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<p>COMPOSITE EXPLODED , IGROUP 301-</p> <p>VIEW</p> <p>GROUP</p> <p>19</p> <p>GROUP</p> <p>17</p> <p>GROUP ____-----------</p> <p>109</p> <p>/</p> <p>+.</p> <p>IGROUPS 14oTSHOWN:I</p> <p>I41-SHORT I I</p> <p>BLOCK</p> <p>UNIVERSAL 43-SERVICE ENGINE SPECIFICATION UNIVERSAL 44-SERVICE ENGINE MODIFICATION-I</p> <p> 42-MINIBLOCK ~_____________--</p> <p>IGRID A2</p> <p>COMPOSITE</p> <p>EXPLODED</p> <p>VIEW</p> <p>GRID A3</p> <p>unvur</p> <p>Ld</p> <p>This manual contains a complete listing of service replacement parts for Kohler 4KW Generator Sets with specification'series code 102. These use the Kohler Model K321 Engine. The manual includes the following main sections in the sequence listed. 1. 2. Composite Exploded Views: generator set. Shows the general reference group location of the main components of the</p> <p>Specification Number Index: Listing of generator set spec numbers arranged in numerical sequence on each page. Group variation numbers are listed in the horizontal line to the right of each spec number. Group Parts Lists: Indicates specific parts for each specification. Illustrations of parts are shown for each of the various parts groups. Illustrations are keyed to the parts numbers found in the parts group listings. Accessory Parts List: The parts listed in this section are not installed but are shipped with the generator set. Accessories are shown in back of manual. Gasket Set Listinq: Lists the part number of the gasket set required for complete overhaul of the unit plus a listing of the individual gaskets and seals which are included in the set. Gaskets and seals are also listed individually in the various parts groups.</p> <p>3.</p> <p>4.</p> <p>5.</p> <p>1</p> <p>NUMBER</p> <p>SIGNIFICANCE</p> <p>1The</p> <p>There are various numbers which must be used in determining how to identify a part number. significance of each of these numbers is explained as follows:</p> <p>SPECIFICATION NUMBER: The generator set specification number, which is found on the nameplate attached to the frame of the generator, indicates model variation or the combination of groups used to build that particular generator set. The spec number is, in effect, a coded number. The first three digits, which are the code designation for generator size and engine model, remain constant in this series while the remaining digits in the spec number are issued in numerical sequence. When the sequential number reaches 99, the next number will be 100, for example: 10299 is followed by 102100-note that the spec number goes from a 5 digit to a 6 digit number in the example. GROUP NUMBER: The group consists of related parts needed to provide one or more related functions.</p> <p>GROUP VARIATION NUMBER: There may be various groupings of parts designed to provide the same function, however, with minor differences. Each of these differences necessitates the assignment of a group variation number. Example, dry air cleaner or oil bath air cleaner--both perform the same function, however, use different parts. PART NUMBER: The part number is the number by which an individual piece part of a generator set is identified and ordered.</p> <p>IHOW</p> <p>TO FIND PART NUMBERS]ARMATURE ASSEMBLY</p> <p>Following is a step-by-step procedure to be used in identifying and ordering a specific part. Item to be ordered: STEP 1: STEP 2: STEP 3:</p> <p>Record the Generator Set specification number from the nameplate on the generator frame. (Sample: 10242A) Turn to the composite views to determine the group in which the armature assembly is located. The armature assembly is in Group 201 - Generator and Mounting. In the Specification Number Index, find specification 10242A in the left-hand vertical column. Under Group 201 - Generator and Mounting column, locate the variation number assigned to specification 10242A. The variation number is 55. Turn to Parts Group 201 - Generator and Mounting. Note that the armatures are identified with Index Letter P--under this letfer locate Variation 55. Armature assembly A-252209 is assigned to this variation.</p> <p>STEP 4:</p> <p>GRID A4</p> <p>GENERATOR</p> <p>SET SPEC.</p> <p>NO.</p> <p>INDEX</p> <p>Gasket Set on GRID Cl3 GRID A5</p> <p>GRID A6</p> <p>GENERATOR</p> <p>SET</p> <p>SPEC.</p> <p>NO.</p> <p>INDEX</p> <p>GRID A7</p> <p>1</p> <p>SERIES</p> <p>102PART NUMBER</p> <p>:NDEX .TR. F</p> <p>DESCRIPTION VARIATION NUMBER Gasket, air horn 1,3,13,15,27,28,37, 38,44,51 Precleaner, element (May be used with filter element 235116) Stud, cleaner l/4 - 20 x 4-718 27,37 Gasket, cleaner 27,37 Elbow, air cleaner 13 Elbow, air cleaner 15 Elbow, air cleaner (Includes nipple) 27,37 Ni;7pl;71/4 x l-118</p> <p>QTY.</p> <p>275341</p> <p>1</p> <p>G</p> <p>237421</p> <p>1</p> <p>H</p> <p>235156</p> <p>1</p> <p>3</p> <p>AC-1787</p> <p>11</p> <p>Kl</p> <p>275259</p> <p>K2</p> <p>235553</p> <p>1</p> <p>K3</p> <p>B3</p> <p>236229</p> <p>1</p> <p>II</p> <p>L</p> <p>X-226-2 Ml Brace, air cleaner 15 Brace, air cleaner 27,37 Elbow, street 90" 27,37 Cup, air cleaner 15 Baffle, air cleaner 15 A-235100 1 Fastener, oil cup 15 Body, upper 15 Seal, air cleaner 38,5i Screw, hex. hd. ii10 - 32 x 5/16 1,3,28,38,44</p> <p>1</p> <p>235539</p> <p>1</p> <p>M2</p> <p>235339</p> <p>1</p> <p>INDEX LTR.</p> <p>DESCRIPTION VARIATION NUMBER Nut, wing 1,3,27,28,37,38,44,51 Cleaner, air - assembly (Includes A,Cl,Dl &amp; El) 133 Cleaner, air 13 Cleaner, air - assembly (Includes O,P,Q &amp; R) 15 Cover, cleaner 1,3,27,37,44 38,51</p> <p>PART NUMBER X-276-7</p> <p>QTY1</p> <p>X-211-6</p> <p>1</p> <p>ABl</p> <p>231414</p> <p>1</p> <p>231415</p> <p>1</p> <p>B2</p> <p>231416 232561</p> <p>1 1</p> <p>272461</p> <p>1</p> <p>63</p> <p>A-230538</p> <p>1</p> <p>237423</p> <p>1</p> <p>Cl</p> <p>235102 237848</p> <p>1 1</p> <p>X-167-2</p> <p>3</p> <p>c2</p> <p>Cover, cleaner 28 Element, filter 1,3,27,37,38,51 44</p> <p>277142</p> <p>1</p> <p>Dl</p> <p>235116 47 083 02</p> <p>1 1</p> <p>D2</p> <p>Element, filter 28 Base, cleaner 1,3,44 28 38,51</p> <p>277138</p> <p>1</p> <p>El</p> <p>235101 236638 237424</p> <p>1 1 1</p> <p>E2</p> <p>Base, cleaner 27,37</p> <p>235123</p> <p>1</p> <p>1.1 GRID</p> <p>A8</p> <p>SERIES</p> <p>102 23 4</p> <p>Cover, scroll 61,62,193,198</p> <p>275824 275827(Discont'd</p> <p>130,164,191,199&gt;229 Bracket, scroll support 61,79,193,198 Brace 229 Screen, air outlet 229 Switch 264 INDEX LTR. Al DESCRIPTION VARIATION NUMBER Baffle, head (Use 237520 after engine serial no. 31849991 27,37,61,62,79,136,164, 193 Baffle, head 191,198,199,206,229,264 A2 Baffle, head (Use 235049 prior to engine serial no. 3185000) (Use 237677 on engine spec suffix "C") 39,145 Baffle, head 174,175,184,192 B Baffle, cylinder (Use 236676 after engine serial no. 3184999) 27,37,39,61,62,79,130, 206,264 Baffle, cylinder 145,164,174,175,184,191, 192,193,198,199,229 C Housing, blower 27,145,174,192,206 37,175,264 39,184 61,62,79,130,164,191,193, 198,199,229 D Baffle, side air 27,61,164,192,199 37,39,62,79,130,145,174, 175,184,191,193,198,206, 229,264 E Scroll 61,62,79,193,198 130,164,191,199 229 F Baffle, air 61,62,79,130,164,191,193, 198,199,229 PART NUMBER Nut (not shown) 264</p> <p>237476</p> <p>236718</p> <p>41 120 02</p> <p>1</p> <p>47 162 06</p> <p>1</p> <p>41 099 04</p> <p>1</p> <p>41 100 02</p> <p>1</p> <p>235049</p> <p>237678</p> <p>237520</p> <p>237677</p> <p>235054</p> <p>235054</p> <p>235901 235934 236289</p> <p>BAFFLES AND SHROUD 2</p> <p>235561</p> <p>236272 235652</p> <p>236717 237475 47 416 01</p> <p>236390</p> <p>2.1-3.1</p> <p>GRID A9</p> <p>INDEX LTR.</p> <p>34fA 8</p> <p>SERIES</p> <p>102</p> <p>DESCRIPTION VARIATION NUMBER</p> <p>PART NUMBER</p> <p>QTY</p> <p>INDEX LTR.</p> <p>DESCRIPTION VARIATION NUMBER</p> <p>PART NUMBER</p> <p>QTY.</p> <p>Use stock of original part numberbefore ordering replacement. Hose l/2 I.D. x 3/4 O.D. x 3-l/8 637 Clamp, hose 6 C Stud, valve cover X-426-3</p> <p>Use stock of original part number before orderinq replacement.</p> <p>X-484-2</p> <p>Pin, camshaft 10,19,24 Spacer, camshaft 10,19,24 Spacer, camshaft 10,19,24 .005</p> <p>235193275066 .OlO 275067</p> <p>1</p> <p>A.R.</p> <p>1,6,7Dl Cover, valve (Standard) 1 Cover, valve (Closed breather) 6,7 Gasket 1,6,7 Seal, breather 1,697 Filter</p> <p>275220</p> <p>A.R.</p> <p>275143</p> <p>Camshaft - assembly 10,19,24 Spring, actuating 10,19,24 E Tappet 10,19,24 Rotator, exhaust valve 10,19 Retainer, exhaust valve 24</p> <p>47 010 06</p> <p>D2</p> <p>275839</p> <p>47 089 01</p> <p>275144</p> <p>1 Fl</p> <p>D-235327</p> <p>231032</p> <p>1</p> <p>230020</p> <p>1,6,7Baffle</p> <p>235118</p> <p>11</p> <p>F2</p> <p>230011</p> <p>1,6,7Reed, breather</p> <p>235117</p> <p>Spring, exhaust valve 10,19 24 Retainer, spring upper 10,19,24</p> <p>235168 235010</p> <p>1,6,7Plate, breather</p> <p>235047</p> <p>1</p> <p>1,6,7Gasket</p> <p>235631</p> <p>1</p> <p>235011</p> <p>1,6,7</p> <p>235048</p> <p>1 Valve, exhaust (Stellite) (Use 237672 on engine spec suffix "D" &amp; later) 10 Valve, exhaust 19,24 (Stellite) 237672</p> <p>235838</p> <p>Valve, intake (Stellite) 10,19,24</p> <p>235582</p> <p>1</p> <p>Keeper, valve 10,19,24</p> <p>240013</p> <p>4</p> <p>Spring, intake valve 10,19 24</p> <p>235168 235010</p> <p>/D</p> <p>Rotator, intake valve 10,19</p> <p>230020</p> <p>Retainer, intake valve 24</p> <p>230011</p> <p>3.2-4.1</p> <p>GRID A10</p> <p>SERIES</p> <p>102 5NDEX TR. DESCRIPTION VARIATION NUMBER Elbow 54 Elbow 56,71 86 Elbow 73 Bracket, regulator 54,56,64,71,73 Regulator 54,56,64,71,73 Hose, flexible 8-l/2 54 Hose, flexible 11 73 Hose, flexible 12-l/4 56,71 PART NUMBER 237813 QTY. 1</p> <p>x-447-5 x-447-10</p> <p>1 1</p> <p>x-215-5</p> <p>1</p> <p>231471</p> <p>1</p> <p>B-230695</p> <p>1</p> <p>x-409-5</p> <p>1</p> <p>X-651-10</p> <p>1</p> <p>INDEX LTR.</p> <p>DESCRIPTION VARIATION NUMBER</p> <p>PART NUMBER</p> <p>235171</p> <p>1</p> <p>QTY</p> <p>Use stock of original part number before ordering replacement. Al Carburetor - assembly 5,40,56,71,78,86 61 1 14</p> <p>Fitting, hose (Swivel) 54,73 Fitting, hose 73 Connector 54,73 Connector 56 71</p> <p>X-653-l</p> <p>1</p> <p>X-652-l</p> <p>1</p> <p>A-236271 E-235501 47 053 13 47 053 15</p> <p>X-296-2</p> <p>1</p> <p>231509 231509</p> <p>2 3</p> <p>A2</p> <p>Ca;;u;t;;</p> <p>- assembly B-237821</p> <p>,B</p> <p>2</p> <p>Adapter, carburetor - assem. (Includes V &amp; W) 56,71 A-237412(Discont'd)l</p> <p>Gasket, carburetor 1,5,14,40,54,56,61,64, 71,73,78,86 Bushing, reducer l/4 I.D. x 3/8 O.D. 54,73 Bushing, reducer 318 I.D. x 718 O.D. 56,71 Bushing, reducer l/4 I.D. x 3/4 O.D. 56,71 73</p> <p>271030</p> <p>C</p> <p>X-202-30</p> <p>X-202-28</p> <p>X-202-7 A-105</p> <p>D</p> <p>Nuk6(;;)pper fuel line only)</p> <p>3E</p> <p>220786</p> <p>Sleeve (Copper fuel line only) 56,71 220547 Elbow (Copper fuel line use 231509) 1,5,14,40,56,61,71,78 Elbow 54 64,73</p> <p>Fl</p> <p>x-391-1</p> <p>F2</p> <p>x-274-9 X-211-8</p> <p>CARBURETOR</p> <p>S</p> <p>5.1 GRID</p> <p>Al 1</p> <p>CCARBURETOR</p> <p>SERIES 102</p> <p>INDEX .TR.</p> <p>DESCRIPTION VARIATION NUMBER</p> <p>PART NUMBER</p> <p>QTY.</p> <p>Use stock of original part number before ordering replacement. ALLincludes variations1,5,14,40,56,61,71,78 and 500. Carburetor - assembly 5,40,56,71,78 61 Carburetor 14,500 - assembly 47 053 15 1</p> <p>A-236271 E-235501</p> <p>1 1</p> <p>Screw, bowl retainer 5,14,40,56,71,78,500 INDEX LTR. DESCRIPTION VARIATION NUMBER Choke, automatic 5,56 40,61,71,78 86 Linkage, choke 5,40,56,61,71,78,86 Gasket, choke 5,40,56,61,71,78,86 Coupling l/8 56,71 Gasket 56,71 Pipe l/8 x 3/4 56,71 Pipe 3/8 x 2 64 Pipe l/4 x 718 73 Valve, needle 56,71 Line, idle 14-13/16 copper 56,71 Valve, adapter 56,71 Venturi 56,71 Clamp, hose 54 Screw, sltd. hd. 5/16 - 18 x 1 1,5,14,40,54,56,64,71&gt; 73,78,86 Screw, hex. hd. l/4 - 20 x l-114 54,56,64,71,73 Z Solenoid 86 PART NUMBER QTY 61 Bowl 1,5,14,40,56,71,78,500 61 Float with lever ALL Pin ALL Gasket, bowl ALL</p> <p>235447 200420</p> <p>1 1</p> <p>N</p> <p>230426 238095 4717501 235466</p> <p>1</p> <p>235448 200418</p> <p>1 1</p> <p>11</p> <p>200408</p> <p>1</p> <p>240285</p> <p>1</p> <p>200376</p> <p>1</p> <p>X-216-24</p> <p>2</p> <p>200375</p> <p>1</p> <p>270550</p> <p>1</p> <p>X-217-6</p> <p>1</p> <p>X-204-6</p> <p>1</p> <p>X-220-5</p> <p>2</p> <p>221282</p> <p>1</p> <p>A-237389</p> <p>1</p> <p>270662</p> <p>1</p> <p>Al</p> <p>237411</p> <p>1</p> <p>X-426-3</p> <p>2</p> <p>x-770-1</p> <p>2</p> <p>X-776-l</p> <p>1</p> <p>47 462 02</p> <p>1</p> <p>CARBURETOR</p> <p>S</p> <p>5.2</p> <p>GRID</p> <p>Al2</p> <p>SERIES 102 5INDEX LTR. G DESCRIPTION VARIATION NUMBER Needle and seat 5,14,40,56,61,71,78 Spring, main fuel adjusting needle ALL Needle, main fuel adjusting 1,5,40,56,71,78 61 500 Needle, main fuel adjusting (Use 47 103 01 after engine serial no. 5125237) 14 K Spring, idle fuel adjusting needle ALL Needle idle fuel adjusting 1,5,40,56,61,71,78 14,500 M Gasket, anti-splash ALL PART NUMBER NDEX TR. DESCRIPTION VARIATION NUMBER PART NUMBER QTY.</p> <p>231555 A 200383 B 235415 200442 47 103 01 C</p> <p>Use stock of original part number before ordering replacement.</p> <p>H</p> <p>Carburetor 54,64,73 Venturi 54,64,73</p> <p>- assembly B-23782 1 1</p> <p>J</p> <p>236666</p> <p>Screw, Venturi set 54,64,73 Washer, split 54,64,73 Screw, idle stop 54,64,73 Spring, idle stop 54,64,73 Arm, cast 54,64,73 Screw, throttle lever 54,64,73 Lever, throttle 54,64,73 Seal, felt 54,64,73</p> <p>X-60-l(Discont'd) l</p> <p>0</p> <p>X-18-2</p> <p>1</p> <p>E 237489 F 200380</p> <p>236554</p> <p>1</p> <p>234208</p> <p>1</p> <p>G</p> <p>L</p> <p>236670</p> <p>1</p> <p>235006 275231</p> <p>H</p> <p>x-51-14</p> <p>1</p> <p>J 200439 K</p> <p>275228</p> <p>1</p> <p>N</p> <p>Repair kit (Includes bowl nut gasket, bowl ring gasket, bowl baffle gasket, needle and seat with gasket, float pin &amp; carburetor gasket) 231555 ALL</p> <p>236669(Discont'd)l 234208 1</p> <p>L</p> <p>Sp;;nz; ;;le adjustment</p> <p>9 &gt;Y Screw, idle adjustment 54,64,73 Nut, load adjustment lock 54,64,73 Screw, load adjustment 54,64,73</p> <p>234206</p> <p>1</p> <p>l</p> <p>ooooooooooooe</p> <p>N</p> <p>236553</p> <p>1</p> <p>3</p> <p>236552</p> <p>1</p> <p>l</p> <p>ooooooooooooo</p> <p>CARBURETOR @'F [NDEX .TR. DESCRIPTION VARIATION NUMBER Carburetor - assembly 501 Venturi 501 PART NUMBER</p> <p>SQTY. 1</p> <p>1</p> <p>5</p> <p>B-237821</p> <p>CARBURETOR</p> <p>3</p> <p>236666</p> <p>1</p> <p>CONTINUED ON GRID Bl</p> <p>5.3 GRID</p> <p>Al3</p> <p>INDEX LTR.</p> <p>574D E F G H</p> <p>SERIES</p> <p>DESCRIPTION VARIATION NUMBER</p> <p>PART NUMBER</p> <p>QTY</p> <p>NDEX TR.</p> <p>DESCRIPTION VARIATION NUMBER</p> <p>PART NUMBER</p> <p>QTY.</p> <p>236669(Discont'd)l Spring, idle adjustment 501 Screw, idle adjustment 501 Nut, load adjustment lock 501 Screw, load adjustment 501 Spring, throttle lever adjusting screw 1,501 Screw, throttle lever adjusting 1,501 234208 234206 236553 236552 1 1 1 1</p> <p>232555</p> <p>1</p> <p>J</p> <p>232556(Discont'd)l</p> <p>u</p> <p>/M</p> <p>\IDEX TR.</p> <p>DESCRIPTION VARIATION NUMBER Bearing, rear ball ALL Plug, pipe 175,248 175,248 Seal, rear oil 175,222,240,248,249,278 Insert, exhaust valve (fW)used after spec suffix ALL</p> <p>PART NUMBER</p> <p>QTY.</p> <p>235376 x-75-31 x-75-17 x-379-9</p> <p>1</p> <p>11 1</p> <p>230170</p> <p>1</p> <p>INDEX LTR.</p> <p>DESCRIPTION VARIATION NUMBER</p> <p>PART NUMBER</p> <p>QTv</p> <p>Balanced</p> <p>f</p> <p>)Use stock of original part number) Ibefore orderins replacement. J When replacing cylinder engines with serial no. block on Dynamic 4110021 and earlier, InstaZZation</p> <p>Insert, intake &amp; exhaust valve (Use exhaust valve insert 230170 on spec suffix "A") ALL Block, cylinder - assembly 175 Block, cylinder - assembly (Iyczudes C,D,E,J,K,M &amp; N)</p> <p>230265 B-237347</p> <p>2 1</p> <p>required due to change in boss height. Instructions are included in the kit. Gasket, camshaft cover ALL Cover, camshaft ALL Bearing, needle ALL Shaft, governor ALL Plug, expansion ALL</p> <p>B-237845</p> <p>1</p> <p>235025 235026 234866 235125-S X-230-11</p> <p>1 1 1 1 1</p> <p>Block, cylinder - assembly 240,249 Block, cylinder - assembly (Includes C,D,E,K,M &amp; N) 248,278</p> <p>B-237857</p> <p>1</p> <p>B-237835</p> <p>1</p> <p>5.4-7.1 GRlDA14</p> <p>SERIES</p> <p>102 zw</p> <p>INDEX LTR. M</p> <p>DESCRIPTION VARIATION NUMBER Guide ALL Shaft, stub ALL Gasket, bearing plate .OlO ALL Gasket, bearing plate ALL Bearing, front ball ALL Plate, bearing ALL Seal, front oil ALL</p> <p>PART NUMBER</p> <p>QTY.</p> <p>235007-S</p> <p>2</p> <p>N</p> <p>236559</p> <p>2</p> <p>0 P</p> <p>235070 235757</p> <p>A.R 1</p> <p>QR</p> <p>235376</p> <p>1</p> <p>45 156 03</p> <p>1</p> <p>X-271-30</p> <p>1</p> <p>UDEX TR.</p> <p>DESCRIPTION VARIATION NUMBER</p> <p>PART NUMBER</p> <p>QTY.</p> <p>Use stock of original part number before ordering replacement.</p> <p>@oQ@/D LC</p> <p>Screw, hex. hd. 3/S - 16 x 2-l/2 (Use variation no. 27 after engine serial no. 3184999) 7,12,61,69,85,97 Screw, h...</p>