

M6-1.00 x 10 M6-1.00 x 12 M6-1.00 x 14 M6-1.00 x 16 M6-1.00 x 20 M6-1.00 x 25 M6-1.00 x 30 M6-1.00 x 40 M6-1.00 x 50

M933-07025-60

M7-1.00 x 25

M933-08010-60 M933-08012-60 M933-08016-60 M933-08020-60 M933-08025-60 M933-08030-60 M933-08030-82

M8-1.25 x 10 M8-1.25 x 12 M8-1.25 x 16 M8-1.25 x 20 M8-1.25 x 25 M8-1.25 x 30 M8-1.25 x 30*

M933-10012-60 M961-10020-60 M933-10020-60 M933-10025-60 M961-10025-60 M933-10025-82 M961-10030-60 M933-10030-60 M933-10030-82 M961-10035-60 M933-10035-60 M933-10035-82 M961-10040-60

M10-1.50 x 12 M10-1.25 x 20 M10-1.50 x 20 M10-1.50 x 25 M10-1.25 x 25 M10-1.50 x 25* M10-1.25 x 30 M10-1.50 x 30 M10-1.50 x 30* M10-1.25 x 35 M10-1.50 x 35 M10-1.50 x 35* M10-1.25 x 40

Pan Head Machine Screws M7985A-03010-20 M3-0.50 x 10 M7985A-03012-20 M3-0.50 x 12 M7985A-04010-20 M7985A-04016-20 M7985A-04020-20 M7985A-04050-20 M7985A-04100-20

M4-0.70 x 10 M4-0.70 x 16 M4-0.70 x 20 M4-0.70 x 50 M4-0.70 x 100

M7985A-05010-20 M7985A-05012-20 M7985A-05016-20 M7985A-05020-20 M7985A-05025-20 M7985A-05030-20 M7985A-05080-20 M7985A-05100-20

M5-0.80 x 10 M5-0.80 x 12 M5-0.80 x 16 M5-0.80 x 20 M5-0.80 x 25 M5-0.80 x 30 M5-0.80 x 80 M5-0.80 x 100

M7985A-06100-20 M6-1.00 x 100

Flat Head Machine Screws M965A-04012-SS

M4-0.70 x 12

M965A-05012-SS M965A-05016-20 M965A-06012-20

M5-0.80 x 12 M5-0.80 x 16 M6-1.00 x 12

* This metric hex bolt’s hardness is grade 10.9.

TP-5868 1/04

Appendix A-7

Metric, continued Part No. Hex Nuts

Dimensions

Type

M934-03-50

M3-0.50

Standard

M934-04-50 M934-04-B

M4-0.70 M4-0.70

Standard Brass

M934-05-50

M5-0.80

Standard

M934-06-60 M934-06-64 M6923-06-80 M982-06-80

M6-1.00 M6-1.00 M6-1.00 M6-1.00

Standard Std. (green) Spiralock Elastic Stop

M934-08-60 M6923-08-80 M982-08-80

M8-1.25 M8-1.25 M8-1.25

Standard Spiralock Elastic Stop

M934-10-60 M934-10-60F M6923-10-80 M6923-10-62 M982-10-80

M10-1.50 M10-1.25 M10-1.50 M10-1.50 M10-1.50

Standard Standard Spiralock Spiralock[ Elastic Stop

M934-12-60 M934-12-60F M6923-12-80 M982-12-80

M12-1.75 M12-1.25 M12-1.75 M12-1.75

Standard Standard Spiralock Elastic Stop

M982-14-60

M14-2.00

Elastic Stop

M6923-16-80 M982-16-80

M16-2.00 M16-2.00

Spiralock Elastic Stop

M934-18-80 M982-18-60

M18-2.5 M18-2.50

Standard Elastic Stop

M934-20-80 M982-20-80

M20-2.50 M20-2.50

Standard Elastic Stop

M934-22-60

M22-2.50

Standard

M934-24-80 M982-24-60

M24-3.00 M24-3.00

Standard Elastic Stop

M934-30-80

M30-3.50

Standard

Washers Part No. M125A-03-80 M125A-04-80 M125A-05-80 M125A-06-80 M125A-08-80 M125A-10-80 M125A-12-80 M125A-14-80 M125A-16-80 M125A-18-80 M125A-20-80 M125A-24-80

ID 3.2 4.3 5.3 6.4 8.4 10.5 13.0 15.0 17.0 19.0 21.0 25.0

Bolt/ OD Thick. Screw 7.0 9.0 10.0 12.0 16.0 20.0 24.0 28.0 30.0 34.0 37.0 44.0

0.5 0.8 1.0 1.6 1.6 2.0 2.5 2.5 3.0 3.0 3.0 4.0

M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24

[ This metric hex nut’s hardness is grade 8.

A-8 Appendix

TP-5868 1/04

KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales and service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com

TP-5868 1/04f E 2004, 2002 by Kohler Co. All rights reserved.

Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65)264-6422, Fax (65)264-6455