Kohler 8-12.5 kW Service Parts Catalog

Marine Generator Sets Models: 8C 8E 10C 10E 12.5C 12.5E TP-5413 5/01c Service Parts

Table of Contents Introduction 1 ................................................................. Numbering System Significance 1 ............................................... Illustrations 1 .................................................................. How to Find Part Numbers 1 .................................................... Hardware References 1 ........................................................ Specification Number Index 2 ................................................... Group 1: Gaskets and Seals 4 .................................................. Group 2: Cylinder Block 5 ...................................................... Group 3: Cylinder Head and Valves 6 ............................................ Group 4: Front Cover Assembly 7 ............................................... Group 5: Camshaft and Valve Control 8 .......................................... Group 5: Camshaft and Valve Control 9 .......................................... Group 6: Crankshaft and Piston 10 .............................................. Group 6: Crankshaft and Piston 11 .............................................. Group 7: Flywheel and Clutch 12 ................................................ Group 8: Oil Pump and Pan 13 .................................................. Group 9: Fan and Water Pump 14 ............................................... Group 10: Intake Manifold 15 ................................................... Group 12: Ignition Module and Spark Plugs 15 .................................... Group 101: Air Intake 16 ....................................................... Group 103: Fuel System 17 .................................................... Group 104: Cooling System 18 .................................................. Group 105: Engine 22 ......................................................... Group 107: Nameplate and Decals 26 ........................................... Group 108: Oil Pressure Switches 28 ............................................ Group 109: Skid and Plant Mounting 29 .......................................... Group 110: Water Temperature Switches 30 ...................................... Group 112: Starter 31 .......................................................... Group 201: Generator and Mounting 32 .......................................... Group 301: Controller and Mounting 34 .......................................... Group 01: Literature 36 ........................................................ Accessories 37 ................................................................ Appendix A Abbreviations A-1 .................................................. Appendix B Common Hardware Application Guidelines A-3 ......................... Appendix C General Torque Specifications A-4 .................................... Appendix D Common Hardware Identification A-5 ................................. Appendix E Common Hardware List A-6 .........................................

1 TP-5413 5/01 Introduction This manual lists service replacement parts for 8--12.5 kW generator sets. At the time of print this manual applied to the generator set specification (spec) numbers listed in the Specification Number Index. On occasion this manual may apply to specs not listed in the Specification Number Index. Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever. 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 set specs and groups. Group Parts Lists. List the part numbers of parts in the groups. Kit Sections. List modules and accessories and their parts. Appendices. Include Abbreviations, Common Hardware Application Guidelines, General Torque Specifications, Common Hardware Identification, and Common Hardware List. x:in:004:002 Numbering System Significance This manual uses the following numbering systems: Specification Number. The product identification number located on the generator set nameplate. Spec numbers break down into groups. Group Number. A unique number representing a parts group needed to assemble a generator set function. For example, Group 101 is the Air Intake group. Variation or Module Number. A group might have several variations. Each variation performs the same function with different parts lists. For example, a 50 Hz generator alternator and a 60 Hz generator alternator both perform the same function, however, with different parts. Each difference requires a group variation or module number. Part Number. The part number identifies an individual assembly, subassembly, component, or accessory kit. x:in:004:003:a Illustrations Illustrations (or exploded-view drawings) best 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 instructions. x:in:004:004 How to Find Part Numbers Use the following steps to locate a service replacement part. 1. Locate the generator set nameplate to identify the generator set spec number . 2. Locate a second generator set nameplate listing accessories to identify installed modules. On some models the accessory nameplate is mounted inside the generator junction box. 3. Turn to the Specification Number Index. The first column lists the generator set spec numbers. The headings identify the groups of parts that make up the generator set. 4. Identify the group most likely to include the service part number. 5. Find the group variation number at the intersection of the spec number row and the group column. Note the variation number. 6. Page forward to locate the group identified in step 4 or find the appropriate page in the Table of Contents. 7. Find the part on the illustration and note the item number of the part or find the part description in the parts list. 8. Select the part number that corresponds to your group variation. The first column lists the illustration item number. Find the variation identified in the Specification Number Index or the module number found on the generator set nameplate in the appropriate column on the right side of the parts list table. Find the quantity used at the intersection of the item number row and the variation column. A blank space at the intersection means the variation/module does not use that part number. x:in:004:005 Hardware References Many common hardware items do not appear in parts manuals or will appear as common hardware entries. A common 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 the factory, use the Common Hardware List in the appendix to identify the common hardware part number and specifications. See Common Hardware Application Guidelines in the appendix for mating hardware instructions. Some hardware items require a specific size or some other characteristic. In that case, use the part number listed in the text. When replacing hardware, do not substitute inferior grade hardware. Replacement hardware grade should be equal to or better than the grade of the manufacturer’s original hardware. Use the Common Hardware List in the appendix to identify the common hardware hardness. x:in:004:006

2 TP-5413 5/01 Specification Number Index Group No. 1 2 3 4 5 6 7 8 9 10 12 Spec No. Variation Number Group Title 8C/8E PA-110302 1 1 1 1 1 1 1 1 1 1 1 PA-110303 3 3 1 1 1 3 3 3 1 1 1 PA-110305 3 3 1 1 1 3 3 3 1 1 1 PA-110306 3 3 1 1 1 3 3 3 1 1 1 PA-110307 3 3 1 1 1 3 3 3 1 1 1 PA-110308 3 3 1 1 1 3 3 3 1 1 1 PA-110309 3 3 1 1 1 3 3 3 1 1 1 PA-110310 3 3 1 1 1 3 3 3 1 1 1 PA-110311 2 2 2 1 2 2 2 2 1 1 1 PA-110312 2 2 2 1 2 2 2 2 1 1 1 GM17772-GA1 2 2 2 1 2 2 2 2 1 1 1 10C/10E PA-110105 1 1 1 1 1 1 1 1 1 1 1 PA-110106 1 1 1 1 1 1 1 1 1 1 1 PA-110109 1 1 1 1 1 1 1 1 1 1 1 PA-110110 3 3 1 1 1 3 3 3 1 1 1 PA-110111 3 3 1 1 1 3 3 3 1 1 1 PA-110112 3 3 1 1 1 3 3 3 1 1 1 PA-110113 3 3 1 1 1 3 3 3 1 1 1 PA-110114 2 2 2 1 2 2 2 2 1 1 1 GM17772-GA2 2 2 2 1 2 2 2 2 1 1 1 12.5C/12.5E PA-110205 2 2 2 1 2 2 2 2 1 1 1 PA-110206 2 2 2 1 2 2 2 2 1 1 1 PA-110209 2 2 2 1 2 2 2 2 1 1 1 PA-110210 2 2 2 1 2 2 2 2 1 1 1 PA-110211 2 2 2 1 2 2 2 2 1 1 1 PA-110212 2 2 2 1 2 2 2 2 1 1 1 GM17772-GA3 2 2 2 1 2 2 2 2 1 1 1

3 TP-5413 5/01 Specification Number Index Group No. 101 103 104 105 107 108 109 110 112 201 301 701 Spec No. Variation Number Group Title 8C/8E PA-110302 2 4 7 20 13 1 3 2 2 3 18 10 PA-110303 2 4 7 23 17 -- 3 2 2 3 19 10 PA-110305 2 4 7 23 26 -- 3 2 2 3 19 10 PA-110306 2 4 17 28 26 -- 3 2 2 3 24 10 PA-110307 6 12 18 31 28 -- 16 2 2 32 26 11 PA-110308 6 12 19 31 28 -- 16 2 2 32 27 11 PA-110309 6 17 19 31 30 -- 16 2 2 32 27 11 PA-110310 6 17 18 31 30 -- 16 2 2 32 26 11 PA-110311 6 17 19 32 48 -- 16 2 2 32 27 11 PA-110312 6 17 18 32 48 -- 16 2 2 32 26 11 GM17772-GA1 6 GR4 18 GR1 48 -- 16 2 2 32 GR2 11 10C/10E PA-110105 2 4 7 5 2 1 3 2 2 7 3 10 PA-110106 2 4 11 20 13 1 3 2 2 7 14 10 PA-110109 2 4 11 20 13 1 3 2 2 7 16 10 PA-110110 2 4 7 23 17 -- 3 2 2 7 19 10 PA-110111 2 4 7 23 26 -- 3 2 2 7 19 10 PA-110112 6 12 18 29 28 -- 16 2 2 33 26 11 PA-110113 6 17 18 29 30 -- 16 2 2 33 26 11 PA-110114 6 17 18 33 48 -- 16 2 2 33 26 11 GM17772-GA2 6 GR4 18 GR1 48 -- 16 2 2 33 GR2 11 12.5C/12.5E PA-110205 2 4 7 6 11 1 4 2 2 4 4 10 PA-110206 2 4 7 19 14 1 4 2 2 4 15 10 PA-110209 2 4 7 19 14 1 4 2 2 4 17 10 PA-110210 2 4 7 19 27 -- 4 2 2 4 17 10 PA-110211 6 12 18 30 29 -- 15 2 2 31 25 11 PA-110212 6 17 18 30 31 -- 15 2 2 31 25 11 GM17772-GA3 6 GR4 18 GR1 48 -- 15 2 2 31 GR3 11

4 TP-5413 5/01 Group 1: Gaskets and Seals Upper and Lower Engine Gasket Kits (Items 2 and 3) do not include Items 4-9. Upper Gasket Kit does not include a cylinder head gasket. Order cylinder head gasket separately from Group 3. Quantity Variation Number Item Part Number Description 1 2 3 1 224704 Engine gasket kit, complete 1 1 1 224705 Engine gasket kit, complete 1 2 224706 Engine gasket kit, upper 1 1 2 224707 Engine gasket kit, upper 1 3 279143 Engine gasket kit, lower 1 1 3 279145 Engine gasket kit, lower 1 4 246058 Gasket, fuel pump 1 1 1 5 224773 Gasket, water pump 1 1 1 6 279112 Seal, front cover 1 1 1 7 224722 Gasket, front cover 1 1 1 8 224748 Gasket, rear retainer 1 8 224749 Gasket, rear retainer 1 1 9 224782 Seal, crankshaft rear 1 9 276192 Seal, crankshaft rear 1 1

5 TP-5413 5/01 Group 2: Cylinder Block Quantity Variation Number Item Part Number Description 1 2 3 1 276194 Block, cylinder (basic) 1 1 224718 Block, cylinder (basic) 1 1 224717 Block, cylinder (basic) 1 2 224719 Block, cylinder (includes crank, pistons, rings, etc.) 1 2 276195 Block, cylinder (includes crank, pistons, rings, etc.) 1 2 224720 Block, cylinder (includes crank, pistons, rings, etc.) 1 3 279188 Plug, 41.6 mm 2 2 2 4 279187 Plug, 51 mm 1 1 1 5 # Plug, 1/4 NPT 3 3 3 6 # Plug, 1/4 NPT 1 1 1 7 279214 Plug, ball (oil gallery) 1 1 1 8 279193 Adapter 1 1 1 9 224726 Liner, cylinder 4 4 9 224727 Liner, cylinder 4 10 279173 Bolt, main bearing cap 6 10 10 11 224716 Transducer (speed sensor) 1 1 1 12 # Screw, M6 x 14 1 1 1 13 276456 Switch, oil pressure 1 1 1 # Common hardware; procure locally.

6 TP-5413 5/01 Group 3: Cylinder Head and Valves Quantity Variation Number Item Part Number Description 1 2 1 GM24858 Cylinder head assembly 1 1 224723 Cylinder head assembly 1 2 224724 Gasket, cylinder head 1 2 224725 Gasket, cylinder head 1 3 224731 Bolt, cylinder head 10 10 4 224791 Dowel, cylinder head to block 2 2 5 224755 Valve, intake, standard 4 5 224757 Valve, intake, standard 4 5 224756 Valve, intake, 0.40 oversized 4 5 224758 Valve, intake, 0.40 oversized 4 6 224754 Valve, exhaust, standard 4 4 6 224753 Valve, exhaust, 0.40 oversized 4 4 7 224759 Spring, valve 8 8 8 224709 Seal, valve stem 8 8 9 224770 Retainer 8 8 10 224708 Lock, valve spring 16 16 11 224762 Cover, rocker arm 1 1 12 279084 Gasket, rocker arm cover 1 1 13 224789 Screw, rocker cover/head 4 4 14 # Washer, flat, 6 mm 4 4 15 279188 Plug, 41.6 mm 1 1 16 279115 Cap, oil, breather 1 1 17 224730 Insert, exhaust valve seat 4 4 18 224728 Insert, intake valve seat 4 18 224729 Insert, intake valve seat 4 19 224794 Hose, PCV 1 1

7 TP-5413 5/01 Group 4: Front Cover Assembly Quantity Variation Number Item Part Number Description 1 1 224721 Cover and seal assembly 1 2 224722 Gasket, front cover 1 3 279111 Seal, front cover 1 4 # Bolt, M6 x 45 1 5 # Bolt, M6 x 40 3 6 # Bolt, M6 x 18 4 7 # Washer, split lock, B6 8 # Common hardware; procure locally.

8 TP-5413 5/01 Group 5: Camshaft and Valve Control

Kohler 8-12.5 kW Service Parts Catalog

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