Service Parts

Engine.
r
I
•E.
Engine Model:
General Motors 8.1 L Powertrain
Generator Models:
80-125RZG
80-125GSG
G80U-G125U
G88-G130
1_
•
LP Gas or Natural Gas

TP-6108 5106e
 Table of Contents
Description Page
Introduction 3
Numbering System Significance 3
Illustrations 3
How to Find Part Numbers 3
Specification Number Index 4
Group 1: Engine Block/Lower End 6
Group 2: Engine Head/Upper End 12
Group 3: Engine Trim Parts 16
Group 4: Flywheel 17
Group 5: Starter 17.
Group 6: Alternator, Pulley, and Belt (Below Engine Serial Number 8.1L05449) 18
Group 6: Alternator, Pulley, and Belt (As of Engine Serial Number 8.1L05449) 19
Group 7: Intake and Exhaust System 20
Group 8: Engine Mounting 20
Group 9: Fuel System, 80/100 kW 21
Group 9: Fuel System (Mixer) 80/100 kW 23
Group 9: Fuel System, 125 kW 24
Group 10: Wiring Harness 28
Group 11: Turbocharger 30
Group 12: Breather 32
 H
Introduction
This manual lists service replacement parts for
80-125RZG. 80-125GSG, and G80U-G125U How to Find Part Numbers
generator sets. Use the following steps to locate a service replacement
part.
Information in this publication represents data available
at the time of print. The generator set manufacturer 1. Locate the generator set nameplate to
Identify the
reserves the rlgnt to change this publication and the generator set spec number.
products represented without notice and without any 2. Turn to the Specification Number Index.
a obligation or liability whatsoever. The
first column lists the generator set spec numbers.
This manual includes the following main sections: The headings identify the groups of parts that make
Table of Contents. Lists the sections of the manual. up the generator set.
Introduction (and other information sections). 3. Identify the group most likely to include the
Contains introductory material about part numbers, service part number.
illustrations, and hardware. 4. Find the group variation number
at the
Specification Number Index. Lists the generator set intersection of the spec number row and the group
specs and groups. column. Note the variation number.
Group Parts Lists. List the part numbers of parts in the 5. Page forward to locate the group
groups. identified in
step 3 or find the appropriate page in the Table of
xin:004 002 Contents.
Numbering System Significance 6. Find the part on the illustration
and note the item
This manual uses the following numbering systems: • number of the part or find the part description In
Specification Number. the parts list.
The product identification
number located on the generator set nameplate. Spec 7. Select the part number that corresponds to
numbers break down into groups. your group variation. The first column lists the
Group Number. A unique number representing a parts illustration item number. Find the variation
group needed to assemble a generator set function. For identified in the Specification Number Index or the
example, Group 4 is the Flywheel group. module number found on the set
nameplate in the appropriate column • ••e right
Variation or Module Number. A group might have side of the parts list table. Find the guar ;y used at
several variations. Each variation performs the same the intersection of the item number r,v 3 and the
function with different parts lists. For example, a 50 Hz variation column. A blank space at the intersection
generator alternator and a 60 Hz generator alternator means the variation/module does not use that part
both perform the same function, however, with different number.
parts. Each difference requires a group variation cr rirt.004 005
module number. Hardware References
Part Number. The part number identifies an individual When replacing hardware, do not substitute inferior

•
assembly, subassembly, component, or accessory kit. grade hardware. Replacement hardware grade should
Lin:OCA 0C3 a be equal to or better than the grade of the
Illustrations manufacturer's original hardware. Use the Common
Illustrations (or exploded-view drawings) best Hardware List in the appendix to identify the common
hardware hardness.
representing the widest range of variations accompany
most groups in this manual. Illustrations do not depict all
details and may not show all parts. Do not use
illustrations for assembly or disassembly.
rin:004 0C4a
1

TP-6108 5105
 Specification !timber Index

Group Title

Group No. 3 4 5 9 10 11 12
Spec No. Variation Number
8ORZG or 80GSG or G80U/G88

•
GM13934-GA1(S) 1 1 1 1 1 1 1 1 1
GM13934GA2(S) 1 1 1 1 1 2 2
GM13934-GA3(S) 1 1 1 1 I I 1 1 I NA NA
GM13934-GA4(S) 1 1 1 NA
GM22407•GA1(S) 1 3 6
GM22407•GA2(S) 1 1 3 1 1 1 1 ; 7 6
GM22407-GA3(S) . 1 1 3 1 .1 1 ; NA 6
GM22407•GA4(S) 1 1 3 1 1 1 1 6
MC4436-CM (F)(S) 1 3 1 1 1 1 5 6
414436-GA2(F)(S) 1 ' 3 1 1 1 1 7 6
GACI4=56- 3 43(F)(S) 1 3 1 1 1 i NA 6
GM34436-GA4 5) 1 3 1 1 NA 6
100RZG or 1000S G or G 100U/G110
GM13934GA5(S- 2 1 1 1
G1.113934-GA6(S/ 2 1 1 1 1 1 2 2 -
GM13934•GA7(S) 1 1 1 1 NA NA
GM13934-GA8(S) 2 1 1 1 1 1 NA NA
GM22407•GA5{S) 2 1 3 1 1 6

•
GM22407•GA6(S) 2 1 . 3 1 1 ; 1 8 6
GA/22407-GA7(S) 2 3 1 1 I 6
GM22407•GA8(S) 2 1 1 I I NA 6
GM34436-GA5(9(S) 2 3 1 1 6 6
GM34436-GA6(F)(S) 2 1 3 1 1 1 8 6
GM34436-GA7(F)(S) 1 3 1 I 1 NA 6
GM34436-GA8(F)(S) 2 1 3 1 1 1 I I NA
125RZG or 125GSG or G125U/G130
.GM20568-GA1(S) 2 2 I 2 2 2 2 1 1 3 4
GM20568•GA2(S) 2 2 I 2 2 2 2 1 1 4 5 1 1
GM20568•GA3(S) 2 2 1 2 2 2 1 2 1 NA NA 1 1
GM20588-GA4(S) 2 2 2 2 1 NA NA
GA25339•GA1(S) 2 2 2 2 2 2 91 6 1 1
GM25339-GA2(S) 2 2 2 2 1 10 6 1 1
GM25339-GA3{S) 2 2 1 2 M-4if 2 2 • 1 - NA 6 1 1
GM25-094A4(S) 2 2 2 2 2 2 1 NA 7 1 1 1
Gbr=A4-GA1 (F)(S) 2 2 2 2 2 2 z 1 9 6 1 1
G (YL-14464-GA2(F)(S) 2 2 2 2 2 6 1
GM3-1464•A3(F)(S) 2 2 1 2 2 6 1
GM34464•GA4(F)(S) 2 2 1 2 2 2 I 2 I 1 NA 7 1
NA Parts fist of this group variation is not available at time of print. Please contact your Supplier of generator parts for
parts information.

4 TP-6108 5106
 Notes

f
i

TP.61 C8 5C6'
 Group 1: Engine Block/Lower End

•r

•I

6 TP6108 5/06

••
-
-

Group 1: Engine Block/Lower End

GM19028 Ring kit, pistCrLetandard ge • •n• •,`•

GM19029 Ring cit, pistbn„030 OS
GM18999 Piston ificonri rod, standard, R147.
GM19301 Piston w/conn rod, .030 OS, RH
GM47375 Piston w/conn rod, standard, LH
GM19002 Piston w/conn rod, .030 OS, LH
GM47376 — 7 Batt, corn 'also-pert ay.'
Not serviced : Separately:Y.. - - .11 .;,
GM190281 . Beefing MC conned189
— Not applicable
GM47377 Nut, corm rod, also part of 4
TBD Block, engine w/pistons
TEID Enine, service partiriltrii:2;"
TBD Ehgine, gasoline '-ittr,;1:1
GM18885 Plug, engine black oil galley..
GM 18886 Pbg, eng. dock od galley, 1/8;27 X 3/8 N PTF
GM16510 P:Lg, engine bock oil galley, auto drain
GM18887
Plug, engine block dl galley, auto drain hex head
1 GM18897 Plug, camshaft 5...e
h.ole
H
z4);z. 7"
.
11 Not app licable--
12 Not applicale:
13 '4.
Not applicable
14 Not applicable
15 GM 18925 Plug, engine block of galley
• 18 Not applicable
17 Not applicable''
1 .: 18 TBD
Plug, engine block cootaitt draliihoit
19 GM18988
Plug, arsine block coolanidrainiviie, -
19 GM16504
, Plug, eng. block coolant drain hcie. 1/4-18 x 0.51
20 Not applicable
• 21 Not applicable
22 Not applicable 1: -
23 GM 18:914
Bott, camshaft s9rea011 With wash,el - .C.15.
24 GM19033 Sprocket, camshaft • 1
25 GM19012 i Chain, camshaft timing
26 GM16476
Pin, camshaft sprocket locator, 1/4 x 5/8
17.7 GM18917
Bolt, water pump, HFH, MIOX1.5x65
.
4 if 28 GM19000 Camshaft, engine (includes 2226;86, 57) 80 kW
28 GM32321
[.. 'T. 29 GM18933 Camshaft engine 100/125 kW.,..:jiki" .P
Sealer, camshaft bearing hale plogi a?7,l,frc,
30 GM18886
Plug eng block al galley. 1/8-27 x 3/8 NPTF
31 GM18963 Gasket, water pump
32 GM19027
Pump ka, water pot 31, 82, 83, 85, 105)
s , 34
Not applicable ::-
• 33
Not app5cable . • " tt
Cel 35 GM 18909 Bolt, engine front cover, M6 X i.o g30
36 GM 1
6476Pin, engine front cover locator, 1/4 x Si3
37 GM18951
!Gasket, engine front cover, also part of 76
38 GM18988

r f33 GM19024 '

Pin, crankshaft balancer locator
Bearing kit crankshaft; std Pce:41:2, 43;147
1 1

r_ 40 GM19025
1 1
Bearing kit. crankshaft it:oust-std., '4
41 GM18971 Seal, crankshaft rear oil t: 1. : 1 =1
42 GM18997 Bee, flywheel, Mll x 1.5 .x 29
43 See Group 4 Flywheel, engine (incl. gear & locator pin) 1
8
44 GM18977 Deflector, crankshaft oil
1- 4$' GM18907 1 1
Pin, flywheel Locator, part of 73±.71.. , • 1 1
46 . Not applicable .
4 .4 • 47 .2 2
Not aapplicable
48 X Not serviced Sep separately
• 49 GM18916 Nut. crankshaft ail deflector
.• 50 Not applicable
77 51 GM 18892 9 9
Fitting, oil filter •.•
52 GM19023
Valve, oil filter bypass 1 1
GM16703 Filter, 2 2
54 GM18953 Bolt, crankshaft bearing cap, M12 1.75X 8 9. 1 1
55 — Not applicable 10 10

W-6108 5/06
7
Group 1: Engine Block/Lower End, continued

115 112 113 0M00-032 03/15/00

116
3
111 .110
116 122
121
117
114 I-

1 07 10
106
94
108 123
27 40-1 5 1P>1
52
194 98 51
103 5
53

45
41
26 35 130
91
3
120
8 119 \ 40
25 •

48
56
7
78
79 60 (

61

67
•I
68

71
70
128
8
VIEWE 89

6108_ 1

TP-6108 5/06


Group 1: Engine Block/Lower End, continue(

Part
Item Number Quanif
56 GM18896 Desert fion Variation
Shaft, al pump drive
57 GM16476 '1 I 2
Pin, oil pump locator, 1/4 x 5/8
58 GM16583 1 1
Retainer, oil putrip drive shalt 1
59 GM 18990 Pump, oil with screen 1
60 GM18958 1 1
Bch. al pump, M10 x 1.5 x 60 1
61 X
62 GM1 Not serviced sepaately, part of 59 4 I
Valve oil pressure
63 GM18894 a Spring, al preaffiiie relief iik&a
64 GM16549 Pin, oil pressure relief valve spring stay
es GM18904 Cover, oil pump 1'
ea X Not serviced separately 1
t 67 GM19009 1 1
68 GM18989 -- Pan, oil (includes pan, Plug,'
69 GM16430.jy Sealer, - al pan,74.:7 1
70 GM18533 1
Plug, oil pan drain, 12-14 .610 :AR
70 GM16526 Plug, oil pan drain, M12 x 1.76 G 44.45 mm long AR
71 GM18938 2 2
72 X Bott, oil pan
1 Net serviced separ Ed* 1 I 1

1
1'73 TBD 13 13
Crankshaft (include`' 94)
74 GM18982 Sprocket, crankshaft er tic
75 GM18972 1 1

I
triolea Seal,crnkshft 1 1
76 GM19006 Cover, engine front (includes cover, seal, Onkel)
77 I GM18943 Balancers crankshaft
1 1
78 GM19021 1 1
Washer, crankshaft balance 1
79 GM19015?c- Bolt. crankshaft liffiillffierA•01.5.. 1
83 — •; Not applicable ak*ile&WEI:1>,. .0 - 1
J:,

81 — Na applicable
4 1
ea x Not serviced separately, part of 32
47
.

83 X
Not serviced separately, pan of 32
Not applicable • c-4112"
85 CW03513 Bolt, water pump cover, Rad 32
86 — Not applicable -
87 ; GM18976 I Stud, crankshaft_ bearingSp
1 6
88 — I Not applicable
89 10 10
Not applicable
!GM16372 Retainer, camshaft -
91 GM18912
Boit, camshaft retainer ';'.'444-
I
92 GM19013 Bearing,cmshft
93 iGM19014 Bearing, camshaft position 4, 5
94 GM18935 Bearing, camshaft, position 43, 4
95 i GM18888 Sealer, crankshaft rear main bearing

•
95 GM16430 Sealant, Lootite
lt;,97 GM18934 Grease, heavy duty muMpuipase
bee GM18907 Pin, dowel flywheel locator -, M6 x 20
• 99 GM18958 -
Pin cylinder head locator, 12 x 5/8 OD
100 I GM16422 Soft, oil pump cover
101 X
Not serviced separately, part of 59
102 I X
Not serviced separately, pen of 59
in,103 GM18913 Bolt, pulley water pump
_103 GM18937 Bolt cill pump drive -
104 GM18936 Pulley, fan 8 water piny
105 X
Not serviced separately, part of 32
106 GM18967 Hose, therm bypass includes hose clamps
tr107 GM18919 Clamp • therm byjitins hose, spring band 35mrn silver
1108 GM18918 , Rt.(
:2 109 See Group 3 Clamp,therbysoingad30mre,1.
Seal, engine coolant thermostat (0-ring) .
110 See Group 3 Thermostat, engine coolant
111 GM19008
Pipe, engine coolant crossover (includes 109-110, 112-115)
112 GM18979 Outlet, water, part of 111
;i,-113 GM18914 Bolt water outlet, part of 111 -
114 X Not serviced separately
f, 115 GM18991
Fitting, heater hose, part of 111
'116 GM18964 Gasket, engine coolant crossover

TP:6108 5/06

9
Group 1: Engine Block/Lower End, continued

_ 0M00-032 03/15/00
115 112
116

122
116 121
117
114
10
1 07 93
106 94
123
108
27
51
104 96
15
103 53

11M101
,
a•
_, \•••<- 41
45

23 Sn 130
"
40

48
75 76
r
78
79 6

49
61
•
68

71
Fit 70

8
VIEWE
128
69
• •
[

OS 1

TP-6106 5/06
 Group 1: Engine Block/Lower End, continued
Part Quant
Item Number
117 GM18920 1 Bolt, engine coolant crossover Description Variation
118 GM18910 1 i 2
Solt camshaft position sensor, M6 x 1 x 20 4 4
119 GM19004 Sensor, camshaft position (includes 120) 1 1
120 X Not serviced separately. part of 119 1 1
121 GM18952
122 Sensor, crankshaft position (Includes 123)
GM18996 Boa crankshaft position sensor
123 X ,::,., 1 1
Not,setviced separately, part of 121 1 I 1
124 ‘...'..C:.:,
N01 1113Plicable: — t-;44:.si.
125 GM189081 '.. Sensor, pump dri .. 'e.:.'
knock:I:1.1**ft' . . .
126 GMI ag 1 3 SbCoil
). .•

126 GM18937 ve, M8 x 125 x 20, heavy hex flange .- -- t. I .... .

2 2
Bolt, el pump drive, M8 x 1.25 x 20 4 4
127 GM19011 Drive. 01
128 GMIES24 1 1
..,.. *.- 1 1
129 ,
130 ; 3
N fitaril
N eatC; of P' ‘
131 SW 9018 Connector; engine :16191 Zit

X hem not sold separately

AR As required
TBD Part number to be determined

cL

L.

788108 Noe
11
Group 2: Engine Head/Upper End

112 OMOO-033 03/28/00

88
89 4 92 92
64 92 86
90
87
7 lob 92 10

S
61
8
90

•
99—it

-72
- "Tr
94

71 111
70
38
le

78
0 85
36
26
79
83
25 52

56 •
69 83
83 83
831919 19
VIEWEI
CYLINDER HEAD
BOLT POSITION
• ts

6108_2

17 -61 C8 5iC6
 -

Group 2: Engine Head/Upper En

. Part Quan tity
Item Number Description
1 , GM18951 Gasket, valve rocker arm cover bolt
2' —>. 7z-• • 3-.- ., Not applicable ..
3 — ... Not applicable
4 — Not applicable
5 — Not applicable
a 6 X Not marked separately, part of 7
•
7 GN118905Y. Cap, oil tiller (IncludeS 6). • ' .
8 GM18973 : Cover, . valve rocker arm (Includes gasket)
: . 9 GM18974 ... Gasket, valve Mcker arm cover, pet
10 GM18975 Bolt, valve rocker arm d 8-r-
center,1146ix 1.0 x .28
11 GM18895 Key, valve stern
12 GM18903 Rotator, valve
ir1 3;b4)1418902 L:- Cap, valve spring "
4_.:t 1.47-Z.`„k:::41: ,Nol aPPliOaql!..,if-
krg amr Spring, valve ;--O:tir
1-6 bk,41 Mug, cylinder e..nd core
17 —
,I /2 14 x
-
Not applicable
18 GM18922 Bolt cylinder head, pos 815,18
eifIfi. ' GM 18923•?fice. cylinder heat
:Poe 412.13
;7 08118717,: Spark plug ?-t.yilit-':', ' ,7.
20 ` 'GM22171 4/.Spark plug (125 kW) :.. ....
20" GM48779 — Metal boat. spark 'plug Wire
21 — (not shown)
Not applicable
22 9 Bolt exhaust manifold, 8 x 1.25 x 30

F
P23 ` GM18958 : 'Pin, cylinder head kcatot1/2 x 5/80C9te
6124 . • -t- ,z . - -.' Not applicable 9C.0 ..... - ,.
:7:t
46425 GM18950 Valve, Intake;
—25 GM18.992 -
Valve, Intake, 0.003 in., OS
25 GM18993 Valve, Intake, 0.015 in., OS
25 GM18994 Valve, Intake, 0.030 in., OS
(17.26 GM18962 ' Valve, exhaust, standard
I. •-
- GM18968 Valve, exhaust, 0.003 in:, OS
Si,26 GM189623 Valve, exhaust, 0.015 ki, OS
26 GM18970 Valve, exhaust, 0.030
in., OS

I 27 GM19020 Lifter. valve

28 GM18946 Rod, valve push, intake
itc28 GM1 8947 :: Rod, valve push, achistret-:
GM18959 Gasket, cylinclethiad LI-I
GM18960 • Gasket, cylinder heeaRH

I 30 GM18983 Head, cylinder (nd. seats & guides) RH_

30 GM18984 Head, cylinder (incl. seats & guqes)
31 GM18995 Guide, valve lifter push rod
GM18948 Arm, valve rocker
—

•
.

• Gall18949'; Bat, valve rocker erre•-5:.•,

Not applicable .:•‘.-7?..,&
- -i.•••:;.:
35 GM19030 Gasket, intake manifold
35 GM47739 Gasket, intake manifold (with flame
38 GM18980 Shield, intake manifold oil splash arrestor)
:e37- Not applicable
y.238
tfr 6418998, Manifold, Intake..tti.,.i
.27
_ 38TED
39 Marifoki, intake (1E
Not applicable
40 — Not applicable
41 Nct applicable
42 Not applicable. r
Na apperablig
44 Not applicable
45 Not applicable
46 — Not appicablo
47 GM18987 Bolt intake manifold, lower intake to
48 — cylinder heed
. Net applicable
. 49 GM19010 Stud, valve rocker win Pivot
• 50 GM18945 . Seal, valve stem al "•.1-
.•
51 GM16521 Nut, valve rocker arm, non -adjustable
52 GM19721 Gasket exhaust manifold
53 GM18940. Guide, valve litter, restrictor valve rotator
X kern not sold separate)
JO Common hardware; procure locally.
AR As required
TBD Pan number to be determined

TP-6108 5/06

13
Group Engine Head/Upper End, continued

112 OM00-033 03/28/00

89
64 92 86

7 100 92

8
90 •
87
?b 10
fr
f\\
(
980E
72 C
94
•
71 111
70
38

78
0 85
36

79
83 22 •[
Vtri
18---1-

69 Sct \ 83eti41
„ 83 83 63
19 19
VIEVE
19 1
CYLINDER HEAD
BOLT POSITION

61082

TP-6136 51C.::


Group 2: Engine Head/Upper End, continued

Quantity
Part
Item Number ' Varlatioi
DettOr101100 1 1 2
1 Not applicable '.tP. .., ' ' :w..'d 9:,:".':.• : '.
55 —
58 — 14 14
! See item 22 ' • 7‘ '
57 X 14 14
Not serviced separately,.port Of 30
58 X Not serviced separately:part of 30 . '
59 — •
Not applicable
. 60 GM19722 I Maniold, exhaust •:•,-,:,;,.:„
•- - 60 G1/28927 I Manifold, exhausi:(128 .1, ; r*14-,-W '• t:' 1
: :'!:41-:-Ii .v.:.- • • I 1
Not applicable
.J applicable - -
63 GM19016 - Harness, rnlportel fu injectIOn
64 GM18900 . Stud. fttel injection rail
- 1 Not-applicable - '.7 - • .;:..,1-:::Tht — 2 2
L — .,
fre =
• .-. totob'
&r17-cabie: .::".- -- .. -
vt.ats 7
'attic& ... -
NolaRlicaP 18
— 0.' ' • Not applicable
TOO -- .; .Engine. 8.1 L
GM18939 ttGasket, throttle body
i';a1,1F- 4 Notappacabfictr;t1;te,;" 1
888K1 Nut throb:10 1451Y.;(P
.....,,,,_±.4or .a0b1140
. 10V2s5:: L,V.
— -' Not aporicabre-
4 — .426 -
75 — Cr.Nct applicable - •--
76 — 7=L P'Not applicable
—7.1:Th r_.-.iN
Ot applicable 't.Z113:,-
A H2171-n
,.X.W..t.
.• ,ttt• Plot ,,,, 22.'..•
separatafaart of:35 7".I . :7
Z79!: GM18941 Retainer valve lifter giiicle3eaficirk$ '
. 80 GM18914 i Bca, vaNe lifter guide retitle( • - 1 .
ris 81 — Not applicable 7
82 — Not applicable
'483. GM18921 I Sok, cylinder head, pcsitipo , 6-1:141' "11c1 ,71.,:',- .,c 24.,,' 24
7te; GM28582 Wire spark plug -- .J.ft"....
- 41
85 GM18928 Petaire. spark plug' ; 8
86 GM18955 Edt, igrttion coil 12 12
'-" 87 GM18966 ' Coil. igniton (engine mods year 20021 16 1 16
.87i, GM38393 Cori, ignibcn (engine mods ' ' 8 • 8
:tea:: •GM1,8908 Batt, Ininng harness bracket % t'.8. 7 a
•- .4 '4
1.789 -,* GM19317 Harness, Ignition coil Wirtnir •t
90 ,G ... M: 18929 isi
Cot lipappfirincgabi
hearn.:7 31;:y.v;, .47.75,,..: ._.,,,:i.,t.,,,t.::,.
91 GM18926, Connecta, inline to engine harness
92 GM18927 Connector, coil ignition 1
4
: GM18942
Stud. throttle bar.. :Skrp-'',
r..
...is* GM18938 Bolt, EGR valve openingcover .e,_
96 GM18981 Cover. EGR valve opening
, z.;-
-:_, ,st7: : . '2 -,•,.:.
97 GM18965 i Gasket, EGR valve opening cover 1
• '98 GM18933 : Sealer al Ili tube 1
.7799_ GM19307 I Tube, al 511er I' -:‘, 1..", AR
:31.".a:;. • -t-'''
2.11r
-1 • ..,;-.6.• 1 1

IJ 100 1GM18911 i Solt, cil filler tube, Ma i 1 x 20 Cr. - "4-

. je101. 1 GM18889 Plug, int mangold, (must use verth4
.2345384ealarn
102 GtAt 8891 i Plug. int manifold (muit Ise With 12345382 sealant
103 jX I Not serviced separately, part of 38

.
,kti. r;
..,..:.. 1
. : 2 .i.
1
• 104 jGMl8goi I Plug, int manifold (must use wtth 12345382 sealant
1 t:' Not serviced separat ey:q-Lt7S 1 1
i•-1 -7:', :::;Ltr'74.7•:"."---.±•- 74H"re ° . ..
M18899 Bolt,map sensor...V .7'0,ir:*:-,:-0,-;4,.., -.• :7(:'..!..2.;;;.C. ••
..107 GM18898 Sertscr, map (includes . : 3
108}-•-,.._,L::.- ••,..-....:•-
_1 08 GA19019 Seal, map sensor, part Of 106 - z.. ;•: : • - • 1 1 • .

109 — 1 1
Not applicable
. . 110 — Not appricatle
' -hs•re!-' • , - i1 1 . .. GM18985 Hose fuel pressure reg xtr.CL: ci",,„ r
••• • .1-.2•66:- ' ' tz,(12;'. GM19016 Harness, m/port fuel injeclion fa,%-;;„ 1 1
.. ._ . `

L. •9:

••••
.
-
1: ..anit.A.ZuF , :,,. #

. •
.. X _. Item not sold separately
Common hardware; procure locally. ..
. . AR As required
TED Part number to be determined
...

I. TP-8108 906
15
Group 3: Engine Trim Parts

See Group 1

See Group 1

7
agg#
0 01
Not exactly as shown

Items not shown: 12-21

Part
item Number Description
• 1 CAM1614/.., SPacIec ran -Ket,:er.,131144"---
• 2 GM16113- Sensor, rnaeneticspeedZ5/8-
3 GM19726: ThermoMakIPGA9014;•
4 GM19727 0-ring, water sensor tube
5 GM19725 Housing, sensor
6 GM19761 Dipstick, modified
7 GM16154 Clamp, sleet tubeA13 In:
8 GM19762.. Tube,Apspok.moclified:
9 GM19731 0-rinvilpsticfc adgIt
•10 GM19734 Adapter, M12-1.75 to
11 GM19457 Controller. governor, DPG
12 GM16118 Plug, 1/2 in. NPT, brass
?..1 13 GM19760 abel, PSI seliatiitiMpeMr:WL
L
14 Bolt, Ma-1.2Siesitscacetherstgradees

16
17 N
• Washes !pcliSig
Bolt, MI-1.25 -x SO, hex
Washer, fiat, 5/16 USS
18 N Washer, lock. 5/16
•19 7: 7: IV Y. Bolt, M8-1.257,4150.940,F.cfg , •"1.:.!..%, :-
21 memos .. Sensor; rnali
22 GM19735 Fitting, 0/8 In-290xlepreeelb9W
23 GM19730 Spacer, dipstick bibe nioNntInd

N Common hardware: procure locally.

16 TP-6108 We
 Group 4: Flywheel
Part
Item I Number
1 GM19764 Flywheel assembly • , 1
2 GM28886 Flywheel assembly (SAE10.11.5) 1
2 GM16135 Housing, flywheel,_ 9AE3 - 1 1 1 ;-
3 , GM19723 Plate. cover 1 ,1
4 i it Washer, flat 1/4 in., SAE
5 I a 4 : 4
Washer, lock 114 In., SAE
6 ; e z--7t: Solt 1/4-20 X 3/4.bici head grade 5 1444 I 4
I Bolt, M10-1.5 x 303,110:5(4110nd
grAde .17 ";a-?: -
C
'. 0
.f.,!:-
• ilex-

I
I Group 5: Starter
• Item

2
Part
Number
GM15175:'
Description
GM17325: 1304:StartaCzPeovar17y
Var.

t 3 -..:4\ A7.'
4 # Ks= • ills&
" Was he r, M5
5 a Nut. flanged, Ma-1.25

# Common hardware; procure locally.

70.01011
17
 Group 6: Alternator, Pulley, and Belt
Below Engine Serial Number 8.1L05449
Note: if the engine serial number is
below 8.1 L05449 and you are 10
replacing the attematOypgrade to
the newer drive system shown on the
following page.

Items not shown: 9, 11-21

2-
61011 0

Qty.
Part Var.
Rem Number Descri•Non 1
em 1.
2 GM22393 • . Belt, ran '-i7 -a a,- :•:c• .--; : . 1
a, r161197404-. Plale4ternalcthnountInAai.::. , 1 1-
-4- GM19741 . 9uPay:idler 1
5 GM19742 Spacer, .437 ID x 2.343 In. 1
8 GM19743 Spacer, .437•D x 2.906 In. 1
.....-..--, - xv
tw171
z.s..,' pr.40;:::, Pulley jaistaii;tsill.‘*,i_____...
,.. -7...'“ ,,,, :
470:` Rt0W4ra Spezer.altemalccanoundng,i3asiax.2.19 in
10 GM19748 Brace, enemata? - 1
11 Ir Nut. M6-1.0 1
12 /I BM, M8-1.25 x 30 hex head grade 8.8 1
13 NUt; flanged: Mal ii i....: - ....”4
14 WC :i. as i Washer; lockF5G85,. -- - :,..
:15 .HIry ; : ":ii.rit Bolt, M:10-1.50:k.99,_ .0.114t0.0.
16 - Washer, lock, M10
17 N Bolt, M10-1.50 x 100. hex heed grade 8.8 I 1
18 0
19 0
20 W
21 N
Solt, M10-1.53 x 40, hex heed grade 8.8
Nut, flanged, M104.50 7"
Bolt, M&1 25 x110, hex head gase 8.8
-.7

Eck M10-1.50x 120, hex head grade 8.8

'fel'
Il 2
L
Cam= hardware: prccure

18 1P-6106


Group 6: Alternator, Pulley, and Belt

As of Engine Serial Number 8.1L05449

Part
Item I Number Description
•rrtAt .GM19748; Brace, aatamatort% •:--.- 7-1,
I tli. --- GM19 -/42^, Spear IIiltatilli zaia ia:-
VA, G/Algr.47- - , Speier:1010;mattr mar
606
-4 GA/19743
5 GM23421
Sperei7437 ID z 2906 in: .
Spacer, idler shat
6 GM19746 : Pulley, tensioner
M1974C2- .., Pulley, kflet-a-T,-"
,...t
.G1023426 - : I 4iicer.jdler.16r6Er&-,.. ‘47437attr..."tta
''''1•iaatt,24.
MIEtt811 7 , I Al ematcFSCliunpyiZ^tir 4,171r1.7:1:nri
10 GM23423: Pate, ldler—I
11 GM16121 Pulley, ;der
12 GM19739 :Bea
e la
Ghtienzr: 2,44.,..wk-t-.7„...
GM1974131 . •
-Plaii.eltematocrnountInga.=:z7:- : ...
...1Nr-' GM.19. 7iff.,, Space; r0374 .x. 6.725 tri..1':F. 5t. „
— 15 .0 . • Nut 146-1.0 1 --
16 II Bolt, kia-/ 25 x 30, hex heed grade 8.8
17 P t 1
Nut, Ganged, M8-1.25
3 ,151/ , 1
%taster, lock- 5/6
1 - •::•,a. ,
ig: ; a Boit M10-t:50x 90, her head grade 8.8
-7
20 a Washer, lock; M10
- 21 a Bolt, M10:1.50 x 1CO, hex head grade 8.8
22 a Sol. 1.410-150 x 40. hex read grade a 8
23 a 2 2
lit,t flanged. M10-1.50
24 ti 1 I Bolt, M8-t25x•110, hex head grade 8.8
1 2
25 4 I Bcit, M10-t.50 x 120, hex head grade 8.8 I.. :1"tti I
26 GM23422 !Washer, later
.4;4. . '•:,
if Common harchvare: pram locally.

1124108 5/06
19
 Group 7: Intake and Exhaust System

Part
• 1
Item Number Description
qn..49al
strunsolle Pipelert
Pipe;leat lade (vi/Y sectony
— 3 ITIMP Braik-et, moalting
4 GM19752 Oarnp, muffler, 3 1,2 it
5 GM19753 Space', .437 ID x .375 in.
4,7$49.7sra Space' 37x -875Ter5-
7 a.M1975S 101,exhaest
t.g, 7 icam789,21:4E Gam
HrrstallatiorTS:
f
(U-boltaii2
8 GM19759 Pipe, rigfihind "--
8 GM28923 Pipe, ride side
9 GM28931 Flange

rr.181:4044;:es
2 ManNic9dislust
13 K123738 Borg M8-125 head ead grade 8.8 --
14 Washer, tat 5/16 in., hardened
15 9 Bolt, M10-1.50 x SO hex head grade 8.8
WaspAlti10
117 :21 -10045051 35; heibead grade ate 2.
Ktablisi graaa

Group 8: Engine Mounting

Part
Item Number Description
G 724- Ma n,
hck 11410-1.5(430 diead gn
Iti&s etrklottanta)W
I Commcn hardware; pccure

20 TP-6108 5/06


F
Group 9: Fuel System, 80/100 kW

r
I

L
•
Part
Item • Number uanti
mimic --- 0fia -rrpan
.. rxer,Tfl .a
„9 COM aSSENT;
Dosed tIon
:1 GM17382.: MIxiii4 fccraplete assembly*
3 i GM1 9729..Adapter,
_ manifold
2 GM 197284 13rigileleCfuref .• -

•
.. . .... . _ ..
4 GM16177 U-Bolt, w/o plate
5 GM19732 Gasket, manifold adapter
-11 GM1973% Gaskitale manifold 10 5.510011e.',4'
' 7 GM1 eti"*P151t3/4 X 3 in.
8 Ght19737:-.1 Valyan4t.t.i.L.....
9 GM16205 EltShing, reducer : • et- .b::
10 GM16207 Pipe, 1 in.
11 GM19756 Pipe, nipple,fitting elbow, 90 degree
1 x 5 112 In
12 GM19757."
13 ' GM19758 • Fael.f..e-r4Pert::
14 .144450 . :',"' .-‘‘::,,
15 • art—
18 0 - —
Washer, lock 1/4 In. SAE

I
3
17 0 Bolt, 1/4-20 x 3/4, hex head "2 1 ! 2
18 0 -- Wa.shattlotIK5/18 2 i2
46; :
fir Nut,5/1818 1;:?%.,, • 2 r 2
. -;44:-Fr-V e-7-52r2Fik
lAsher711818/16 54
Bolt, 5/16-18 x 1 1/4, hex head ' 2
Washer, lock, M8 ; 2
2 2
it Common hardware; procure locally. 3 3
• Mixer components are shown on following page.

TP.6 1 08 5/06

21
Group 9: Fuel System, 80/100 kW

Part
Rem Number Description
1 raM28887 Clamp, hose 5523 1/2 in..,
1 GM29581. Clamp, hose 544 41/4 81.1;1.
2 GM24538 Meer, NG,27
2 GM29593 Mixer, NG
2 GM17362 Mixer, LP Gas
2. GM28969 Mixer, LP Gas
IGM24341:- FittlrC1/2 }APT x 3/8 bushing
4 GM16177 U-Bolt,5,018 x1 9/8 x 212 In.
5 GM19733 Gasket qntake manttoleto adapter)
6 GM29588 Valve, throttle 60 Min
7 GM29587 Pipe, nipple 3/4 x 2 in.
7 GM24548 Pipe, nipple 1 x 2 in.
7 GM29612 e tx.1.; y21g:
8 GM29593- Brack- PipessuppOrt
Gmnsei -*9
10 GM29592 lmahihan -adapter ,

11 GM29594 Adapter, mixer to throttle body

11 GM29589 Adapter, 475 mixer
12 memo 1-.10.4e,1111X AvIlaPte!Pktiltoga body
12 G/429588 Hoie,475 to vela..
13 GM29596 Regulate', Fh/61 •
14 GM29608 Senior. coolant -
15 GM29039 Sensor, Inlet air
18 GM16205 Bushing, reducing 1 NPT-W4 In.
17 GM16207 Pipe, 1 In. ening elbow • f; :"
18 GM19756 Pipe, nipple 1 x 5 1/2 In.^
19 GM19758 Bushing, 1 1/4- 1 In..44`.-sir„.
20 GM28887 Clamp, hose 5-52 3 172in.--

22 TP.6108 5t6
 L
Group 9: Fuel System (Mixer) 80/100 kW
Part Quan
Item Number Variation
1.. GM17393 Gasket, mixer to air hcm 1 2
2 GM17388 Screw. 10-24 1 1
x
3 GM17394 Spring; air valve5/8. SEMS ' 5 5
4 GM17384 1
Diaphragm, silcone, natural gas 1 •
4 GM17009 Diaphragm, silicone, LP
5 GM17380 Ida screw
6 "f GM17391 Spring:Illescrewt-
GM17395'; Galt 7 elbody to mixer
' v
8 Gal ma) -24 x578, SEMS
1

fp
L.

1.
•

TP-6108 5106

23
Group 9: Fuel System, 125 kW

16 21
27, 28, 29

4, 6
emu 4

24 TP-6108 5/06


ft

Group; Fuel System, 125 kV1

I
Part Queen
Item Number
Desc ion Variation
1 GM28888 Clamp, hose, 3 in. 4
1 GM29601- • Clamp, hose, 2 3/4-3 5/8 in.
2 GM25970;•; Clamp, hose, 2 1/4 in.
2
Clamp, hose, 1 9/16-2 1,2 in.
3 GM28892 Clamp, 3/8 in. (M4)
4 GM19729 Adapter. manifold
) 4 GM29591 Adapter, mantlold -
gieT. 5 GM181 , 77' U-bolt '•ir•-•• --
• Vivi 6 GM19733lem .Gasket (intake -
manifold to adapter)
7 GM28766 Gasket, LC-50 (5C/43 mm) valve t-•.4 * 3-
8 GM23714 Gasket, mixer adapter
9 GM28911 Bracket mixer mounting
10 GM28912- Tube w/wastegate fitting 2
l:t 10
Tube, turbo to throttle
inr. 10 GM2g5$3t Rains 1/8 MPT x
11 1/4 hosebarb SO deg. eibow (net
Adapter, elbow 90 deg. lute shownri,
11 GM296C0
bow, rubber 90 des tube to throttle
12 GM29915 Clamp, hose, 5 in
13 GM28.916 •
•Hose, pushIcok, 1/4 In. ID x 1/2 in OD, 11 -
14 GM28917, -Mixer CA475M (nat. gas) _ •
14 GM28919,,z4.i.' .MIxer CA475M (LP)
14 GM28966 Mixer N16-475-5A
15 GM25971 Regulator •
15 GM28970 Regulator
7 .:(- 16 GM25972 ,p,-0 Bracket, regulator
16' GM2959721;44: Bracket, regulator
17 GM25973 .--,-;:vte Bushing, reducer
18 GM16203 " Pipe, nipple, 1 x 6 in
I. 19 GM28920
20 GM28924
Adapter. intake ebow
.f..47.;,. 21 Ga.,128925 -- Hose, turbo outlet. Sin,
.T.4 Bracket, mixer support
22 GM28
928Hose hump reducer
•
23 GA.428934 •••; Mow intake
'
• 1
23 GM^9602 Elbow, imake
23 GM29582
24 GM28887 Plug, brass 1/8 in. NPT
Clamp, hose. 3 1 2 in. 1
25 GM28933 7' 1
26 GM23715 • Screw. 10-24 x 2 1/2 socket head
Throttle assembl y
27 See Group 11 - Heat shield, Intake elbow 4,
28 See Group i f Spacer (not shown)
29 GM29598 Spacer. 1/4 x 53 in. (not shown)
30 GM28918 2
• 31 - GM296017ty Fraing. 1/8 NPT x 3/8 90 deg elbow 1
p, hose, 2 314-3 5/8 In
32: GM29586 VaNe, throttle 60 mm
33 GM29592
34 Gasket (manifold adapter) •.
s Sensor. inlet air 1-
35 IGM24341 Fitting. 112 MPT x 3/8 in. FPT bushing t
36 GM29608 Sensor. cool
a nt
.,37.1 SeeGra-silt Clamp and
. , V-b, 234 In.
38 GM29586 ;4; Sensor 02 y.l.
-, 39 ' GM29613 7
iltt Elbow, turbo exhaust (w/02 pertr1/4,,,, 9•: . ,

• •

1. 1P-8108 5/06

25
Group 9: Fuel System, 125 kW, continued


F
Group 9: Fuel System, 125 kW, continue(
Part Ouanti
item Number Variation
1
Description
GM288881 ••••:-L Clamp, hose, 3 in. 3 4 I 9 I 10
1 GM29601 Clamp, hose, 2 3/4-3 5/8 in.
2 GM25970

I
Clamp, hose, 2 1/4 In.
2 GM29603 C lamp, hose, 1 9/16-2 1/2 in.
3 GM28892 Clamp. 3/8 in. (M4)
4 GM19729 Adapter, manifold
• 4 GM29591?..L. Adapter, manifold
5 GM16177

I • 6 GM19733
7 GM28766
8 GM23714
U-bolt • •
Gasket (intake manifold to adapter)
Gasket, LC-50 (5)/41 mm) vaNe
Gasket, mixer adapter
9 GM28911 Bracket, mixer mounting 2 2

I Ght28912 7.3.:{p:
••,-,410 GM29599

11 GM28913
Tube wAvastegate rating • .1.n:r, •
Tube, turbo to throttle

Adapter, elbow 90 deg. tube

.6 W:1"
rating, 1/8 MPT x 1/4 hosebarb90deig.AINtsiSnot sham
1

•
11 GM29600 Elbow, rubber 90 deg. tube to throttle

I 12 GM28915
• 13 GM28916
Clamp, hose. 5 in.
Hose, pushlock, 1/4 in. ID x 1/2 In OD, it
14 GM28917.Ze Mixer CA475M (net. gas)
14 GM28919
1

hexer CA475M (LP)

14
Mixer N16475-5A
15 GM25971
15 GM28970
Regulator
Regulator 1 1
16 GM25972. 1 Bracket, regulator
- 16 GM2959t Bracket, regulator : ;•• •:"'
• 17 GM25973 Bushing, reducer
18 GM145203 Pipe, nipple, 1 x 6 in.
19 GM28920
Adapter, intake elbow
20 GM28924
Hose, turbo outlet, 3 in.
21 Bracket, mixer support

I
22 GM28926a1.1 Hose, hump reducer
GM28934:A/r Elbow, Intake
23 GM29602 Elbow, intake
23 GM29582 Plug, brass 1/8 in. NPT
24 GM28887 Clamp, hose, 3 1/2 in.

I 25 GM28933 Screw, 10-24 x 2 1/2 socket head

28 GM23715-.* Throttle assembly
•

See Grouff11 , Heat shield, Intake elbow

28 See Group 'ti Spacer (not shown)
29 GM295913 Spacer, 1/4 x 5/8 in. (not shown)

I 30 GM.28918
31 GM29601
Fitting, 1/8 NPT x 3/8 90 deg. e/bcnv
Clamp, hose, 2
GM29588 .;:, Valve, throttle 603/4-3
GM29592
nun
5/8 in. .

Gasket (maniford adapter_ )

•
34 GM29609 Sensor, inlet air
35 GM24341 Fitting, 1/2 MPT x 3/8 in. FPT bushing
36 Gtv129608 Sensor, coolant
SeeGroupil: Clamp, V-bend, .23/4
-r-112.1238 'Gkt7_958.5.7.;T- Sensor, 02 c .111e: f!'
x"7"t'
439 .Gmz9st3 Elbow, turbo,

I
TP45108 5/06

27'
Group 10: Wiring Harness

Quantity
Part • Variation
Item Number Desert • Non 1 2' 3 4 5
GM19738 Plate. FS mounting ....pc' --r- -
GM19745. Harnell; ivire7:-.L:IT 1..:; -' •
.1 ' i

acme; "fternaii, Wire Eakr .. r -

GM19763 Module, NG ECG eorltrd, 80 kW
GM19766 Module, NG ECU control, 100 kW
GM19765 Module, LP ECU control, 80 and 100 kW
GP422170 Module, LP ECU control 435 kW
$4
1.

GM25969 Module, NG ECU - 125141/..

GM29607 Module,-ECU contd.. ° 12:.
GM29610 lialacir:Ectr
GM29584 Clamp, steel tube, 1 in..
.-oiie

0M29604 Isolator, relay box

10

Kr".•197
ttit

GM29605 Bracket relay bor.t...,- -

by

...
iti
t

c1.0.. cmto•cr•o•co 4.- ;

GM29611 timess, wire, solenoid valve :...-

If :.,,. • : Washer, flat 1/4 in,;. SAE • .., . •
GM24188. Washer, lock 1/4 In., SAE
GM28961 Bolt, 1/420 x 3/4, hex head grade 5
I/ Bolt, 1/4-20 x 1 1/4, hex head grade 5
i i •

II - : ., • - Bolt, 1/4-20 x 1, hex head grade 5

II ' Bolt M6-1.0 x 20, hex head grade 8.8
014,428963 Washer, lock, M6 ••
N Bolt, M10-1.50 x 15 hex head grade 8.8
N Nut, 1/420
N Bolt, 1/420x 1/2
re-

a - - I Bolt, 1/4-20 x 1 1/2, hex head grade 5

-.,

28 TP-6108 5/06
 I
Notes
1
r
I
I

-6108 5/06

29
Group 11: Turbocharger

it

30 TP•6108 5/Q8 •


Group 11: TurbochargE

Part
Item Number Var
• 1': GM28893 G Descri •
2 T.- GM26894 -- ;
Spacer..75 00 x .44 10 x .625 (not shown) 2
3 • GM19730 Spacer, 2
4 dipstick -. .
GM28897 Turbocharger - 2
5 GM45896 : 1
6 Assy., exhaust inlevturb- mtg.
GM28899 Plate assembly, oil drain
Tr:: GM28900 - . readier assembly,14 drainpipe 1
:1 8 ''. GM28901:. Hoes, on draft); 7/8 1
9 GM28902 f-. In..10:3 in.
Nose oil supply -.:,tf,[..teigjit. .1
10 . GM28903 - Fitting oil T
11 GM20904 Elbow, supplyturb
turbo exhaust 1
12 GM289C5 ear, mbcer support 1
13: GM289141 Hose ":`, 1-
14: GM19753 See pec .
.155 043614'. tie IDi ;375:
, t
s/ ithiact Ie 3
16 ' GM28928 . Gasket. tiaOch
17 GM28929 Gasket, oil drain
ntakelbelet
arger '- -;:k...1 1 1
18 GM28930 Clamp, V-band, 2 3/4 in.
f 11
19 GM28898 Weldmount, bracket mounting exhiturto
1

TP-61C8 51t6

31
 Group 12: Breather

Oty,
Var.
Item Number DescritIon
GM28889 Clamp, hose, 9/16 in. OD (speng type) 4
GM28890 Clamp, hose 3/4 in. OD (iping-type) 2
GM28891 Cap oil lilt - 1
4 GM16158 Hose, PCV 3/8 in.
5 GM28695 Clamp, hose, 13/16-1 1/2 in. 2
6 GM28896 Va've. PCV
7 GM28907 Bracket, breather . 1
8 GM28908 Hose, breather 1
GM28909 Fitting, 3/8 x 1/2 in. tioie mericleic. 1
10 GM28918 Fitting. 1/8 NPT 3/8 in.' 1
11 GM28910 Hcse, PCV 1/2 x 2 in. 1

32
 r

Technical Literature

Generator Set Model

8ORZG

• Literature Kit
GM11260-KP
Order
1002612009 / 000120
ft

0
. 0„ 9001
(
we 4 Waft

O
KHLER. NATIONALLY REGISTERED

PO WER SYSTEMS
G16-16
 L

GM11260-KP June 25, 2006

Lit Kit, General Maint, 8ORZG

Sales Order: 1002612009

Table Of Contents
Wiring Diagrams

TP-6274
W/D 20RZ/30-125RZG/30-50RZGB, Industrial
Operation

TP-6101
O/M Supplement, GM Engines
TP-6161
O/M DecMaker 3± w/Comm, Dec-Maker 1
Parts

TP-5708
P/C 17-800 kW, Accessories, Gas
TP-6009
P/C Controllers, Industrial
TP-6102
P/C 30-125RZG, 30/50RZGB, Industrial
TP-6108
P/C GM 8.1L Powertrain, 80-125 kW

•
L
•