Page 2 - Table of Contents
TP-6270 11/06 2 Table of Contents Description Page Introduction 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Numbering System Significance 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Illustrations 3 . ...
Page 3 - Introduction; Numbering System Significance
3 TP-6270 11/06 Introduction This 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 represe...
Page 4 - Specification Number Index
4 TP-6270 11/06 Specification Number Index Group No. 1 2 3 4 5 6 7 8 9 10 12 13 14 15 Spec No. Variation Number Group Title GM30507-GA1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 GM30507-GA2 1 1 1 1 1 1 1 1 2 2 1 1 2 1 GM30507-GA3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 GM30507-GA4 1 1 1 1 1 1 1 1 2 2 1 1 2 1 GM37403-GA1 2 2 ...
Page 5 - Group 1: Cylinder Block
5 TP-6270 11/06 Group 1: Cylinder Block 6270_1 Quantity Var. No. Item Part Number Description 1 1 GM35737 Block assembly, cylinder 1 4 252771 Plug PT1/4 2 5 252566 Plug 1 6 252078 Plug 1 7 GM35519 Plug 50 1 8 252728 Plug 2 9 225924 Plug 30 6 12 225703 Bolt 8 13 252933 Bush 1 Quantity Var. No. Item P...
Page 7 - Group 2: Gear Housing
7 TP-6270 11/06 Group 2: Gear Housing 6270_2 Quantity Var. No. Item Part Number Description 1 1 GM35736 Housing assembly, gear 1 4 GM35720 Plug, screw 1 5 GM35721 Plug 1 6 252931 Oil seal 1 7 GM35464 Cover assembly, pump 1 8 GM35463 Cover, lube oil pump 1 9 GM35653 Valve, relief 1 10 GM35578 Spring ...
Page 10 - Group 3: Mounting Flange and Oil Sump
10 TP-6270 11/06 Group 3: Mounting Flange and Oil Sump 6270_3 Quantity Var. No. Item Part Number Description 1 1 256750 Parallel pin 8 x 16 2 2 229114 Mounting flange 1 3 252998 Gasket 1 4 229505 Bolt, M10 x 20 6 5 252714 Bolt 4 6 225706 Spacer 1 7 252701 Bolt, M8 x 35 3 8 GM35492 Sump assembly, oil...
Page 12 - Group 4: Cylinder Head
Page 16 - Group 5: Intake Manifold
16 TP-6270 11/06 Group 5: Intake Manifold 6270_5 Quantity Var. No. Item Part Number Description 1 1 GM35433 Pipe, breather 1 2 229425 Clamp 2 3 GM35452 Manifold, intake 1 5 GM33685 Gasket, intake manifold 1 6 252697 Bolt 4 7 252707 Bolt 2 8 225778 Gasket 1 9 GM35579 Joint 1 10 252697 Bolt 4 11 22571...
Page 17 - Group 6: Camshaft and Drive Gear
17 TP-6270 11/06 Group 6: Camshaft and Drive Gear 6270_6 Quantity Var. No. Item Part Number Description 1 1 252819 Tappet 6 2 225718 Rod, push 6 3 GM35453 Camshaft assembly 1 4 252804 Metal, thrust 1 6 256587 Gear, camshaft 1 7 252669 Key 7 x 14 1 8 GM35734 Nut, lock M14 plated 1 9 225818 Bolt, M8 x...
Page 18 - Group 6: Camshaft and Drive Gear, continued
18 TP-6270 11/06 Group 6: Camshaft and Drive Gear, continued 6270_6_2 Quantity Var. No. Item Part Number Description 2 1 363039 Tappet 6 2 GM47300 Rod, push 6 3 GM47301 Camshaft assembly 1 9 225816 Bolt, M6 x 12 2 10 GM47302 Shaft, idle gear 1 11 GM47303 Gear assembly, idle 1 14 GM47306 Bolt, M6 x 3...
Page 19 - Group 7: Crankshaft and Piston
19 TP-6270 11/06 Group 7: Crankshaft and Piston 6270_7 Quantity Var. No. Item Part Number Description 1 1 GM35454 Crankshaft assembly 1 2 256750 Parallel pin 8 x 16 1 5 GM35455 Gear, crankshaft 1 6 252669 Key 7 x 14 1 8 256654 Spring pin 1 9 GM35456 V-pulley, crankshaft 1 10 252937 Washer 1 11 25276...
Page 20 - Group 7: Crankshaft and Piston, continued
20 TP-6270 11/06 Group 7: Crankshaft and Piston, continued 6270_7_2 Quantity Var. No. Item Part Number Description 2 1 GM47309 Crankshaft assembly 1 2 256750 Parallel pin 8 x 16 1 5 229748 Key, 4 x 12 1 6 GM47307 Gear, crankshaft 1 8 GM47320 Flywheel assembly 1 11 363081 Gear, frt. diff. drive 1 12 ...
Page 21 - Group 8: Lubrication Oil System
21 TP-6270 11/06 Group 8: Lubrication Oil System 6270_8 Quantity Var. No. Item Part Number Description 1 1 GM35468 Dipstick 1 2 252759 Guide, dipstick 1 3 225775 Gasket 1 4 GM35487 Pipe assembly, oil inlet 1 8 252701 Bolt, M8 x 35 2 9 GM35419 Switch, oil pressure 1 10 252084 Bolt 1 11 GM35471 Pipe a...
Page 22 - Group 8: Lubrication Oil System, continued
22 TP-6270 11/06 Group 8: Lubrication Oil System, continued 6270_8_2 Quantity Var. No. Item Part Number Description 2 1 GM47323 Dipstick, lub. oil 1 2 256582 Stud 1 3 229678 Filter, oil 1 4 GM47322 O-ring 1 5 GM47324 Pipe assembly, lub, oil 1 9 229498 Bolt, M6 x 10 plated 2 10 GM35419 Switch, oil pr...
Page 23 - Group 9: Cooling Water System
23 TP-6270 11/06 Group 9: Cooling Water System 6270_9 Quantity Var. No. Item Part Number Description 1 2 1 GM35472 Pump assembly, water 1 1 3 GM35488 Gasket 1 1 4 GM35489 Plate 1 1 8 GM29476 Gasket 1 1 9 GM35490 Pipe, water pump 1 1 11 252839 O-ring 1 1 13 GM35720 Plug, screw 2 2 14 225818 Bolt, M6 ...
Page 25 - Group 10: Fuel Injection Pump
25 TP-6270 11/06 Group 10: Fuel Injection Pump 6270_10 5 Quantity Variation Number Item Part Number Description 1 2 1 GM35742 Injection pump assembly 1 1 2 GM35478 Bracket, pump 1 1 3 252696 Bolt, M8 x 16 1 1 4 252697 Bolt 1 1 5 344746 Solenoid (24 V models) 1
Page 27 - Group 12: Fuel Injection Valve
27 TP-6270 11/06 Group 12: Fuel Injection Valve 6270_12 Quantity Var. No. Item Part Number Description 1 1 GM35743 Fuel injector 3 2 GM35494 Nozzle assembly 3 5 256520 Nut, nozzle case 3 6 GM35479 Holder assembly, nozzle 3 10 256521 Spring nozzle 3 11 256522 Seat, nozzle spring 3 12 256523 Plate, st...
Page 28 - Group 12: Fuel Injection Valve, continued
28 TP-6270 11/06 Group 12: Fuel Injection Valve, continued 6270_12_2 Quantity Var. No. Item Part Number Description 2 1 GM47337 Valve assembly, injection 3 2 GM47336 Holder, nozzle 3 3 GM47338 Nozzle assembly 3 4 256774 Clamp assembly, line 1 7 225418 Bolt, M4 x 14 hex socket 2 9 GM47340 Pipe, fuel ...
Page 29 - Group 13: Fuel Line and Filter
29 TP-6270 11/06 Group 13: Fuel Line and Filter 6270_13 Quantity Var. No. Item Part Number Description 1 1 GM35541 Bracket, filter 1 2 GM32359 Filter, fuel 1 3 225819 Bolt M8 x 30 plated 2 4 X-386-93 Pipe, fuel oil 1 5 X-386-135 Pipe, fuel oil 1 6 252670 Clamp 4
Page 30 - Group 13: Fuel Line and Filter, continued
30 TP-6270 11/06 Group 13: Fuel Line and Filter, continued 6270_13_2 Quantity Var. No. Item Part Number Description 2 1 GM47042 Filter assembly, fuel 1 2 GM47346 Spring, taper valve 1 3 GM47349 Lever 1 4 229709 Cup, strainer 1 5 229550 O-ring 1 6 250821 Retainer 1 7 229708 Spring 1 8 GM10979 Element...
Page 31 - Group 14: Starting Motor
31 TP-6270 11/06 Group 14: Starting Motor 6270_14 Quantity Var. No. Item Part Number Description 1 2 1 344743-P Starter, 12 V 1 1 GM39020 Starter, 24 V 1 2 225895 Armature assembly 1 3 GM35772 Ball bearing 1 4 GM35769 Ball bearing 1 6 225898 Field coil assembly 1 7 225899 Screw 4 8 225900 Brush (+) ...
Page 35 - Group 101: Air Intake
TP-6270 11/06 35 Group 101: Air Intake 1 2 3 5 6 7 8 9 10 13 11 12 11 4 7 7 7 6270_101 Quantity Variation Number Item Part Number Description GR1 2 1 X-426-19 Clamp, hose, 1/2 in. 1 1 2 X-426-6 Clamp, hose, 1.56/2.5 in. 1 1 3 278856 Cover, plastic 1 1 4 X-400-28 Spacer, 0.282 ID x 0.5 OD x 0.531 in....
Page 36 - Group 103: Fuel System
36 TP-6270 11/06 Group 103: Fuel System 1 2 3 4 6 7 8 9 10 11 12 5 11 See Group 13 for additional fuel system parts. 6270_103a 5 A A See Group 13 13 14 5 5 5 5 15 16
Page 38 - Group 104: Cooling System
38 TP-6270 11/06 Group 104: Cooling System 1 2 3 4 5 6 7 9 10 11 12 1374 14 15 17 18 19 20 21 22 73 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...
Page 44 - Group 107: Nameplate and Decals
44 TP-6270 11/06 Group 107: Nameplate and Decals Quantity Part Variation Number Item Number Description GR5 GR14 3 1 249810 Decal, warning “Hot Coolant” 1 1 1 2 344282 Decal, “Notice Zinc Anode” 1 1 1 3 226917 Decal, negative battery connection 1 1 1 4 344295 Decal, equipment ground 1 1 1 5 GM14167 ...
Page 45 - Group 109: Skid and Plant Mounting
TP-6270 11/06 45 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 Quantity Part Variation Number Item Number Description GR6 2 1 GM31907 Tray, drip 1 1 GM37600 Tray, drip 1 2 GM30382 Support, engine, left side 1 2 GM32403 Support, engine, right si...
Page 46 - Group 201: Generator and Mounting
46 TP-6270 11/06 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 32 31 39 38 37 34 34 35 34 24 25 26 21 22 23 36 10 6270_201a 13 15 40
Page 48 - Group 301: Controller and Mounting
48 TP-6270 11/06 Group 301: Controller and Mounting 1 2 3 4 5 6 7 8 8 9 9 10 10 “LO” Lead Connections “LO” Leads See Group 201 See Group 201 12 11 13 14 15 16 16 16 17 16 18 19 14 14 20 21 6269_301 22 23 23 23 F3 F2 F1 A B C A B C 22 24 25 26 27
Page 50 - Parts List: Accessories; Circuit Breakers; Electrical System
50 TP-6270 11/06 Parts List: Accessories Qty. Description Part No. Circuit Breakers Circuit Breaker Kit GM30331-KA(KP)8 1 Terminal, jumper 249956 1 Plate, circuit breaker GM30022 4 Screw, pan head, 6-32 x 3/16 in. X-49-21 1 Circuit breaker, 42 A, 250 V, 2-pole X-506-43 1 Installation Instructions TT...
Page 52 - Miscellaneous Accessories
52 TP-6270 11/06 Parts List: Accessories Qty. Description Part No. Oil Press. and Water Temp. Sender GM24405-KA1 1 Adapter, sender 225307 1 Sender, water temperature 249287 1 Fitting, 45 deg. street elbow 267428 1 Sender, oil pressure 343473 Preheat Kit, 12 Volt GM32117-KA(KP)1 1 Wiring harness 2292...
Page 53 - Sound Shield
53 TP-6270 11/06 Parts List: Accessories Qty. Description Part No. Siphon Break PA-229928 1 Installation Instructions TT-1268 1 Valve, siphon break (includes *) GM32985 1 *Valve, duct 328666 1 *Cap, siphon valve GM32984 1 *Loop, siphon valve loop GM32988 Siphon Break GM24866-KA1 1 Tubing, clear flex...
Page 55 - Appendix A Abbreviations
TP-6270 11/06 Appendix 55 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC analog to digital converter adj. adjust, adjustment ADV advertising dimension...
Page 57 - Appendix B Common Hardware Application Guidelines
TP-6270 11/06 57 Appendix Appendix B Common Hardware Application Guidelines Use the information below and on the following pages toidentify proper fastening techniques when no specificreference for reassembly is made. Bolt/Screw Length : When bolt/screw length is not given, use Figure 1 as a guide. ...
Page 58 - Appendix C General Torque Specifications
TP-6270 11/06 58 Appendix Appendix C General Torque Specifications American Standard Fasteners Torque Specifications Torque Assembled into Cast Iron or Steel Assembled into Aluminum Size Torque Measurement Grade 2 Grade 5 Grade 8 Aluminum Grade 2 or 5 8-32 Nm (in. lb.) 1.8 (16) 2.3 (20) — 10-24 Nm (...
Page 59 - Appendix D Common Hardware Identification
TP-6270 11/06 Appendix 59 Appendix D Common Hardware Identification Screw/Bolts/Studs Head Styles Hex Head or Machine Head Hex Head or Machine Headwith Washer Flat Head (FHM) Round Head (RHM) Pan Head Hex Socket Head Cap orAllen t Head Cap Hex Socket Head or Allen t Head Shoulder Bolt Sheet Metal Sc...
Page 60 - Appendix E Common Hardware List; American Standard
TP-6270 11/06 60 Appendix Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions Hex Head Bolts (Grade 5) X-465-17 1/4-20 x .38 X-465-6 1/4-20 x .50 X-465-2 1/4-20 x .62 X-465-16 1/4-20 x .75 X-465-1...
Page 61 - Metric
TP-6270 11/06 Appendix 61 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Hex Head Bolts (Partial Thread) M931-05055-60 M5-0.80 x 55 M931-06040-60 M6-1.00 x 40 M931-06055-60 M6-1.00 x 55 M931-06060-60 M6-1.00 x 60 M931-06060-SS M6-1.00 x 60 M931-06070-60 M6-1.00 x 70 M...
