Service Parts

Industrial Generator Sets

Models:
650--1000REOZDB
See Group 701: Literature, inside this manual for
part numbers of engine and accessory parts catalogs

See TP-6009 Parts Catalog Industrial Controllers

for controller parts

TP-6284 5/04
 Table of Contents
Subject Page Subject Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Group 201: Generator and Mounting . . . . . . . . 14
Numbering System Significance . . . . . . . . . . . . . 1 Alternator Part Number and Mount Type . . . . 16
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Control and Harness . . . . . . . . . . . . . . . . . . . . . . . 18
How to Find Part Numbers . . . . . . . . . . . . . . . . . . 1 Group 701: Literature . . . . . . . . . . . . . . . . . . . . . . 20
Hardware References . . . . . . . . . . . . . . . . . . . . . . 1 Kit List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Specification Number Index . . . . . . . . . . . . . . . . . 2 Cooling System Kits . . . . . . . . . . . . . . . . . . . . . . . 22
Group 101: Air Intake . . . . . . . . . . . . . . . . . . . . . 4 Appendix A Abbreviations . . . . . . . . . . . . . . . . . . A-1
Group 104: Cooling System . . . . . . . . . . . . . . . . 6 Appendix B Common Hardware
Group 105: Engine . . . . . . . . . . . . . . . . . . . . . . . . 10 Application Guidelines . . . . . . . . . . . . . . . . . . . A-3
Routine Engine Service Parts . . . . . . . . . . . . . . 11 Appendix C General Torque Specifications . . . . A-4
Group 107: Nameplate and Decals . . . . . . . . . . 11 Appendix D Common Hardware Identification . A-5
Group 109: Skid and Plant Mounting . . . . . . . . 12 Appendix E Common Hardware List . . . . . . . . . A-6
 Introduction
This manual lists service replacement parts for How to Find Part Numbers
650--1000REOZDB generator sets.
Use the following steps to locate a service replacement
At the time of print this manual applied to the generator part.
set specification (spec) numbers listed in the
Specification Number Index. On occasion this manual 1. Locate the generator set nameplate to identify the
may apply to specs not listed in the Specification generator set spec number.
Number Index. 2. Locate a second generator set nameplate listing
Information in this publication represents data available accessories to identify installed modules. On
at the time of print. Kohler Co. reserves the right to some models the accessory nameplate is mounted
change this publication and the products represented inside the generator junction box.
without notice and without any obligation or liability 3. Turn to the Specification Number Index. The
whatsoever. first column lists the generator set spec numbers.
This manual includes the following main sections: The headings identify the groups of parts that make
up the generator set.
Table of Contents. Lists the sections of the manual.
4. Identify the group most likely to include the
Introduction (and other information sections). service part number.
Contains introductory material about part numbers,
illustrations, and hardware. 5. Find the group variation number at the
intersection of the spec number row and the group
Specification Number Index. Lists the generator set column. Note the variation number.
specs and groups.
6. Page forward to locate the group identified in
Group Parts Lists. List the part numbers of parts in the step 4 or find the appropriate page in the Table of
groups. Contents.
Kit Sections. List modules and accessories and their 7. Find the part on the illustration and note the item
parts. number of the part or find the part description in
the parts list.
Appendices. Include Abbreviations, Common
Hardware Application Guidelines, General Torque 8. Select the part number that corresponds to
Specifications, Common Hardware Identification, and your group variation. The first column lists the
Common Hardware List. illustration item number. Find the variation
x:in:004:002 identified in the Specification Number Index or the
Numbering System Significance module number found on the generator set
nameplate in the appropriate column on the right
This manual uses the following numbering systems: side of the parts list table. Find the quantity used at
Specification Number. The product identification the intersection of the item number row and the
number located on the generator set nameplate. variation column. A blank space at the intersection
Specification numbers break down into groups. means the variation/module does not use that part
number.
Group Number. A unique number representing a parts x:in:004:005
group needed to assemble a generator set function. For Hardware References
example, Group 101 is the Air Intake group.
Many common hardware items do not appear in parts
Variation or Module Number. A group might have manuals or will appear as common hardware entries. A
several variations. Each variation performs the same common hardware entry lists the size of the hardware.
function with different parts lists. For example, a 50 Hz For example, an item that appears as “Hardware,
generator alternator and a 60 Hz generator alternator 3/8-16” in the text means that the piece is 3/8-16 size.
both perform the same function; however, with different Obtain common hardware locally or, if contacting the
parts. Each difference requires a group variation or factory, use the Common Hardware List in the appendix
module number. to identify the common hardware part number and
Part Number. The part number identifies an individual specifications. See Common Hardware Application
assembly, subassembly, component, or accessory kit. Guidelines in the appendix for mating hardware
x:in:004:003:a instructions.
Illustrations Some hardware items require a specific size or some
Illustrations (or exploded-view drawings) best other characteristic. In that case, use the part number
representing the widest range of variations accompany listed in the text.
most groups in this manual. Illustrations do not depict all When replacing hardware, do not substitute inferior
details and may not show all parts. Do not use grade hardware. Replacement hardware grade should
illustrations for assembly or disassembly. be equal to or better than the grade of the
x:in:004:004a manufacturer’s original hardware. Use the Common
Hardware List in the appendix to identify the common
hardware hardness.
x:in:004:006

TP-6284 5/04 1
 Specification Number Index

Group Title

Group No. 101 104 105 107 109 201 301 701
Spec No. Variation Number

Model
650REOZDB
GM30408-GA1 * * 1 GR1 * * [ 206
GM30408-GA2 * * 2 GR1 * * [ 209
750REOZDB
GM30408-GA3 * * 3 GR1 * * [ 208
GM30408-GA4 * * 4 GR1 * * [ 208
900REOZDB
GM30408-GA5 * * 5 GR1 * * [ 210
GM30408-GA6 * * 6 GR1 * * [ 210
1000REOZDB
GM30408-GA7 * * 7 GR1 * * [ 212
GM30408-GA8 * * 8 GR1 * * [ 212
* Configured group. Refer to the generator set nameplate for the module number. Turn to the respective group on the following
pages for parts breakdowns.
[ Configured group. Refer to the generator set nameplate for the module number. See TP-6009 P/C Controllers
for controller parts lists.

2 TP-6284 5/04
 Notes

TP-6284 5/04 3
Group 101: Air Intake
Left Side 17 13
Right Side 16 10
5
6 10
4
10
7 10
12
10 14
13
3 7
8 7
3 15
9 11
1
7
10

13
10
2 12
18
10
19
10

14

15
7 6284_101

4 TP-6284 5/04
 Group 101: Air Intake
Quantity
Module
Item Part Number Description GM24329-MA2 GM31567-MA1
1 GM28399 Air cleaner assembly 2
2 GM30578 Clamp, hose 2
3 279715 Mount, air cleaner (18.00 in. ID) 4
4 A-279714 Air cleaner assembly (DDC) (right side) 1
5 279738 Element, air cleaner (primary) 1
6 279722 Cap, rain 2
7 279743 Clamp, hose, 8.38/8.69 in. 6
8 GM23518 Hose, hump (8.00” ID) 1
9 X-522-112 Tube, steel 1
10 279717 Clamp, hose, 8.63/8.94 in. 8
11 347957 Hose, 45 deg. elbow (8.00 in. ID) 1
12 X-522-115 Tube, steel 2
13 GM23519 Hose, 90 deg. elbow (8.00 ID) 3
14 X-522-114 Tube, steel 2
15 GM28302 Hose, straight air (8.00 in. ID) 2
16 A-361366 Air cleaner assembly (left side) 1
17 279738 Element, air cleaner 1
18 GM31566 Brace, air cleaner heavy duty 1
19 GM31563 Bracket, heavy duty air cleaner 1

TP-6284 5/04 5
Group 104: Cooling System

47
48

46
41 26
42 27 5
64 2 6
43 3 7
1
44 4 8
40 9
10
23 38
24 39
25

37
28 22
29
30
31
32

36 33 21
34 13
45 14
35 20
15
59 11 16
60 17 12
49 18 63
19
To radiator vent line
50 51

52

56

55

57

54

61

53

58

GM31745

6 TP-6284 5/04
 Group 104: Cooling System
Quantity
Module

GM30703-MA1
GM30954-MA1
GM30954-MA2
GM31745-MA1
GM31763-MA1
Item Part Number Description
1 GM30483 Radiator assembly 1 1
1 GM30485 Radiator assembly 1
1 GM30484 Radiator assembly 1
1 GM30486 Radiator assembly 1
2 GM30405 Hose, reducer 1 1 1 1 1
3 274824 Clamp, hose, 3.68/4 in. 1 1 1 1 1
4 291542 Clamp, hose, 3.25/3.56 in. 1 1 1 1 1
5 X-281-31 Hose, radiator, straight, 2 in. ID 1 1 1 1 1
6 249887 Clamp, hose, 2.25/2.56 in. 2 2 2 2 2
7 X-6359-16 Hose, rubber 1 1
7 X-6359-14 Hose, rubber 1 1 1
8 X-426-9 Clamp, hose, .25/.70 in. 2 2 2 2 2
9 X-6359-7 Hose, rubber, straight, .25 in. ID 1 1 1 1 1
10 X-426-9 Clamp, hose, .25/.70 in. 2 2 2 2 2
11 GM32036 Bracket, coolant tube 1 1
11 GM30400 Bracket, water tube 1 1
11 GM32037 Bracket, coolant tube 1
12 286283 Clamp, muffler, 3.12 in. 1 1 1 1 1
13 GM30351 Support, radiator (rh) 1 1 1 1
14 GM30352 Support, radiator (lh) 1 1 1 1
15 X-801-9 Washer,hardened,.688 ID x 1.373 in. OD 4 4 4 4
16 X-6011-3 Washer, beveled, .68 ID x 1.5 in. OD 4 4 4 4
17 GM31741 Tube, lower radiator (jacket water) 1 1
17 GM30403 Tube, lower radiator 1 1
17 GM31758 Tube, lower radiator 1
18 X-507-7 Hose, radiator, straight, 3 in. ID 1 1 1 1 1
19 291542 Clamp, hose, 3.25/3.56 in. 2 2 2 2 2
20 X-256-1 Valve, drain ( 3/8 in. NPT) 2 2 2 2 2
21 GM30330 Support, radiator 1 1 1
21 GM33878 Support, radiator (rh) 1
22 X-801-9 Washer, hardened, .688 ID x 1.373 in. OD 4 4 4 4
23 299892 Fan, pusher 1 1 1 1
23 GM31749 Fan, pusher 1
24 X-129-57 Bolt, hex cap 6 6 6 6 6
25 290945 Washer, hardened, .531 ID x 1.06 in. OD 6 6 6 6 6
26 X-281-31 Hose, radiator, straight, 2 in. ID 1 1 1 1 1
27 249887 Clamp, hose, 2.25/2.56 in. 2 2 2 2 2
28 GM30405 Hose, reducer 1 1 1 1 1
29 274824 Clamp, hose, 3.68/4 in. 1 1 1 1 1
30 291542 Clamp, hose, 3.25/3.56 in. 1 1 1 1 1
31 X-6014-116 Hose, radiator wire insert 1 1
31 X-6014-114 Hose, radiator wire insert 1 1
31 X-6014-8 Hose, radiator wire insert 1
32 249887 Clamp, hose, 2.25/2.56 in. 2 2 2 2 2
33 X-6014-53 Hose, radiator, straight, 3 in. ID 1 1 1 1 1
34 291542 Clamp, hose, 3.25/3.56 in. 2 2 2 2 2
35 GM30402 Tube, lower radiator 1 1 1 1 1
36 GM31761 Tube, lower radiator 1 1
36 GM30401 Tube, lower radiator 1 1
36 GM31762 Tube, lower radiator 1
37 X-6370-7 Connector, hose 2 2 2 2 2
38 X-6359-3 Hose, rubber, straight, .25 in. ID 1 1 1 1 1
39 X-426-9 Clamp, hose, .25/.70 in. 2 2 2 2 2
40 GM30875 Tube, upper radiator (intercooler) 1 1
40 GM30404 Tube, upper radiator 1 1
40 GM31757 Tube, upper radiator 1
41 X-272-25 Hose, radiator, straight, 1.25 in. ID 1 1 1 1
41 X-272-27 Hose, radiator, straight, 1.25 in. ID 1
42 X-426-8 Clamp, hose, .81/1.75 in. 2 2 2 2 2
43 X-272-29 Hose, radiator, straight, 1.25 in. ID 1 1 1 1
43 X-272-25 Hose, radiator, straight, 1.25 in. ID 1
44 X-426-8 Clamp, hose, .81/1.75 in. 2 2 2 2 2
45 GM30330 Support, radiator 1 1 1
45 GM33879 Support, radiator (l.h.) 1

TP-6284 5/04 7
Group 104: Cooling System, continued

47
48

46
41 26
42 27 5
64 2 6
43 3 7
1
44 4 8
40 9
10
23 38
24 39
25

37
28 22
29
30
31
32

36 33 21
34 13
45 14
35 20
15
59 11 16
60 17 12
49 18 63
19
To radiator vent line
50 51

52

56

55

57

54

61

53

58

GM31745

8 TP-6284 5/04
 Group 104: Cooling System, continued
Quantity
Module

GM30703-MA1
GM30954-MA1
GM30954-MA2
GM31745-MA1
GM31763-MA1
Item Part Number Description
46 GM32750 Support, tube 1 1 1 1 1
47 286283 Clamp, muffler, 3.12 in. 1 1 1 1 1
48 X-722-5 Clamp, muffler, 2.12 in. 1 1 1 1 1
49 X-582-25 Connector, hose + vibra seal 3 3 3 3 3
50 X-582-38 Connector, hose 1 1 1 1 1
51 X-202-60 Bushing, reducing (3/4 in. to 3/8 in.) 1 1 1 1 1
52 GM32319 Adapter bushing 1 1 1 1 1
53 GM31122 Bracket, mounting belt guard 1 1 1 1 1
54 GM31117 Guard, belt (right side) 1 1 1 1
54 GM32040 Guard, belt (right side) 1
55 GM31121 Bracket, belt guard 2 2 2 2 2
56 GM31119 Guard, belt (top) 1 1 1 1 1
57 GM31118 Guard, belt (left side) 1 1 1 1
57 GM32041 Guard, belt (left side) 1
58 GM31120 Guard, belt (bottom) 1 1 1 1 1
59 X-6014-114 Hose, radiator wire insert 1 1 1 1 1
60 249887 Clamp, hose, 2.25/2.56 in. 2 2 2 2 2
61 X-400-198 Spacer, .437 ID x .875 OD x .25 in. 1 1 1 1 1
63 X-6011-4 Washer, beveled, .44 ID x 1.25 in. OD 2 2 2
64 GM23500 Cap, radiator 1 1 1 1 1

TP-6284 5/04 9
Group 105: Engine

1 2
3

4
6

Quantity
Part Variation Number
Item Number Description 1 2 3 4 5 6 7 8
1 GM29887 Engine, 650 12V-2000 Series, 24 V, 60 Hz 1
1 GM29888 Engine, 650 12V-2000 Series, 24 V, 50 Hz 1
1 GM29889 Engine, 750 12V-2000 Series, 24 V, 60 Hz 1
1 GM29890 Engine, 750 12V-2000 Series, 24 V, 60 Hz 1
1 GM29891 Engine, 900 12V-2000 Series, 24 V, 60 Hz 1
1 GM29892 Engine, 900 12V-2000 Series, 24 V, 60 Hz 1
1 GM29893 Engine, 1000 12V-2000 Series, 24 V, 60 Hz 1
1 GM29894 Engine, 1000 12V-2000 Series, 24 V, 60 Hz 1
2 GM10772 Strap, ground (14 in.) 1 1 1 1 1 1 1 1
3 X-22-26 Washer, lock, .521 ID x 1.24 in. OD 1 1 1 1
4 X-22-12 Washer, lock, .262 ID x .743 in. OD 8 8 8 8
5 272713 Solenoid 1 1 1 1
6 223033 Strap, ground 1 1 1 1
7 259632 Bumper 2 2 2 2

10 TP-6284 5/04
 Group 105: Engine
Routine Engine Service Parts
Quantity
Part Variation Number
Item Number Description 1 2 3 4 5 6 7 8
1 GM30210 Filter, fuel 8 8 8 8 8 8 8 8
2 365528 Filter, oil 16 16 16 16 16 16 16 16
3 GM35176 Belt, alternator 1 1 1 1 1 1 1 1
4 GM35177 Thermostat 1 1 1 1 1 1 1 1
5 GM35178 O-ring, thermostat 1 1 1 1 1 1 1 1
6 GM35810 Fan belt kit 1 1 1 1 1 1 1 1

Group 107: Nameplate and Decals

Quantity
Variation Number
Item Part Number Description GR1
1 224233 Decal, 1-800 number 1
2 238402 Decal, caution positive term. only 1
3 249808 Decal, warning rotating parts 2
4 249809 Decal, caution, hot engine 2
5 249810 Decal, warning hot coolant 1
6 255882 Decal, caution stdby svc connect 1
7 294520 Decal, danger 1
8 257438 Decal, danger moving rotor 1
9 GM13227 Decal, warning fan force 1
10 GM13228 Decal, warning lifting support 1
11 364116 Decal, caution welding disconnect 2
12 327004 Nameplate, model/ratings, Kohler 1
13 347166 Decal, electrical equipment 1
14 347272 Decal, Power 2
15 347273 Decal, System 2
16 X-6232-3 Decal, stripes 1
17 X-6246-1 Decal, Kohler Power System 1
18 X-6275-7 Logo, Kohler 2
19 GM15300 Decal, exhaust piping 1
20 GM19296 Decal, fuel type 1

TP-6284 5/04 11
Group 109: Skid and Plant Mounting

Oil Pan View

1

6
7

5 8 9

Detailed Mounting Views

Solid mounting

10

13

12 14
11

Isolation mounting

21
20
20

15 23

19
19

18 16 18 22
17 16
17

Generator end Radiator end

12 TP-6284 5/04
 Group 109: Skid and Plant Mounting
Quantity
Module

GM29802-MA1
GM29802-MA2
GM29802-MA3
GM29802-MA4
GM29802-MA5
GM29802-MA6
GM29802-MA7
GM29802-MA8
GM29798-MA1
GM29798-MA2
GM29798-MA3
GM29798-MA4
GM29798-MA5
GM29798-MA6
GM29798-MA7
GM29798-MA8
Item Part Number Description
1 GM29793 Skid 1 1
1 GM29794 Skid 1 1
1 GM29795 Skid 1 1
1 GM29830 Skid 1 1
1 GM29831 Skid 1 1
1 GM31856 Skid 1 1
1 GM31858 Skid 1 1
1 GM31857 Skid 1 1
2 GM30600 Foot, engine mounting 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
3 GM30477 Foot, engine mounting (right side) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
4 GM29796 Foot, engine mounting (left side) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
5 GM30602 Valve, oil drain 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
6 X-582-1 Connector, hose + vibra seal 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
7 X-75-3 Plug, pipe ( 1/2 in. NPT) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
8 X-577-35 Hose, rubber, straight, .62 in. ID 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
9 X-426-3 Clamp, hose, .56/1.06 in. 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
10 M931-24120-60 Screw, hex cap 4 4 4 4 4 4 4 4
11 M934-24-80 Nut, hex 4 4 4 4 4 4 4 4
12 M934-20-80 Nut, hex 8 8 8 8 8 8 8 8
13 361668 Plate, spacer mounting 4 4 4 4 4 4 4 4
14 M125A-24-80 Washer, plain 4 4 4 4 4 4 4 4
15 361919 Vibromount 2 2
15 361054 Vibromount 2 2 2 2 2 2
16 X-25-152 Washer, plain, 1.06 ID x 5.25 in 4 4 4 4 4 4 4 4
17 M982-24-60 Nut, hex exlastic stop 4 4 4 4 4 4 4 4
18 M934-20-80 Nut, hex 8 8 8 8 8 8 8 8
19 361039 Plate, generator mounting 4 4 4 4 4 4 4 4
20 M931-24160-60 Screw, hex cap 4 4 4 4 4 4 4 4
21 X-22-15 Washer, lock, .456 ID x 1.058 in. OD 2 2 2 2 2 2 2 2
22 X-22-16 Washer, lock, .326 ID x .883 in. OD 2 2 2 2 2 2 2 2
23 361054 Vibromount 2 2 2 2
23 361919 Vibromount 2 2 2 2

TP-6284 5/04 13
Group 201: Generator and Mounting
50 51
39 40 41 49
38 35
52
30
36 47
49
48
Insulated Standoffs
43, 44 33, 34

45 31
46 37

1
26

19
24
25
22
23
Component of
item 1, Alternator 17

18

15 7, 8 2
16 Alternator
Mounting
Bracket

Skid
42 14 9, 10, 3
28 29
11
4
13 6
63

62 30 12
5
27 Solid Mount Isolation Mount
Mounting Detail

Alternator Parts
64 69
36 70
66
65
65

67
68
72
12 3 4 5 6
32

61

53 54 55 56 57 58 59 60 Inner Panel Side View 6284_201

29 30

14 TP-6284 5/04
 Group 201: Generator and Mounting
Item Part Number Description Qty. Item Part Number Description Qty.
1 See chart page 29 229353 Mount, controller 4
14 Alternator assembly 1 30 X-22-12 Washer, lock, .262 ID x .743 in. 8
2 M931-20140-60 Screw, hex cap, 3/4-pt. mtg., 31 X-22-13 Washer, lock, .20 ID x .595 in. OD 1
isolation 2/4 32 361478 Retainer, inner panel 2
2 M931-24160-60 Screw, hex cap, 4-pt. mtg., 33 GM21264 Harness, inner panel gound 1
isolation, 7M alternator 4 34 361567 Base, tie wrap (not shown) 2
3 361734 Vibromount, 3-pt. mtg. 2 35 X-67-151 Screw (DVR mounting backet) 6
3 361734 Vibromount, 4-pt. mtg., 4 36 GM31958 Door, junction box 1
3 361919 Vibromount, 4-pt. mtg. (5M4044 37 GM13561 Bracket, dr panel mounting, bottom 1
only, 7M) 4 38 GM13563 Panel, inner door 1
4 361733 Plate, generator mounting 2/4 39 GM13562 Bracket, door panel mounting, top 2
4 361039 Plate, generator mounting (5M4044 40 282829 Vibromount 6
only, 7M) 4 41 X-22-18 Washer, lock, .172 ID x .595 in. OD 12
5 M982-20-80 Nut, hex elastic stop, 3-pt. mtg. 2 42 272684 Relay 1
5 M982-20-60 Nut, hex elastic stop, 4-pt. mtg. 4 43 X-6217-10 Screw, hex flange machine 25
5 M982-24-60 Nut, hex elastic stop, 4-pt. mtg., 7M 4 44 295009 Retainer 2
5 X-400-239 Spacer, 4-pt. mtg., 5M alternator 4 45 GM17571 Cover, access 1
6 X-25-155 Washer, plain 8 46 X-50-2 Screw, slotted pan head machine 4
6 X-25-152 Washer, plain, 7M 8 47 X-6274-7 Rod, threaded 3
7 M931-20120-60 Screw, hex cap, 3-pt. mtg. 2 48 X-6086-6 Washer, spring, .39 ID x .81 in. OD 6
7 M931-20120-60 Screw, hex cap, 4-pt. mtg., 5M 49 X-25-118 Washer, plain, .406 ID x 1 in. OD 9
alternator 4 50 X-83-7 Nut, hex, 3/8-16, zinc 6
7 M931-24120-60 Screw, hex cap, 4-pt. mtg., 7M 51 X-6128-29 Insulator, standoff, 3/8-16 x 2 in. 3
alternator 4 52 X-634-23 Bushing, 1.968 x 2.50 in. NPT 2
8 X-400-241 Spacer (5M) 2/4 53 X-49-26 Screw, cross recess PHM 2
9 290743 Shim 4 54 292821 Fuse holder 1
10 290744 Shim 4 55 GM28584 Strip, marker 1
11 291191 Shim 4 56 292937 Fuse, 20 A 1
12 M934-20-80 Nut, hex elastic stop, 3/4-pt. mtg. 2/4 57 239298 Fuse, 5 A 1
12 M934-24-80 Nut, hex elastic stop, 7M alternator 4 58 X-49-6 Screw, pan head 6-32 x 1/2 4
13 361061 Plate, generator mounting 3-pt. 59 299090 Marker, strip 1
mtg., 5M044, 7M) 2 60 295314 Block , terminal 1
13 GM30445 Plate, generator mounting 4 61 X-634-16 Bushing, 1.312 x 1.50 in. NPT 1
14 M934-20-80 Nut, hex elastic stop 4/8 62 X-634-23 Bushing, 1.968 x 2.50 in. NPT 1
15 M933-16030-82 Screw, hex cap 5M 6 63 361186 Panel, junction box, inner 1
15 M933-16045-82 Screw, hex cap 7M 6 64 X-67-43 Screw, thread-cutting 27
16 X-801-5 Washer, hardened, .656 ID x 1.06 6 65 347160 Capacitor 1
17 M931-12050-82 Screw, hex cap (5M) 16 66 328725 Voltage regulator, DVR2000 1
17 M931-12040-82 Screw, hex cap (7M) 16 67 279778 Fuse, 5 A 1
18 M125A-12-80 Washer, plain 16 68 279779 Cap, fuse 1
19 328903 Screen, 5M alternator 1 69 347071 Exciter rectifier assembly 1
19 328904 Screen, 7M alternator 1 69 347070 Exciter rectifier assembly, 7M alt. 1
22 X-83-7 Nut, hex, zinc, 3/8-16 2 70 279772 Diode, standard polarity 1
23 X-6086-6 Washer, spring, .39 ID x .81 in. OD 2 70 279773 Diode, standard polarity, 7M alt. 1
24 X-25-118 Washer, plain, .406 ID x 1 in. OD 4 71 279774 Diode, reversing polarity 1
25 X-22-14 Washer, lock, .391 ID x .975 in. 4 71 279775 Diode, reversing polarity, 7M alt. 1
26 361271 Bus, ground 1 72 279776 Surge suppressor 1
27 365476 Bracket, inner panel 1 72 279777 Surge suppressor, 7M alt. 1
28 X-6217-10 Screw, hex flange machine 25

TP-6284 5/04 15
Group 201: Generator and Mounting
Alternator Part Number and Mount Type
Use this table to identify the module number’s alternator part number (item 1, page 13) and mount type.

Alternator
Module Alternator Part Mount
Number Description Number Type
GM29691-MA1 5M4030, 10-Lead GM11976 Isolation
GM29691-MA2 5M4030, 10-Lead GM11976 Solid
GM29691-MA3 5M4032, 10-Lead A-361756 Isolation
GM29691-MA4 5M4032, 10-Lead A-361756 Solid
GM29691-MA5 5M4034, 10-Lead A-361757 Isolation
GM29691-MA6 5M4034, 10-Lead A-361757 Solid
GM29691-MA7 5M4036, 10-Lead A-361758 Isolation
GM29691-MA8 5M4036, 10-Lead A-361758 Solid
GM29691-MA9 5M4038, 10-Lead A-361762 Isolation
GM29691-MA10 5M4038, 10-Lead A-361762 Solid
GM29691-MA11 5M4164, 4-Lead GM12022 Isolation
GM29691-MA12 5M4164, 4-Lead GM12022 Solid
GM29691-MA13 5M4166, 4-Lead A-361763 Isolation
GM29691-MA14 5M4166, 4-Lead A-361763 Solid
GM29691-MA15 5M4272, 4-Lead GM12023 Isolation
GM29691-MA16 5M4272, 4-Lead GM12023 Solid
GM29691-MA17 5M4276, 4-Lead A-361760 Isolation
GM29691-MA18 5M4276, 4-Lead A-361760 Solid
GM29691-MA19 5M4278, 4-Lead A-361761 Isolation
GM29691-MA20 5M4278, 4-Lead A-361761 Solid
GM29675-MA1 5M4036, 10-Lead A-361758 Isolation
GM29675-MA2 5M4036, 10-Lead A-361758 Solid
GM29675-MA3 5M4038, 4-Lead A-361762 Isolation
GM29675-MA4 5M4038, 4-Lead A-361762 Solid
GM29675-MA5 5M4044, 4-bus A-361765 Isolation
GM29675-MA6 5M4044, 4-bus A-361765 Solid
GM29675-MA7 7M4046, 4-bus A-361766 Isolation
GM29675-MA8 7M4046, 4-bus A-361766 Solid
GM29675-MA9 5M4168, 4-Lead A-361763 Isolation
GM29675-MA10 5M4168, 4-Lead A-361763 Solid
GM29675-MA11 5M4280, 4-Lead A-361764 Isolation
GM29675-MA12 5M4280, 4-Lead A-361764 Solid
GM29675-MA13 7M4170, 4-bus A-361767 Isolation
GM29675-MA14 7M4170, 4-bus A-361767 Solid
GM29675-MA15 7M4282, 4-bus A-361768 Isolation
GM29675-MA16 7M4282, 4-bus A-361768 Solid
GM29675-MA17 7M4284, 4-bus A-361769 Isolation
GM29675-MA18 7M4284, 4-bus A-361769 Solid

16 TP-6284 5/04
 Notes

TP-6284 5/04 17
Control and Harness

To LWL Switch in Radiator

20
19
2

3
2

7 6 4
5
Items 21--30 are not shown.
8
11
9 12

10

Inner panels

13 16

17
14
18
15

Decision-Maker 550, 600 volt maximum

6021_301

18 TP-6284 5/04
 Control and Harness
Quantity
Module

GM30870-MA1
GM30870-MA2
GM30870-MA3
GM31025-MA1
GM31025-MA2
GM31025-MA3
Item Part Number Description
1 361184 Panel, junction box top 1 1 1 1 1 1
2 X-6217-10 Screw, hex flange machine 24 24 24 24 24 24
3 361826 Panel, junction box bottom 1 1 1 1
3 328901 Panel, junction box bottom 1 1
4 GM30897 Harness, engine power (includes item 21) 1 1 1 1 1 1
5 GM30896 Harness, engine (includes items 22--30) 1 1
5 GM32761 Harness, engine (includes items 22--30) 1
5 GM32760 Harness, engine (includes items 22--30) 1
5 GM30907 Harness, engine (includes items 22--30) 1 1
6 238915 Boot 2 2 2 2 2 2
7 X-672-6 Clamp, insulation, 1.38 in. 2 2 2 2 2 2
8 GM10166 Sender, temperature 1 1 1
9 364364 Adapter, bushing 1 1 1
10 365499 O-ring 1 1 1
11 365624 Sender, oil pressure 1 1 1
12 GM31040 Adapter, bushing 1 1 1
13 295314 Block, terminal 1 1 1
14 255080 Marker, strip 1 1 1
15 X-49-6 Screw, cross recess pan head 1 1 1
16 GM13980 PCB assembly, CT burden resistor 1 1 1
17 X-70-12 Nut, hex machine screw, 8-32 4 4 4
18 X-712-9 Spacer, .25 OD, .5 in. 4 4 4
19 GM11718 PCB assembly, Marathon excitation interface 1 1 1
20 M965A-06012-20 Screw, pan head machine 4 4 4
21 GM28568 Connector, 5 pin 1 1 1 1 1 1
22 233959 Diode, 6 A 3 3 3 3 3 3
23 GM28623 Clamp, cable (P6 and P3) 3 3 2 2 2 2
24 GM28574 Connector, 4-pin (P6) 1 1 1 1 1 1
25 GM11496 Connector, 3-pin (P2) 1 1 1 1 1 1
26 292800 Connector, cable (P1) 1 1 1 1 1 1
27 295145 Connector, 24-pin (P1) 1 1 1 1 1 1
28 337131 Connector, plug, 6-pin (P3) 1 1 1
29 GM28873 Connector, 4-pin (P3) 1 1 1 1 1 1
30 GM28375 Connector, 55-pin P4) 1 1 1 1 1 1

TP-6284 5/04 19
Group 701: Literature
Quantity
Part Variation Number
Item Number Description 206 208 210 212
1 TP-5374 Warranty, 1 Year Limited 1 1 1 1
2 TP-5578 O/I/S/M Marathon Alternator Magna DVR 1 1 1 1
3 TP-5583 S/M 350--2800 kW, Industrial 1 1 1 1
4 TP-5700 I/M Industrial 1 1 1 1
5 TP-5750 O/M 20–2000 kW 1 1 1 1
6 TP-6009 P/C Controller, Industrial 1 1 1 1
7 TP-6117 P/C Accessories, 230--2000 kW diesel 1 1 1 1
8 TP-6140 O/M Controller Setup & Application, Decision-Maker 550 1 1 1 1
9 TP-6199 O/I/S/M Marathon DVR2000E 1 1 1 1
10 TP-6200 O/M Decision-Maker 550, version 2.10 1 1 1 1
11 TP-6216 W/D 1350--2000REOZDB, 2500/2800REOZD 1 1 1 1
12 TP-6284 P/C 650--1000REOZDB 1 1 1 1
13 TP-6297 O/M 12V/16V2000 DDC 1 1 1 1
14 TP-6298 S/M 12V/16V2000 DDC 1 1 1 1
15 TP-6301 P/C DDC/MTU 12V2000, 650--750 kW 1 1
15 TP-6302 P/C DDC/MTU 16V2000, 900--1000 kW 1 1

20 TP-6284 5/04
 Kit List
This section lists the part numbers of modules/kits not listed in the Group Parts Lists. Refer to the generator set nameplate or the list
below to identify the module/kit number installed on your generator set. See the sections following this page for the parts list of the
module/kit.

650 kW 750 kW 900 kW 1000 kW

Controllers
See Parts Catalog TP-6009 for parts lists.

Cooling Systems
Unit-Mounted Radiator (See Group 104 for parts lists)
Remote Radiator Set-up GM31867-MA1 GM31867-MA1 GM31867-MA1 GM31867-MA1
Block heater, 480 V, 3 phase (with isolation valves) GM29883-KA1 GM29883-KA1 GM29883-KA6 GM29883-KA6
Block heater, 240 V, 1 phase GM29883-KA2 GM29883-KA2 GM29883-KA7 GM29883-KA7
Block heater, 480 V, 1 phase GM29883-KA3 GM29883-KA3 GM29883-KA8 GM29883-KA8
Block heater, 240 V, 3 phase GM29883-KA4 GM29883-KA4 GM29883-KA9 GM29883-KA9
Block heater, 380 V, 3 phase GM29883-KA5 GM29883-KA5 GM29883-KA10 GM29883-KA10

Optional Kits
See Parts Catalog TP-6117 for parts lists.

Paint and Miscellaneous Parts

Paint, Kohler Cream Beige All models use 221338 Spray Can, 221337 Gallon

TP-6284 5/04 21
Cooling System Kits
Qty. Description Part No.

Remote Radiator Setup GM31867-MA1

2 Clamp, hose, 2.25/2.56 in. 249887
2 Clamp, hose, 3.68/4 in. 274824
2 Hose, reducer GM30405
2 Bracket, belt guard GM31121
1 Bracket, mounting belt guard GM31122
1 Guard, belt (rs) GM32298
1 Guard, belt (ls) GM32299
1 Guard, belt (top) GM32300
1 Guard, belt (bottom) GM32301
1 Cover, front GM32302
1 Adapter bushing GM32319
1 Bushing, reducing ( 3/4 in. to 3/8 in.) X-202-60
1 Spacer, .437 ID x .875 OD x .25 in. X-400-198
1 Connector, hose X-582-38
2 Hose, radiator, straight, 2 in. ID X-6014-8
2 Connector, hose X-6370-7

Block Heater Kits

Kits: GM29883-KP1--GM29883-KP5
Common Unique Parts
Qty. Description Parts GM29883-KP1 GM29883-KP2 GM29883-KP3 GM29883-KP4 GM29883-KP5
1 Heater, block 361240 361246 361247 361248 361249
1 Element, block heater service GM29665 GM29666 GM29667 GM29668 GM29669
1 Hose, coolant 44 in. X-6367-1 X-6367-1 X-6367-1 X-6367-1 X-6367-1
1 Tag, hang 279047
1 Tag, instruction 299896
4 Vibromount, controller 328645
1 Tee, pipe (3/4 x 3/4 x 3/4 A-108
NPT)
2 Valve, shutoff (3/4-14 NPT) GM19666
1 Connector, swivel 37 deg. GM29562
flared
1 Bracket, block heater GM30921
1 Bracket, block heater GM30922
1 Bushing, reducing (3/4 x 1 in. X-202-1
NPT)
1 Tee, pipe (1 x 1 x 1 NPT) X-203-2
2 Pipe (3/4 NPT x 2.00 in.) X-206-2
1 Pipe (3/4 NPT x 1.38 in.) X-206-9
1 Pipe (1 NPT x 1.50 in.) X-218-24
8 Washer, lock, .326 ID x .883 X-22-16
in.OD
2 Elbow, street (45 deg x 3/4 X-274-15
in. NPT)
4 Stud, 5/16-18 x 1.5 in. X-352-65
4 Clamp, hose, .69/1.25 in. X-426-12
2 Connector, hose X-582-15
2 Connector, hose X-582-8
2 Washer, beveled, .44 ID x X-6011-4
1.25 in. OD
1 Hose, coolant X-6367-14
1 Plug, pipe (1 in. NPT) X-75-13

22 TP-6284 5/04
 Cooling System Kits
Block Heater Kits, continued
Kits: GM29883-KP6--GM29883-KP10
Common Unique Parts
Qty. Description Parts GM29883-KP6 GM29883-KP7 GM29883-KP8 GM29883-KP9 GM29883-KP10
1 Heater, block 361240 361246 361247 361248 361249
1 Element, block heater service GM29665 GM29666 GM29667 GM29668 GM29669
1 Hose, coolant X-6367-14 X-6367-14 X-6367-14 X-6367-14 X-6367-14
1 Tag, hang 279047
1 Tag, instruction 299896
4 Vibromount, controller 328645
1 Tee, pipe (3/4 x 3/4 x 3/4 A-108
NPT)
2 Valve, shutoff (3/4-14 NPT) GM19666
1 Connector, swivel 37 deg. GM29562
flared
1 Bracket, block heater GM30921
1 Bracket, block heater GM30922
1 Bushing, reducing (3/4 x 1 in. X-202-1
NPT)
1 Tee, pipe (1 x 1 x 1 NPT) X-203-2
2 Pipe (3/4 NPT x 2.00 in.) X-206-2
1 Pipe (3/4 NPT x 1.38 in.) X-206-9
1 Pipe (1 NPT x 1.50 in.) X-218-24
8 Washer, lock, .326 ID x .883 X-22-16
in.OD
2 Elbow, street (45 deg x 3/4 X-274-15
in. NPT)
4 Stud, 5/16-18 x 1.5 in. X-352-65
4 Clamp, hose, .69/1.25 in. X-426-12
2 Connector, hose X-582-15
2 Connector, hose X-582-8
2 Washer, beveled, .44 ID x X-6011-4
1.25 in. OD
1 Hose, coolant X-6367-14
1 Plug, pipe (1 in. NPT) X-75-13

TP-6284 5/04 23
 Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.
A, amp ampere cfm cubic feet per minute exh. exhaust
ABDC after bottom dead center CG center of gravity ext. external
AC alternating current CID cubic inch displacement F Fahrenheit, female
A/D analog to digital CL centerline fglass. fiberglass
ADC analog to digital converter cm centimeter FHM flat head machine (screw)
adj. adjust, adjustment CMOS complementary metal oxide fl. oz. fluid ounce
ADV advertising dimensional substrate (semiconductor) flex. flexible
drawing cogen. cogeneration freq. frequency
AHWT anticipatory high water com communications (port) FS full scale
temperature coml commercial ft. foot, feet
AISI American Iron and Steel Coml/Rec Commercial/Recreational ft. lbs. foot pounds (torque)
Institute conn. connection
ALOP anticipatory low oil pressure ft./min. feet per minute
cont. continued g gram
alt. alternator CPVC chlorinated polyvinyl chloride
Al aluminum ga. gauge (meters, wire size)
crit. critical gal. gallon
ANSI American National Standards CRT cathode ray tube
Institute gen. generator
(formerly American Standards CSA Canadian Standards genset generator set
Association, ASA) Association GFI ground fault interrupter
AO anticipatory only CT current transformer
Cu copper GND, ground
API American Petroleum Institute
cu. in. cubic inch gov. governor
approx. approximate, approximately
cw. clockwise gph gallons per hour
AR as required, as requested
CWC city water-cooled gpm gallons per minute
AS as supplied, as stated, as
suggested cyl. cylinder gr. grade, gross
ASE American Society of Engineers D/A digital to analog GRD equipment ground
ASME American Society of DAC digital to analog converter gr. wt. gross weight
Mechanical Engineers dB decibel HxWxD height by width by depth
assy. assembly dBA decibel (A weighted) HC hex cap
ASTM American Society for Testing DC direct current HCHT high cylinder head temperature
Materials DCR direct current resistance HD heavy duty
ATDC after top dead center deg., ° degree HET high exhaust temperature,
ATS automatic transfer switch high engine temperature
dept. department
auto. automatic hex hexagon
dia. diameter
aux. auxiliary Hg mercury (element)
DI/EO dual inlet/end outlet
A/V audiovisual HH hex head
DIN Deutsches Institut fur Normung
avg. average e. V. HHC hex head cap
AVR automatic voltage regulator (also Deutsche Industrie HP horsepower
AWG American Wire Gauge Normenausschuss) hr. hour
AWM appliance wiring material DIP dual inline package HS heat shrink
bat. battery DPDT double-pole, double-throw hsg. housing
BBDC before bottom dead center DPST double-pole, single-throw HVAC heating, ventilation, and air
BC battery charger, battery DS disconnect switch conditioning
charging DVR digital voltage regulator HWT high water temperature
BCA battery charging alternator E, emer. emergency (power source) Hz hertz (cycles per second)
BCI Battery Council International EDI electronic data interchange IC integrated circuit
BDC before dead center EFR emergency frequency relay ID inside diameter, identification
BHP brake horsepower e.g. for example (exempli gratia) IEC International Electrotechnical
blk. black (paint color), block EG electronic governor Commission
(engine) EGSA Electrical Generating Systems IEEE Institute of Electrical and
blk. htr. block heater Association Electronics Engineers
BMEP brake mean effective pressure EIA Electronic Industries IMS improved motor starting
bps bits per second Association in. inch
br. brass EI/EO end inlet/end outlet in. H2O inches of water
BTDC before top dead center EMI electromagnetic interference in. Hg inches of mercury
Btu British thermal unit emiss. emission in. lbs. inch pounds
Btu/min. British thermal units per minute eng. engine Inc. incorporated
C Celsius, centigrade EPA Environmental Protection ind. industrial
Agency int. internal
cal. calorie
EPS emergency power system int./ext. internal/external
CARB California Air Resources Board
CB circuit breaker ER emergency relay I/O input/output
cc cubic centimeter ES engineering special, IP iron pipe
engineered special ISO International Organization for
CCA cold cranking amps ESD electrostatic discharge Standardization
ccw. counterclockwise est. estimated J joule
CEC Canadian Electrical Code E-Stop emergency stop JIS Japanese Industry Standard
cert. certificate, certification, certified etc. et cetera (and so forth)
cfh cubic feet per hour

TP-6284 5/04 Appendix A-1

k kilo (1000) MTBF mean time between failure RHM round head machine (screw)
K kelvin MTBO mean time between overhauls rly. relay
kA kiloampere mtg. mounting rms root mean square
KB kilobyte (210 bytes) MW megawatt rnd. round
kg kilogram mW milliwatt ROM read only memory
kg/cm2 kilograms per square µF microfarad rot. rotate, rotating
centimeter N, norm. normal (power source) rpm revolutions per minute
kgm kilogram-meter NA not available, not applicable RS right side
kg/m3 kilograms per cubic meter nat. gas natural gas RTV room temperature vulcanization
kHz kilohertz NBS National Bureau of Standards SAE Society of Automotive
kJ kilojoule NC normally closed Engineers
km kilometer NEC National Electrical Code scfm standard cubic feet per minute
kOhm, kΩ kilo-ohm NEMA National Electrical SCR silicon controlled rectifier
kPa kilopascal Manufacturers Association s, sec. second
kph kilometers per hour NFPA National Fire Protection SI Systeme international d’unites,
kV kilovolt Association International System of Units
kVA kilovolt ampere Nm newton meter SI/EO side in/end out
kVAR kilovolt ampere reactive NO normally open sil. silencer
kW kilowatt no., nos. number, numbers SN serial number
kWh kilowatt-hour NPS National Pipe, Straight SPDT single--pole, double--throw
kWm kilowatt mechanical NPSC National Pipe, Straight-coupling SPST single--pole, single--throw
L liter NPT National Standard taper pipe spec, specs
LAN local area network thread per general use specification(s)
L x W x H length by width by height NPTF National Pipe, Taper-Fine sq. square
lb. pound, pounds NR not required, normal relay sq. cm square centimeter
lbm/ft3 pounds mass per cubic feet ns nanosecond sq. in. square inch
LCB line circuit breaker OC overcrank SS stainless steel
LCD liquid crystal display OD outside diameter std. standard
ld. shd. load shed OEM original equipment stl. steel
manufacturer tach. tachometer
LED light emitting diode OF overfrequency
Lph liters per hour TD time delay
opt. option, optional TDC top dead center
Lpm liters per minute OS oversize, overspeed
LOP low oil pressure TDEC time delay engine cooldown
OSHA Occupational Safety and Health TDEN time delay emergency to
LP liquefied petroleum Administration normal
LPG liquefied petroleum gas OV overvoltage TDES time delay engine start
LS left side oz. ounce TDNE time delay normal to
Lwa sound power level, A weighted p., pp. page, pages emergency
LWL low water level PC personal computer TDOE time delay off to emergency
LWT low water temperature PCB printed circuit board TDON time delay off to normal
m meter, milli (1/1000) pF picofarad temp. temperature
M mega (106 when used with SI PF power factor term. terminal
units), male ph., ∅ phase TIF telephone influence factor
m3 cubic meter
PHC Phillips head crimptite (screw) TIR total indicator reading
m3/min. cubic meters per minute
PHH Phillips hex head (screw) tol. tolerance
mA milliampere
PHM pan head machine (screw) turbo. turbocharger
man. manual
PLC programmable logic control typ. typical (same in multiple
max. maximum locations)
PMG permanent-magnet generator
MB megabyte (220 bytes) pot potentiometer, potential UF underfrequency
MCM one thousand circular mils ppm parts per million UHF ultrahigh frequency
MCCB molded-case circuit breaker PROM programmable read-only UL Underwriter’s Laboratories, Inc.
meggar megohmmeter memory UNC unified coarse thread (was NC)
MHz megahertz psi pounds per square inch UNF unified fine thread (was NF)
mi. mile pt. pint univ. universal
mil one one-thousandth of an inch PTC positive temperature coefficient US undersize, underspeed
min. minimum, minute PTO power takeoff UV ultraviolet, undervoltage
misc. miscellaneous PVC polyvinyl chloride V volt
MJ megajoule qt. quart, quarts VAC volts alternating current
mJ millijoule qty. quantity VAR voltampere reactive
mm millimeter R replacement (emergency) VDC volts direct current
mOhm, mΩ power source VFD vacuum fluorescent display
milliohm rad. radiator, radius VGA video graphics adapter
MOhm, MΩ RAM random access memory
megohm VHF very high frequency
RDO relay driver output W watt
MOV metal oxide varistor ref. reference
MPa megapascal WCR withstand and closing rating
rem. remote w/ with
mpg miles per gallon Res/Coml Residential/Commercial
mph miles per hour w/o without
RFI radio frequency interference wt. weight
MS military standard
RH round head xfmr transformer
m/sec. meters per second

A-2 Appendix TP-6284 5/04

 Appendix B Common Hardware Application Guidelines

Use the information below and on the following pages to Steps for common hardware application:
identify proper fastening techniques when no specific
reference for reassembly is made. 1. Determine entry hole type: round or slotted.

Bolt/Screw Length: When bolt/screw length is not given, 2. Determine exit hole type: fixed female thread (weld
use Figure 1 as a guide. As a general rule, a minimum nut), round, or slotted.
length of one thread beyond the nut and a maximum
length of 1/2 the bolt/screw diameter beyond the nut is For round and slotted exit holes, determine if
hardware is greater than 1/2 inch in diameter, or
the preferred method.
1/2 inch in diameter or less. Hardware that is
Washers and Nuts: Use split lock washers as a bolt greater than 1/2 inch in diameter takes a standard
locking device where specified. Use SAE flat washers nut and SAE washer. Hardware 1/2 inch or less in
with whiz nuts, spiralock nuts, or standard nuts and diameter can take a properly torqued whiz nut or
spiralock nut. See Figure 2.
preloading (torque) of the bolt in all other applications.
3. Follow these SAE washer rules after determining
See Appendix C, General Torque Specifications, and
exit hole type:
other torque specifications in the service literature.
a. Always use a washer between hardware and a
slot.
Preferred Nut/Bolt Clearance
1 2 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.

Unacceptable Nut/Bolt Clearance

2
3 1

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. Cap screw
2. Entry hole types
3. 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. hardware
6. Exit hole types

Figure 2 Acceptable Hardware Combinations

TP-6284 5/04 Appendix A-3

Appendix C General Torque Specifications

Use the following torque specifications when service oiled threads. Increase values by 15% for nonplated
literature instructions give no specific torque values. threads. All torque values are +0%/--10%.
The charts list values for new plated, zinc phosphate, or

American Standard Fasteners Torque Specifications

Assembled into Cast Iron or Steel Assembled into
Torque Aluminum
Size Measurement Grade 2 Grade 5 Grade 8 Grade 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 into
Aluminum
Size (mm) Grade 5.8 Grade 8.8 Grade 10.9 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) —

A-4 Appendix TP-6284 5/04

 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

Lock or Elastic Grade 5
with Washer

Flat Head (FHM) Square Grade 8

Grade 8/9 (Hex Socket

Round Head (RHM) Cap or Acorn
Head)
Metric
Pan Head Wing
Number stamped on 5.8
Hex Socket Head Cap or Washers hardware; 5.8 shown
Allent Head Cap
Washer Styles
Hex Socket Head or Allent
Head Shoulder Bolt Plain

Sheet Metal Screw Split Lock or Spring

Stud Spring or Wave

Drive Styles
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) Plain Washers
1/4-20 x 1 9/32 x 5/8 x 1/16
Length In Inches (Screws and Bolts) 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 Lock Washers
Length In Millimeters (Screws and Bolts) 5/8
Distance Between Threads In Millimeters Internal Dimension
Major Thread Diameter In Millimeters

TP-6284 5/04 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 Part No. Dimensions Part No. Dimensions Type
Hex Head Bolts (Grade 5) Hex Head Bolts, cont. Hex Nuts
X-465-17 1/4-20 x .38 X-6238-14 3/8-24 x .75 X-6009-1 1-8 Standard
X-465-6 1/4-20 x .50 X-6238-16 3/8-24 x 1.25
X-465-2 1/4-20 x .62 X-6238-21 3/8-24 x 4.00 X-6210-3 6-32 Whiz
X-465-16 1/4-20 x .75 X-6238-22 3/8-24 x 4.50 X-6210-4 8-32 Whiz
X-465-18 1/4-20 x .88 X-6210-5 10-24 Whiz
X-465-7 1/4-20 x 1.00 X-6024-5 7/16-14 x .75
X-6024-2 7/16-14 x 1.00 X-6210-1 10-32 Whiz
X-465-8 1/4-20 x 1.25
X-465-9 1/4-20 x 1.50 X-6024-8 7/16-14 x 1.25 X-6210-2 1/4-20 Spiralock
X-465-10 1/4-20 x 1.75 X-6024-3 7/16-14 x 1.50 X-6210-6 1/4-28 Spiralock
X-465-11 1/4-20 x 2.00 X-6024-4 7/16-14 x 2.00 X-6210-7 5/16-18 Spiralock
X-465-12 1/4-20 x 2.25 X-6024-11 7/16-14 x 2.75 X-6210-8 5/16-24 Spiralock
X-465-14 1/4-20 x 2.75 X-6024-12 7/16-14 x 6.50
X-6210-9 3/8-16 Spiralock
X-465-21 1/4-20 x 5.00 X-129-15 1/2-13 x .75 X-6210-10 3/8-24 Spiralock
X-465-25 1/4-28 x .38 X-129-17 1/2-13 x 1.00 X-6210-11 7/16-14 Spiralock
X-465-20 1/4-28 x 1.00 X-129-18 1/2-13 x 1.25 X-6210-12 1/2-13 Spiralock
X-125-33 5/16-18 x .50 X-129-19 1/2-13 x 1.50 X-6210-15 7/16-20 Spiralock
X-125-23 5/16-18 x .62 X-129-20 1/2-13 x 1.75 X-6210-14 1/2-20 Spiralock
X-125-3 5/16-18 x .75 X-129-21 1/2-13 x 2.00
X-129-22 1/2-13 x 2.25 X-85-3 5/8-11 Standard
X-125-31 5/16-18 x .88 X-88-12 3/4-10 Standard
X-125-5 5/16-18 x 1.00 X-129-23 1/2-13 x 2.50
X-129-24 1/2-13 x 2.75 X-89-2 1/2-20 Standard
X-125-24 5/16-18 x 1.25
X-125-34 5/16-18 x 1.50 X-129-25 1/2-13 x 3.00
X-125-25 5/16-18 x 1.75 X-129-27 1/2-13 x 3.50
X-125-26 5/16-18 x 2.00 X-129-29 1/2-13 x 4.00 Washers
230578 5/16-18 x 2.25 X-129-30 1/2-13 x 4.50 Bolt/
X-125-29 5/16-18 x 2.50 X-463-9 1/2-13 x 5.50
X-129-44 1/2-13 x 6.00 Part No. ID OD Thick. Screw
X-125-27 5/16-18 x 2.75
X-125-28 5/16-18 x 3.00 X-129-51 1/2-20 x .75 X-25-46 .125 .250 .022 #4
X-125-22 5/16-18 x 4.50 X-129-45 1/2-20 x 1.25 X-25-9 .156 .375 .049 #6
X-125-32 5/16-18 x 5.00 X-129-52 1/2-20 x 1.50 X-25-48 .188 .438 .049 #8
X-125-35 5/16-18 x 5.50 X-25-36 .219 .500 .049 #10
X-125-36 5/16-18 x 6.00 X-6021-3 5/8-11 x 1.00 X-25-40 .281 .625 .065 1/4
X-125-40 5/16-18 x 6.50 X-6021-4 5/8-11 x 1.25 X-25-85 .344 .687 .065 5/16
X-6021-2 5/8-11 x 1.50 X-25-37 .406 .812 .065 3/8
X-125-43 5/16-24 x 1.75 X-6021-1 5/8-11 x 1.75 X-25-34 .469 .922 .065 7/16
X-125-44 5/16-24 x 2.50 273049 5/8-11 x 2.00
X-125-30 5/16-24 x .75 X-25-26 .531 1.062 .095 1/2
X-6021-5 5/8-11 x 2.25 X-25-15 .656 1.312 .095 5/8
X-125-39 5/16-24 x 2.00 X-6021-6 5/8-11 x 2.50
X-125-38 5/16-24 x 2.75 X-25-29 .812 1.469 .134 3/4
X-6021-7 5/8-11 x 2.75
X-25-127 1.062 2.000 .134 1
X-6238-2 3/8-16 x .62 X-6021-12 5/8-11 x 3.75
X-6238-10 3/8-16 x .75 X-6021-11 5/8-11 x 4.50
X-6238-3 3/8-16 x .88 X-6021-10 5/8-11 x 6.00
X-6238-11 3/8-16 x 1.00 X-6021-9 5/8-18 x 2.50
X-6238-4 3/8-16 x 1.25
X-6238-5 3/8-16 x 1.50 X-6239-1 3/4-10 x 1.00
X-6238-1 3/8-16 x 1.75 X-6239-8 3/4-10 x 1.25
X-6238-6 3/8-16 x 2.00 X-6239-2 3/4-10 x 1.50
X-6238-17 3/8-16 x 2.25 X-6239-3 3/4-10 x 2.00
X-6238-7 3/8-16 x 2.50 X-6239-4 3/4-10 x 2.50
X-6238-8 3/8-16 x 2.75 X-6239-5 3/4-10 x 3.00
X-6238-9 3/8-16 x 3.00 X-6239-6 3/4-10 x 3.50
X-6238-19 3/8-16 x 3.25 X-792-1 1-8 x 2.25
X-6238-12 3/8-16 x 3.50 X-792-5 1-8 x 3.00
X-6238-20 3/8-16 x 3.75 X-792-8 1-8 x 5.00
X-6238-13 3/8-16 x 4.50
X-6238-18 3/8-16 x 5.50
X-6238-25 3/8-16 x 6.50

A-6 Appendix TP-6284 5/04

Metric
Hex head bolts are hardness grade 8.8 unless noted.

Part No. Dimensions Part No. Dimensions Part No. Dimensions

Hex Head Bolts (Partial Thread) Hex Head Bolts (Partial Thread), Hex Head Bolts (Full Thread),
M931-05055-60 M5-0.80 x 55 continued continued
M931-06040-60 M6-1.00 x 40 M960-16090-60 M16-1.50 x 90 M961-14025-60 M14-1.50 x 25
M931-06055-60 M6-1.00 x 55 M931-16090-60 M16-2.00 x 90 M933-14025-60 M14-2.00 x 25
M931-06060-60 M6-1.00 x 60 M931-16100-60 M16-2.00 x 100 M961-14050-82 M14-1.50 x 50
M931-06060-SS M6-1.00 x 60 M931-16120-60 M16-2.00 x 120
M931-06070-60 M6-1.00 x 70 M961-16025-60 M16-1.50 x 25
M931-16150-60 M16-2.00 x 150
M931-06070-SS M6-1.00 x 70 M933-16025-60 M16-2.00 x 25
M931-06075-60 M6-1.00 x 75 M931-20065-60 M20-2.50 x 65 M961-16030-82 M16-1.50 x 30*
M931-06090-60 M6-1.00 x 90 M931-20100-60 M20-2.50 x 100 M933-16030-82 M16-2.00 x 30*
M931-06145-60 M6-1.00 x 145 M931-20120-60 M20-2.50 x 120 M933-16035-60 M16-2.00 x 35
M931-06150-60 M6-1.00 x 150 M931-20140-60 M20-2.50 x 140 M961-16040-60 M16-1.50 x 40
M931-20160-60 M20-2.50 x 160 M933-16040-60 M16-2.00 x 40
M931-08035-60 M8-1.25 x 35 M961-16045-82 M16-1.50 x 45
M931-08040-60 M8-1.25 x 40 M931-22090-60 M22-2.50 x 90 M933-16045-82 M16-2.00 x 45
M931-08040-82 M8-1.25 x 40* M931-22120-60 M22-2.50 x 120 M933-16050-60 M16-2.00 x 50
M931-08045-60 M8-1.25 x 45 M931-22160-60 M22-2.50 x 160 M933-16050-82 M16-2.00 x 50*
M931-08050-60 M8-1.25 x 50 M931-24090-60 M24-3.00 x 90 M933-16060-60 M16-2.00 x 60
M931-08055-60 M8-1.25 x 55 M931-24120-60 M24-3.00 x 120 M933-16070-60 M16-2.00 x 70
M931-08055-82 M8-1.25 x 55* M931-24160-60 M24-3.00 x 160
M931-08060-60 M8-1.25 x 60 M933-18035-60 M18-2.50 x 35
M931-08070-60 M8-1.25 x 70 M933-18050-60 M18-2.50 x 50
M931-08070-82 M8-1.25 x 70* Hex Head Bolts (Full Thread) M933-18060-60 M18-2.50 x 60
M931-08075-60 M8-1.25 x 75 M933-04006-60 M4-0.70 x 6 M933-20050-60 M20-2.50 x 50
M931-08080-60 M8-1.25 x 80 M933-20055-60 M20-2.50 x 55
M931-08090-60 M8-1.25 x 90 M933-05030-60 M5-0.80 x 30
M931-08095-60 M8-1.25 x 95 M933-05035-60 M5-0.80 x 35 M933-24060-60 M24-3.00 x 60
M931-08100-60 M8-1.25 x 100 M933-05050-60 M5-0.80 x 50 M933-24065-60 M24-3.00 x 65
M931-08110-60 M8-1.25 x 110 M933-24070-60 M24-3.00 x 70
M933-06010-60 M6-1.00 x 10
M931-08120-60 M8-1.25 x 120 M933-06012-60 M6-1.00 x 12
M931-08130-60 M8-1.25 x 130 M933-06014-60 M6-1.00 x 14 Pan Head Machine Screws
M931-08140-60 M8-1.25 x 140 M933-06016-60 M6-1.00 x 16
M931-08150-60 M8-1.25 x 150 M7985A-03010-20 M3-0.50 x 10
M933-06020-60 M6-1.00 x 20 M7985A-03012-20 M3-0.50 x 12
M931-10040-82 M10-1.25 x 40* M933-06025-60 M6-1.00 x 25
M931-10040-60 M10-1.50 x 40 M933-06040-60 M6-1.00 x 40 M7985A-04010-20 M4-0.70 x 10
M931-10045-60 M10-1.50 x 45 M933-06050-60 M6-1.00 x 50 M7985A-04016-20 M4-0.70 x 16
M931-10050-60 M10-1.50 x 50 M7985A-04020-20 M4-0.70 x 20
M933-07025-60 M7-1.00 x 25 M7985A-04050-20 M4-0.70 x 50
M931-10050-82 M10-1.25 x 50
M931-10055-60 M10-1.50 x 55 M933-08010-60 M8-1.25 x 10 M7985A-04100-20 M4-0.70 x 100
M931-10060-60 M10-1.50 x 60 M933-08012-60 M8-1.25 x 12 M7985A-05010-20 M5-0.80 x 10
M931-10065-60 M10-1.50 x 65 M933-08016-60 M8-1.25 x 16 M7985A-05012-20 M5-0.80 x 12
M931-10070-60 M10-1.50 x 70 M933-08020-60 M8-1.25 x 20 M7985A-05016-20 M5-0.80 x 16
M931-10080-60 M10-1.50 x 80 M933-08025-60 M8-1.25 x 25 M7985A-05020-20 M5-0.80 x 20
M931-10080-82 M10-1.25 x 80 M933-08030-60 M8-1.25 x 30 M7985A-05025-20 M5-0.80 x 25
M931-10090-60 M10-1.50 x 90 M933-08030-82 M8-1.25 x 30* M7985A-05030-20 M5-0.80 x 30
M931-10090-82 M10-1.50 x 90* M7985A-05080-20 M5-0.80 x 80
M933-10012-60 M10-1.50 x 12
M931-10100-60 M10-1.50 x 100 M7985A-05100-20 M5-0.80 x 100
M931-10110-60 M10-1.50 x 110 M961-10020-60 M10-1.25 x 20
M931-10120-60 M10-1.50 x 120 M933-10020-60 M10-1.50 x 20 M7985A-06100-20 M6-1.00 x 100
M931-10130-60 M10-1.50 x 130 M933-10025-60 M10-1.50 x 25
M931-10140-60 M10-1.50 x 140 M961-10025-60 M10-1.25 x 25
M933-10025-82 M10-1.50 x 25 Flat Head Machine Screws
M931-10180-60 M10-1.50 x 180
M960-10330-60 M10-1.25 x 330 M961-10030-60 M10-1.25 x 30 M965A-04012-SS M4-0.70 x 12
M933-10030-60 M10-1.50 x 30
M931-12045-60 M12-1.75 x 45 M933-10030-82 M10-1.50 x 30* M965A-05012-SS M5-0.80 x 12
M960-12050-60 M12-1.25 x 50 M961-10035-60 M10-1.25 x 35 M965A-05016-20 M5-0.80 x 16
M960-12050-82 M12-1.25 x 50* M933-10035-60 M10-1.50 x 35 M965A-06012-20 M6-1.00 x 12
M931-12050-60 M12-1.75 x 50 M933-10035-82 M10-1.50 x 35
M931-12050-82 M12-1.75 x 50 M961-10040-60 M10-1.25 x 40
M931-12055-60 M12-1.75 x 55
M931-12060-60 M12-1.75 x 60 M933-12016-60 M12-1.75 x 16
M931-12060-82 M12-1.75 x 60 M933-12020-60 M12-1.75 x 20
M961-12020-60F M12-1.50 x 20
M931-12065-60 M12-1.75 x 65
M931-12075-60 M12-1.75 x 75 M933-12025-60 M12-1.75 x 25
M931-12080-60 M12-1.75 x 80 M933-12025-82 M12-1.75 x 25*
M931-12090-60 M12-1.75 x 90 M961-12030-60 M12-1.25 x 30
M931-12100-60 M12-1.75 x 100 M961-12030-82F M12-1.50 x 30
M933-12030-60 M12-1.75 x 30
M931-12110-60 M12-1.75 x 110
M933-12035-60 M12-1.75 x 35
M961-12040-82 M12-1.25 x 40*
M933-12040-60 M12-1.75 x 40
M933-12040-82 M12-1.75 x 40*

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

TP-6284 5/04 Appendix A-7

Metric, continued
Part No. Dimensions Type
Hex Nuts
M934-03-50 M3-0.50 Standard
M934-04-50 M4-0.70 Standard
M934-05-50 M5-0.80 Standard
M982-05-60 M5-0.80 Elastic Stop
M934-06-60 M6-1.00 Standard
M934-06-64 M6-1.00 Std. (green)
M6923-06-80 M6-1.00 Spiralock
M982-06-80 M6-1.00 Elastic Stop
M934-08-60 M8-1.25 Standard
M6923-08-80 M8-1.25 Spiralock
M982-08-80 M8-1.25 Elastic Stop
M934-10-60 M10-1.50 Standard
M934-10-60F M10-1.25 Standard
M6923-10-80 M10-1.50 Spiralock
M6923-10-62 M10-1.50 Spiralock[
M982-10-80 M10-1.50 Elastic Stop
M934-12-60 M12-1.75 Standard
M934-12-60F M12-1.25 Standard
M6923-12-80 M12-1.75 Spiralock
M982-12-80 M12-1.75 Elastic Stop
M982-14-60 M14-2.00 Elastic Stop
M6923-16-80 M16-2.00 Spiralock
M982-16-80 M16-2.00 Elastic Stop
M934-18-80 M18-2.5 Standard
M982-18-60 M18-2.50 Elastic Stop
M934-20-80 M20-2.50 Standard
M982-20-80 M20-2.50 Elastic Stop
M934-22-60 M22-2.50 Standard
M934-24-80 M24-3.00 Standard
M982-24-60 M24-3.00 Elastic Stop
M934-30-80 M30-3.50 Standard

Washers
Bolt/
Part No. ID OD Thick. Screw
M125A-03-80 3.2 7.0 0.5 M3
M125A-04-80 4.3 9.0 0.8 M4
M125A-05-80 5.3 10.0 1.0 M5
M125A-06-80 6.4 12.0 1.6 M6
M125A-08-80 8.4 16.0 1.6 M8
M125A-10-80 10.5 20.0 2.0 M10
M125A-12-80 13.0 24.0 2.5 M12
M125A-14-80 15.0 28.0 2.5 M14
M125A-16-80 17.0 30.0 3.0 M16
M125A-18-80 19.0 34.0 3.0 M18
M125A-20-80 21.0 37.0 3.0 M20
M125A-24-80 25.0 44.0 4.0 M24

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

A-8 Appendix TP-6284 5/04

 KOHLER CO. Kohler, Wisconsin 53044
Phone 920-565-3381, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KohlerPowerSystems.com
Kohler Power Systems
Asia Pacific Headquarters
TP-6284 5/04 7 Jurong Pier Road
Singapore 619159
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