MODEL

4CM21

4000 WATT- 129 VOillAC, -:RE~:R.EA'il'ONAlVEHIClE

GENERATOR SET OWNER'S MANUALCONTENTS

SUBJECT PAGE SUBJECT • PAGEService and Adjustment Points 2 Trouble Shooting-Engine 7Engine General Specifications 2 Schematic Diagram-Generator Set ~ 8Fuel Consumption 2 Generator Service 9Generator - General Details '" 2 Trouble Shooting-Generator 9Pre-Start Instructions ....................•... 3 Controller Operation ..•....................... 9Starting-Stopping Procedures 3 Engine Parts Identification ..........•........ 10Preventive Maintenance .. ~ 3 Parts Ordering~nstructions 11Battery Connection 3 Engi ne Parts ' 11Service Schedule 4 Mounting Parts 12Air Cleaner Service 4 Exhaust Parts 12Lubricating Oil 4 Generator Parts ..........•.................... 13Carburetor Adjustment 5 Controller Parts 14Automatic Choke Adjustment 5 Storage Instructions 15Governor Adj ustment 6 Opt i ona 1 Accessori es 15Cooling System Service , ~ 6 Operating Hour-Service Log .......•.•.......... 16Ignition System Service 7 Warranty .................•.........•.......... 16

SAFETY PRECAUTIONSSafety is built into every engine driven generator; however, like any other electro-mechanical device it can present serious threat to life and

limb if imprudently operated and maintained, Remember that the best safeguards against accidents are to keep ever mindful of the potentialdangers and to always use good common sense. In the interest of safety, some general precautions are presented below - keep these in mind!

WARNING - HIGH VOLT AGE! Remember that the function of a generator set is to produce electricity and wherever electrical energy ispresent, there is the potential danger of electrocution. Keep everyone, especially children, away from the set while it is running and take pre­cautions to prevent unqualified personnel from tampering with or attempting to operate your generator set. Have the set and electrical circuitsserviced only by qualified technicians and make sure that the battery is disconnected before any service is performed to prevent unintentionalstarting. Wiring should be inspected frequently - replace leads that are frayed or in poor condition. Be especially careful not to come in contactwith electrical equipment when standing in water or on wet ground or when your hands are wet.

WARNING - LETHAL EXHAUST GAS! The engine powering your generator discharges deadly carbon monoxide as part of the exhaust• gas when operating. Carbon monoxide is particularly dangerous in that it is odorless but keep in mind that it can cause death if inhaled for even

a short period of time. Never operate the generator set inside a building unless the exhaust gas is piped safely outside or operate in any areawhere exhaust gas could accumulate and seep back inside an occupied building. Keep exhaust system tight and in good condition at all times toprevent leakage. Avoid breathing exhaust fumes when working on or near the generator set.

WARNING - DANGEROUS FUELS! Use extreme caution when handling, storing and using fuels - they are highly volatile and explosivein vapor state. Store gasoline only in approved red containers clearly marked GASOLINE - store in well-ventilated area out of the reach ofchildren and away from any flame or spark producing equipment. Don't store gasoline inside home or any occupied building. Never add fuel totank while engine is running to prevent spilled fuel from igniting on contact with hot parts or from ignition spark. With gaseous fuel, make surethe system meets all safety codes and have it serviced only by qualified technicians.

WARNING - MOVING, HOT PARTS! Imprudent operation creates hazards to life and limb - never operate with safety guards removed,keep hands, feet, clothing away from moving and hot parts. Remember that an engine gets hot while running, and exhaust system componentsget extremely hot. Know how to make emergency stops - don't allow inexperienced persons to operate your set. Always disconnect battery or re­move spark plug while working on equipment. Never tamper with governor setting to gain more power - the governor establishes safe operat­ing limits. Overspeed not only shortens engine life but can be extremely hazardous.WARNING - GENERAL PRECAUTIONS! Handle starting batteries carefully - they are filled with acid which can eat thru clothing, bumskin, and cause blindness. Keep in mind that a battery gives off highly flammable hydrogen gas while being charged - charge only in well venti~lated area. While electrical energy produced in an engine ignition system may not be strong enough to cause injury, reaction to shock producedcould cause you to pull away and into contact with hot or moving parts - keep away from ignition system while operating. Never operate with­out adequate muffler or with faulty exhaust system - exposure to excessive noise is not only tiring but can lead to impairment of hearing.

KOHLER CO., KOHLER, WIS. 53044

STOP-START

SWITCH

TOIL

.DRAIN

AIR CLEANER

FUEL PUMP

OIL FILL TUBE

AND DIPSTICK

FIGURE 1 -- MAIN COMPONENTS-SERVICE & ADJUSTMENT POINTS

Engine: Kohler 4-stroke cycle, air-cooled single cylinder gasoline Model K321 engine. All have theKohler patented ACR (Automatic Compression Release) feature for quick, easy starting. Other generalspecifications are:

LUBE OIL CAPACITy 1-3/4 Quarts

SPARK PLUG SIZE (XH-10 or Equivalent) l4mmSPARK PLUG GAP 025"

BREAKER POINT GAP 020"

BATTERY (55 amp. hr. minimum) 12 volt

FUEL (Regular grade gasoline) 85 Octane Minimum

The following chart is provided to help you calculate the approximate fuel consumption of yourset at various load levels.

APPROXIMATE FUEL CONSUMPTION

APPROXIMATE CONSUMPTION IN GALLONS (U.S. STD.) PER HOUR AT

1/4 LOAD

1/2 LOAD3/4 LOADFULL LOAD

.35 Ga11on

.46 Gallon.575 Gallon.74 Gallon

Generator: Kohler rotating armature (alternating current) type with built-in exciter which functions asa starting motor to crank the engine during starting then switches to its generating function after theengine starts. Exciter cranking permits higher cranking speeds for longer periods of time thus providesbetter starting under all conditions.

2

OPERATING INSTRUCTIONS

PRE - START INSTRUCTIONSBefore each start, open the compartment and make the following checks:

OIL LEVEL: Must be in safe range.AIR INLETS: Must be clear.COMPARTMENT: Keep interior clean.

AIR CLEANER: Must be properly installed.FUEL FILTER: Service if needed.~ Make sure supply is adequate.

STARTING - STOPPING PROCEDUREThe START-STOP switches inside the motor home and on the controller are momentary contact

switches which means that they must be held in the STAR T position until the set starts running orwhen stopping, held in the STOP position until the unit comes to a complete halt. Whenever possible,allow a brief cooling period by running the unit at low or no load for a few moments just prior to shut­down.

PREVENTIVE MAINTENANCEIn addition to the routine services listed in this manual, there are other important steps that

should be taken to keep 3. generator set in top condition. Usually, tools and instruments required forthese additioClal steps are not available to the generator set owner. For this reason, the set should bereturned periodically to an authorized Service Center for complete servicing and tune-up. The benefitsof such service will not only be noted immediately in improved performance, but, most important, incontinued satisfactory operation during a long, trouble free service life.

A

BATTERY NEGATIVE TO

"N" TERMINAL

GROUND

STRAP

TOVEHICLE

FRAME

BATTERY POSITIVE TO

RELAY "C" POSITIVE (p)

USING SEPARATE BATTERY

FOR GENERATOR SET

B

VEHI CLE FRAME

GROUND STRAP

VEHI CLE FRAME

BATTERY POSITIVE TO

RELAY "C" POSITI VE (p)

USING SAME BATTERY

AS VEHICLE ENGINE

BATTE RY NE GA TI VE

TO VEHI CLE FRAME

I

FIGURE 2 -- BATTERY CONNECTIONS-(A) SEPARATE BATTERY (B) SAME BATTERY AS VEHICLE ENGINE

3

SERVICE PROCEDURESERVICE SCHEDULEDAILY (OR BEFORE EACH START UP) ~EVERY 100 HOURS (OR 12 MONTHS -- WHICHEVER

I

OCCURS FIRST)

• Check oil 1eve 1 .I• Service spark plug.

• Keep cooling air inlets and outlets

Iclean.

I.Check breaker points.

I• Remove loose dirt from compartment.I• Check genera tor brushes.

EVERY 50 HOURS (OR 6 MONTHS -- WHICHEVER

I• Retighten electrical connections.I

OCCURS FIRST)I

I• Check mounti ng bolts and vi bro mounts.

• Change 1ube oi 1. !• Replace air cleaner element.• Service air cleaner.

I• Service fuel filter .

IEVERY 200 HOURS OR EVERY YEAR

.• Check battery.

!• "Tune up" at authori zed servi ce center.

AIR CLEANEREngine is equipped with a dry type air cleaner. Every 50 hours remove element and service by

tapping element lightly against flat surface to dislodge loose surface dirt--do not clean in any liquid orblowout with compressed air as this will ruin filter material in element. ~ce (with genuine Kohlerreplacement element only) after each 100 hours £l' if guod clean operating conditIons are encountered,thlS can be extended up to 200 hours.

LUBRICATING OILTo be on the safe side, check oil in engine crankcase daily or before each start to insure that the

level is in the safe range between the Land F marks on dipstick. Do not operate set if level exceedsthe "F" mark or if b.elow "L" mark.

I CAUTION: CHECK OIL ONLY WHEN SET IS NOT IN OPERATION. I

Change oil at 50 hour intervals or every 6 months--whichever occurs first. Change more fre­quently if operating under dirtv, dusty conditions, If possibl~, drain oil while hot.

OIL CAPACITV-1% GTS.Use only oils having the API Service se classifications. Use SAE 30 weight oils when tempera­

ture is above 32° F., SAE 10W-30 for 0° F. to 32° F. range or SAE 5W-20 when temperature fallsbelow 0° F.

FIGURE 3 -- OIL LEVEL MARKS ON DIPSTICK

•4

COVER

BACK PLA~E~

SEAL ""

GENUINE

FIGURE 4 -- AIR CLEANER COMPONENTS

CARBURETOR ADJUSTMENT

-I

Lack of power and black sooty exhaust smoke usually indicates that fuel mixture is too rich. An"overrich" mixture may also be caused by a clogged air cleaner--check this before readjusting carbu­retcH. Fuel mixture nlay be too lean if engine "skips" or backfires. Note that an overrich conditioncou1d a1so be caused by an inlproperly adjusted choke.

Main Fuel Adjustment: For preliminary setting, turn MAIN FUEL screw in clockwise direction until itbottoms lightly (do not force) then back out Z turns. With engine thoroughly warmed up and running at1800 RPM· and full load; turn MAIN FUEL screw in until engine slows down (lean setting) then turnscrew out until engine regains speed and then starts to slow down (overrich setting). Turn screw backin until it is positioned halfway between lean and overrich settings--when properly adjusted, enginewill operate with steady governor action.

Idle Adjustrnent: On generator set app1ications, the idle systenl functions only as the engine UHnes upthru idle range to 1800 RPM. For this reason, idle system has o'11y a mo~entary effect. To adjust.stop engine then turn IDLE FUEL screw all the way in (clockwise) until it bottoms lightly (do not forcescrew), then back out 1-1/4 turns--no further adjustment is needed.

MOVE LEVER IN DIRECTION

OF ARROW TO INCREASE CHOKEMAIN FUEL

ADJUSTMENT~(2 TURNS) ~

CHOKE PLATE

IDLE FUEL

ADJUSTMENT

(1-1/4 TURNS)

#43 DRILL

(.089") _----......... F1

II

LEVER

CLAMP

BOLT~

t----- CHOKE

LEV ER

ARM

NOTCH

IN

BASE

FIGURE 5 - CARBURETOR ADJUSTMENTS FIGURE 6 - AUTOMATIC CHOKE ADJUSTMENT

AUTOMATIC CHOKEChokes are set at the factory but may have to be readjusted to suit local conditions. Remove air

cleaner from carburetor to observe position of choke plate. Choke adjustment must be made on coldengine. If starting in extreme cold, choke should be in full closed position before engine is started. Alesser degree of choking may be needed in milder temperatures. If adjustment is required, proceed asfollows: .

1. Move choke arm until hole in cross shaft lines up with slot in bearings.Z. Insert #43 drill (.089) thru hole and push all the way down to engine manifold to engage in

notch in base of choke unit (see accompanying figure).3. Loosen clamp bolt on choke lever, push arm upwardto move choke plate toward closed

position for increased choke or away to decrease choking effect. When properly positioned,tighten clamp bolt then remove drill.

4. After replacing air cleaner, check for evidence of binding in linkage--correct if necessary.Be sure choke is fully open when engine is at normal operating temperatures.

5

GOVERNOR ADJUSTMENTThe governor functions to maintain engine speed under changing load conditions and also acts as

a speed limiting device. Governor is set in the factory and further adjustment should not be requiredunless linkage works loose or becomes disconnected. Readjustment should be made if engine surgeswith changing load or if speed drops considerably when a normal load is applied.

Initial Adjustment: With engine stopped, loosen (do not remove) hex. nut securing governor arm togovernor cross shaft. Grasp end of cross shaft with pliers and turn shaft as far as possible in counter­clockwise direction--tab on shaft will stop internally against governor gear mechanism. Hold shaft inthis position, pull governor arm all the way away from carburetor then retighten governor arm nut tocomplete initial adjustment.

Speed Adjustment: This set must be operated at 1800 RPM. If frequency or overspeed condition issuspected, check RPM with hand tachometer and readjust as follows: With constant speed arrangement,loosen speed adjusting nut to decrease speed or tighten to increase speed.

GOVERNOR ARM

CROSS SHAFT

ARM

RETAINING

NUT

THROTTLE

LINKAGE

CARBURETOR

SPEED ADJUSTING NUTS

SPEED CONTROL BRACKET

FIGURE 7 - GOVERNOR COMPONENTS AND ADJUSTMENT POINTS

Sensitivity Adjustment: If speed drops considerably when a normal load is applied, governor should beset for greater sensitivity. If set too sensitive, speed surging will occur with changing load. Governorsensitivity is adjusted by repositioning governor spring in holes provided on arm and speed controlbrackets. Increase tension on spring (and sensitivity) by moving spring hooks into holes spaced furtherapart--conversely, decrease sensitivity by reducing tension on spring. Recheck engine speed andreadjust as needed after changing sensitivity.

COOLING SYSTEMKohler Air- Vac cooling is used on this set. With this system, cooling air is drawn into the genera­

tor set compartment, circulated from the generator end, around the cooling fins and finally ejected asheated air downward thru the Air- Vac scroll at the flywheel end of engine. High-temperature cutout oncylinder head will stop the generator set if overheating occurs. Keep intake louvers, generator coolingopenings, cooling fins and scroll work clean and unobstructed at all tiDIes to prevent overheating--do notoperate with blower housing, scroll or cooling shrouds removed as this will also cause overheating.

6

FIGURE 8 -- COOLING AIR CIRCULATION

IGNITION SYSTEM

FIGURE 9 -- BREAKER POINT GAP

Spark Plug: Every 100 hours remove plug and check condition. Good operating conditions are indicated1£ plug has light coating of gray or tan deposit. A dead white, blistered coating could indicate overheat­ing. A black (carbon) coating may indicate an "overrich" fuel mixture caused by clogged air cleaner orimproper carburetor adjustment. Do not sandblast, wire brush, scrape or otherwise service plug inpoor condition--best results are obtained with new plug. Set standard and resistor type spark plug gapat .025". Tighten plug to 22 ft. lbs. torque when installing. Use 14 mm resistor type XH10 plug forsuppression of radio noise.

Breaker Points: Every 200 hours breaker points should be inspected and serviced. If oxidized, dirtyor oily, clean with coarse cloth--do not use emery cloth or- sandpaper. Slightly pitted points can bedressed with point file--replace badly pitted or burned points. The gap must be adjusted after pointsare serviced or replaced since this setting establishes ignition timing. To adjust, turn engine over byhand until points are at maximum opening--check with feeler gauge. If gap is not. 020", loosen adjust­ing screw then shift movable plate until. 020" gap is obtained. After retightening screw, recheck tomake sure gap is still properly set. ---

TROUBLE SHOOTING - ENGINEIf trouble occurs, don't overlook causes that seem too obvious to be considered such as an empty

fuel tank--check for the simplest causes first. To operate, an engine must have fuel, a good ignitionspark and, of course, good compression--keep this in mind when trying to pinpoint the cause.

I

HARD STARTING OR LOSS OF POWER

a. Faulty ignition.

1. Leads grounded or loose.2. Breaker points faulty or

improperly gapped.

3. Spark plug faulty or improp­

erly gapped.4. Coil or condenser defective.

b. Faulty carburetion.

1. Fuel line clogged (dirt-gum).

2. Fuel pump faulty.

3. Carburetor dirty or improp­

erly adjusted.

4. Choke faulty or improperly adjusted.c. Poor compression.

1. Head loose or gasket leaking.

2. Valves sticking or leaking.3. Piston rings worn.

OPERATING ERRATICALLY

a. Clogged fuel line.b. Water in fuel.

c. Vent in fuel system plugged.

d. Faulty fuel pump.

e. Gasket leaking (carb.-manifold).

f. Governor improperly set.

g. Carburetor improperly adjusted.

7

KNOCKINGa. Fuel octane too low.

b. Ignition timing wrong.

c. Carbon build-up in combustionchamber.

d. Engine overheated.

OCCASIONAL "SKIP" AT HIGH SPEED

a. Spark plug fouled, faulty or gaptoo wide.

b. Ignition timing wrong.

c. Carburetor improperly adjusted.

OV ERHEA IING

a. Ai r intake openi ngs to compartmentobstructed

b. Oil 1eve 1 too high (or low).c. Fuel mixture too lean.

d. Ignition timing wrong.

e. Engine overloaded.

f. Tappet clearance too close.g. Air vac outlet obstructed.

BACKFIRING

a. Carburetor set too lean (MainFue 1) .

b. Breaker points improperly gapped(timing) .

c. Valve sticking.

LOAD

L.Z 15 GROUNIID

- - -II( .•

Q

r-u----lI iR~~OTfi Il-o,~ ·\O-:---t-------,

I ~ I ItH - - ISW '.-'}j- HOURS I ILAMP',) 11 I 91

j J.", 1--=----=-+---, i'i\ 10- - - - - - - t ---1:-=---=--=--======---~: :

I: III II: III III IIIII I

I' I

I: II--~ I, II: ~_U: III ~-r" III ~_I __ :J1«-'1--I__ J

r­IIII

LB-!810 -1400

LD-1408-1414

•.. ------

-2200

LY-IBI5-1600

LD+1410-1400

STOP

LW-JOI6-1500

Ii-',

LW-1803-91!5

~iLY-1804-ILl22~1

SHUT

SOL.

WH!TE

u_ - - - - REMOTE SWiTC:H~

STOP 0);--0- ••6- J____ ..I I

STOP I START

L *

Ik2--c=J--<

FUEL

OfF

2CR--------------f~fuy ,---C'~JiQUB( -""~r;!IR-6-5~-!/ ~~~ - - - - -.l.

..•. ,--, ,_/ =-

."•....•G')c:;urrJ~0IIG')rrJ:zrrJ~-i0QC)

;u(/)rrJ-i::E:•....•;u•....•:zG')0•....•):>G');u):>3:

CyclicCompensator

+ 12 VOLT -

IIIIIIIIII... --II

IIIJ

NOT USED ONTWO WIRE PLANTS

LI!u L2

CyclicCompensator

THIS DRAWING IN DESIGN AND DETAIl.. IS OURPROPERTY AND MUST NOT BE USED EXCEPTIN CONNECTION WITH auI'! WORI(. ALL RIGHTSOF DESIGN OR INVENTION ARE RESE:R ••••ED.

KOH LER CO.KOHLER. WIS., U.S.A.

NAME

DIAGRAM WIRING

248374••• 0<;. lit· •• <lI.ImI)

GENERATOR SERVICEGenerators do not normally require service on a regular basis; however, it is a good idea to

remove the end cover and check the commutator and brushes at least every six months or every 50hours or more often under dusty, dirty conditions. Make a visual check of the commutator first--if athin skinlike film of uniform thickness is evident on the surface, this usually indicates normal operation--this film acts as a lubricant and promotes longer brush life. If the surface is streaked or has ridgesof dirt, clean it with a coarse cloth or, if this doesn't work, use fine sandpaper or a commutator stone-­do not use emery cloth. Lift brushes and check surface--replace brush if unevenly worn or when worn~to about 1/2". Use genuine Kohler replacement brushes only--substitutes may not be of correctmaterial and will wear out rapidly or cause commutator damage. Other common causes for rapid brushwear are wrong brush tension, rough commutator surface, high mica on commutator and brush chatter.Blow dust out with i!.l. compressed air after servicing generator.

TROUBLE SHOOTING-GENERATORSome common causes of possible generating problems that can be detected and corrected without

test instruments are listed below. If routine service or the suggested corrective action fails to solvethe particular problem, contact a qualified electrical technician to remedy the malfunction. The infor­mation on Controller Operation provided on pages 8 and 9 is furnished to help the technician pinpointcauses of generator and controller problems.

PROBLEMPOSSIBLE CAUSE

NO OUTPUT

• LOOSE TERMINAL CONNECTIONS:Check for loose or bad connections--clean and tightenas needed. • BATTERY LEADS REVE RSED:

Make sure negative terminal is grounded.• BRUSHES NOT SEATED:

Check for loose springs or brushes sticking in holders.Correct condition. • DIRTY COMMUTATOR:

Poor brush contact caused by build up of dirt or oily film oncommutator--clean with coarse cloth or fine stone or sandpaper.• SHORT IN AC CI RCUIT:

If engine labors while running or jerks while being cranked,check for short circuit in AC line.• OPEN GENERATOR FIELD:

Have technician check for this condition.

LOW OUTPUT OR

• ENGINE SPEED TOO LOW:Check speed with tachometer--load speed should be 1800 RPM

EXCESSI VE DROP

(full load).Readjust governor speed and sensitivity as required.IN VOLTAGE

• OVERLOAD:If all possible electrical loads are on at the same time, overload

condition may exist--turn off unnecessary loads .• ENGINE IN POOR CONDITION: Faulty ignition, excessive carbon, poor compression,clogged air cleaner or any other condition ~ausing poor performance of the enginemay show up in reduced output.

Repair or service engine as needed.

CONTROLLERThe controller, which is the unit on top of the generator, controls the set thru all phases of

operation. The set may be started and stopped at the switch on the controller or the switch inside themotor horne. Refer to the controller illustration on page 14 for parts identification and to the wiringdiagram on the opposite page to trace the sequence of operation as explained in the following.

1.

2.

SWITCH IN STAR T POSITION: This completes the starting circuit allowing battery current to flowfrom the positive terminal thru cranking contactor C and back to battery negative terminal. Thiscurrent magnetically draws contacts of C closed which allows heavy battery current to flow thruthe cranking series windings and the exciter armature thus motoring the engine for starting. Theinitial current also activates the choke coil. The switch must be released to open the crankingcircuit immediately after the engine starts.

SWITCH I~ R UN (CENTER) POSITION: Switch returns to run position when released. Enginequickly comes up to speed and power is furnished from the generator collector rings thru terminalsLl and L2. As exciter voltage rises, lCR and 2CR relay coils energize. Contacts of lCR con­nect the battery charging circuit to the battery. Contacts of 2CR allow the battery charging relay(regulator relay) RR to sense battery voltage which varies the charge rate from 1 to 6 amps byopening or closing the circuit thru resistor lR2.

.--

3. SWITCH IN STOP POSITION: This grounds out the magneto ignition system at terminal 5 to stopthe engine- -the switch must be held in the stop position until the engine comes to a complete halt-­if released too soon the engine may restart.

9

~7

PARTS ORDERING INSTRUCTIONSMost of the parts listed on the following pages are for routine services while others, such as the

repair kits, are for overhaul of faulty components. Complete assemblies are also listed for unitreplacement of components in the event this method is more advantageous timewise.

Authorized Kohler service centers have the complete list of parts for this set and should becalled upon for repair and replacement whenever possible. Refer to the yellow pages of your telephonedirectory for the nearest dealer. When ordering parts, always report the MODEL, SERIAL ANDSPECIFICA TION numbers as found on the nameplate--this data will enable the dealer to procure thecorrect part for your generator set.

K321 ENGINE PARTSITEM PART NO.DESCRIPTION

1

237678Baffle, head2

237671Head, cy1 inder3

237658Gasket, cylinder head4

Block, cylinder5

220791Boot6

235041-SPlug, spark (XH-10)7

235054Baffle, cylinder

8a

235838Valve, exhaust-

235168Spring-

A-235327Tappet-

230020Rotator

8b

235582Va 1ve, intake-

235168Spring-

A-235327Tappet-

240013Retainer (lower)-

235011Retainer (upper)

9

B-235646CamshaftlOa

235070Gasket (.010)lOb

235757Gasket11

235376Bearing, ball12

235815Plate, bearing13a

X-271-30Sea 1, oil (front)13b

X-379-9Seal, oil (rear)14

A-235741Stator, magneto

15

220980Points (set)-A-220136Cover

-220174

Gasket-

220297Grommet

-235786

Condenser-

X-489-1Rod, push

16a

237552Dipstick16b

237012Tube, oil fi1117

235561Housing, blower18

236474Support19

277227Rotor19a

A-236252F1ywhee 120

237475Scro~ 1, air-vac-237476

Cover, scroll ITEM PART NO.DESCRIPTION

21

237462Base, oil pan22

235353Gasket, pan23

235026Cover, gear235025

Gasket, cover

24a

275143Cover, valve24b

275144Gasket24c

235118Filter24d

235117Baffle24e

235047Reed24f

235631Plate24g

235048Gasket

25I 235652

Baff1 e, side26

A-235807Pump, fue 147 516 01

Line, fue 1

27a

X-276-6Nut, wing27b

237423Cover27c

235116E1ement27d

237424Base27e

275341Gasket27f

237423Seal

28

I A-236271 Carburetor275167

Gasket, carburetor29

I A-21 0101Filter, fuel

30

I235776

I Choke, automati c

240285

Gasket

235466Linkage

31

236763Ring set (std.)32

A-236631Piston (std.)33

A-237344Rod, conn. (std.)

34

B-237104Crankshaft

35

230989Cutout - hi. temp.

36

I237129 Elbow, exhaus tAC-1536

Nut, lock

37

147 462 02

Valve, fuel solenoid

•

11

r MOUNTING PARTS

SUPPORT, GENERATOR~

(237467 )

/III~BRACKETCARBURETOiNG! NE (R. H. ) I '(237465) SIDE

/BRACKET

(237464j ENGINE (L.H.)

~SUPPORT, ENGINE*(237466)

* NOTE: Rail centerline mounting parts shown--slide-out tray mounting uses same engine brackets but

supports are part of tray (slide tray part number 237500).

BRACKET~NER<TOR)

SUPPORT ..r

NUT---------

(X-83-2) /BOLT (X-7-35)

/WASHER~~ WASHER

ii jf ~ (X-25-100):c=--------,'T----;.:-:-::.::. "::::?, 1I ·-·=.::::=~--=-..:L-- 'I

TEE, RUBBER :,~-;:_-_-_::-:._-:.~----.-_', ~(237451)~----:~--::t----, CUP (237452)

.,': '~-- JCj----, SPRING:: (237463)oi

~ ""WASHER"" (X-25-101)LOCKWASHER

SPACERS3" LONG FORGENERATOR END(X-400-82 -

2 REQUIRED)

2-7/8" LONG FORENGINE END

(X-400-84 -

2 REQUIRED)

EXHAUST PARTS (OPTIONAL)

MUFFLER, QUIET-TUNED(237485)

TAILPIPE NOT FURNISHEDBY KOHLER--FACE AWAYFROM AI R STREAM

J;ASTRAP, HANGER(237549)

NOT SHOWNSPARK ARRESTOR

(237949)

(237535)

12

ITEM QTY.

1

1

2

13

1

4

15

1

6

4

7

1

8

1

9

1

10

1111

I

4

12

1

13

1

1114I1

115

1

16

1

17

4

18

8

19

4 PART NUMBER

242365

242830

242596

X-758-1

A-252209

A-242391

237793

242294

242281

252163252164

A-242014

242196242088

242663

242840

232414

232413

233773

283741

242189

242191

242230

SEE BRUSH, BRUSH SPRING DETAIL BELOW

-DESCRIPTION

Cover, generator endBracket, end

Ring, brush

Beari ng, ba 11

Armature - assembly

Pole, field - assembly

Frame, generatorBaffle, air

Fan, cooling

Support, engine-generator

Guard, generator support

Coil, field - assembly

Bol t, thruResistor, fiel d

Stud, resistor

Nut, resistor stud

Condenser, AC (0-392)

Condenser, DC (0-242)

Compensator, cyclic

Diode, cyclic compensator

Brush, AC

Spring (AC & DC brushes)Brush, DC

~SPRING' AC & DC BRUSH

~ BRUSH./ -DC

•

13

CONTROLLER PARTS LISTING

RR

~CONTROLLER - ASSEMBLY (COMPLETE)

ITEMPART NUMBERDESCRIPTION

1

X-363-1 Bracket, resistor mounting

la

X-363-2 Bracket, resistor mounting

2

245291 Resistor, lR2

3

245445 Relay lCR

4

243890 Resistor R2

5

237939 Connector, 1ead

-237747

Connector, external

6

245269 Relav RR

7

245448 Block, terminal

8

248376 Switch, rocker

9

248375 Bracket, switch mounting

10

248370 Box, controll er

11

266118 Stri p, termi na1

12

248371 Cover, controller

13

X-567-4 Connector

14

233442 Solenoid, crankinq (C)

15

245445 Relay 2CR

16

248366 Bracket, controller mounting (Right Side)

-248367

Bracket, controller mounting (Left Side)

17

A-248895 Controller - assembly (Complete)

14

STORAGE INSTRUCTIONSIf your generator set is to be out of service for a considerable length of time, the following steps

should be taken to preserve the set before placing it in storage.

STEP 1: Drain oil from crankcase (while hot) then flush with clean light weight oil. Refill crankcasewith regular weight oil after flushing with the light oil.

STEP 2: Drain fuel from filter sediment bowl, carburetor bowl, and fuel tank. This is done to pre­vent the gasoline from becoming "stale" which results in formation of gum.

STEP 3: Remove the spark plug, pour about 1 tablespoon of oil into the hole, crank the engine severaltimes then reinstall the spark plug.

STEP 4: Clean exterior surfaces of generator set then spread a light film of oil over any unpaintedmetallic surfaces which could corrode.

STEP 5: Place dust cover over the generator set and store in cool, dry space.

POPULAR OPTIONSSome of the popular generator set accessory kits which can be quickly added to your recreational

vehicle are described below. These are available from your local Kohler Generator Set Dealer.

HOUR-METER KITS: The hour meter kit includes an attractive panel with hour meter and stop-startswitch as shown below. The hour meter registers the total running time on your generator set. Withthis, you'll know exactly when it's time to service your generator set. You can also start and stop yourgenerator set at the switch on this panel--an amber light in the switch glows whenever the set is running.The panel can be mounted in a convenient location on the dashboard or partition in your recreationalvehicle. Order Kit #A-237955 when a IO-foot length of coaxial cable is required or Kit #A-237956 whena 3D-foot long coaxial cable is needed.

LIGHTED STOP-STAR T SWITCH KITS: Without a lighted indicator switch you may have a hard timedetermining if your generator set is actually running. These kits include an indicating stop-start switch,coaxial leads and all hardware for mounting in convenient spot in your recreational vehicle. The switchglows with an amber light whenever the generator set is operating. In addition to the convenience ofknowing at a glance whether your set is running or not, this feature eliminates the possibility of damagedue to attempts to start the set when it is already running. Order Kit #237961 for switch with IO-footlong coaxial lead or Kit #237962 for 3D-foot coaxial lead.

I HOUR METER KIT I

KDHLERGENERATDR SET

Ie ~@111[]][[]]]111(l)

II~ TOTAL HOURS

HOUR--1METER

15

START

STOP

CONNECTOR PLUGS

INTO RECEPTACLE

IN CONTROLLER

II LIGHTED INDICATOR

SWITCH (PART OF

HOUR METER KIT)

~ HOUR-METER

PANEL

r

OPERATING HOUR - SERVICE lOGThe following is provided to help you keep an accnD"lUlative record of operating hours on your

generator set and the dates required services were perfonned. Enter hours to the nearest quarterhour.

r

DATEOPERATING HOURSSERVICE RECORD

RUN

HOURS RUNACCUMULATIVEDATE! SERVICE

I: IIiIII~I!:I! :iII:II

DATEOPERATING HOURSSERVI Ct: RECORD

RUN

HOURS RUNACCUMULATIVEDATE 1 SERVICE

I: I:I: !:I:I;II:II IIII

Limited On~-Year Generator Set & Accessories Warranty *Your Kohler Generator Set and Accessories have been manufactured and inspected with care byexperienced workdl'en~ Kohler Co. warrants for One year, each generator set and its accessoriesto be free from defects' in materials and workmanship if properly installed, maintained and operatedin accordance with the Owner's Manual instructions.

Repair or replacement at Kohler's option will be furnished to the customer where inspection toKohler Co. 's satisfaction discloses any such defects in normal usage within one year after sale tothe original user.NO CLAIM WILL BE ALLOWED FOR CONSEQUENTIAL DAMAGE OR FOR ANY EXPENSE OTHERTHAN MATERIALS AND LABOR FOR REPAIR OR REPLACEMENT AT KOHLER CO. 'S FACTORYOR AN AUTHORIZED SERVICE STATION.

ANY IMPLIED WARRANTY IS LIMITED IN DURATION TO THE DURATION OF THIS ONE-YEARWARRANTY.

*In compliance with 1975 Consumer Product Warranties Law

KOHLER CO. KOHLER, WISCONSIN 53044

~

:1

TP1040/527 ULI

KOHLER

••KOHLER CO. KOHLER, WISCONSIN 53044 FOUNDED IN 1873