9EFOZD Parts Manual

8/10/2019 9EFOZD Parts Manual

1/76


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TP-6270 11/102

Table of ContentsDescription Page

Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Numbering System Significance 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Illustrations 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Find Part Numbers 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hardware References 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specification Number Index 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 1: Cylinder Block 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 2: Gear Housing 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 3: Mounting Flange and Oil Sump 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 4: Cylinder Head 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 5: Intake Manifold 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 6: Camshaft and Drive Gear 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 7: Crankshaft and Piston 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 8: Lubrication Oil System 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 9: Cooling Water System 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 10: Fuel Injection Pump 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 11: Governor 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 12: Fuel Injection Valve 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 13: Fuel Line and Filter 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 14: Starting Motor 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 15: Gasket Set 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 101: Air Intake 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 103: Fuel System 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 104: Cooling System 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 105: Engine 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 107: Nameplate and Decals 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 109: Skid and Plant Mounting 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 201: Generator and Mounting 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 301: Controller and Mounting 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 701: Literature 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paint and Miscellaneous Parts 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts List: Accessories 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A. Glossary of Abbreviations 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B. Common Hardware Application Guidelines 69. . . . . . . . . . . . . . . .

Appendix C. General Torque Specifications 70. . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix D. Common Hardware Identification 71. . . . . . . . . . . . . . . . . . . . . . . .

Appendix E. Common Hardware List 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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IntroductionThis manual lists service replacement parts for8.5EFOZD/10EOZD, 9EFOZD/10EOZD, and 7EFOZD/9EOZD generator sets.

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

This manual includes the following main sections:

Table of Contents. Lists the sections of the manual.

Introduction (and other information sections).Contains introductory material about part numbers,illustrations, and hardware.

Specification Number Index. Lists the generator setspecs and groups.

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

Kit Sections. List modules and accessories and theirparts.

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

x:in:004:002

Numbering System Significance

This manual uses the following numbering systems:

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

Group Number. A unique number representing a partsgroup needed to assemble a generator set function. For

example, Group 101 is the Air Intake group.Variation or Module Number. A group might haveseveral variations. Each variation performs the samefunction with different parts lists. For example, a 50 Hzgenerator alternator and a 60 Hz generator alternatorboth perform the same function; however, with differentparts. Each difference requires a group variation ormodule number.

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

x:in:004:003:a

Illustrations

Illustrations (or exploded-view drawings) best

representing the widest range of variations accompanymost groups in this manual. Illustrations do not depict alldetails and may not show all parts. Do not useillustrations for assembly or disassembly.

x:in:004:004a

How to Find Part Numbers

Use the following steps to locate a service replacementpart.

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

2. Locate a second generator set nameplate listingaccessories to identify installed modules. Onsome models the accessory nameplate is mountedinside the generator junction box.

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

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

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

6. Page forward to locate the group identified in

step 4 or find the appropriate page in the Table ofContents.

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

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

x:in:004:005

Hardware References

Many common hardware items do not appear in partsmanuals or will appear as common hardware entries. Acommon hardware entry lists the size of the hardware.For example, an item that appears as Hardware,3/8-16 in the text means that the piece is 3/8-16 size.Obtain common hardware locally or, if contacting thefactory, use the Common Hardware List in the appendixto identify the common hardware part number andspecifications. See Common Hardware ApplicationGuidelines in the appendix for mating hardwareinstructions.

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

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

x:in:004:006


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Specification Number Index

Group No. 15 101 103 104 105 107 109 201 301 701

Spec No. Variation Number

Group Title

GM30507-GA1 1 GR1 GR2 GR3 GR4 GR5 GR6 GR7 GR16 44








GM37403-GA1 2 2 3 3 3 3 2 3 3 69

GM37403-GA2 2 2 3 3 4 3 2 3 3 69

GM37403-GA3 2 2 4 3 5 3 2 3 3 69

GM55351-GA1 2 3 5 4 6 4 3 4 4 69

GM55351-GA2 2 3 5 4 7 4 3 4 4 69

GM55350-GA1 1 4 6 5 8 5 4 5 5 71

GM55350-GA2 1 4 7 6 9 5 4 5 6 71

GM55350-GA3 1 4 6 5 8 6 4 6 5 72

GM55350-GA4 1 4 7 6 9 6 4 6 6 72

GM55350-GA5 3 4 6 5 10 5 4 5 5 71

GM55350-GA6 3 4 7 6 11 5 4 5 6 71

GM55350-GA7 3 4 6 5 10 6 4 6 5 72

GM55350-GA8 3 4 7 6 11 6 4 6 6 72


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Group 1: Cylinder Block

6270_1

Item Description

QuantityVar. No.

Part Number 11 GM35737 Block assembly, cylinder 14 252771 Plug PT1/4 25 252566 Plug 16 252078 Plug 17 GM35519 Plug 50 18 252728 Plug 29 225924 Plug 30 6

12 225703 Bolt 813 252933 Bush 1

Item Description

QuantityVar. No.

Part Number 114 252771 Plug PT1/4 124 GM35740 Bearing, main (std) 427 229802 Bearing (piar) 130 225705 Bolt 1431 GM33836 Gasket, cylinder head 132 225709 Bearing, main 435 225710 Bearing, thrust 238 GM35428 Spacer 1


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Group 1: Cylinder Block, continued

6270_1_2

See Group 5

See Group 5

Item Description

Quantity

Var. No.

Part Number 2 31 GM47257 Block assembly, cylinder 1 15 252078 Plug 1 16 252028 Plug 4 47 GM47254 Plug 45 1 1

8 252771 Plug PT1/4 1 19 GM47253 Plug 25 3 3

10 225703 Bolt 8 813 GM47256 Bushing, camshaft 1 114 252728 Plug 1 115 GM47258 Main bearing set 4 427 229802 Bearing (pair) 127 GM79275 Bearing 230 225705 Bolt 14 1431 GM47255 Gasket, cylinder head 1 132 225710 Bearing, thrust 2 235 GM47259 Main bearing, 0.25 US 4 4


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Group 2: Gear Housing

6270_2

Item Description

Quantity

Var. No.

Part Number 11 GM35736 Housing assembly, gear 14 GM35720 Plug, screw 15 GM35721 Plug 16 252931 Oil seal 17 GM35464 Cover assembly, pump 18 GM35463 Cover, lube oil pump 19 GM35653 Valve, relief 1

10 GM35578 Spring 111 GM35520 Plug 112 GM35429 Flange, gear case 113 GM35430 Stud, M8 x 25 314 250837 Cap 115 256531 Cover 116 252932 Knock, pipe 217 GM35421 O-ring 4

Item Description

Quantity

Var. No.

Part Number 118 GM35465 Rotor, inner 119 GM35466 Rotor, outer 120 GM35467 Screw, M6 x l6 721 252764 O-ring, pump 122 GM35522 Bolt, M8 x 85 323 252684 O-ring 124 252696 Bolt, M8 x 16 425 252696 Bolt, M8 x 16 326 256798 Bolt, M8 x 55 plated 1227 GM35732 Nut 328 252750 Cover, blind 129 256796 O-ring 130 252693 Bolt 231 252998 Gasket 1


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Group 2: Gear Housing, continued

6270_2_2

Item Description

Quantity

Var. No.

Part Number 2 31 GM47261 Case, gear 1 13 GM47262 Bolt, stud M8 3 34 GM47270 Cover assembly, gear case 14 GM79276 Cover assembly, gear case 15 GM47272 Cover assembly, gear case 15 GM79277 Cover assembly, gear case 1

6 GM47269 Cover, gear case 1 18 229634 Oil seal 18 GM79278 Oil seal 19 GM35720 Plug, screw 2 2

10 GM47266 Cover assembly, pump 1 111 GM47265 Cover, lub. oil pump 1 112 GM35653 Valve, relief 1 113 GM47271 Spring 1 114 GM35520 Plug 1 115 GM47267 Rotor, inner 1 116 GM47268 Rotor, outer 1 117 GM35467 Screw, M6 x 16 8 8

Item Description

Quantity

Var. No.

Part Number 2 318 GM47263 Cover, pump timing 1 119 229674 Pipe, knock 4 420 GM47260 O-ring 1 121 GM47264 O-ring 3 322 252764 O-ring, fuel injection pump 1 123 225816 Bolt, M6 x 12 1 1

24 252693 Bolt 4 425 225921 Bolt 4 426 225921 Bolt 3 327 363207 Bolt, M6 x 60 7 728 229766 Bolt, M6 x 65 plated 2 229 GM35732 Nut 3 330 GM46206 Gasket, liquid 1 131 250837 Lub oil cap 1 132 252684 O-ring 1a p-32.0 1 133 252750 Cover, blind 1 134 256796 O-ring 1a s-24.0 1 135 252693 Bolt 2 2


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Group 3: Mounting Flange and Oil Sump

6270_3

Item Description

Quantity

Var. No.Part Number 1

1 256750 Parallel pin 8 x 16 22 229114 Mounting flange 13 252998 Gasket 14 229505 Bolt, M10 x 20 65 252714 Bolt 46 225706 Spacer 17 252701 Bolt, M8 x 35 38 GM35492 Sump assembly, oil 1

Item Description

Quantity

Var. No.Part Number 1

9 225386 Drain plug M22 111 225425 Seal washer 112 252696 Bolt, M8 x 16 613 252703 Bolt 2214 256750 Parallel pin 8 x 16 215 225866 Case assembly 117 252930 Rear oil seal 118 363430 Bolt, M8 x 30 6


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Group 3: Mounting Flange and Oil Sump

6270_3_2

Item Description

Quantity

Var. No.

Part Number 2 31 256750 Parallel pin 8 x 16 2 22 GM47276 Backplate 12 GM79279 Backplate 13 229505 Bolt, M10 x 20 7 7

4 252714 Bolt 3 35 363026 Parallel pin 6 x 10 2 26 229671 Case assembly, oil seal 1 18 250836 Oil seal 1 19 229761 Bolt, M6 x 22 plated 10 10

10 GM47274 Spacer, oil sump 1 111 GM47275 Sump assembly, lub. oil 1 112 GM47273 Plug, M16 1 114 363448 Washer, seal 16S 1 115 252695 Bolt, M8 x 12 1 116 225819 Bolt, M8 x 30 plated 1 117 252703 Bolt 11 1118 252704 Bolt 3 319 GM46206 Gasket, liquid 1 1


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Group 4: Cylinder Head

6270_4


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13TP-6270 11/10

Group 4: Cylinder Head

Item Description

Quantity

Var. No.

Part Number 1 31 363110 Lifter, engine 2 22 225818 Bolt, M8 x 14 42 252696 Bolt, M8 x 16 43 GM35440 Shaft assembly, rocker 1 14 GM35441 Shaft, rocker arm 1 16 GM35442 Support, rocker arm 2 27 GM35443 Support, rocker arm 2 28 GM35444 Stud 3 39 252815 Spring 3 3

10 GM35447 Arm assembly, rocker 6 611 229844 Valve screw 6 613 252817 Nut, M8 6 614 250999 Cap 6 615 GM35448 Head assembly, cylinder 115 GM79283 Head assembly, cylinder 119 250835 Valve guide 3 321 GM35449 Guide, valve 3 323 252732 Plug 40 2 224 GM35438 Valve, intake 3 325 GM35439 Valve, exhaust 3 326 225713 Spring, valve 6 627 250882 Retainer 6 628 225766 Seal, valve stem 328 GM52156 Seal, valve stem 3

29 250844 Valve seal 329 225766 Valve seal 330 250806 Pin, cotter 6 632 252744 Seat 3 333 GM35451 Retainer, nozzle 3 334 GM35495 Washer 3 335 250963 Spring pin 2 236 252699 Bolt, M8 x 25 plated 2 237 252703 Bolt 3 338 252704 Bolt 6 639 250837 Cap 1 140 GM35446 Bonnet assembly, head 1 141 GM35431 Plate, baffle 1 142 252805 Baffle 1 143 GM35434 Plate, diaphragm 1 144 GM35435 Cover, diaphragm 1 145 GM35436 Diaphragm 1 146 GM35437 Spring, diaphragm 1 1

49 GM35445 Gasket, bonnet 1 150 363201 Screw, tapping 5 x 10 4 451 363201 Screw, tapping 5 x 10 4 452 252470 Cap nut 3 353 250801 O ring 3 354 252684 O-ring 1 155 GM35450 Protector, nozzle 3 356 252998 Gasket 1 1


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Group 4: Cylinder Head, continued

6270_4_2


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Group 4: Cylinder Head, continued

Item Description

Quantity

Var. No.

Part Number 21 363110 Lifter, engine 22 252696 Bolt, M8 x 16 23 GM47297 Protector, nozzle 34 229624 Gasket 65 GM47277 Cap, valve 66 GM47291 Head assembly, cylinder 1

14 GM35426 Guide, valve 615 GM47278 Plug 35 216 GM47299 Plug 1/16, screw 117 GM47281 Valve, intake 318 GM47282 Valve, exhaust 319 GM47283 Spring, valve 620 GM35587 Retainer, spring 621 GM35423 Cotter, valve 1222 GM35424 Seal, valve stem 323 GM35425 Seal, valve stem 324 250963 Spring pin 6 x 12 225 GM47284 Support assembly, arm 126 GM47285 Shaft assembly, rocker 129 GM47286 Support, rocker arm 330 363034 Spring 231 GM47290 Arm assembly, rocker 632 229844 Valve screw 634 252817 Nut, M8 x p1.0 6

35 252345 Clip 236 363213 Screw, m5 x 16 137 252702 Bolt 338 250837 Lub oil cap 139 GM47289 Bonnet assembly, head 140 GM47279 Plate, baffle 141 GM47280 Baffle, breather 142 GM47280 Baffle, breather 243 GM47296 Diaphragm assembly 144 GM35434 Plate, diaphragm 145 GM35435 Cover, diaphragm 146 GM35436 Diaphragm 147 GM35437 Spring, diaphragm 150 GM47295 Gasket, bonnet 151 GM47287 Cover, bonnet 152 GM47288 Gasket, bonnet cover 153 363201 Screw, tapping 5 x 10 454 363201 Screw, tapping 5 x 10 4

55 GM47298 Screw, 5 x 16 256 252684 O-ring 1a p-32.0 157 225817 Bolt, M6 x 20 358 225429 Bolt, M6 x 75 Plated 659 GM47293 Plug, glow 360 GM47294 Connector, glow plug 161 GM46206 Gasket, liquid 162 GM47292 Gasket, manifold 1


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Group 5: Intake Manifold

6270_5

Item Description

Quantity

Var. No.

Part Number 11 GM35433 Pipe, breather 12 229425 Clamp 23 GM35452 Manifold, intake 15 GM33685 Gasket, intake manifold 16 252697 Bolt 47 252707 Bolt 28 225778 Gasket 19 GM35579 Joint 1

10 252697 Bolt 411 225717 Gasket, exhaust manifold 1


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Group 6: Camshaft and Drive Gear

6270_6

Item Description

Quantity

Var. No.

Part Number 11 252819 Tappet 62 225718 Rod, push 63 GM35453 Camshaft assembly 14 252804 Metal, thrust 16 256587 Gear, camshaft 17 252669 Key 7 x 14 18 GM35734 Nut, lock M14 plated 19 225818 Bolt, M8 x 14 2

10 GM35459 Shaft, idle gear 111 GM35461 Gear assembly, idle 114 GM35460 Bush, idle gear 1

15 252702 Bolt 316 GM19682 Bolt, gear 417 GM35462 Gear, pump 118 GM35711 Flange 119 GM35714 Washer, spring 1


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Group 6: Camshaft and Drive Gear, continued

6270_6_2

Item Description

Quantity

Var. No.

Part Number 21 363039 Tappet 62 GM47300 Rod, push 63 GM47301 Camshaft assembly 19 225816 Bolt, M6 x 12 2

10 GM47302 Shaft, idle gear 111 GM47303 Gear assembly, idle 114 GM47306 Bolt, M6 x 35 plated 315 GM19682 Bolt, gear 416 GM47304 Gear, pump 1

17 GM47305 Flange 118 252666 Washer, spring 119 252725 Nut 1


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Group 7: Crankshaft and Piston

6270_7

Item Description

Quantity

Var. No.

Part Number 1 41 GM35454 Crankshaft assembly 1 12 256750 Parallel pin 8 x 16 1 15 GM35455 Gear, crankshaft 1 16 252669 Key 7 x 14 1 18 256654 Spring pin 1 19 GM35456 V-pulley, crankshaft 1 1

10 252937 Washer 1 111 252763 Bolt, V pulley 1 112 252401 Bolt, flywheel 6 613 229117 Flywheel assembly 1 115 252774 Gear, ring 1 116 GM35457 Piston w/ring 3 318 GM35458 Ring set, piston 3 3

22 225395 Pin, piston 3 323 229738 Circlip 6 624 225838 Rod assembly, connecting 3 328 225726 Bushing piston pin 3 329 225723 Bolt 6 630 225724 Bearing, crankpin 3 332 225725 Crank bearing 3 334 GM35738 Piston w/ring, 0.25 OS 334 GM79284 Piston w/ring, 0.25 OS 336 GM35739 Ring set, 0.25 OS 336 GM79285 Ring set, 0.25 OS 3


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Group 8: Lubrication Oil System

6270_8

Item Description

QuantityVar. No.

Part Number 11 GM35468 Dipstick 12 252759 Guide, dipstick 13 225775 Gasket 14 GM35487 Pipe assembly, oil inlet 18 252701 Bolt, M8 x 35 29 GM35419 Switch, oil pressure 1

10 252084 Bolt 111 GM35471 Pipe assembly, oil 112 GM35550 Bolt assembly, joint 113 252677 Joint bolt 114 252734 Washer 8, seal 115 252734 Washer 8, seal 116 363452 Washer, seal 217 250989 Nut, M6 1

18 252834 Filter, oil* 119 252697 Bolt 320 GM35469 Bracket assembly, filter 121 GM35470 Bracket, filter 122 256582 Stud 123 225776 Gasket 1

* A Kohler-brand oil filter is available for generator models using thisvariation. Oil filter GM47465 has 18% more media than filter 252834for greater contaminant-holding capacity.


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Group 8: Lubrication Oil System, continued

6270_8_2

Item Description

Quantity

Var. No.Part Number 2 3

1 GM47323 Dipstick, lub. oil 1 12 256582 Stud 1 13 229678 Filter, oil 13 250952 Filter, oil 14 GM47322 O-ring 1 15 GM47324 Pipe assembly, lub, oil 1 19 229498 Bolt, M6 x 10 plated 2 2

10 GM35419 Switch, oil pressure 1 111 GM47325 Pipe assembly, hydraulic 1 112 GM35550 Bolt assembly, joint 2 213 252734 Washer 8, seal 2 214 252677 Joint bolt 3 2 215 252734 Washer 8, seal 2 216 252759 Guide, dipstick 1 1


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23TP-6270 11/10

Group 9: Cooling Water System

6270_9a

Item Description

Quantity

Var. No.

Part Number 1 2 5 61 GM35472 Pump assy., water 1 11 GM79286 Pump assy., water 1 13 GM35488 Gasket 1 1 1 14 GM35489 Plate 1 1 1 18 GM29476 Gasket 1 1 1 1

9 GM35490 Pipe, water pump 1 1 1 111 252839 O-ring 1 1 1 113 GM35720 Plug, screw 2 2 2 214 225818 Bolt, M6 x 14 plated 2 2 2 215 225817 Bolt, M6 x 20 2 2 2 216 252701 Bolt, M8 x 35 1 1 1 117 256798 Bolt, M8 x 55 plated 3 3 3 318 225428 V-belt 1 118 226929 V-belt (24 V models) 1 119 252845 V-pulley 1 1 1 120 229408 Thermostat cover 1 1 1 121 249865 Gasket 1 1 1 122 252699 Bolt, M8 x 25 plated 1 1 1 1

Item Description

Quantity

Var. No.

Part Number 1 2 5 623 252773 Packing 16 2 2 2 224 252757 Plug M16 2 2 2 225 256734 Petcock assembly 1 1 1 125 225704 Valve 1 1 1 128 250967 Gasket 8, round 1 1 1 1

29 252695 Bolt, M8 x 12 1 1 1 130 252705 Bolt 1 1 1 131 GM35473 Pipe assembly 1 132 GM35475 Pipe assembly 1 133 GM35477 Clamp 1 134 229411 Clamp 2 235 GM35482 Tube, corrugated 1 136 GM35474 Pipe assembly 1 137 GM35476 Pipe, water 1 138 229411 Clamp 2 239 GM35580 Gasket 1 1


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24 TP-6270 11/10

Group 9: Cooling Water System, continued

6270_9_2

Item Description

Quantity

Var. No.

Part Number 3 41 GM47326 Pump assembly, water 1 13 GM47329 Cover 1 14 GM47328 Gasket 1 19 GM47333 Screw, M6 x 12 4 4

10 229780 Plug 1 111 GM47330 O-ring 1 112 GM35704 Plug, drain 1 113 GM47327 Gasket, water pump 1 114 250967 Gasket 8, round 1 115 252695 Bolt, M8 x 12 1 116 252704 Bolt 3 3

17 GM47331 V-pulley, water pump 1 118 GM47044 Belt, 36 in. 1 119 225816 Bolt, M6 x 12 4 420 GM42711 Cover, thermostat 1 121 252706 Bolt 1 122 252699 Bolt, M8 x 25 plated 1 123 252757 Plug m16 2 224 GM42701 Plug, drain 1 125 252773 Packing 16 2 226 249865 Gasket 1 127 GM47332 Adjuster, belt 1 128 252697 Bolt 1 129 GM35491 Bolt 129 GM46241 Bolt 1


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25TP-6270 11/10

Group 10: Fuel Injection Pump

6270_10

5

6

7

Item Description

Quantity

Var. No.

Part Number 1 21 GM35742 Injection pump assembly 1 12 GM35478 Bracket, pump 1 13 252696 Bolt, M8 x 16 1 14 252697 Bolt 1 1

5 225461 Solenoid kit (includes items 6, 7) 15 GM58632 Solenoid (24 V models) 16 225388 Solenoid (12 V) 17 225427 O-ring 1


26/76

26 TP-6270 11/10

Group 10: Fuel Injection Pump, continued

6270_10_2

See Group 6

1

2

3

4

Item Description

Quantity

Var. No.

Part Number 31 GM47334 Pump assembly, fuel injection 12 225461 Solenoid kit (includes items 3, 4) 13 225388 Solenoid (12 V) 14 225427 O-ring 1


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27TP-6270 11/10

Notes


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28 TP-6270 11/10



29/76

29TP-6270 11/10


Item Description

Quantity

Var. No.

Part Number 41 GM79290 Pump assy., injection 14 256776 Stud 25 GM79291 Camshaft 16 GM79292 Support, camshaft 17 GM79293 Key, parallel 18 256528 Key 19 GM79294 Plunger w/barrel 3

12 256721 Pin 313 GM47305 Flange 114 GM79295 Retainer, spring 315 GM79296 Spring, plunger 316 GM79297 Tappet assy. 320 256700 Shim 340 GM42718 Stopper 341 252849 O-ring 342 252849 O-ring 143 GM79298 Valve assy., delivery 346 GM79299 Spring, delivery 347 250839 Gasket 348 GM79300 Locking 349 225779 Deflector 150 GM79301 Plug, deflector 151 GM79302 O-ring 152 GM79303 Plug, deflector 1

53 GM79304 Valve assy., delivery 359 256729 Packing 164 GM79305 Rack, control 165 256780 Bush, rack 166 256694 Spacer 167 256695 Clip 168 256696 Pinion 369 GM79306 Pinion 370 GM79307 Retainer, spring 371 GM79308 Screw, pinion 372 GM79309 Plug 173 252850 O-ring 174 256699 Spring 175 256782 Cover 176 GM79310 Gasket, lower cover 177 GM79311 Cover, body side 178 GM79312 Gasket, side cover 179 GM79313 Stopper, rack 1

80 363448 Washer, seal 16S 181 225804 Spring washer 6 282 252666 Washer, spring 183 225808 Pin 284 GM79314 Ball bearing 185 256556 Ball bearing 186 GM79315 O-ring 4d p15 387 GM19690 Screw, M5 x 12 888 225815 Screw m 6 x 16 489 GM79316 Bolt, M5 x10 plated 390 225824 Nut 291 252725 Nut 192 GM79317 Collar 193 GM79318 Bolt 196 252851 Gasket 197 256755 Cover 1


30/76


31/76

31TP-6270 11/10


Item Description

Quantity

Var. No.

Part Number 51 GM79287 Injection pump assy. 14 GM42717 Joint 1

10 GM42750 Key, woodruff 4 x 16 137 GM42718 Stopper 138 GM42719 O-ring 139 GM42719 O-ring 140 GM69340 Setting, delivery 349 GM42721 Spring 357 GM42724 Plug 158 GM42725 Barrel plug 159 GM42726 Packing 360 GM42726 Packing 161 GM42727 Plug 162 GM42729 Lifter 163 GM42730 Timer set 164 GM42731 Timer component 167 GM42732 O-ring 168 GM42733 Ring, backup 169 GM42734 O-ring 170 GM42735 Packing 171 GM42736 Ring, backup 172 GM79288 Plug, timer 173 GM42737 Packing, head 174 GM42738 Spring, timer 1

76 GM42740 Joint 177 GM42741 O-ring 178 GM42742 Packing, timer 198 GM42743 Piston 199 GM52211 Damper assy. 1

100 GM42745 Plug 1101 225424 Seal washer 12s 1102 GM42748 Seal washer 1103 256518 Plug 1105 GM42753 Bolt 4106 GM42746 Pump assy., feed 1107 GM52212 O-ring 1108 GM42747 O-ring 1110 225424 Seal washer 12s 2111 225424 Seal washer 12s 2112 GM35714 Washer, spring 1113 GM42749 Parallel pin, 5 x 14 2114 225808 Pin 2

115 250972 Joint bolt 6 1117 250800 O-ring 1118 GM42752 O-ring 1119 GM42735 Packing 1120 229498 Bolt, M6 x 10 plated 1124 GM42754 Bolt, M8 x 45 4125 GM35734 Nut, lock M14 plated 1127 GM42755 Joint 12, pipe 1129 GM35478 Bracket, pump 1130 252696 Bolt, m8 x 16 1131 252697 Bolt 1


32/76

32 TP-6270 11/10

Group 11: Governor


33/76

33TP-6270 11/10

Group 11: Governor

Item Description

Quantity

Var. No.

Part Number 12 GM79319 Gasket, case 13 GM79320 Gasket, cover 14 GM79321 Case assy., governor 15 252849 O-ring 17 GM79322 Link L=29.3 18 GM79323 Link L=29.8 19 GM79324 Link L=28.8 1

10 GM79325 Link L=30.3 111 GM79326 Nut, M6 112 225415 Shaft, governor lever 113 GM79327 Shaft assy., control 120 GM42758 Nut 121 GM79328 Spring, lever 122 GM79329 Lever, control 123 GM79330 Bolt, limiter 224 GM79331 Shim, t=0.6 125 225786 Spacer assy. 131 GM79332 Lever assy., governor 132 252592 Shim set 250 GM19694 Spring, set 160 GM79333 Spring, starting 161 GM79334 Shim set, lever 165 GM79335 Shim, t=1.0 166 229692 Retainer, shaft 1

67 GM79336 Circlip 168 229757 O-ring 1a s-7 169 229498 Bolt, M6 x 10 plated 170 225825 Lock nut 171 GM79337 Weight assy., governor 175 GM66399 Nut, governor weight 176 225781 Sleeve 177 225784 Bolt, idle limit 178 GM79338 Cover 179 GM79339 Cover, governor case 180 GM79340 Screw, adjusting 181 GM79341 Spring 182 225702 Nut, cap 183 225423 Seal washer 6 284 225825 Lock nut 185 GM52219 O-ring 186 GM79342 Nut 187 363452 Washer, seal 10S 1

88 225424 Seal washer 12s 289 225809 Pin, snap 4 190 256517 Plug 191 229498 Bolt, M6 x 10 plated 492 225818 Bolt, M6 x 14 plated 293 225817 Bolt, m6 x 20 494 229764 Bolt 395 225825 Lock nut 196 GM19695 Bolt, control 197 GM79343 Angleich assy. 1

130 GM79344 Spring, governor 1131 GM79345 Cap nut 1132 GM79346 Plate 1133 225461 Solenoid kit, stop (includes O-ring) 1134 250970 Gasket 1


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34 TP-6270 11/10

Group 11: Governor, continued


35/76

35TP-6270 11/10

Group 11: Governor, continued

Item Description

Quantity

Var. No.

Part Number 2 33 GM42756 Packing, case 1 14 GM42757 Packing 1 16 252849 O-ring 1 1

22 GM42758 Nut 1 123 GM42759 Spring 1 124 GM42760 Lever, regulator 1 125 225784 Bolt, idle limit 1 160 229692 Retainer, shaft 1 164 GM42762 Seal washer 1 166 256518 Plug 1 168 229498 Bolt, M6 x 10 plated 1 169 225825 Lock nut 1 178 GM52219 O-ring 1 184 225818 Bolt, M6 x 14 plated 2 285 225818 Bolt, M6 x 14 plated 4 486 225817 Bolt, m6 x 20 10 1089 GM42763 Cover, case 1 1

104 225461 Solenoid kit, s top (includes O-ring) 1104 GM58632 Solenoid, stop (24 V) 1


36/76

36 TP-6270 11/10

Group 12: Fuel Injection Valve

6270_12

Item Description

Quantity

Var. No.

Part Number 1

1 GM35743 Fuel injector 32 GM35494 Nozzle assembly 35 256520 Nut, nozzle case 36 GM35479 Holder assembly, nozzle 3

10 256521 Spring nozzle 311 256522 Seat, nozzle spring 312 256523 Plate, stop 313 256707 Pin 614 256524 Shim set 326 225374 Retainer 1

Item Description

Quantity

Var. No.

Part Number 1

29 225418 Bolt, M4 x 14 hex socket 130 256774 Clamp assembly, line 133 225418 Bolt, M4 x 14 hex socket 235 GM35484 Pipe assembly, injection 139 GM35485 Pipe assembly, injection 143 GM35486 Pipe assembly, injection 147 GM35573 Pipe, fuel oil 248 GM35483 Pipe, fuel oil 149 GM35574 Cap 150 249843 Hose clamp 7


37/76

37TP-6270 11/10

Group 12: Fuel Injection Valve, continued

6270_12_2

Item Description

Quantity

Var. No.

Part Number 21 GM47337 Valve assembly, injection 32 GM47336 Holder, nozzle 33 GM47338 Nozzle assembly 34 256774 Clamp assembly, line 17 225418 Bolt, M4 x 14 hex socket 29 GM47340 Pipe, fuel injection 1

13 GM47341 Pipe, fuel injection 117 GM47342 Pipe, fuel injection 121 225406 Joint 122 GM47339 Pipe assembly, return 128 GM47345 Gasket, return 329 GM47343 Pipe, fuel oil 130 249843 Hose clamp 231 229662 Nut 332 GM47344 Valve assembly, check 138 225424 Seal washer 12S 240 Clamp (see Group 103) 241 Fuel line (see Group 103) 1


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38 TP-6270 11/10

Group 12: Fuel Injection Valve, continued

6270_12_3

Item Description

Quantity

Var. No.

Part Number 31 GM47337 Valve assembly, injection 32 GM47336 Holder, nozzle 33 GM47338 Nozzle assembly 34 GM79347 Shim set, adjusting 3

15 256774 Clamp assembly, line 118 225418 Bolt, M4 x 14 Hex. Socket 220 GM47340 Pipe, fuel injection 124 GM47341 Pipe, fuel injection 128 GM47342 Pipe, fuel injection 132 GM47339 Pipe assembly, return 138 GM79348 Pipe, fuel oil 139 GM47343 Pipe, fuel oil 140 GM47345 Gasket, return 341 225406 Joint 142 229662 Nut 343 GM47344 Valve assembly, check 149 225424 Seal washer 12s 250 249843 Hose clamp 251 252670 Clamp 2


39/76

39TP-6270 11/10

Group 13: Fuel Line and Filter

6270_13

Item Description

Quantity

Var. No.

Part Number 11 GM35541 Bracket, filter 12 GM32359 Filter, fuel 13 225819 Bolt M8 x 30 plated 24 X-386-93 Pipe, fuel oil 15 X-386-135 Pipe, fuel oil 16 X-426-9 Clamp 4


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40 TP-6270 11/10

Group 13: Fuel Line and Filter, continued

6270_13_2

Item Description

Qty.

Var.

Part Number 2 31 GM47042 Filter assembly, fuel 11 GM79281 Filter assembly, fuel 12 GM47346 Spring, taper valve 1 13 GM47349 Lever 1 14 229709 Cup, strainer 1 15 229550 O-ring 1 16 250821 Retainer 1 17 229708 Spring 1 18 GM10979 Element, fuel filter 1 19 GM47347 Screw, M4 1 1

Item Description

Qty.

Var.

Part Number 2 310 225811 O-ring 1 111 229758 Bolt w/washer, M8 x 70 1 112 229552 Bolt, pipe joint 1 113 256567 Joint 12, pipe 1 115 Clamp (see Group 103) 215 252670 Clamp 216 Fuel line (see Group 103) 116 GM79282 Fuel line 117 225424 Seal washer, 12S 2 218 GM47348 Bracket, filter 1 119 252696 Bolt, M8 x 16 2 2


41/76


42/76

42 TP-6270 11/10

Group 14: Starting Motor, continued

6270_14_2

Item Description

Quantity

Var. No.

Part Number 31 229704 Starter 12 363417 Cover terminal 13 252630 Stopper set, pinion 14 GM47353 Switch, magnet 15 252631 Washer set, thrust 16 363004 Armature 17 363005 Cover assy., rear 18 GM47351 Holder assembly, brush 19 363008 Brush (--) 2

10 GM47352 Brush (+) 1

Item Description

Quantity

Var. No.

Part Number 311 363009 Spring, brush 412 363006 Cover kit, dust 113 363007 Shift lever kit 114 363092 Yoke assy. 115 363078 Case, gear 116 363093 Through bolt 217 363079 Pinion 118 363010 Bolt, M6 x 37 219 225820 Bolt, M10 x 30 plated 219 229768 Bolt, M10 x 30 2


43/76

43TP-6270 11/10

Group 15: Gasket Set

6270_15

Item Description

Quantity

Var. No.

Part Number 11 GM35741 Gasket set 12 GM33836 Gasket, cylinder head 1

3 252764 O-ring, pump 14 250844 Valve seal 35 GM35450 Protector, nozzle 36 252744 Seat 37 GM35445 Gasket, bonnet 18 225778 Gasket 19 225717 Gasket, exhaust man 1

10 225425 Seal washer 111 225766 Seal, valve stem 312 225775 Gasket 113 GM35580 Gasket 114 249865 Gasket 115 GM35421 O-ring 416 250967 Gasket 8, round 117 252734 Washer 8, seal 218 GM35517 Gasket 219 250801 O ring 320 252684 O-ring 221 256796 O-ring 122 363452 Washer, seal 223 GM33685 Gasket, intake manifold 124 225776 Gasket 1


44/76

44 TP-6270 11/10

Group 15: Gasket Set, continued

6270_15_2

25

Item Description

Quantity

Var. No.

Part Number 21 GM47354 Gasket set 12 GM47255 Gasket, cylinder head 13 252764 O-ring, fuel injection pump 14 GM35424 Seal, valve stem 35 GM47297 Protector, nozzle 36 GM47295 Gasket, bonnet 17 GM47292 Gasket, manifold 18 GM35425 Seal, valve stem 39 252734 Washer 8, seal 4

10 252684 O-ring 211 GM47322 O-ring 112 GM47260 O-ring 1

Item Description

Quantity

Var. No.

Part Number 213 GM47264 O-ring 314 229624 Gasket 615 GM47288 Gasket, bonnet cover 116 252773 Packing 16 217 225424 Seal washer 418 GM47345 Gasket, return 319 GM47327 Gasket, water pump 120 250967 Gasket, round 121 363448 Washer, seal 16S 122 256796 O-ring 123 249865 Gasket 125 GM46206 Gasket, liquid 1


45/76

45TP-6270 11/10

Group 15: Gasket Set, continued

6270_15_3

25

Item Description

Quantity

Var. No.

Part Number 31 GM79289 Gasket set 1


46/76


47/76

TP-6270 11/10 47

Group 103: Fuel System

1

2

3

4

6

7

8

9

10

11

12

5

11

See Group 12 and Group 13 for additional fuel system parts.6270_103b

5

A A

See Group 13

13

14

5

5

5

5

15

16

ItemPart

Description

Quantity

Variation NumberNumber GR2 GR9 3 4 5 6 7

1 229051 Pump, fuel 1 1 1 1 11 344740 Pump, fuel 1 12 229168 Lead assembly 1 1 1 1 1 1 13 X-555-1 Elbow, street, 1/4 x 1/4 1 1 1 1 1 1 14 X-391-25 Connector, 90 deg. 5/16 in. ID hose 1 1 1 1 1 1 15 X-426-9 Clamp, hose, .25/.70 in. 2 2 6 2 6 2 26 X-386-101 Fuel line, flexible 1 1 1 16 X-386-79 Hose 1 1 17 229065 Bracket, fuel pump 1 1 1 17 GM38396 Bracket, fuel pump 1 1 18 M125A-12-80 Washer 2 2 2 29 M933-12020-60 Bolt, hex head 2 2 2 2

10 X-101-25 Nut, hex elastic stop 3 3 3 3 3 3 311 X-25-40 Washer 6 6 6 6 6 6 612 X-284-39 Grommet 3 3 3 3 3 3 3

13 X-386-135 Line, flex fuel 1 113 -- Line, fuel (See Group 13) 114 X-386-79 Hose 1 114 -- Hose (See Group 12) 115 GM41018 Bracket, fuel filter mounting 1 1 116 M931-08070-60 Screw, hex cap 1 1 1


48/76

48 TP-6270 11/10

Group 104: Cooling System

1

2

34

5

6

7

9

10

11

12

13

74

1415

17

18

19

20

21

2273

24

25

26

27

28

29

30

31

32

33

34

35

36 37

38

39

42

44

45

49

50

33

54

48

45

47

41

46

43

58

55

56

57

8

2

2

3

3 50

31

45

45

59

23

16

51

52

4

4

6270_104a

71

72

Note: Items 1--7, and 51 are removed when an optional sound shield is installed.


49/76

TP-6270 11/10 49

Group 104: Cooling System

Item

Part

Description

Quantity

Variation Number

Number GR3 GR10 3 4 5 6

1 GM30592 Guard, belt 1 1 1 11 GM38459 Guard, belt 1 12 X-284-39 Grommet 3 3 3 3 3 33 X-25-40 Washer, plain 3 3 3 3 3 34 229330 Screw, wing 3 3 3 3 3 35 GM30573 Bracket, belt guard 1 1

5 GM33857 Bracket, belt guard 1 15 GM38461 Bracket, belt guard 1 16 GM30571 Bracket, belt guard 1 16 GM33855 Bracket, belt guard 1 16 GM38462 Bracket, belt guard 1 17 GM30572 Bracket, belt guard 1 17 GM33856 Bracket, belt guard 1 17 GM38460 Bracket, belt guard 1 18 X-400-170 Spacer, 0.344 ID x 0.625 OD x 0.143 in. 1 1 1 19 229125 V-Belt, 27 in. 1 1 1 19 GM13660 V-Belt, 25.5 in. 1 1

10 GM30244 Pulley, pump drive 1 110 GM42280 Pulley, pump drive 1 1 1 111 M125A-10-80 Washer, plain 3 3 3 3 3 312 M933-10025-60 Screw, HC M10-1.50 3 3 3 3 3 313 GM46963 Service Kit, Seawater Pump* (before serial number 2104903) 1 113 GM46964 Service Kit, Seawater Pump* (before serial number 2104903) 113 -- Pump, seawater (serial number 2104903 and later, see item 74) 1 1 1 1 1 1

14 GM30243 Bracket, seawater pump 1 1 1 114 GM38443 Bracket, seawater pump 1 115 M931-08060-60 Screw, HC 2 2 2 216 GM30263 Switch, pressure 1 1 1 1 1 117 260115 Manifold, exhaust 1 1 1 117 GM37631 Manifold, exhaust 1 118 241311 Neck 1 1 1 1 1 119 M125A-08-80 Washer 6 6 6 6 6 620 M931-08120-60 Screw, hex head cap 6 6 6 620 M931-08100-60 Screw, hex head cap 2 220 M931-08140-60 Screw, hex head cap 4 421 249905 Gasket, exhaust 1 1 1 1 1 122 229063 Tube, mixing 1 1 1 1 1 123 X-25-85 Washer, 5/16 2 2 223 M125A-08-80 Washer, plain 424 X-125-5 Screw, 5/16-18 x 1 4 4 4 424 M933-08025-60 Screw, hex cap 4 425 GM47556 Thermostat 1 1 1 1 1 1

26 229963 Gasket, water outlet 1 1 1 1 1 127 229064 Cover, thermostat 1 1 1 1 1 128 X-25-85 Washer 2 2 2 228 M125A-08-80 Washer, plain 2 229 X-125-31 Screw, 5/16-8 x 0.875 2 2 2 229 M933-08020-60 Screw, hex cap 2 230 229232 Hose, coolant 1 1 1 130 GM37677 Hose, molded coolant 1 130 GM12028 Sleeving, expandable (not shown) 1 131 X-426-8 Clamp, hose, 1 15/16 x 1 3/16 2 2 2 2 2 232 GM30020 Hose, molded coolant 1 1 1 132 GM37404 Hose, molded coolant 1 133 X-426-8 Clamp, hose, 1 15/16 x 1 3/16 2 2 2 2 2 234 229064 Cover, thermostat 1 1 1 1 1 135 229963 Gasket, water outlet 1 1 1 1 1 136 X-25-85 Washer 2 2 2 236 M125A-08-80 Washer, plain 2 2

37 X-125-31 Screw, 5/16-8 x 0.875 2 2 2 237 M933-08020-60 Screw, hex cap 2 238 229057 Hose, molded coolant 1 1 1 138 344880 Hose, molded coolant, 1.10 in. ID 1 139 X-426-8 Clamp, hose, 1 15/16 x 1 3/16 2 2 2 2 2 241 X-400-104 Spacer, 0.375 ID x 0.75 ID x 0.5 in. 1 1 1 141 X-400-262 Spacer, 6.60 ID x 12.70 OD x 8.38 L 2 241 X-400-263 Spacer, 6.60 ID x 12.70 OD x 12.08 L 1 141 X-400-264 Spacer, 8.74 ID x 18.55 OD x 16.08 L 1 1

* Seawater pump service kit includes pump GM46936 (item 74), item 14 bracket, and hardware.


50/76

50 TP-6270 11/10

Group 104: Cooling System, continued

1

2

34

5

6

7

9

10

11

12

13

74

1415

17

18

19

20

21

2273

24

25

26

27

28

29

30

31

32

33

34

35

36 37

38

39

42

44

45

49

50

33

54

48

45

47

41

46

43

58

55

56

57

8

2

2

3

3 50

31

45

45

59

23

16

51

52

4

4

6270_104a

71

72

Note: Items 1--7, and 51 are removed when an optional sound shield is installed.


51/76

TP-6270 11/10 51

Group 104: Cooling System, continued

13

61

62

63

64

65

66

67

68

69

70

Pump 344089 ComponentsBefore S/N 2104903

Pump GM46936 ComponentsS/N 2104903 and later

74 61

62

63

6468

69

70

Item

Part

Description

Quantity

Variation Number


42 GM30880 Exchanger, heat 1 1 1 142 GM37676 Exchanger, heat 1 143 260085 Zinc anode 1 1 1 1 1 144 X-312-46 Hose, 0.63 in ID 1 1 1 144 GM38472 Hose, molded seawater 1 145 X-426-3 Clamp, hose, 1/2 x 1 13/32 4 4 4 4 4 446 X-582-2 Connector, hose 1 1 1 146 X-391-2 Connector, 90 deg., 5/8 in. ID hose 1 147 X-391-2 Connector, 90 deg., 5/8 in. ID hose 1 1 1 1 148 X-312-4 Hose, 0.63 in. ID 1 1 1 148 X-312-62 Hose, 0.63 in. ID 1 149 229232 Hose 1 1 1 149 GM37678 Hose, molded coolant 1 150 X-426-8 Clamp, hose, 1 15/16 x 1 3/16 2 2 2 2 2 251 X-672-21 Clamp, insulated 1 1 1 152 X-672-3 Clamp, insulated 1 1 1 154 X-391-2 Connector, 90 deg., 5/8 in. ID hose 1 1 1 1 154 X-391-23 Connector, 90 deg. ( 3/4 in. ID hose) 155 359037 Bottle, overflow 1 1 1 1 1 156 X-426-9 Clamp, hose 2 2 2 2 2 257 X-386-34 Hose 1 1 1 1 1 158 229980 Cap 1 1 1 1 1 159 GM30570-WHT Bracket, water bottle 1 1 1 159 GM38437-WHT Bracket, water bottle 1 161 344306 Plate, cover 1 1 1 1 1 162 344584 Gasket 1 1 1 1 1 163 229826 Kit, impeller (includes gasket) 1 1 1 1 1 164 344043 Bearing, ball 1 1 1 1 1 165 344585 Housing 1 166 344606 Pulley 1 1

67 344587 Shaft, drive 1 168 GM16865 Seal 1 1 1 1 1 169 GM22995 Seat, ceramic 1 1 1 1 1 170 GM17702 Key 1 1 1 1 1 171 GM38448 Bracket, heat exchanger 1 172 X-672-33 Clamp, insulated, 2.62 in. 2 273 X-25-85 Washer, 5/16 4 4 4 473 M125A-08-80 Washer, plain 4 474 GM46936 Pump, seawater (serial number 2104903 and later) 1 1 1 1 1 1


52/76

52 TP-6270 11/10

Group 105: Engine

18

14

5

17

2

6270_105a

To Oil Pan

19

16

1

320

4

6 87

9 10

11

1213

15

12 Volt Mounting 24 Volt Mounting Alternator Removed

15

2

4 21

22

23

24

25


53/76

TP-6270 11/10 53

Group 105: Engine

Item

Part

Description

Quantity

Variation Number

Number GR4 GR11 GR17 GR18 3 4 5 6 7 8 9 10 11

1 229113 Guard, generator fan 1 1 1 1 1 1 1 1 1 1 12 229212 Bracket, alternator fan 1 1 1 12 254784 Arm, alternator adjusting 1 12 324410 Arm, alternator adjusting 12 GM60300 Arm, alternator adjusting 1 13 249872 Switch, high temperature cutout 1 1 1 1 1 1 1 1 1 1 1 1 1

4 256924 Alternator 1 1 1 1 1 1 14 344742 Alternator 1 1 1 15 359653 Valve, drain 1 1 1 1 1 1 1 1 1 1 1 1 16 GM28823 Sender, temperature 1 1 1 1 1 1 1 1 1 1 1 1 17 GM52087 Engine assembly, 3TNV82A--GGK

(see Groups 1-15 for parts) 1 1 1 17 GM55412 Engine assembly, 3TNV82A--XKMR

(see Groups 1-15 for parts) 1 1 1 17 GM35300 Engine assembly, 3TNV76

(see Groups 1-15 for parts) 1 17 GM52086 Engine, Yanmar 3TNV76--GGK2

(see Groups 1-15 for parts) 1 1 18 GM30245 Bushing, adapter 1 1 1 1 1 1 1 1 1 1 1 1 19 M934-06-60 Nut, hex, 6 mm 1 1 1 1 1 1 1 1 1

10 X-22-11 Washer, lock, 0.262 ID x 0.469 in. OD 2 2 1 1 1 1 1 2 211 X-22-16 Washer, lock, 0.326 ID x 0.883 in. OD 5 5 5 5 2 2 2 2 2 2 2 2 212 X-22-26 Washer, lock, 0.521 ID x 1.24 in. OD 1 1 1 1 1 1 1 113 X-22-5 Washer, lock, 0.326 ID x 0.62 in. OD 1 1 1 1

14 X-25-145 Washer, plain, 0.859 ID x 1.185 in. OD 1 1 1 1 1 1 1 115 X-400-258 Spacer 1 1 1 1 115 X-400-260 Spacer 1 1 1 115 X-400-152 Spacer, 0.344 ID x 0.625 OD x 1.5 in. 1 1 1 116 X-426-9 Clamp, hose, 0.25/0.720 in. 1 1 1 1 1 1 1 1 1 1 1 1 117 X-6084-1 Clip, hose 1 1 1 1 1 1 1 1 1 1 1 1 118 X-651-34 Hose 1 1 1 1 1 1 1 1 1 1 1 1 119 X-67-113 Screw, hex washer, thread-forming 2 2 2 2 2 2 2 2 2 2 220 X-6238-10 Screw, 3/8-16 x 0.75 1 1 1 1 1 1 1 1 1 1 1 1 121 X-431-37 Terminal, flag, female 1 1 1 122 X-400-41 Spacer 1 123 344815 Guard, alternator fan 1 1 1 124 229484 Pulley, tension assembly (Kit GM33125-KA1) 1 1 1 1 1 125 249959 Adapter, bushing 1 1 1 1 1 1 1 125 GM48799 Adapter, bushing 3/8-18 x M16 1 1 1 1 1

Note: Items 17 and 18 are removed when an optional sound shield is installed.


54/76


55/76

TP-6270 11/10 55

Group 109: Skid and Plant Mounting

1

2

3

4

5

6

7

8

9

10

11

12

7

8

10

10

11

12

6

15

6270_109a

10

11

11

Item

Part

Description

Quantity

Variation Number

Number GR6 2 3 4

1 GM31907 Tray, drip 1 11 GM37600 Tray, drip 1 12 GM30382 Support, engine, left side 1 12 GM32403 Support, engine, right side 1 12 GM58979 Support, engine 2 23 M125A-12-80 Washer 7 83 M125A-10-80 Washer 7 84 # Screw, hex head 8 8 8 85 X-22-26 Washer, lock, 0.521 ID x 1.24 in. OD 15 X-22-14 Washer, lock, 0.391 ID x 0.975 in. OD 16 # Hardware, M8 8 8 8 87 278322 Vibromount 4 47 225124 Vibromount 4 48 X-25-96 Washer, plain, 0.406 ID x 2 in. OD 4 4 4 49 LK-0606-1515 Lead 1 1 1 1

10 X-22-12 Washer, lock, 0.262 ID x 0.743 in. OD 4 4 4 411 # Hardware, M6 2 2 2 212 # Hardware, M8 4 4 4 415 M982-08-80 Nut, elastic stop 4 4 4 4

# Common hardware; procure locally.


56/76

56 TP-6270 11/10

Group 201: Generator and Mounting

6

5 7

4

3

2

1 9

8

12

11

16

17

14

18

19

20 30

33

27

28

29

3231

39

38

37

34

34

3534

24

25

26

21

22

23

36

10

6270_201a

13

15

40


57/76

TP-6270 11/10 57

Group 201: Generator and Mounting

Item

Part

Description

Quantity

Variation Number


1 GM29342 Stator assembly 1 11 GM29787 Stator assembly 1 11 GM29301 Stator assembly 1 12 229109 Guard, generator fan 1 1 1 1 1 13 257442 Clip, speed 1 1 1 1 1 14 X-67-125 Screw, tapping, 10-24 1 1 1 1 1 1

5 229097 Plate, locator 1 1 1 15 229349 Plate, locator 1 16 229356 Pin, knurled 2 2 2 2 2 27 M933-10012-60 Screw, M10-1.50 6 6 6 5 5 58 GM28588 Disc, drive 1 19 X-6238-3 Screw, 3/8-16 x 0.875 8 8 8 8 8 8

10 257017 Disc, drive 2 2 2 210 257014 Disc, drive 2 211 M933-08016-60 Screw, HC M8-1.25 8 8 8 8 8 812 M125A-08-80 Washer 8 8 8 8 8 813 229346 Disc, fan locator 1 114 225215 Fan, generator 1 114 225214 Fan, generator 1 1 1 115 X-6351-7 Nut, flange, whiz lock, M5-0.8 4 4 4 415 X-6284-2 Screw, slotted pan head machine 4 4 4 4 4 416 X-400-189 Spacer 4 4 4 4 4 417 A-229147 Rotor assembly (includes item 18) 1 1 1 117 A-229837 Rotor assembly (includes item 18) 1 1

18 X-758-15 Bearing, ball 1 1 1 1 1 119 229110 O-ring 1 1 1 1 1 120 GM24810 Bracket, end 1 1 1 1 1 121 GM37366 Box, junction 1 1 1 121 GM38488 Box, junction 1 122 GM30021 Plate, circuit breaker 1 1 1 122 GM46204 Plate, circuit breaker 1 123 X-67-64 Screw, self-tapping 4 423 X-6216-1 Screw, self-tapping 4 4 4 424 X-6266-1 Connector, cable 1 1 1 1 1 125 GM29689 Panel, junction box louver 1 1 1 125 GM38781 Panel, junction box louver 1 126 X-6216-1 Screw, self-tapping 10 10 10 10 10 1027 X-801-3 Washer, hardened 3 3 5 5 3 328 X-6051-20 Screw, hex head 4 4 4 428 M931-10235-60 Screw, hex head 4 429 X-97-15 Screw, hex, 10-24 4 4 4 4 4 430 344567 Exciter, armature 1 1 1 1 1 131 X-25-129 Washer, plain 1 1 1 1 1 132 X-6238-3 Screw, 3/8-16 x 0.875 1 1 1 1 1 132 X-22-1 Washer, lock 1 1 1 1 1 133 A-229152 Circuit board, diode board 1 1 1 1 1 134 X-283-3 Terminal 3 3 3 3 3 335 X-51-8 Screw, 8-32 x 0.75 5 5 5 5 5 536 X-22-7 Washers, #8 5 5 5 5 5 537 X-712-17 Spacer 3 3 3 3 3 338 X-67-135 Screw, tapping, 10-24 3 3 3 3 3 339 GM30341 Exciter assembly, field 1 1 1 1 1 140 X-22-14 Washer, lock, 0.391 ID x 0.975 in. OD 1 1 1 1 1 1

Note: Item 25 is not used when an optional sound shield is installed. The sound shield parts are listed in the Accessory section of this manual.


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58 TP-6270 11/10

Group 301: Controller and Mounting

1

2

3

4

5

6

7

88

9

9

10

10

LO Lead Connections

LO Leads

See Group201

See Group201

12

11

13

14

151616

1617

16 1819

14

14

20

21

6269_301

2223

23

23

F3

F2

F1

A B

C

A

B

C

22

24

2526

27


59/76

TP-6270 11/10 59

Group 301: Controller and Mounting

Item

Part

Description

Quantity

Variation Number


1 282829 Vibromount 4 4 4 4 4 42 GM28483 SCR module 1 1 1 1 1 13 GM34969 Controller assembly, ADC 2100 (kit includes instructions) 1 1 1 1 1 14 GM50489 Harness, engine 1 1 1 14 GM50492 Harness, engine 1 15 GM29671 PCB assembly, relay board, 12 V 1 1 1 1

5 GM29778 PCB assembly, relay board, 24 V 1 16 X-22-11 Washer, lock, 0.262 ID x 0.469 in. OD 2 2 2 2 2 27 X-22-12 Washer, lock, 0.262 ID 0.743 in. OD 2 2 2 2 2 28 X-22-20 Washer, lock, 0.172 ID x 0.373 in. OD 8 8 8 8 8 89 X-67-64 Screw, self-tapping 6 6 6 6 6 6

10 X-6210-4 Nut, flange whiz, 8-32 8 8 8 8 8 811 GM28678 Connector, weathertight 1 1 1 1 1 112 320711 Connector, 9-position 1 1 1 1 1 113 GM29998 Connector, 6-position, blk, male 1 1 1 1 1 114 358337 Fuse, 10 A, 250 V 1 1 1 114 223316 Fuse, 10 A, 250 V 2 2 2 215 229989 Connector, receptacle 1 1 1 1 1 116 233959 Diode, 6 A 4 4 4 4 4 417 GM15493 Connector, weathertight, 3-position 1 1 1 1 1 118 292370 Connector, plug, 2-position 1 1 1 1 1 119 GM29249 Connector 1 1 1 1 1 120 GM49746 Relay, 12 V 1 1 1 120 GM49747 Relay, 24 V 1 1

21 200705 Grommet, round 1 1 1 1 1 122 223316 Fuse, 10 A, 250 V 2 223 238426 Fuse holder, 0.25 x 1.25 in. 3 324 358337 Fuse, 10 A, 250 V 1 125 M7985A-05012-20 Screw, pan head machine 1 1 1 1 1 126 M934-05-50 Nut, hex, 5 mm 1 1 1 1 1 127 X-81-8 Nut, hex, 1/4-20 1 1 1 1 1 1

Group 701: Literature

Item

Part

Description

Quantity

Variation Number

Number 44 69 71 72

1 TP-6691 Warranty, Marine (32 kW & below) 1 1 1 12 TP-5620 Safety Precautions, Marine 1 1 1 13 TP-6252 O/M 8--32EOZD/6.5--27EFOZD, Marine 1 13 TP-6710 O/M 9--32EOZD, Marine 1 14 TP-6253 I/M EOZ/EFOZ/EOZD/EFOZD Models, Marine 1 14 TP-6711 I/M 9--32EOZD, Marine 1 15 TP-6255 S/M 8--32EOZD/6.5--27EFOZD, Marine 1 1 1 16 TP-6270 P/C 9/10EOZD, 7/8.5/9EFOZD Marine 1 1 1 17 TP-6412 O/M Yanmar TNV Series 1 17 TP-6702 O/M Yanmar 0ATNV 1 18 TP-6293 S/M Yanmar TNV Series, Marine 18 TP-6382 S/M Yanmar 2TNV/3TNV 18 TP-6703 S/M Yanmar 0BTNV 1 19 TP-6666 I/M Low Sulfur Fuel Lbl Instr, Yanmar 1 1 1

Paint and Miscellaneous PartsItem

PartNumber Description

1 221334 White paint, gallon can (Chris Craft White)1 221335 White paint, spray can (Chris Craft White)1 GM48126 White paint, spray can (Matterhorn White)

The change from Chris Craft to Matterhorn White was made inproduction on 1/1/2006; the serial break is #2082007.


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Parts List: AccessoriesQty. Description Part No.

Circuit Breakers

Circuit Breaker Kit GM30331-KA(KP)81 Terminal, jumper 2499561 Plate, circuit breaker GM300224 Screw, pan head, 6-32 x 3/16 in. X-49-21

1 Circuit breaker, 42 A, 250 V, 2-pole X-506-431 Installation Instructions TT-1394

Circuit Breaker Kit GM30331-KA(KP)91 Plate, circuit breaker GM300224 Screw, pan head, 6-32 x 3/16 in. X-49-211 Circuit breaker, 42 A, 250 V, 2-pole X-506-431 Installation Instructions TT-1394

Circuit Breaker Kit GM30331-KA(KP)101 Plate, cover 2291831 Plate, circuit breaker GM300222 Screw, pan head, 6-32 x 3/16 in. X-49-212 Screw, pan head, 6-32 x 1/4 in. X-49-251 Circuit breaker, 42 A, 250 V, 1-pole X-506-602 Nut, flange whiz, 6-32 X-6210-3

1 Installation Instructions TT-1394

Circuit Breaker Kit GM30331-KA(KP)111 Plate, cover 2291831 Plate, circuit breaker GM300222 Screw, pan head, 6-32 x 3/16 in. X-49-212 Screw, pan head, 6-32 x 1/4 in. X-49-251 Circuit breaker X-506-692 Nut, flange whiz, 6-32 X-6210-31 Installation Instructions TT-1394

Circuit Breaker Kit GM30331-KA(KP)453 Boot 2389151 Plate, circuit breaker GM300246 Screw, pan head, 6-32 x 3/16 in. X-49-211 Circuit breaker, 20 A, 600 V, 3-pole 2692511 Installation Instructions TT-1395

Circuit Breaker Kit GM30331-KA(KP)553 Boot 2389151 Decal, notice 2462421 Plate, circuit breaker GM373776 Screw, pan head, 6-32 x 3/16 in. X-49-211 Circuit breaker, 30 A, 480 V, 3-pole X-506-661 Installation Instructions TT-1395

Circuit Breaker Kit GM30331-KA(KP)563 Boot 2389151 Decal, notice 2462421 Plate, circuit breaker GM373776 Screw, pan head, 6-32 x 3/16 in. X-49-211 Circuit breaker, 35 A, 480 V, 3-pole X-506-671 Installation Instructions TT-1395

Circuit Breaker Kit GM46334-KA(KP)11 Decal, notice 2462421 Decal, fuse panel GM459061 Plate, circuit breaker GM462051 Bracket, fuse holder GM463321 Guard, breaker GM579524 Screw, Machine X-49-21 Circuit breaker, 42 A, 250 V, 2-pole X-506-43

Qty. Description Part No.

Circuit Breaker Kit GM46334-KA(KP)21 Decal, notice 2462421 Terminal, jumper 2499561 Decal, fuse panel GM459061 Plate, circuit breaker GM462051 Bracket, fuse holder GM463321 Guard, breaker GM57952

4 Screw, Machine X-49-21 Circuit breaker, 42 A, 250 V, 2-pole X-506-43

Circuit Breaker Kit GM46334-KA(KP)31 Plate, cover 2291831 Decal, notice 2462421 Decal, fuse panel GM459061 Plate, circuit breaker GM462051 Bracket, fuse holder GM463321 Guard, breaker GM579524 Screw, Machine X-49-21 Circuit breaker, 80 A, 250 V, 1-pole X-506-52

Circuit Breaker Kit GM46334-KA(KP)41 Plate, cover 2291831 Decal, notice 246242

1 Decal, fuse panel GM459061 Plate, circuit breaker GM462051 Bracket, fuse holder GM463321 Guard, breaker GM579524 Screw, Machine X-49-21 Circuit breaker, 35 A, 250 V, 1-pole X-506-46

Circuit Breaker Kit GM46334-KA(KP)51 Decal, notice 2462421 Decal, fuse panel GM459061 Plate, circuit breaker GM462051 Bracket, fuse holder GM463321 Guard, breaker GM579524 Screw, Machine X-49-21 Circuit breaker, 33 A, 250 V, 2-pole X-506-39

Circuit Breaker Kit GM46334-KA(KP)91 Decal, notice 2462421 Terminal, jumper 2499561 Decal, fuse panel GM459061 Plate, circuit breaker GM462051 Bracket, fuse holder GM463321 Guard, breaker GM579524 Screw, Machine X-49-21 Circuit breaker, 30 A, 250 V, 2-pole X-506-36

Electrical System

Harness, 12 in., Pigtail GM32332-KP11 Harness, pigtail GM32324

Harness, 15 in., Remote Panel GM32333-KP1

1 Harness, extension GM30248

Harness, 25 in., Remote Panel GM32333-KP21 Harness, extension GM32323

Harness, 100 ft. Remote Panel GM32333-KP41 Harness, extension GM47391

Harness, Y-Connection GM32333-KP51 Harness, Y remote gauge GM49054

Harness, Y-Connection GM32333-KP61 Harness, Y remote gauge GM62759


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6TP-6270 11/10

Parts List: AccessoriesQty. Description Part No.

Isolated Ground System GM31865-KA(KP)11 Adapter, sender 2293231 Grommet 2007051 Starter relay, 12 VDC GM497461 Sensor, pressure GM70917--11 Solenoid GM304121 Harness, Engine 9 EOZD Yanmar GM55382

1 Bus, isolated ground GM318681 Alternator, battery charging GM319191 Transformer, High Impedence Iso. GM514841 Tag, hang battery negative GM354131 Bracket, support GM330291 Spacer,.406 ID x .625 OD x .297 in. X-400-751 Cable, battery X-545-1611 Cable, battery (black) X-545-1782 Stud (metric) X-6054-231 Insulator, standoff X-6128-351 Installation Instructions TT-1407

Isolated Ground System GM31865-KA(KP)21 Grommet 2007051 Adapter, sender 2293231 Relay GM49747

1 Sensor, pressure GM70917--11 Transformer, High Impedence Iso. GM514841 Switch, high temp. cutout GM292891 Bus, isolated ground GM318681 Alternator, battery charging GM319201 Bracket, support GM330291 Tag, hang battery negative GM354131 Solenoid GM304131 Harness, Engine 9 EOZD Yanmar GM553824 Spacer X-400-1271 Spacer,.406 ID x .625 OD x .297 in. X-400-751 Cable, battery X-545-1611 Cable, battery (black) X-545-1782 Stud (metric) X-6054-235 Insulator, standoff X-6128-351 Installation Instructions TT-1407

Isolated Ground System GM31865-KA(KP)31 Grommet 2007051 Adapter, sender 2293231 Sensor, pressure GM70917--11 Switch, high temp. cutout GM292891 Bus, isolated ground GM318681 Alternator, battery charging GM319191 Bracket, support GM330291 Relay, 12 VDC GM497461 Transformer, High Impedence Iso. GM514841 Solenoid GM525841 Harness, Engine 9 EOZD Yanmar GM553824 Spacer X-400-1271 Spacer,.406 ID x .625 OD x .297 in. X-400-751 Cable, battery X-545-1611 Cable, battery (black) X-545-178

1 Cable, battery (black) X-545-1792 Stud (metric) X-6054-235 Insulator, standoff X-6128-351 Installation Instructions TT-1407


Isolated Ground System GM31865-KA(KP)41 Grommet 2007051 Adapter, sender 2293231 Sensor, pressure GM70917--11 Switch, high temp. cutout GM292891 Solenoid GM304131 Bus, isolated ground GM31868

1 Alternator, battery charging GM319201 Bracket, support GM330291 Relay GM497471 Harness, Engine 9 EOZD Yanmar GM553821 Transformer, High Impedence Iso. GM514844 Spacer, X-400-1271 Spacer,.406 ID x .625 OD x .297 in. X-400-751 Cable, battery X-545-1611 Cable, battery (black) X-545-1781 Cable, battery (black) X-545-1792 Stud (metric) X-6054-235 Insulator, standoff X-6128-351 Installation Instructions TT-1407

Isolated Ground System GM31865-KA(KP)51 Grommet 200705

1 Adapter, sender 2293231 Sensor, pressure GM70917--11 Switch, high temp. cutout GM292891 Bus, isolated ground GM318681 Alternator, battery charging GM319191 Tag, hang battery negative GM354131 Relay, 12 VDC GM497461 Transformer, High Impedence Iso. GM514841 Bracket, support GM330291 Harness, Engine 9 EOZD Yanmar GM529561 Spacer,.406 ID x .625 OD x .297 in. X-400-751 Cable, battery X-545-1611 Cable, battery (black) X-545-1782 Stud (metric) X-6054-236 Insulator, standoff X-6128-35

Isolated Ground System,

Sound Shield GM31865-KA(KP)61 Grommet 2007051 Adapter, sender 2293231 Sensor, pressure GM70917--11 Switch, high temp. cutout GM292891 Bus, isolated ground GM318681 Alternator, battery charging GM319191 Bracket, support GM330291 Relay, 12 VDC GM497461 Transformer, High Impedence Iso. GM514841 Relay, cranking 12V GM525841 Harness, engine 9 EOZD Yanmar GM529561 Spacer X-400-1271 Spacer,.406 ID x .625 OD x .297 in. X-400-751 Cable, battery X-545-1611 Cable, battery (black) X-545-178

1 Cable, battery (black) X-545-1792 Stud (metric) X-6054-235 Insulator, standoff X-6128-35

Isolated Standoff GM38314-KA12 Nut, hex, 6mm M934-06-602 Stud (metric) X-6054-231 Insulator, standoff X-6128-35

Oil Pressure Sender GM32112-KA(KP)11 Adapter, sender 2293231 Sensor, pressure GM70917--11 Installation Instructions TT-1438


62/76


63/76

63TP-6270 11/10

Parts List: Accessories, continuedQty. Description Part No.

ABYC Conversion, 10EOZD GM41041-KA(KP)21 Filter assembly, fuel/water separator GM410131 Element, water separator GM410141 Bracket, fuel/water separator GM410541 Bracket, water bottle GM410551 Decal, notice GM503782 Connector, hose + vibra seal X-380-4

2 Connector, 90 deg., 5/16 in. ID hose X-391-251 Elbow, street, 90 deg. x 1/4 in. NPTF X-555-12 Line, flex fuel X-6251-121 Line, flex fuel X-6251-131 Line, flex fuel X-6251-7

Fuel/Water Separator GM31994-KP11 Filter assembly, fuel/water separator GM321811 Element, water separator GM321821 Installation Instructions TT-1375

Fuel Attachment Block GM33129-KA(KP)11 Fuel block 2298351 Connector, hose X-380-41 Fuel line, flexible X-6251-121 Fuel line, flexible X-6251-9

2 Connector, 90 deg., 5/16 in. ID hose X-391-252 Spacer, 0.357 ID x 0.625 OD x 0.656in. X-400-1006 Clamp, hose, 0.38/0.88 in. X-426-18

Keel Cooling Conversion GM32201-KA(KP)21 Gasket, exhaust 2499051 Flange, exhaust outlet 254692

Keel Cooling Conversion GM32201-KA(KP)61 Gasket, exhaust 2499051 Flange, exhaust outlet 2546921 Guard, belt GM38783

Keel Cooling Conversion GM64291-KA(KP)11 Gasket, exhaust 2499051 Flange, exhaust outlet 2546921 Guard, belt GM38783

Keel Cooling Conversion GM64624-KA(KP)11 Gasket, exhaust 2499051 Flange, exhaust outlet 254692

Siphon Break PA-2299281 Installation Instructions TT-12681 Valve, siphon break (includes *) GM329851 *Valve, duct 3286661 *Cap, siphon valve GM329841 *Loop, siphon valve loop GM32988

Siphon Break GM24866-KA11 Tubing, clear flexible plastic GM348831 Clamp, hose, .25/.70 X-426-91 Valve, siphon break (includes *) GM32985

1 *Valve, duct 3286661 *Cap, siphon valve GM329841 *Loop, siphon valve loop GM32988

Tray, Stainless Steel GM42297-KA(KP)11 Tray, drip GM38793

Tray, Stainless Steel GM49018-KA(KP)41 Tray, drip GM40846


Sound Shield

Siphon Break Hose Connection GM32339-KA(KP)12 Coupling, hose 3449342 Grommet, round X-284-421 Hose, .63 ID X-312-16

2 Clamp, hose, .56/1.06 in. X-426-31 Clamp, hose, .25/.70 in. X-426-91 Tubing, Clear Flexible Plastic GM348831 Valve, siphon break GM32985

1 Valve, duct 3286661 Cap, siphon valve GM329841 Loop, siphon valve vent GM32988


Siphon Break Hose Connection GM32339-KA(KP)22 Coupling, hose 3449342 Grommet, round X-284-421 Hose, .63 ID X-312-342 Clamp, hose, .56/1.06 in. X-426-31 Clamp, hose, .25/.70 in. X-426-91 Tubing, Clear Flexible Plastic GM34883

1 Valve, siphon break GM329851 Valve, duct 3286661 Cap, siphon valve GM329841 Loop, siphon valve vent GM32988



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64 TP-6270 11/10


Sound Shield GM30508-KA(KP)11 Installation instructions TT-13828 Washer, 0.281 x 0.625 x 0.065 X-25-1424 Washer, plain, 0.406 x 0.812 x 0.065 X-25-378 Clamp, hose, 2.75/1.81 X-426-162 Clamp, hose, 1.06/0.56 X-426-34 Screw, hex cap, 1/4-20 X-465-24

4 Screw, hardened, 3/8-16 x 0.62 X-6238-32 Hose, 2.0 in. ID x 6.0 in. GM100731 Tube, exhaust, 2 in. OD 2298894 Connector, outside GM154861 Base, 22.75 x 36.75 in. GM319251 Extruded rail, 21.22 in. GM303862 Extruded rail, 28.38 in. GM293183 Extruded rail, 21.22 in. GM303852 Extruded rail, 17.25 in. 3446861 Tube, exhaust, 2 in. OD 3446941 Door, engine end, 18.58 x 17.54 in. GM345441 Door, generator end, 18.58 x 17.54 in. GM346001 Door, left hand nonservice side, 21.32 x 22 in. GM345961 Door, right hand service side, 21.32 x 22 in. GM345131 Panel, junction box, 15.4 x 14.4 in. GM346171 Panel, nonservice side, 8.9 x 22 in. GM34571

1 Panel ADC, service side, 8.9 x 22 in. GM345541 Roof, 30.3 x 18.6 in. GM345641 Rail, engine end, 18.75 x 4.5 in. GM345791 Bulkhead panel, generator end rail,

18.75 x 4.5 in. GM3458524 Screw, drill, #8 stainless steel X-794-5

2 Retainer, stainless steel, 0.485 in. GM299182 Stud, wing head GM299205 Washer, plain, #6 screw size M125A-06-805 Screw, hex cap, M6 x 16 mm M933-06016-608 Washer, plain, 0.219 ID x 0.5 OD X-25-361 Hose, seawater pump, 0.63 ID x 40 in. X-312-131 Fuel return line, flex., 44 in. X-6251-141 Fuel inlet line, flex., 22 in. X-6251-95 Clamp, hose, 0.38/0.88 in. X-426-184 Bolt, hex cap, 1/4-20 x 0.875 X-465-228 Screw, pan head, 10-24 x 1/2 X-50-15

1 Cable, battery, red, (+) to starter X-545-1771 Cable, battery, black (--) to ground

connection on engine block X-545-1762 Washer, nylon, 0.296 ID x 0.516 OD X-6278-152 Seal, push-on trim, 5.81 in. X-6422-142 Seal, push-on trim, 3.19 in. X-6422-171 Connector, hose, 1/4 NPT X-380-41 Hose, oil drain 0.375 ID/0.625 OD x 30 in. X-651-51 Washer, lock, 3/8 in. thread size X-22-141 Nut, hex, 10 mm M6923-10-801 Washer, plain, #10 screw size M125A-10-801 Washer, lock, 1/4 in. thread size X-22-121 Panel, ADC, 8.4 x 4.4 in. GM302511 Bushing, nylon, 0.672 ID X-634-252 Frame, circuit breaker, 5.8 x 2.3 in. GM298993 Foam, insulation acoustic 359584

1 U-channel, 15 in. X-6047-71 Clamp X-672-21


Sound Shield GM38536-KA(KP)13 Foam, acoustic insulation (Yanmar) 3595844 Connector, outside corner GM154861 Battery lug GM207442 Frame, circuit breaker GM298992 Retainer GM299182 Stud, wing head GM29920

1 Panel, sound shield ADC lead GM302511 Hose, radiator GM320521 Rail subassembly sound shield, front GM345081 Base, sound shield GM385393 Rail, sound shield GM385401 Rail, sound shield GM385412 Rail, sound shield GM385421 Door subassembly, sound shield, front GM385461 Door subassembly, sound shield, right hand GM385471 Door subassembly, sound shield, left hand GM385481 Door subassembly, sound shield, rear GM385491 Tube, exhaust GM385621 Panel subassembly, bulkhead connection GM385631 Panel subassembly, sound shield exhaust GM385682 Rail, sound shield GM385781 Panel, subassembly, sound shield, right hand GM38581

1 Panel subassembly, sound shield, left hand GM385841 Roof, subassembly, sound shield GM385891 Panel, junction box GM386031 Panel, junction box GM424535 Washer, plain M125A-06-801 Washer, plain M125A-10-805 Screw, hex cap M933-06016-601 Screw, hex cap M933-10020-602 Washer, lock, 0.262 ID x 0.743 in. OD X-22-121 Washer, lock, 0.391 ID x 0.975 in. OD X-22-149 Washer, plain, 0.281 ID x 0.625 in. OD X-25-1428 Washer, plain, 0.219 ID x 0.5 in. OD X-25-364 Washer, plain, 0.406 ID x 0.812 in. OD X-25-371 Hose, 0.63 ID X-312-511 Connector, hose + vibra seal X-380-41 Fuel line, flexible 22 in. X-6251-91 Fuel line, flexible 44 in. X-6251-14

4 Clamp, hose, 1.81/2.75 in. X-426-162 Clamp, hose, 0.56/1.06 in. X-426-35 Clamp, hose, 0.38/0.88 in. X-426-184 Bolt, hex cap X-465-225 Bolt, hex cap X-465-248 Screw, pan head, 10-24 x 1/2 X-50-151 Cable, battery X-545-1751 Cable, battery, black X-545-1931 Conduit, convoluted X-6003-261 Conduit, convoluted X-6003-271 Conduit, convoluted X-6003-321 Conduit, convoluted X-6003-141 Conduit, convoluted X-6003-481 Conduit, convoluted X-6003-1051 Channel, U X-6047-272 U-channel X-6047-45

4 Bolt, hex cap X-6238-32 Washer, nylon X-6278-151 Bushing, 0.672 x 0.875 in. NPT X-634-252 Seal, push-on trim X-6422-142 Seal, push-on trim X-6422-171 Hose, rubber, straight, 0.375 in. ID X-651-15

24 Screw, drill #8 stainless steel X-794-5


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65TP-6270 11/10


Sound Shield GM58981-KA(KP)11 Installation instructions TT-15124 Washer, fiber (0.25 ID x 0.71 in. OD) 2228891 Decal, danger 2945203 Foam, insulation acoustic 3595844 Connector, outside corner GM154862 Frame, circuit breaker (5.8 x 2.3 in.) GM29899

2 Retainer, stainless steel (0.485 in.) GM299182 Stud, wing head GM299201 Hose (2.0 in. ID x 5.0 in.) GM320521 Base (35.5 x 22.3 in.) GM385393 Extruded rail (18.35 in.) GM385401 Extruded rail (18.35 in.) GM385411 Tube, exhaust (2 in. OD x 12.24 in.) GM385621 Panel, junction box (7.9 x 14 in.) GM424531 Extruded rail (27.1 in.) GM603731 Extruded rail (16.8 in.) GM603741 Panel, junction box, with louvers (7 x 14 in.) GM663741 Panel, ADC (8.4 x 4.4 in.) GM665271 Door, R.H. service side (19.4 x 19.2 in.) GM781111 Door, generator end (14 x 14.7 in.) GM781121 Panel ADC, service side (19.2 x 9.7 in.) GM781131 Extruded rail, w/ inserts (27.1 in.) GM78340

1 Extruded rail, w/ inserts (16.8 in.) GM783411 Door, engine end (18.1 x 14.7 in.) GM786711 Panel, nonservice side (19.15 x 8.9 in.) GM786721 Door, L.H. nonservice side (20.1 x 19.5 in.) GM786731 Rail, engine end (18.3 x 4.5 in.) GM786741 Exhaust panel (4.1 x 14.7 in.) GM786751 Roof (29.1 x 18 in.) GM786761 Bulkhead panel, generator end rail (18.3 x 4.5 in.) GM786774 Washer, plain (#6 screw size) M125A-06-801 Washer, plain (#10 screw size) M125A-10-804 Screw, hex cap (M6 x 16 mm) M933-06016-601 Screw, hex cap (M10 x 20 mm) M933-10020-601 Washer, lock (0.391 ID x 0.975 in OD) X-22-148 Washer, plain (0.203 ID x 0.438 in. OD) X-25-1157 Washer, plain (0.281 x 0.625 x 0.065) X-25-1424 Washer, plain (0.406 ID x 0.812 in. OD x 0.065) X-25-371 Hose, seawater pump (0.63 ID x 31.5 in.) X-312-15

1 Connector, hose (1/4 NPT) X-380-44 Clamp, hose (2.75/1.81 in.) X-426-162 Clamp, hose (1.06/0.56 in.) X-426-35 Clamp, hose (0.38/0.88 in.) X-426-184 Bolt, hex cap (1/4-20 x 0.875) X-465-223 Screw, hex cap (1/4-20) X-465-248 Screw, pan head (10-24 x 1/2) X-50-151 Cable, battery, red (+) to starter (26 in.) X-545-1751 Cable, battery, black (--) (31 in.) X-545-1931 Conduit, convoluted (30 in.) X-6003-141 Conduit, convoluted (32 in.) X-6003-261 Conduit, convoluted (24 in.) X-6003-271 Conduit, convoluted (34 in.) X-6003-321 Conduit, convoluted (29 in.) X-6003-481 Conduit, convoluted (22 in.) X-6003-1051 U-channel (7.5 in.) X-6047-27

2 U-channel (4.5 in.) X-6047-454 Screw, hardened (3/8-16 x 0.62) X-6238-31 Fuel inlet line, flex. (22 in.) X-6251-91 Fuel return line, flex. (36 in.) X-6251-182 Washer, nylon (0.296 ID x 0.516 in. OD) X-6278-151 Bushing, nylon (0.672 ID x 0.875 in. NPT) X-634-252 Seal, push-on trim (5.81 in.) X-6422-142 Seal, push-on trim (3.19 in.) X-6422-171 Hose, oil drain (0.375 ID/0.625 in. OD x 34 in.) X-651-154 Screw (1/4-20 x 2 in.) X-73-33

24 Screw, drill (#8 stainless steel) X-794-5


Sound Shield GM63566-KA14 Washer, Fiber .25 ID x .71 in. OD 2228891 Decal, negative battery conn. 2269171 Coupling, bulkhead pipe 2292701 Decal, pos. battery connection 2381623 Decal, warning rotating parts 2498081 Decal, danger, high voltage 294520

1 Decal, caution--not a step 3431651 Decal, equipment grd 344295

23 Insert, threaded, 1/4--20 in. 34448416 Pin, threaded (1/4--20 * 1.18) 345283

1 Decal, warning 3453318 Insert, threaded, #10--24 3462581 Decal, fuel inlet 3592781 Decal, Fuel Return 3592793 Foam, acoustic insulation (Yanmar) 3595841 Decal, Warning Fire Port GM101484 Connector, Outside Corner GM154861 Duct, Air Outlet GM259582 Frame, Circuit Breaker GM298992 Retainer GM299182 Clip, Speed GM299192 Stud, Wing Head GM29920

2 Seal, Dampening GM299213 Latch GM299801 Duct, Air Outlet GM300191 Hose, Radiator GM320521 Rail, Sound Shield (Front) GM321831 Block, Junction GM336841 Barrier, Battery Terminal GM338281 Base, Sound Shield GM385393 Rail, Sound Shield GM385401 Rail, Sound Shield GM385411 Door, Sound Shield (Front) GM385501 Door, Sound Shield (LH) GM385521 Tube, Exhaust GM385621 Panel, Bulkhead Connection GM385641 Panel, Rear Exhaust GM385661 Panel Sound Shield (LH) GM385821 Roof, Sound Shield GM38590

1 Panel, Junction Box GM424531 Block, Junction GM477851 Decal, Caution GM586991 Foam Kit, Sound Shield GM589841 Door, Sound Shield (Rear) GM603701 Duct, Air Inlet GM603712 Rail, Sound Shield GM603732 Rail, Sound Shield GM603741 Decal, Drain GM627941 Baffle, Air Intake Duct GM635091 Panel, Junction Box GM663741 Panel, Sound Shield (RH) GM665221 Door, Sound Shield (RH) GM665231 Duct, Air Intake GM665251 Duct, Air Intake GM665261 Panel, Sound Shield ADC Lead GM66527

1 Lead LK--0620--15151 Grommet, Round X--284--322 Button, Plug X--301--351 Hose,.63 in. ID X--312--151 Connector, hose + Vibra Seal X--380--42 Clamp, hose, .69/1.25 in. X--426--124 Clamp, hose, 1.81/2.75 in. X--426--165 Clamp, hose, .25/.70 in. X--426--91 Cable, Battery X--545--1751 Cable, Battery (Black) X--545--1931 Connector, Hose 5/8 x 1/2 MIP Brass X -- 582 -- 12 Connector, Hose X--582--391 Connector, hose + Vibra Seal X--582--9


66/76

66 TP-6270 11/10


Sound Shield GM30508-KA(KP)11 Conduit, convoluted X--6003--1051 Conduit, convoluted X--6003--141 Conduit, convoluted X--6003--261 Conduit, convoluted X--6003--271 Conduit, convoluted X--6003--321 Conduit, convoluted X--6003--48

1 Channel, U X--6047--111 Channel, U X--6047--141 Channel, U X--6047--271 Channel, U X--6047--422 U--Channel X--6047--451 Stud, Metric X--6054--224 Clip, Speed X--6220--31 Line, Flex Fuel X--6251--181 Line, Flex Fuel X--6251--91 Logo, Kohler X--6275--12 Washer, Nylon X--6278--152 Washer, Nylon X--634--252 Seal, Push--On Trim X--6422--142 Seal, Push--on Trim X--6422--171 Hose, rubber, straight, .375 in. ID X -- 651 -- 153 Plug, pipe ( 3/8nptf) white nylon X --75--55


67/76

TP-6270 11/10 Appendix 67

Appendix A Abbreviations

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

A, amp ampere

ABDC after bottom dead center

AC alternating current

A/D analog to digital

ADC analog to digital converter

adj. adjust, adjustmentADV advertising dimensional

drawing

AHWT anticipatory high watertemperature

AISI American Iron and SteelInstitute

ALOP anticipatory low oil pressure

alt. alternator

Al aluminum

ANSI American National StandardsInstitute(formerly American StandardsAssociation, ASA)

AO anticipatory only

API American Petroleum Institute

approx. approximate, approximately

AR as required, as requestedAS as supplied, as stated, as

suggested

ASE American Society of Engineers

ASME American Society ofMechanical Engineers

assy. assembly

ASTM American Society for TestingMaterials

ATDC after top dead center

ATS automatic transfer switch

auto. automatic

aux. auxiliary

A / V audiovisual

avg. average

AVR automatic voltage regulator

AWG American Wire GaugeAWM appliance wiring material

bat. battery

BBDC before bottom dead center

BC battery charger, batterycharging

BCA battery charging alternator

BCI Battery Council International

BDC before dead center

BHP brake horsepower

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

blk. htr. block heater

BMEP brake mean effective pressure

bps bits per second

br. brass

BTDC before top dead centerBtu British thermal unit

Btu/min. British thermal units per minute

C Celsius, centigrade

cal. calorie

CARB California Air Resources BoardCB circuit breaker

cc cubic centimeter

CCA cold cranking amps

ccw. counterclockwise

CEC Canadian Electrical Code

cert. certificate, certification,certified

cfh cubic feet per hour

cfm cubic feet per minute

CG center of gravity

CID cubic inch displacement

CL centerline

cm centimeterCMOS complementary metal oxide

substrate (semiconductor)

cogen. cogeneration

com communications (port)

coml commercial

Coml/Rec Commercial/Recreationalconn. connection

cont. continued

CPVC chlorinated polyvinyl chloride

crit. critical

CRT cathode ray tube

CSA Canadian StandardsAssociation

CT current transformer

Cu copper

cu. in. cubic inchcw. clockwise

CWC city water-cooled

cyl. cylinder

D/A digital to analog

DAC digital to analog converter

dB decibel

dBA decibel (A weighted)

DC direct current

DCR direct current resistance

deg., degree

dept. department

dia. diameter

DI/EO dual inlet/end outlet

DIN Deutsches Institut fur Normunge. V. (also Deutsche Industrie

Normenausschuss)DIP dual inline package

DPDT double-pole, double-throw

DPST double-pole, single-throw

DS disconnect switchDVR digital voltage regulator

E, emer. emergency (power source)

EDI electronic data interchange

EFR emergency frequency relay

e.g. for example (exempli gratia)

EG electronic governor

EGSA Electrical Generating SystemsAssociation

EIA Electronic IndustriesAssociation

EI/EO end inlet/end outlet

EMI electromagnetic interferenceemiss. emission

eng. engine

EPA Environmental ProtectionAgency

EPS emergency power system

ER emergency relayES engineering special,

engineered special

ESD electrostatic dis

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